Appendix C Cut-and-Cover Tunnel Design ExampleAPPENDIX C- EXAMPLE CUT AND COVER BOX TUNNEL ‘The purpose of this design example is to provide guidance to the application of the AASHTO LRFD Bridge Design Specifications when designing concrete cut and cover box tunnel structures. Reference is made to the AASHTO LRED specifications throughout the design example. Specific references to sections are denoted by the letter "S" preceeding the specification article ot1. Tunnel Section Geometry and Materials The tunnel is a reinforced concrete double-chamber box structure. It is located entirely below grade and is built using cut and cover construction. Because the water table is located above the tunnel, hydrostatic soil pressures surround the structure. Figure | shows the internal dimensions for one of the openings. These dimensions serve as the starting point for the structural dimensions shown in Figure 2. a | Figure 1 : | Z E ! a | e | BARRIER, 7 |) 40" 12’. | 12'.0" 44-0" | BARK [SILDE Pa great amma fs ne fa | | 1.1 Tunnel Section Dimensions Box interior width, x 35.75 ft Box interior height, y 20.00 ft Interior wall thicknes 1.00 Exterior wall thickness 2.00 ft Bottom slab thickness 175 ft Top slab thickness = 2.50 ft Soil depth, Z; = 10.00 f Water depth, Z, 5.00 ft Total depth, D = 34.25 ft Box total width, B = 76.50 ft Width between centroids of exterior walls, B, 74.50 ft Box total height, H = 24.25 ft Height between centroids of slabs, Hy = 22.13 ft Figure 2 shows the geometry of the underground cut and cover box cross-section, c2Figure 2 Section Dimensions 1.2 Material Propertie Unit weight of conerete .7, = Unit weight of soil, 4 = Unit weight of water, Yu = Unit weight of saturated soil, Yu: Coeff, of earth pressure at rest, ky Coeff, of water for earth pressure, k= 150 pef, 130 pof 62.4 pet 67.6 pet 0s 1 os2. Computer Model of Tunnel The analysis of the tunnel subjected to applied loads and the design of the structural components are performed using a model generated by general purpose structural analysis computer software, Concrete walls and slabs are modeled as a rigid frame, composed of groups of members that are interconnected by a series of joints (see Section 4.0 Analysis Model Input and Section 5.0 Analysis Model Diagram), All joints are located along the centroids of the structural components. Members are modeled as one foot wide segments in the longitudinal direction of the tunnel to represent a one-foot-wide "slice" of the structure. AASHTO LRED factored loads and load combinations are applied to the members and joints as required. The structure is analyzed to determine member forces and reactions, which will be used to esign individual structural components of the tunnel. 2.1 Model Supports Universal restraints are applied in the Y-translation and X-rotation degrees of freedom to all members Spring supports located at joints spaced at I'-0" on center are used to model soil conditions below the bottom slab of the tunnel. Springs with a K constant equal to 2600 k/ft are used, applied only in the downward Z direction. The spring support reaction will account for the earth reaction load. 3. Load Determination ‘The tunnel is located completely below grade and is subjected to loading on all sides. The self