PROJECT SEMESTER REPORT

(Project Semester June-December 2019)

Business Development & Detailed Design of Bogie Repair Shed, New

Bongaigaon, Assam.

Submitted by

(Deepak Kumar)
101782007

Under the Guidance of:

Dr. Tanuj Chopra Dr. Prem Pal Bansal Mr. Vinay Panday
Associate Professor Associate Professor & Head Manager /WS
Civil Department Civil Department RITES
T.I.E.T (Patiala) T.I.E.T (Patiala)

DEPARTMENT OF CIVIL ENGINEERING

Thapar Institute of Engineering and Technology, Patiala
(Deemed to-be-University u/s 3 of the UGC Act, 1956)
 DECLARATION

I hereby declare that the project work entitled Refurbishing of LHB Coaches at Carriage & Wagon
Workshop, North East Frontier Railway (NFR), New Bongaigaon, Assam is an authentic record
of my own work carried out at RITES Ltd. Gurugram as requirements of six months project
semester for the award of degree of B.E (Civil Engineering), Thapar Institute of Engineering and
technology, Patiala, under the guidance of Mr. Vinay Panday (Manager/WS) and Dr. Tanuj Chopra
(Associate Professor), during 10 July to 10 December, 2019.

DEEPAK KUMAR
101782007
Date: 10-12-2019

Certified that the above statement made by the student is correct to the best of our knowledge and
belief

Dr. Tanuj Chopra Mr. Vinay Panday

Associate Professor Manager /WS
Civil Department RITES
T.I.E.T (Patiala)

Faculty Coordinator Industry Coordinator

 ACKNOWLEDMENT
An Endeavour over a period can be successful only with the advice and support of well wishes. I
take this opportunity to express my gratitude and appreciation to all those who encouraged me to
do this project.

I am deeply indebted to Dr. Tanuj Chopra (Internal Mentor) Thapar Institute of Engineering and
Technology, Patiala for providing me this opportunity to carry out the SIX months Industrial
training at RITES LTD, GURGAON.

I would like to express a deep sense of gratitude profusely to Mr. Rajiv Mahajan (I.R.S.M.E).

I would also like to express a deep sense of gratitude profusely to Mr. N.C. Srivastava (G.M/WS).

I express my profound and sincere thanks to Mr. Vinay Panday (Manager/WS), Mr. Mohit
Garg (AM/WS) who acting as a mariner’s compass and steered me in my project voyage with his
excellent guidance and constant inspiration.

I also extend thanks to all the faculty members of Thapar Institute of Engineering and Technology,
Patiala for their external support and guidance.

I would also like to express my gratitude to the Librarian, RITES Ltd, for providing helpful study
material.
 ABSTRACT
During my training period I have learned various Civil Engineering activities which will help me
in my whole career. There I had the opportunity to work with brilliant minds. The Training helped
me in understanding the practical implementation of various theories which I studied in my
classroom sessions & also how proceeds with any project as a whole from the award of the Tender
to the execution of project. My training covers the design of the Industrial shed with EOT cranes
& Foundation Including the work of the Tendering along with Estimation.

For instance, for the design of the Industrial shed involved not only Civil engineering knowledge
also the some basic of the EOT cranes. This design also involved the design of Purlin, Connections,
Base Plate & Pile cap used for foundation. All the formulae and methods that we had studied in
our classes are being employed here for the analysis.

The design of Industrial shed involves very deep understanding of the STAAD & some of the
relevant codes like IS: 800-2007, IS: 801, IS: 875 (part 1-3), IS: 456-2000, IS: 6403-1981, IS:
2911-2010 & some material standards IS: 2062. The design of the foundation with SBC for
isolated, raft footing & pile foundation is also involved in the project the practical aspect of the
training was the most important part for me.
 TABLE OF CONTENTS
CHAPTER-1 INTRODUCTION………………………………..………………………. 1-10

1.1 About Company ...………………………………………………………….………….... 1

1.2 RITES Organization Structure …………………………………………………..……... 2
1.3 Workshop SBU (Erstwhile R.W/I.E SBU)………………………………..……………. 3
1.4 Steps involved in any project in RITES …………………….………………..……….... 4
1.5 Introduction to the Project ………………………………………………………..….….. 5
1.6 Location and Overview of Site …………………………………………………….….... 6
1.7 Proposed Workshops Summary ……………………………………………….………. 6-8
1.8 Topographical survey for the Project………………………………………….…….… 9-10
1.8.1 Scope of Work…………………………………………………………….………. 9
1.8.2 Approach and Methodology……………………………………………….……... 10

CHAPTER-2 TENDERING …………………..……….……………………………….. 11-31

2.1 Methodology………………………………………………………………………….. 11
2.2 Introduction of E-Tendering In RITES……………………………………………….. 11
2.3 Preparation of Bid Document………………………………………………………… 12
2.4 Contents Of Tender Documents……………………………………………………… 12
2.5 Preparation of Estimates For Works.……………………………………………….. 12-15
2.5.1 The Detailed Estimate Components……………………………………….…….. 13
2.5.2 Procedure for preparation detailed estimates……………………………….…….14
2.5.3 Technical check of detailed estimates…………………………………………….15
2.5.4 Preparation of estimates planning & consultancy…………………...……………15
2.6 Contracts And Forms……………………………………………….………………….16
2.6.1 Contract documents…………………………………………………………………16
2.7 Publicity of Tenders……………………………………………………………….... 16-20
2.7.1 Time Limit For Publicity Of Tenders…………………………………………….. 17
2.7.2 Re-Invitation Of Tenders / Extension Of Period…………………………………. 17
2.7.3 Specimen Press Notice For Publication In News Paper………………………….. 17
2.8 Uploading Of Bid Document………………………………………………………… 18
2.8.1 Cost Of Tender Document………………………………………………………...19
2.9 Earnest Money Deposit (EMD)………………………………………………………. 19
2.10 Pre-Qualification Of Tenderers – Joint Ventures…………………………………….. 19
2.11 One Packet And Two Packet Systems………………………………………………... 19
2.12 Evaluation of Tenders………………………………………………………………. 20-22
2.12.1Preparation And Scrutiny Of Briefing Note On Technical Bid…………...………. 20
2.12.2 Evaluation Of Technical Bids By Tender Committee………………………….. 21-22
2.13 Opening Of Financial Bids …………………………………………………………… 22
2.14 Preparation And Scrutiny Of Briefing Note ………………………………...……… 22-23
2.15 Performance Guarantee ……………………………………………………….……… 23
2.16 Tender Of Project Sambalpur, Orissa.………………………………………………. 24-25
2.16.1 List of Documents…………………………………………………………...…. 24-25
2.17 Qualifying Criteria For Works Contracts……………………………………………. 26-28
2.18 Notice Inviting Tender……………………………………………………………….. 28
2.19 Table Of Milestone(S)…………………………………………………………….…. 29-31

CHAPTER-3 ESTIMATION OF PROJECT……………………………………….……. 32

3.1 Estimation of Project……………………………………………..……….………….... 32

CHAPTER-4 GEO-TECHNICAL INVESTIGATION…………………………...……. 33-44

4.1 Scope of Work……………………………………………………………..………..…. 33
4.2 Field Investigation Observations & Sampling………………………………..……... 33-34
4.3 Test Procedures For Field Test…………………………………………………….….. 34
4.4 Sub Soil Stratification…………………………………………………………...…... 35-37
4.5 Sample Calculation For General Shear Failure……………………………..…….… 38-39
4.6 Safe Bearing Capacity Calculation For Raft……………………..……………............ 40
4.7 Ultimate Bearing Capacity Of Pile Based On SPT N Value…………………....…….. 41
4.8 Recommendations & Conclusions…………………………………………..…….….. 42
4.9 Summary of Safe Bearing Capacity……………………………………………........ 42-43
4.10 Summary Of Safe Bearing Capacity Of Pile Foundation……………………………. 44
CHAPTER-5 INTRODUCTION OF THE PEB…………………...…….………......... 45-56
5.1 The Merits Of Pre-Engineered Buildings…………………………………….….…… 45-46
5.2 Basic Terms Used In The PEB Structure………………….……………………….… 46-52
5.3 Standard Structural Systems…………………………………………………….…..... 53-54
5.3.1 Some Of The Structural Systems………………………………………….……. 53-54
5.4 Secondary Structural Framing…………………………………………….………..…. 54-56
5.5 Catwalks & Walkways………………………………………………………….….....… 56
CHAPTER-6 DESIGN OF BOGIE REPAIR SHED……………………………......... 57-104
6.1 Building Description…………………………………….……………………….…... 57
6.2 Design Loads………………………………………….………………………….….. 58
6.3 Design Codes………………………………………….……………………….…….. 58
6.4 Design Assumptions…………………………………….…………………………. 59-60
6.5 Deflection Limitation…………………………………….…………………….……. 61
6.6 Load Combinations……………………………………….…………………….…… 62
6.7 STAAD Modeling of Frame……………………………….……………………….. 63
6.8 Properties of the members………………………………….…………………..… 64-65
6.8.1 Material Specification of members…………………………………………...…. 65
6.9 Support condition of the Structure………………………….…………………...…. 66
6.10 Loading on the structure…………………………………….……………………. 67-69
6.10.1 Calculation of load…………………………………………………………… 67-68
6.11 Design Methodology of the Base Plate …………………….……………………. 70-73
6.11.1 General design procedure……………………………………………………. 71-72
6.12 Design of Base Plate & Anchor Bolt……………………….…………………..... 74-83
6.13 Design Methodology of Connection Plate………………….……………………. 84-85
6.13.1 General design procedure of the connection plate…………………………… 84-85
6.14 Design of the connection plate frame IS: 800-2007………….…………………... 86-87
6.15 Design Methodology of the Purlin…………………………….…………………. 88-89
6.15.1 General design procedure of the Purlin………………………………………. 88-89
6.16 Design of the Purlin in the BRS Shed………………………….………………… 90-99
6.17 Design Methodology of the Crane beam……………………….….…………… 100-101
6.18 Design of Gantry Girder in STAAD…………………………….……………… 101-102
6.18.1 Modeling of the Crane Beam in STAAD…………….………………………….. 101
6.18.2 Load combination………………………………………………………………... 102
6.18.3 Properties of the members……………………………………………………….. 102
6.18.4 Loading on the crane Beam……………………………………………………… 102
6.19 Column reactions from the STAAD for foundation design…….………………. 103-104
CHAPTER-7 DESIGN OF THE PILE CAP FOR FOUNDATION……………..... 105-108
7.1 Material Specification……………………………………………………………….. 105
7.1.1 Construction materials and durability considerations…………………………. 105
7.2 Design of Pile Cap……………………………………...…………………………. 105-108
CHAPTER-8 INSPECTION OF RAW MATERIAL……………………….…........... 109
8.1 Suggestive QAP details ……………………………………………………………… 109
LIST OF ATTACHED APPENDIX
1. Appendix-1 (Survey Sheet)
2. Appendix-2 (Estimation of Sarla Project)
3. Appendix-3 (G.A Drawings of Super-Structure)
4. Appendix-4 (G.A Drawings of Foundation)
5. Appendix-5 (Q.A.P)
List of the Figures
1.1 General Arrangement Drawing………………………………………………………....... 5
1.2 Master plan……………………………………………………………………………...... 6
1.3 Artistic Expression of Proposed Buildings……………………………………………….. 8
4.1 Location Plan of bore holes…………………………………………………………........ 33
4.2 Grain size distribution……………………………………………………………………. 37
4.3 Lab test result…………………………………………………………………………….. 37
5.1 Anchor bolts……………………………………………………………………………… 46
5.2 Base plate & base angle ………………………………………………………………..... 46
5.3 Bay spacing……………………………………………………………………………….. 47
5.4 Bracket……………………………………………………………………………………. 47
5.5 Building width……………………………………………………………………………. 47
5.6 Clear span……………………………………………………………………………...…. 47
5.7 End wall…………………………………………………………………………………... 49
5.8 Fixed base…………………………………………………………………………...……. 49
5.9 Grit………………………………………………………………………………………... 49
5.10 Multi-gable building………………………………………………………….…………. 50
5.11 Pitch (Roof) ………………………………………………………………….………… 50
5.12 Portal frame………………………………………………………………..……………. 50
5.13 Purlins……………………………………………………………………………...……. 51
5.14 Rafters………………………………………………………………………………...…. 51
5.15 Wheel base………………………………………………………………………………. 51
5.16 “Z”-section…………………………………………………………………………....…. 52
5.17 General Pre-engineered building…………………………………………………...….... 52
5.18 Multi-Gable building (used in our project) …………………………………………...... 53
5.19 Sub-Structure……………………………………………………………………….…... 54
5.20 Portal bracing ………………………………………………………………………...... 55
5.21 Cross-bracing……………………………………………………………………………. 55
6.1 Proposed Bogie Repair Shop Sectional View………………………………………………60
6.2 Geometric Model of the Structure……………………………………………………......…63
6.3 Properties of the Frame…………………………………………………………………..... 64
6.4 Properties of bracing……………………………………………………………………..... 65
6.5 Supports at columns……………………………………………………………………..… 66
6.6 Support condition………………………………………………………………………..… 66
6.7 Loads on the structure……………………………………………………………………... 69
6.8 3-D view of base plate at foundation …………………………………………………….. 70
6.9 Detail of the anchor bolts………………………………………………………………….. 70
6.10 Forces acted on the base plate……………………………………………………………. 71
6.11 General Base plate details………………………………………………………………... 73
6.12 Gusset Plate………………………………………………………………………….….... 84
6.13 General detail drawing of the connection ……………………………………………..… 87
6.14 Purlins…………………………………………………………………………………..... 88
6.15 Stepped Column……………...………………………………………………………...... 100
6.16 Crane beam………………………………………………………………………………. 101
6.17 Properties of Member……………………………………………………………...…….. 102
6.18 Loading on the crane beam ……………………………………....................................... 102
6.19 Reaction node Position………………………………………………………………....… 103
List of the Tables
2.1 Milestone schedule……………………………………………………………………… 29-31
6.1 Building Description……………………………………………………………………… 57
6.2 Design Loads……………………………………………………………………………... 58
6.3 Properties of Frame members…………………………………………………………….. 64
6.4 Material Specification…………………………………………………………………….. 65
6.5 Crane Loads……………………………………………………………………………… 101
6.6 Properties of Crane members……………………………………………………………. 102
6.7 Reaction node Position…………..…………………………………………………… 103-104
 CHAPTER-1
INTRODUCTION