weight load of the conerete structure is applied vertically downward as component dead load. Vehicular live loads and vertical earth pressure are applied in the vertical downward direction to the top slab. Buoyancy forces are applied vertically upward to the bottom slab, Lateral forces from live load, soil overburden, horizontal earth pressure, and hydrostatic pressure are applied to the exterior walls. Load designations are referenced from LRED Section 3.3.2 (see Figure 3). | Ls AG wr ah / a [ee Ay ia A Abb HEA A a ENS 2 EAT T BEM Gi ens En Figure 3 Loads Applied to Structure ca3.1 Total Dead Loads Dead loads are represented by the weight of all components of the tunnel structure and the vertical earth pressure due to the dead load of earth fill. Conerete dead load (per foot length) (DC) Top slab = 0.15 ksf x (76.5 2.5) = 28.69 kip Bottom slab = 0.15 ksf x (76.51.75) = 20.08 kip Interior wall = 0.15 ksf x (1 20) 3.00 kip Exterior walls (2) = 0.15 ksf x 2% (2% 20) = 12.00 kip Vertical earth pressure (EV) EV= 1.30 ksf Soil wt= 1.30 ksf 76.50 99.45 kip 3.2 Live Load Live load represents wheel loading from an HS-20 design vehicle. It is assumed that the wheels act as, point loads at the surface and are distributed downward in both directions through the soil to the top slab of the tunnel. The load distribution is referenced from LRFD Section 3.6.1.2.6. Figure 4 shows the distribution of the wheel loads to the top slab, 4kips 16 kips 16 kips Wheel Loads for HS-20 Figure 4 Live Load Distribution 4k ui -oyre 0.04 ksf —_($3.6.1.2.6) 16k =o>= 0.16 ksf controls @,y osLi LS~ Sureh, Ht= 016 x 7650 = 12.240 kip Max(qwiqws) = 1231 % 3.3 Lateral Earth Pressure EH,, EH,, EH, EH, Lateral earth pressure is typically represented by the equation: © = kyyn The following lateral pressures are applied to the exterior walls of the tunnel (see Figure 5): EH, =LL surcharge EH, = Lateral earth pressure due to soil overburden, EH, = Horizontal earth pressure EH, = Hydrostatic pressure 34.25 24,25 4 \ EF EMI ER EH2~ EHS Figure $ Lateral Earth Pressure Distribution EHS csCalculate the lateral earth pressures: EH, = ko(Ys*Murch) 0.080 ksf EH) = Ky(15%M, + Youn) = 0.494 ksf n= 5.00f Nag 5.00 f EH3= Koy, + You™Maa) = 1.314 ksf n= 5.00f Ng = 29.25 ft Ea = ku(¥u%tty) = 1.825 ksf_ y= 29.25 ft 3.4 Buoyancy Load WA Area of water displaced, A A=BXH= 1855125 sq. ft Buoyancy =A yy= 115.76 kif (along tunnel) OK WA = Buoyancy 1513 kif B o73.5 Load Factors and Combinations Loads are applied to a model using AASHTO LRED load combinations, referenced from LRED Table 3.4.1-1. The loads, factors, and combinations for the applicable design limit states are given in Table 1 ‘Table 1: Load Factors and Load Combinations Vertical pressue from dead load of earth fill Dead load of structural components and nonstructural attachments LS - Live load surcharge EH - Horizontal earth pressure load WA - Water load and stream pressure LOAD FACTORS Load Combination Limit State Strength 1 Strength 3 Service 1 Service 4 cs4. Analysis Model Input 4.1 Joint Coordinates ‘The cross section of the tunnel model lies in the X-Z global plane. Each joint is assigned X and Z coordinates to locate its position in the model, See Section 5.0 and Figure 6 for a diagram of the model. 