1.1 ABOUT COMPANY

REGISTERED OFFICE CORPORATE OFFICE

SCOPE MINAR, Core-1 RITES BHAWAN
LAXMI NAGAR, NO.1, SECTOR-29
DELHI-110092 GURGAON-122001

RAIL INDIA TECHNICAL AND ECONOMIC SERVICES (RITES)

RITES Limited (राइट्सलिलिटे ड)is an engineering consultancy company, specializing in the field

of transport infrastructure, Established in 1974 by the Government of India. The company's initial
charter was to provide consultancy services in rail transport management to operators in India and
abroad. In overseas projects, RITES actively Pursues and develops cooperation with local
consultants/firms both as a mean of maximum utilization of local expertise and as an effective
instrument of transfer technology. RITES, is internationally recognized as a leading consultant
with operational experience of 36 countries in Africa, Asia, Middle East and Central America. It
has executed projects in over 62 countries on every major continent. As of 2011, it was executing
projects in over 30 countries. RITES have since diversified into planning and consulting services
for other infrastructure, including airports, ports, highways and urban planning. It has been
awarded the status of MINIRATNA in 2002.

RITES, has been handling Project Management Consultancy assignments for the past few decades.
While some of the Clients, particularly Government Departments and Public Sector Undertaking,
insist upon RITES a[1] dopting the Tender Document and Contract Management procedures of

1
specific organizations such as that of Railways, CPWD, State PWD, MES, World Bank etc. yet
there are also cases of clients leaving it to RITES to decide on the documentation and procedures.
Some organizations such as Indian Railway, CPWD, MES, World Bank etc, have also printed their
Standard Tender Documents and Manual for the guidance of the officer and field Engineers and
these are followed in execution of works in their organization.

1.2 RITES ORGANIZATION STRUCTURE

2
 1.3 WORKSHOP SBU (ERSTWHILE R.W/I.E SBU)

Workshop division of RITES provides turn-key and expert consultancy from concept to
commissioning in the field of setting of Production & Maintenance with qualified technical
personnel having extensive experience in various aspects of Manufacturing technology. RITES
Provides: -

➢ Techno-Economic Feasibility Studies

➢ Detailed Project Report
➢ Tendering Services & Contract Management
➢ Design of Workshops
➢ Modernization / Augmentation Projects
➢ Productivity & Repair environment Improvement
➢ Undertake Turnkey Project of modernization and expansion of existing workshop /
production units
➢ Incentive Scheme and Motivational Package.

Ropeways division of RITES provides turn-key and expert consultancy from concept to
commissioning in the field of setting of ropeways with qualified technical personnel having
extensive experience in various aspects of ropeways systems. RITES, is a member of O.I.T.A.F.,
an internationally recognized organization for ropeway systems and also a committee member of
bureau of Bureau of Indian Standard for ropeway systems. RITES Provides-

➢ Techno-economic feasibility studies.

➢ Detailed project reports including design and engineering.
➢ Tender evaluation and Finalization.
➢ Quality Assurance.
➢ Testing & Commissioning.
➢ Bid Process Management

3
 1.4 STEPS INVOLVED IN ANY PROJECT IN RITES

Business Development

1. Preparation of offer
2. Preparation of Input estimate
3. Submission to Client
4. Comparison of LOA with Offer
5. Preparation of Input estimate
6. Vetting from Finance

Preparation of Feasibility Report/DPR

1. Collection of site details/Data
2. Detailed Survey
3. GEOTECH
4. Detailed Design
5. Costing & Estimation
6. Analysis /FIRR
7. Requirements of Clearances
Tendering Procedure/Bid process management
1. Preparation of tender as per RITES Guidelines
2. Preparation of BOQ
3. Preparation of Technical specifications
4. Technical sanction from Competent Authority
5. NIT Publication and Inviting tenders
6. Tender Evaluation
7. Tender Finalization
8. Approval of Competent authority
9. Issuance of Letter of award to technically qualified & L-1 Bidder
Project Execution
1. Collecting BGs and Insurances from Contractor
2. Preparation of Detailed work Programme / bar Chart
3. Approval of QAP
4. Drawings & design approval
5. Material inspection
6. Verification of Contractor's bills and payment
7. Supervision and Problems solving
8. Quality Control
9. Final bill finalization of Contractor
Billing and Fee Realization
1) Raising of RITES Fee bills as per Milestones agreed

4
 1.5 INTRODUCTION TO PROJECT

1. Name of Work: Setting up of Facilities for refurbishing of LHB coaches at C&W

Workshop, NF Railway, New Bongaigaon.

2. Date of signing of MoU: 30.01.2018

3. Contract Value: Rs.106.32 Crores (including RITES fee)

4. RITES fee: @8.5% + Taxes on cost of Work.

5. Date of LOA to Executing Agency: 01.11.2018.

6. Executing Agency: M/s ISGEC Heavy Engineering, Noida.

7. Awarded Value: Rs. 92.87 crores. In which

• Civil: 61.58 crores.

• Mech.: 25.46 crores.
• Electrical: 5.83 crores

8. Completion Period: Targeted completion: 31.05.2020

9. Main Features – Construction of 2 PEB sheds (120X33 m) with coach over coach concept,
one shed (120X33) for ancillary works; Bogie Repair Shop; supply & installation of M&P.

Fig:-1.1 General Arrangement Drawing

5
1.6 LOCATION AND OVERVIEW OF SITE

1. The Total Land Available at Site is about 255 Acres

2. Of These 255 Acres, 45 Acres is the covered Workshop area and total workshop boundary
is 210 Acres
3. The Site is accessible through the Dangtal road which passes through the New Bongaigaon
railway junction
4. The distance Between the railway station and Workshop is 4.5 kms via dangtol road
5. The site has gentle and plain contours all around.
6. The site is surrounded by farm lands on the south &west, residential areas on the north,
access road on the east, and railway line on the north &within.
7. The surrounding is lush green with existing Railway workshops.
8. The surrounding farmlands and villages create a peaceful and calm environment.

Fig:-1.2 Master plan

1.7 PROPOSED WORKSHOPS SUMMARY

1. LHB COACH REPAIR SHOP BAY-2: The main workshops of the LHB Project where
the LHB Coaches are repaired and the maintenance are taken place. There are two bays
equipped with separate sections for the maintenance of the coaches like RMPU Sections
etc. Coach on Coach system is to be taken place in each of the bays which are of height
12.7 meters (Gantry Height) and is equipped with two 50 ton cranes to carry the coaches

6
 in each bays .It is a State of the Art Facility and is connected to the Electrical and
mechanical sections on the West side and brake, draft gear etc as well as SSE building on
the north side. There are common foundations for the RCC sections & BAY-1, BAY 1 &
BAY-2 and a provision for common foundation in BAY-2 & Adjacent BAY for Future
Expansion.
2. CARPENTRY/ PLUMBING WORKSHOP(BAY-3): This Bay is positioned after the
main bays i.e. BAY-1 & 2 and is used for the repair works of the sleepers ,doors, Toilets
& other accessories of the LHB Coaches as well as the water & plumbing sections.
3. BOGIE REPAIR SHOP: The Second main workshops of the LHB Project where the
Bogies are sent after the processing work done in the LHB Workshops. Here the bogies
and its components are Shot Blasted and then Painted at the paint booth.
4. MECHANICAL SECTION (R.C.C Building): Another Section in front of the BAY-1
and comprising of the Mechanical Stores where the Mechanical repair works are to be
carried on. It is a 2 storey building with the Ground floor for the respective sections and
the First floor for the SSE Officers.
5. ELECTRICAL SECTION (R.C.C Building): One of the sections in front of the BAY-1
comprising of Roof mounted package unit. Light and Fan section and electronic laboratory.
It is also a two storey RCC building with the ground floor as sections and first floor as SSE
Offices.
6. BIO-MAINTENANCE FACILITY: One of the Significant building in the LHB Project
as a coach enters this area first before entering the main BAYS and it is equipped with the
modern Bio-Technology method that cleanses the coaches.
7. CBC/DRAFT GEAR/BRAKE SECTION: The smaller repair sections which consists of
the DRAFT GEAR, BRAKE and CBC Sections.
8. SSE OFFICE CUM STORE: The offices of the Senior Section Engineer on the First floor
and the stores in the ground floor.
9. CMT BUILDING: The Central Metallurgical Testing Lab is another significant building
where the research and testing of bio-effluent particles etc are done along with the other
smaller machines that are used for testing which are required in the process.
10. ROAD DEVELOPMENT & HARD FLOORING: A 5000 Sq. of road development is
also being done for the better transport system facility and new Hard floorings in and
around the Workshop wherever needed is being done as well.
11. MAIN GATE : A New High Main Gate is also being proposed right at the entry to the
Workshop premises
12. SCRAP YARD: A 5000 sq. Scrap yard for the accumulation of the scraps is also being
constructed near the CRS.
13. RAIL TRACK: Five new Rail tracks, 3 Towards the CRS and 2 at the BRS Workshop is
also to be constructed.
14. LANDSCAPING: A Significant importance is also given to the Restoration and
Development of the green belt affront of the Mechanical & Electrical sections.

7
15. PROP TOILET BLOCKS: Provision of Washrooms & Toilets (Male & Female) is also
being proposed at desired locations around the workshops to facilitate the Officers and
Work persons. Separate Toilets are also being made in the Electrical and Mechanical
Sections as well for the Workers engaged in the CRS.
16. RENOVATION WORKS: The Renovation works such as Roofing, Flooring & Repair of
the Required Workshops & Buildings are also proposed in buildings like CWM Office,
CLS, BRS, CBS, WTS & workshop sections.

Fig: -1.3 Artistic Expression of Proposed Buildings

8
 1.8 TOPOGRAPHICAL SURVEY FOR THE PROJECT

Topographical survey has to be carried out for about 255 acres of total land at New Bongaigaon,
Assam.
1.8.1 Scope of Work

1. Entire existing work shop area & Proposed area for augmentation:
• To pick up the spot levels of existing and proposed area with spot level 5m x 5m grids
& contour interval 0.5 m.
• All structures/ buildings/tanks within the workshop and proposed area with
dimension (Length x width x height).
• Recording elevation showing size & heights of existing shed & building of workshop.
• Preparation of survey plan, elevation of existing shed and building & contour map of
the workshop.
2. Existing Rail connectivity with main rail line: -

Detailing of loop/yard lines approaching to workshop with formation level with an

interval of 50m from takeoff point to main line shall be carried out as per site requirement.

3. Open area apart from existing workshop and yard lines:

• To pick up the spot levels of existing and proposed area at 100 m grid interval with
contour interval of 0.5m.
• Assessment of nos. of trees, their girth and height etc.
4. The survey work will be carried out with respect to GTS bench mark or any other bench
mark suggested by RITES.
5. Land use pertaining to proposed area for augmentation with rail connectivity.
6. All HT/LT/Telephone lines to be marked, if any.
7. Connection of road approaching to workshop with Type NH/SH/Other roads & width of
the roads etc.
8. Alignment of existing underground water lines, communication lines, EDP lines, sewerage
lines and power lines etc., if any, will also be recorded.
9. Marking of proposed yard lines and building with un-washable / rain proof yellow colour
paint. The same shall be reflected in drawing also.