4.2 Member Definition Members are defined by 2 beginning joint and an end joint, J, and J,, respectively, where i and j represent joint numbers. All members are composed of concrete and represent a one foot wide "slice" of the tunnel section. ca5. Analy: Model Diagram ‘The computer model represents a one foot wide slice of the cross-section of the tunnel, Members are sd by series of joints at their endpoints to form a frame, and are located along the centroids of the walls and roof and floor slabs. Joints in the 100 series and 200 series represent the floor and roof slabs respectively. Joints in the 300 and 500 series repre represents the interior wall, The bottom diagram of Figure 5 shows all joints in the structure, while the top diagram shows only the joints at the intersections of slabs and walls. int the exterior walls, while the 400 series Figure 6 Centroid of the Frame and Joint Joints 302, 402, and 502 at the base of the exterior walls and joints 305, 405, and 505 at the top of the exterior walls are included to determine shear at the face of the top and bottom slabs.6. Application of Lateral Loads (EH) Lateral pressures EH, through EH, from Section 3.3 are applied to the members of the model as shown below. See Figure 7 for the horizontal earth pressure and hydrostatic pressure load distributions, 6.1 Exterior Wall Loads Due to Horizontal Earth Pressure EH Calculate pressure at top of wall: 3 4 tata 0.s{ BH 5. 6 5+ 2t* sj. 0.494 ksf (1000? * Too °) Pressure at base of wall = 1314 ksf (see calculation in Sec. 3.3) Calculate interval increment for loading all exterior wall members: _ G31 = 0.49) _ 5 The two tables below show the lateral earth pressure values (ksf) at the beginning and end of each member of the exterior walls: A 0.164 ksf ‘Member J[_start end Member] start end) 301 131 11s 301 “131-115 302 115 0.99 502 “11S -0.99 303 0.99 0.82 503 0.99 -0.82 304 0.82 0.66 504 082 -0.66 305 0.66 0.49 505 -0.66 _-0.496.2 Exterior Wall Loads Due to Hydrostatic Pressure EH, Calculate pressure at top of wall: oa YwXDy) = 1] ————- 5 0.312 ksf yore) 1[ 24.5) Pressure at base of wall = 1.825 ksf (see cales. in See. 3.3) Calculate interval increment for loading all exterior wall members: (83-03), $ 0.303 ksf The two tables below show the lateral hydrostatic pressure values (ksf) at the beginning and end of each member of the exterior walls: Member _]__ start end [Member] start end) 301] 1.83 1.52] 501 “183 -1.52| 302) 1.52 1.22] 502 “152 -1.22| 303) 1.22 0.92 503} 122-092] 3004) 0.92 0.61 504] 092 0.61 305] 0.61 031 505 061-031 Figure 7 shows the load distribution along the exterior walls (members 301 to 305 and S01 to 505) for horizontal earth pressure (EH) and hydrostatic pressure (EH) 304, 305 308” 505 303 302 302 301 Members Figure 7 Load Distribution for EH, and EH,7. Structural Design Calculations - General Informat 7.1 Concrete Design Properties Modulus of elasticity of steel, Ey 29000 ksi Yield strength of steel reinforcement, f, = 60 ksi Compressive strength of conerete, f, = 4 ksi 7.2 Resistance Factors Resistance factors for the strength limit state using conventional conerete construction are referenced from AASHTO LRED Section 5.5.4.2. Flexure = 0.90 (@) varies from 0.75 to 0.9 (0.75 is conserverative) Shear © = 0.90 Compression © = 0.7 since no spirals or ties 8. Interior Wall Design 8.1 Factored Axial Resistance ($5.7.4.4) For members with tie reinforcement using LRFD eq, (5.7.4.4-3): P, = 0.80 [0.85%f,x(A, - Ay) + f*Aq] Where: Ago 1.76 in’ (#6 at 6", ea. face) Aye 144,00. in’ Where A,= 12-12 in? (assuming wall thickness = 1 foot) P= 471.37 kip Factored axial resistance of reinforced concrete using LRFD eq, (5.7.4.4-1): P,= OP, ©=09 for flexure Where: tored axial resistance jominal axial resistance P,= factored applied axial force P= 424.24 kip Check Py 1 My = moment on compression member due to factored gravity loads that result in no appreciable sidesway calculated by conventional first-order elastic frame analysis; always positive (kip-ft) Mn 179.92 kip-ft M.= 179.92 kip-ftjored flexural resistance (LRFD $,7.3.2.1 The factored resistance M, shall be taken as: M,=M, Where: © = resistance factor = 0.9 M,= nominal resistance (kip-in) The nominal flexural resistance may be taken as (5 2)_a My =Ayfy (2.-$)-a.4,{ 2) (LRED eq. 5.7.3.2.2-1) Do not consider compression steel for calculating M, Where: A,~ area of nonprestressed tension reinforcement (in’) £,= specified yield strength of reinforcing bars (ksi) 4, = distance from extreme compression fiber to centroid of nonprestre a= depth of equivalent stress block (in) = B * ¢ Where: B, = stress block factor specified in Section 5.7.2.2 of LRFD ¢= distance from the extreme compression fiber to the neutral axis (af) sed tensile reinforcement (in“) LRED eq, (5.7.3.1.2+4) O85-P_B, Where: AS 2.0 in? S= 60.0 ksi f= 40st B, 0.85 b 12.0 in 346 in 2.94 in M,= 3153.53 kip-in = 262.79 kip-ft om, 236.51 kip-& OK ( Mc) M= 236.51 kip = M, >MyCreate interaction diagram ASSUME Prin 1.0% Asnin = 3.6 in” Aspro (total) 4,00 in? choose #9 at 6" E,= 29000 ksi Bi 0.85 Y= 15 in 0.85 « f= 34 ksi Ay in? = 360 in? A=A 2.0 in? Atzero moment point using LRFD eq, (5.7.4.5-2) o=07 P,= 0.85 xf. x(Ap- Ag+ Ag Xf,= 1450 kip op, 1015 kip At balance point calculate P,, and M, y= 16.65 in ay= BiXe= 1415 in 70,003 ) 1 f, | ) (c-4)} = 70 ksi Te Ps> fy; set fs=fy Aeomp= © %D 199.8 in? y= a/2= 7.07625 in OP, = O [0.85 xf xbx a+ AXf-AxG]= 485 kip M,= 7442 kip-in- —620_—kip-ft Ah = 29 in (oss Pb) M,= 2838.2 kip-in = 237 kip-ftAtintermediate points ain | c=aby tuksi | tks | sks | OM, ka | OP ips aT 0 29 34 | aan | 36 | 657 | 60 292 30 3 35 36 38 | 635 | 60 298 36 4 47 48 so | 476 | 60 355 90 5 59 60 sr | 381 | 60 aor | 133 6 11 2 o | 317 | 60 435 | 167 7 82 84 66 | 22 | 60 461 195 8 94 96 69 | 238 | 60 asa | 224 10 ns | 120 2 | 190 | 60 sa. | 281 12 iat | 144 5 159 | 60 sas | 338 15 116 | 180 nm | 17 | 60 561 | 424 18 212 | 216 7% | 106 | 60 sas | 509 19 24 | 28 | 79 | 100 | 60 337 | 538 21 2a7 | 252 80 a1 | 60 507 | 595 23 ani | 276 81 3 | 60 465 | 652 25 204 | 300 81 76 | 60 410 | 709 0 1015 End i} 77 28 End2| 255 28 Note © may decrease from 0.90 to 0.75 as a increases from 0.0 to ab. Use 0.75 to be conservative. Where: A 12 @P,= © (Aconp Ad) 2085 XE, + AL «AGL, kips c-20Pr= Pn Interaction Diageam 1200 1000 800 600 400 200 ° 200 300 Mr= Mn 400 500 600 c2t9.2 Shear Design ($5.8.3.3) ‘The nominal shear resistance, V,, shall be determined as the lesser of LRFD eq, 5.8.3.3-1 LRFD eq. 5.8.3.3-2: Vi=Ve+Vy or V, = 0.25 x