9
1.8.2 Approach and Methodology to be adopted for carrying out the detailed survey

a. Before starting topographic survey, Sub consultant Firm shall ensure that horizontal and
vertical control of area of interest has been established. Sub consultant Firm shall carry out
the survey work w. r. t. Survey of India (GTS) bench mark or any other bench mark
suggested by Railways.
b. All measurements shall be taken by using Total Stations of minimum 2” (two second)
Accuracy as per DIN standard Accuracy as per DIN standard with data downloading
facility of brands and shall be recorded directly on to it. The linear measurements shall
have an accuracy of 5mm.
c. During Topographic survey, all existing topographical details, such as available features
like buildings, road, electric lines etc shall be picked up as existing on 12 ground w.r.t
reference frame established above. Spot levels shall be picked up at an interval of 20m or
at closer interval so as to depict actual ground.
d. Details regarding bunds, bunded streams, irrigation works, High flood level (HFL) and
back water etc. in the vicinity of the proposed area should be collected since these might
affect the future safety of the area.
e. Necessary jungle clearance for proper execution of the work, wherever required, shall have
to be done by the Sub Consultant Firm at no extra cost.
f. All text size and presentation of drawings, legend, scale etc. shall be as per sample, which
will be supplied by RITES during execution of survey.
g. The Sub Consultant Firm shall carryout physical verification of the plan prepared above
with the help of hard copies using his own surveyors at site.
h. After making necessary corrections as may be required, the Sub Consultant Firm shall
submit the final drawings in hard copy and soft copy to RITES for further work.
i. The Sub Consultant Firm shall follow a standardized feature code and level/la information
to ensure standardization, any data not-compatible with the same shall not be.

Detailed survey sheet is attached in the Appendix-1.

10
 CHAPTER-2

TENDERING PROCEDURE/BID PROCESS MANAGEMENT

2.1 METHODOLOGY
The Tender System is one of the most effective methods of securing competitive rates for
execution of works. The exceptions made to the general rule that the tenders should be called for
in all cases are based only on practical consideration in order to avoid delay and unnecessary
formalities in cases of works of comparatively small value.

Tenders can be classified into the following classes: -

i) Single Tender: - When only one source of supply is available then single tender is addressed to
the selected supplier. The system of Single Tender should be resorted to only in exceptional
circumstances.

ii) Limited Tender: - This type of tender is addressed to a limited number of suppliers, who are
the reliable source of supply. Decision for calling Limited Tenders in place of Open Tenders

a) Work is required to be done in urgency and in short period.

b) The job is of a special nature which could be executed only by a few special type of Consultants
/ Contractors who are well versed with the job.
c) Justification for hiring of consultant should be available on file.

iii) Open Tender: - is open to all the suppliers within the country who can supply the required
quantity and quality of materials. Such invitation is made by advertising in newspapers, journals
etc.

2.2 INTRODUCTION OF E-TENDERING IN RITES

• The system of e-Tendering has been introduced in RITES Ltd. through National
Informatics Centre (NIC).
• E-Tendering system shall be applicable for works having estimated cost put to tender more
than Rs. 10 Lakhs.
• At present the Application Service Provider (ASP) is NICSI/NIC through Central Public
Procurement Portal (URL: https://etenders.gov.in/eprocure/app). User’s manual for
bidders has been hosted on this web page by ASP.
• ASP is available through RITES IT Department to provide support for supply of
documentation covering 'User Manual' and ‘Vendor Manual’ for implementation of the
system along with required training to RITES officials and interested contractors.
• It is mandatory for all bidders to have Class – III Digital Signature Certificate (DSC) in the
name of the person who will sign the bid from any of licensed Certifying Agency (CA).

11
 Bidders can see the list of licensed CAs from the link http://www.cca.gov.in. Subsequently,
bidders are required to get the same registered with ASP.

2.3 PREPARATION OF BID DOCUMENT

• Preparation of Estimate and preparation of Tender Documents of these Guidelines should

be referred to The Project Co-ordinator and his team will be responsible for correctness of
the formulae adopted in BOQ.
• The list of documents to be scanned and uploaded by the intending bidder shall be as
Tender document. However if any, clarification in documents/deficient documents are
required then the same can be sought from the bidder by Convenor of the Tender
Committee. In the cases, where Convenor of Tender Committee is not associated with the
work for which tenders are invited, Project Coordinator shall assist Convenor of Tender
Committee to seek clarifications from the bidder. The clarifications/deficient documents
can be obtained from bidders online only once. In case, the clarifications/deficient
documents are to be obtained more than once, the same shall be done through e-mail by
concerned officials. The clarifications/deficient documents shall not be obtained by
post/courier.

2.4 CONTENTS OF TENDER DOCUMENTS

In case of works for which tenders are to be invited, except in cases where the Client insists
upon adoption of a particular format such as that of CPWD, Railways, World Bank, MES
etc, RITES Standard Tender Document which has been issued separately should be
adopted. In all cases of modifications of the Standard Tender Documents, specific approval
of the Competent Authority should be taken before issue of NIT. While putting up the
Tender Document for approval of the Competent Authority, the Project Coordinator should
list out all deviations proposed in RITES Standard Tender Document and reasons for the
same. If, as per contract between RITES and the Client, the tender document is to be
approved by the Client, no separate approval of Tender Document is required from the
competent authority of RITES. The approval of RITES competent authority will, however,
be necessary if the pre-qualification criteria are different from RITES standard tender and
contract document for works.

2.5 PREPARATION OF ESTIMATES FOR WORKS

Preliminary Estimate is required to be prepared in order to facilitate the Client to accord

Administrative Approval and Expenditure Sanction. These estimates should be prepared
on the following basis.

• Building Works:- On the basis of plinth area rates published by CPWD with Delhi Base
index of 100 as on 1/10/2007 read with up to date correction slips and updating it with cost
index. CPWD issues such Cost Index figures from time to time to facilitate updating of

12
 plinth area rates. Extra provisions for superior specifications not covered in the scope of
PAR to be taken in the Preliminary Estimate.
• Railway Works: - Where supply of P. Way material is to be given by Zonal Railway:-
Track items based on the rates circulated by Railway Board/Zonal Railways and adding
the factors of transportation by road, contractor’s profit, taxes etc. Earthwork and ballast
supply based on the prevailing rates in the project area.
• Road Work:- Length of road, no. of lanes etc worked out and the rate per unit area, length
or other such method adopted for ready and rough calculation, so as to give an approximate
idea of the cost involved in the proposal.
• Railway Bridges:- On the basis of Bridge opening / span and the number of Tracks to be
crossed, adopting Unit Rate per meter of opening per Track.
• Road Over Bridges:- On the basis of area of road on bridge proper and on approaches,
Unit rate per Sq. Meter of approach will vary depending on the design.