f, xb, ¥ dy Note V, is not considered Where: . v = [oor sede X 8. ya, <0.126- yb . . eta Mp Pde LRED eg, (5.14.5.3+1) Where For slab concrete shear (V,), refer to LRFD Section 5.14.5 A,f,d,(cot0 + cota): sina ——_____ LRFD eq. (5.8.3.3-4) 5 Where for a= 90° and 6 = 45° Where: A,= area of reinforcing steel in the design width (in*) b= design width (in) 4, effective depth from extreme compression fiber to centroid of tensile force in tensile reinforcement ( d= 2775 V,= shear from factored loads (kip) M,= moment from factored loads (kip-in) ‘A,= area of shear reinforcement within a distance s (in’) 0 = spacing of stirrups (in) = 12 in effective web width taken as the minimum web width within the depth d, (in) tive shear depth taken as the perpendicular distance to the neutral axis (in) 4,= 0.9 dor0.72%*h — (LRED section 5.8.2.9) d= 24.98 in a = 1233 Use c-22Maximum shear and associated moment from analysis output: Vu= 28 kip M,= 63.0. kip-ft V.= 63.42 kip value controls, orV.= 83.92 kip V.= 0.00 kip Vp= 63.42 kip V,= 299.70 kip therefore V, = 63.42 kip = 0.90 OV,= $7.08 kip >Vu0K c-2310. Bottom Slab Design 10.1 Slenderness Check (S5.7.4.3) K> 0.65 B= 0.85 lu= 37.25 f= 447 in = 18.75 in d= LR = 21.0 in a= 3.25 in 9261 in’ #8 bardia,= 1,00 in r= 6.06 in kx(/o= 47.93 From analysis output where My = 13 kip-t P= 23.6 kip M;= 57.1 kip-A P= 23.6 kip 34 -n(B) = 3127 Consider slendemess since * (I,/r) is greater than 34 -»{%4) Calculate EI: 3834.25 ksi I, 9261 int c= 8 in EI= 3427836.25 kip-in’ I= 202.34 in EI= 6855672.51 kip-in’ Myy= 61.20 kip-ft M 57.10 kip-ft Note: Myo does not include effects of vertical live load surcharge 1.07 Section Dimensions c-24Approximate Method (LRFD 4.5.3.2.2) pe #-# «kk -1,)? P.= 801.51 kip Moment Magnification (The components for sidesway will be neglected. Bracing moment will not include lateral force influence. Live load surcharge is excluded also.) Cam 06 + o4( Me) = 069 (M2 Py 23.6 kip Ba 1.00 M.= 8, < Moy + 8, Ma, 61.20 kip-ft Muar=-32.88 kip-ft M.= 2832 kip-tt where May = 28.32 kip-ft Factored flexural resistance Do not consider compression steel for calculating M, c= 2.73 in a= 232 in M,= 1667.36 kip-in = 138.95 kip-ft M,= ®M,= 125.05 kip-ft_ OK (@ Me) MeM, -25Create interaction diagram Assume Pyun= 1.0% Asnin = 2.52 in? Agroy (total) 3.16 in? choose #8 at 6" E,= 29000 ksi Bi- 08s Y= 10Sin 0.85 « f= 34 ksi Ay in? = 252 in? A= A= Atzero moment point Py 1036 kip oP, 725 kip Atbalance point calculate P,, and M, = 1125 in a= 9.56 in f 62 ksi fs> fy; set Ps = fy emp 114.75 in? y= 4.78125 in oP, 271 kip M,= 3303 kipsin = 275 kip- oint (conservatively ignore compressive reinforeiny an 2.3 im M,= 1500.6 kip-in = 125 kip-f At zero ‘axial loat c-26At intermediate points ain | c=ar) | Avan in’| fast | tsi | sisi | om, icn | OP ‘nr kips 125 0 23 27 276 36 552 | 60 lis 2 3 35 36 48 423 60 139 6B 4 47 48 58 317 | 60 162 107 5 59 60 64 254 | 60 178 139 6 1 n 68 212 | 60 190 168 7 82 84 70 181 60 200 196 8 94 96 R 159 | 60 207 25 9 106 108 "4 141 60 212 253 10 ns 120 5 127 | 60 215 282 WL 129 132 16 us | 60 215 310 12 141 144 1 106 | 60 213 339 1B 153 156 78 98 60 208 368 14 165 168 9 a 60 201 396 15 176 180 9 85 60 192 425 16 18.8 192 80 9 60 180 453 0 2s Endif 13 24 End2| 57 24 Note © may decrease from 0.90 to 0.75 as a increases from 0.0 to ab. Use 0.75 to be conservative, 27Pr= @Pn Interaction Diagram 50 100 150 200 250 c-2810.2 Shear Design (5.8.3.3) Va= Vet Ve V,= 0.25 xf. xb, x dy d= 16.88 in For slab concrete shear (V,), see LRED Section 5.14.5 12.00 Maximum shear and associated moment from analysis output: Vom Ve orV= Whei vr Va vi ov, 19.4 kip 44.96 kip 56.10 kip AY 0.00 kip 44.96 kip 202.50 kip 40.46 kip = 100 M,= 30.3 kip-ft value controls in? and s= 12 in therefore V, = 44.96 kip > Vu OK c-2911. Exterior Wall Design 11.1 Slenderness Check (LRFD 5.7.4.3) K> 0.65 B= 0.85 lu= 22.13 ft = 265.5 in = 21.75 in d= 2008 = 24.0 in a= 3.25 in 13824 in! #8 bar dia. = 1.00 in r= 6.93 in kx 24.91 From analysis output where M,= 171.4 kip-ft P= 34.4 kip M;= 137.2 kip-ft P= 34.4 kip aw -n(¥) = 1901 (My / Consider sendemess since * (./*) is greater than 34 ~ 12 Mu | Calculate El: E,= 3834.25 ksi I,= 13824 int c= 9.5 in EI= 7330894.82 kip-in’ I= 285.29 in! EI= 14661789.6 kip-in” Myo = 61.20 kip-ft M,= 137.20 kip-ft Note: Mg, does not include effects of vertical live load surcharge = 0.45 Inside Face Figure 9 Section Dimensions c-30Approximate Method (LRFD 4.5.3.2.2) x? - EL (k + 1,)? P.= 4858.82 kip Moment Magnification (The components for sidesway will be neglected. Bracing moment will not include lateral force influence. Live load surcharge is excluded also.) / Ca= 06 + 04{ Me = 1.10 \Ma P= 34.4 kip &= Ll IM, = 8) X Myy + 3-Ma, M,= Muar = M.= 38.46 kip-ft where Moy ~ Factored flexural resistance Do not consider compression stee! for calculating M, c= 2.73 in a= 232 in M,= 1951.76 kip-in = 162.65 kip-ft M,= ®M,= 146.38 kip-fi OK @ Me) ost 61.20 kip-t -26.50 kip-ft 34.70 kip-ft M>M,Create interaction diagram Assume Pyun= 1.0% Asnin = 2.88 in? Agroy (total) 3.16 in? choose #8 at 6" E,= 29000 ksi Bi 0.85 Y= 12 in 0.85 « f= 34 ksi Ay in? = 288 in? A= A= Atzero moment point Py 1158 kip oP, 811 kip Atbalance point calculate P,, and M, = 13.05 in a= 11,09 in fr 65 ksi fs > fy; set Ps = fy Meonp™ 133.11 in? y= 5.54625 in oP, 313 kip OM,= 4176 kip-in = 348 kip- oint (conservatively ignore compressive reinforeiny an 2.3 im M,= 1756.6 kip-in = 146 kip- At zero ‘axial loat c-32intermediate point ain by eyksi | tksi | gp ksi | omen | OP ips 146 0 23 27 | 26 | 36 | o2 | 60 179 24 3 35 36 4s | 449 | 60 au 63 4 47 48 ss | 31s | 60 zas— | 107 5 59 60 64 | 235 | 60 273 | 139 6 1 2 68 1st | 60 293 | 168 7 82 84 7 | 143 | 60 310 | 196 8 94 96 n | us | 60 324 | 225 9 106 | 108 “4 92 | 60 335 | 253 10 us | 120 5 m | 60 343 | 282 u no | 132 16 so | 60 343 | 310 13 153 | 156 8 37 | 60 saa | 368 15 176 | 180 9 20 | 60 336 | 42s 17 200 | 204 80 3 | 60 312 | 482 19 24 | 228 81 2 | 60 276 | 539 21 247 | 252 sl -10 | 60 227 | 596 0 ail Top of wall 17 34 Bot. of wall 137 34 Note © may decrease from 0.90 to 0.75 as a inereases from 0.010 ab. Use 0.75 to be conservative, c-33Pr= Pn 900 800 700 600 500 400 300 200 100 Interaction Diagram % = - a . a 150 200 250 300 350 Mr= Mn o-s411.2 Shear Design (S5.8.3.3) ‘Maximum shear from analysis output: Ve= 20.76 kip Whe B= 2 b 2 in = 19.58 in V, = 0.0316 x Bx £05 xb, xd, LRED eq. (5.8.3.3-3) V.= 29.69 kip A= 0 in? and s= 12 in 0.00 kip Vp= 29.69 kip V,= 234.90 kip therefore V, 29.69 kip OV,= 26.72 kip > Vu OK c-36