The Preliminary estimate should invariably provide for the probable escalation in the prices based
on trend of increase in price of materials and labour for the period between estimate preparation
and start of work as also during the period of construction.

The estimate should include RITES fee which should include fees of sub consultants, for project
management.

Following steps need to be taken before preparation of the estimates:

• Freeze the requirement of project and specifications of work with the Client.
• Prepare concept plan based on the requirement and obtain approval of the Client.
• Where required, conduct sub-soil investigations and tests to determine subsoil Strata and
the safe bearing capacity of soil for design of foundations.

2.5.1 The Detailed Estimate Components: -

1) References of Name of Work, Estimate Number and Report on the Estimate should be prepared
in a lucid form understandable by the Client. It should be comprehensive enough under each
sub-head as mentioned below:
a) History: - Particulars relating to the initiation of and reasons leading up to the proposal
and its general purposes including reference to previous correspondence, documents and
specifications, where necessary.
b) Design:- A description of the original proposals and those finally adopted particularly with
regard to location, sitting and design, also with reference to specifications, calculations and
drawings, where necessary, type of foundation, type of superstructure plinth area and no.
of storey’s.

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 c) Scope:- An explicit statement as to what work is and what is not covered by the estimate;
also a reference to what arrangements are being made for any portions of work which are
not included in the estimate.
d) Rates: - Particulars and basis as to how the rates have been arrived at giving references to
the Standard Schedule of Rates and Non-Scheduled Rates and also to the details
accompanying the estimate, where necessary, with any special explanation connected
therewith.
e) Cost: - Estimated Cost of the work and a comparison with the amount originally provided
under any previous administrative sanction or detailed estimate in case of revision.
f) Method:- The method proposed for carrying out the work - whether by lump sum contract,
item rate or percentage rate contract or any combination of these.
g) Establishment: - Details of any provision made in the estimate for work charged
establishment, when necessary.
h) Construction Plants :- Any special methods of construction to be adopted with reference
to specifications, etc. and details of the arrangements that have been provided for necessary
Construction Plant, tools etc.
i) Land: - Whether land for the work is available free of encumbrance. Arrangements for
acquisition of land, where necessary.
j) Time: - Estimated time of completion from the date of award of Works Contract.

2) Name and Designation of the official preparing the Estimate and the official doing technical
check
3) Detailed Statement of Measurements for each item of Work based on the drawings.
4) Rate analysis for items not available in Standard Schedules of Rates along with supporting
documents for rates of materials and labour.
5) Supporting documents when rates are based on prevailing market rates in the project area.
6) Supporting documents when rates are based on the trend of rates of items in tenders accepted
in the recent past duly updated for factors likely to affect the cost.

2.5.2 Procedure for preparation detailed estimates: -

• As far as possible for building works, the items of works should be classified under various
items of DSR (Delhi Schedule of Rates). The latest version now in use is DSR 2018. While
working out the estimate for DSR 2018 items, the rates for these items should be taken
after deducting GST on works Contract for each item and cost of all items should be worked
out like this based on their quantities. The cost as per DSR should be enhanced by
prevailing %age of Cost Index in the project area, circulated by CPWD. CPWD issues from
time to time the prevailing Cost Index in different regions of the country.
• Where other Schedules are applicable (MES, Railways, State PWD etc.), the items may be
taken from the corresponding Schedule of Rates duly enhanced by the prevailing Cost
Index.

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 • Items that cannot be covered by any Standard Schedule of Rates will come under the
category of Non Schedule items. The estimates for these items should be prepared on the
basis of the trend of rates of such items in tenders accepted in the recent past duly updated
for factors likely to affect the cost. Average rate of two or three (preferably three) accepted
tenders may be considered.
• Rate at which Labour contractors supply labour. From the rates quoted, 10% may be
deducted towards Labour Contractor’s profit, to arrive at the rate at which the Labour is
paid by the Labour Contractor.
• Contractor’s Overheads and Profit for Building Works, Colony roads etc. For uniformity,
this should be taken at 15% of the cost of materials, labour and on hire/running charges for
Plant and Machinery based on CPWD practice.
• The minimum level for preparation of Detailed Estimate shall be Engineer. The Detailed
Estimates are to be technically checked by the Project coordinator or a nominated officer
not below the rank of a Manager.

2.5.3 Technical check of detailed estimates: -

• The Cost Index adopted on the DSR or other schedules items have been correctly taken.
• Cost of Non-schedule items has been prepared, where feasible, correctly by comparison
with a similar item existing in the Standard Schedule of Rates.
• In case of Non-schedule items prepared based on the manufacturers specifications or
RITES’ experience, the quantities of materials, wastages, etc. have been correctly
considered.
• The elements of taxes/cesses, overheads and profit, contingences and RITES’ fee have
been taken as per standard norms or provisions in the contract agreement with the Client
as applicable.

2.5.4 Preparation of estimates for survey /geo-tech/ planning/ consultancy/ design etc.

Considering the fact that there are no standard / published Schedule of Rates or Analysis of Rates
for preparing estimates for Survey, Geo-tech Investigations, Planning, Consultancy or Design
assignments etc. the estimates for such services may be prepared on the basis of past experience
of cost of hiring such services. This can be done by adopting one of the following two methods.

• The estimated cost may be prepared on the basis of the trend of tenders for similar works
accepted in the recent past duly updated for factors likely to affect the cost. Average cost
of two or three accepted tenders may be considered. The factors affecting the cost can be
a) Time lag between the date of acceptance of tenders and the preparation of estimate.
In such cases, the effect of general escalation in costs due to inflation can be
factored in.
b) Difference in the scope of work between the accepted tenders and the work for
which the estimate is being prepared.

15
 c) Complexity of the assignment, remoteness of area, law and order issues etc.

• By analysis of input costs: The scope of the assignment can be divided into various items
and the estimate can be framed for each item by assessing the cost of inputs involved like
rentals of survey/geo-tech instruments, salary of surveyors, engineers, CAD operators and
other skilled/unskilled workers, expenditure on transportation of staff and equipment to
site and adding overheads and profits @ 15% on the cost elements. The quantity of man-
hours / months and the salary of engineers/designers etc. can be assessed on the basis of
experience.

2.6 CONTRACTS AND FORMS

When two or more persons have common intention communicated to each other to create some
obligation between them, there is said to be an “Agreement”. An “Agreement” which is
enforceable by law is a “Contract”

2.6.1 Contract documents: -

1) Part I–Technical Bid This consists of following sections

• Notice Inviting Tender and Instructions to Tenderers.
• Tender & Contract Form
• Special Conditions
• Schedules A to F
• Technical Specifications
• Drawings (B)
2) Part II–Financial Bid the revised standard formats for Percentage and Item Rate Tenders have
been issued separately. These should be followed as applicable.
3) Drawings At the stage of invitation of tender all drawings, adequate to understand the specific
scope of work involved and those required for execution of the work at site for at least the first
few months should be ready and included in the Tender Document.

2.7 PUBLICITY OF TENDERS

For ‘Open Tenders’ of works costing over Rs.50 Lac wide publicity should be given to the Notice
Inviting Tenders. Tenders must be invited in the most open and public manner possible by
advertisement in the press both in English and Hindi as also in the local language dailies, if the
local language is different from Hindi. The number of newspapers in which advertisement should
be published would depend upon the cost of work as per details given below:

For works costing more than Rs.25 Crore tender should be published in English Newspapers of
Two National dailies & in Hindi/Regional Language Newspapers it should be Four Hindi dailies,
or Three Hindi dailies and one Regional Language daily, or Two Hindi dailies and two Regional

16
Language dailies. In case decision is taken to lower the pre-qualification/eligibility criteria
subsequent to appearance of NIT in the newspapers, suitable corrigendum should be got uploaded
in RITES website. In such cases, the relevant dates like, last date of issue of tender documents, of
pre-bid meeting, of submission of tenders and of opening of tenders may also be suitably extended.

2.7.1 Time Limit For Publicity Of Tenders

The following time limits between the date of uploading of tenders on website, and the date of
opening of the tenders are laid down but this period may be varied at the discretion of the officer
competent to accept the tenders in terms of SOP. In order to ensure keen competition, the time
schedule given below shall be adhered to as the minimum. Any reduction in time period shall be
only in rare cases if approved by the Competent Authority under SOP for recorded reasons.

• 10 days in the case of works costing up to Rs two crores.

• 2 weeks in the case of works costing more than Rs. two crores and up to Rs. Ten crores.
• 3 weeks in case of works costing more than Rs.10 crores.
• It has to be ensured that the Tender Documents are ready well before the date of Call of
Tender date from which the Tender Papers will be available for issue to the tenderers / date
of uploading of Tender Document in RITES website.

2.7.2 Re-Invitation Of Tenders / Extension Of Period

In case of re-invitation of tenders, all the formalities mentioned above shall be observed. The
circumstances leading to the need for retendering should be carefully considered so that necessary
modifications in the Tender Documents may be made while retendering. In cases when the dates
and time for sale and receipt of tenders are required to be extended or qualification criteria are to
be changed due to unavoidable circumstances, a proper notice for the same will be put up on the
notice board of SBU and in the Web Site of RITES. While retendering for the work, tender will
not be issued to the contractor, who has defaulted leading to forfeiture of Earnest Money.

2.7.3 Specimen Press Notice For Publication In News Paper

In case of e-Tendering there is no necessity to publish a large size Press Notice in News Papers.
Only a condensed form of Notice Inviting e-Tenders is to be published in leading News Papers as
per these Guidelines for wide publicity as mentioned below:

17
 RITES LTD

Notice Inviting e-Tenders

The ………… (Designation of the Officer), RITES Ltd. invites on behalf of …………………. online item rate /
percentage rate / combination of item rate & percentage rate / lump sum bids on single / two packet system for the
following work(s):-

1. NIT No. ……………………Name of Work………………..Estimated Cost Rs……………. Earnest

Money………Period of completion…………….Last time & date of submission of bid………….

2. NIT No. ……………………Name of Work………………..Estimated Cost Rs……………. Earnest

Money………Period of completion…………….Last time & date of submission of bid………….

The bid forms and other details can be obtained from the website https://etenders.gov.in/eprocure/app Addendum /
Corrigendum, if any, shall be hosted online only

The press notice should not be published in the tabular form, which occupies much more space
than required and ultimately increases the cost of advertisement.

2.8 UPLOADING OF BID DOCUMENT

1. All the documents such as NIT including Information and Instructions for contractors, all
the conditions of NIT, Schedule of Quantities, Drawings and other documents shall be
uploaded at one time.
2. System Administrator of concerned SBU or his authorized representative shall enter the
names and other required particulars of Tender Creator and Tender Publisher for every
tender in the E-tender system.
3. Under no circumstances bid document is to be got uploaded through Application Service
Provider (ASP). In case of any difficulty, concerned officials can seek assistance from IT
Department, RITES or ASP.
4. The tenders can be published online from 9.00 AM up to 6.55 PM on any day between
Mondays to Saturday.
5. There should be a minimum gap of 24 hours between Bid submission End Time & date
and Bid Opening Time & date.
6. The bid submission end date or Bid opening date should not fall on Sunday.
7. Notice Inviting Tenders and Instructions to Tenderers the tender document can be modified
by RITES by issue of addenda/corrigenda till seven days prior to the deadline for
submission of tenders. However, the System does not permit the Financial Bid to be
modified after the Bid Submission Start Date and Time. Therefore, if any modification is
to be made in the Financial Bid, it has to be done before commencement of Bid Submission
Start Date and Time. The Financial Bid can be changed / modified through
addenda/corrigenda by Tender Creator and Tender Publisher only up to the start of the Bid
submission time and date. The Financial bid cannot be changed/ modified once the Bid

18
 submission time and date start. However, extension of the deadline for submission of
tenders may be given at any time before Bid opening date and time.

2.8.1 Cost Of Tender Document

In E-Tendering the tenders are not being physically sold to the bidders, however the cost of tenders
shall be kept keeping in view the number of documents to be downloaded. Hence following scale
of charges shall be applicable to the bidders: -

1) Works costing up to Rs.1 crore: Rs.2500/-.

2) Works costing more than Rs.1 crore and up to Rs.10 crores, Rs.7,000/- (minimum) and
Rs.10,000/- (maximum) depending on the number of documents to be downloaded.
3) Works costing more than Rs.10 crores, Rs.12,000/- (minimum) and Rs.18,000/- (maximum)
depending on the number of documents to be downloaded.

2.9 EARNEST MONEY DEPOSIT (EMD)

The bids shall be accompanied by Earnest Money Deposit (EMD) amounting to 1% of the
estimated cost subject to a maximum of Rs.25 lakhs in any one of the following forms :

1) Banker’s Cheque / Pay Order / Demand Draft issued by any Scheduled Commercial Bank
drawn in favour of RITES Ltd. and payable at Gurgaon / Delhi /______
2) Request for unconditional extension of bid validity from bidders shall be sought by Project
Coordinator through e-mail
3) Regarding exemption from payment of Cost of Tender Document and Earnest Money Deposit,
for Micro and Small Enterprises (MSEs) Order, 2012 are applicable to only Supply and Service
Contracts.

2.10 PRE QUALIFICATION OF TENDERERS – JOINT VENTURES

RITES Standard Tender & Contract Document lays down the Qualification Criteria and the
requirements to be fulfilled if the bidder happens to be a Joint Venture. Joint Ventures may be
permitted only for Large Works. Joint Ventures may also be permitted for Composite Works
falling in the category of Normal Works. Composite Works are defined as works involving two or
more components which are of distinctly different character like Formation & Bridges, P-way
Linking, Signalling, Long Span Bridges (span more than 45 meters), Railway Electrification,
Highway/Runway, Building, Air-Conditioning etc.

2.11 ONE PACKET AND TWO PACKET SYSTEMS

For works costing up-to Rs.3 Crores, Single Packet System shall be adopted with both Technical
and Financial Bids opened simultaneously.

For works costing more than Rs.3 Crores, normally Two Packet System shall be adopted with the
Technical Bid opened first and evaluated. The Financial Bids of only those tenderers who have
19
come out successful in the Technical Bid will be opened at a later date. The Financial Bids shall
as far as possible be opened within 30 days of date of receipt of tenders. However where it is
desirable to take up prequalification process separately first and issue tender documents to only
the prequalified applicants, prior approval of competent authority shall be taken. This decision is
to be taken based on the nature of work, time available and likely response to the qualification
process. There shall be no objection if P.Q. process is taken up simultaneously for more than one
work, indicating particulars of each work distinctly. In such a case, applicants need not submit
credentials separately for each work. But applicants have to be judged separately for each work
and list of applicants qualifying for a particular work cannot be adopted for another work.

2.12 EVALUATION OF TENDERS

Following steps shall be required in evaluation of tenders:-

1) Preparation of Briefing Note on Technical Bids by Tender Briefing Committee and its scrutiny
by Project Co-ordinator as per procedure explained later.
2) Evaluation of Technical Bids.
3) Verification of authenticity of credentials relating to Work Experience and any other
documents as per tender provisions submitted by the bidders whose Technical Bids are
otherwise found acceptable. This is a parallel activity to be done simultaneously with the steps
to be taken as per Sl. Nos. 4, 5 & 6 of this para. The project Coordinator concerned, however,
should ensure that before submission of recommendations by the Tender Committee on
financial bid to the Tender Accepting Authority, verification of authenticity of
Credentials/documents of 'L-1' bidder is completed. The project Coordinator may make use of
fax/email or depute an officer not below the rank of a Manager for verification of the
credentials discreetly and expeditiously so that tenders are decided within their validity.
4) Opening of Financial Bids.
5) Preparation of Briefing Note on Financial Bids by Tender Briefing Committee and its scrutiny
by the Project Co-ordinator.
6) Evaluation of Financial Bids.
7) No Post-tender modification by any tenderer shall be taken into consideration. As regards suo-
moto rebate / discount offered by any tenderer after opening of tenders.
8) In case any of the self attested documents turns out to be misleading or false, the EMD of the
concerned tenderer will be forfeited and Business dealings banned.

2.12.1 Preparation And Scrutiny Of Briefing Note On Technical Bid

1. Salient Features of Tender

a) Brief Scope of Work
b) Estimated Cost
c) Type of Tender - Item Rate or Percentage Rate or Lump Sum
d) Stipulated Period of Completion

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 e) Names of News Papers and dates when NIT published
f) Date of Pre-Bid Conference
g) Date and Time When tenders opened
h) Date up-to which tender offers are valid.

2. Salient details of offer by each tenderer which must be present in the briefing note
1. Name of tenderer
2. Number allotted to the tenderer
3. Technical Bid which includes
i) Earnest Money Deposit
ii) Authority to Sign
iii) Qualification Information
iv) Deficient documents /information in the Technical Bid.

2.12.2 Evaluation Of Technical Bids By Tender Committee

The Tender Committee may go through the briefing note and tender documents and evaluate the
tender as under: -

1. First check whether any of the tenderers is currently on RITES’ Negative List of
Contractors. In case any tenderer is found to be on the Negative List of Contractors, then
his tender may not be processed further and this fact be brought out in the Tender
Committee’s recommendations. In case none of the tenderers is in the Negative List of
Contractors then a certificate to this effect should be recorded in Tender Committee’s
recommendations.
2. Then check the Earnest Money Deposit of the Tenderers whose Technical Bids have been
opened to confirm that the same are in order (unless the tenderers are exempted from
payment of Earnest Money as matter of Government Policy). If the Earnest Money
Deposit is not in order, no further action need be taken for evaluating the Technical Bids
of such Tenderers. Similar action should be taken with regard to Cost of Tender
Document when the tender has been submitted in a form downloaded from RITES
website.
3. The Tender Committee will review the “Authority to sign”, “Integrity Pact” and
“Qualification Criteria” and other details furnished in the Technical Bid of those
Tenderers whose Earnest Money Deposit has been confirmed to be in order (unless the
tenderer(s) is /are exempted from payment of Earnest Money as a matter of Govt. policy).
If any details are deficient or are not in order, the following procedure shall be adopted.
4. Clarification/information need be called for only to obtain clarifications on documents
originally submitted along with the bid. (Since members of Tender Opening Committee
are required to initial all documents submitted by bidders in support of meeting the
qualification criteria, only such documents as initialled by the members of Tender

21
 Opening Committee, will be considered as “originally submitted along with the bid”.) In
no case should the bidder be asked or allowed to submit additional documents in support
of his meeting the qualifying criteria, which were not submitted along with the original
bid. Where it is decided to call for information/clarification from any bidder, on any
document already submitted along with the original bid, such request may be issued by
a letter giving a reasonable period of 10 to 12 days for submission. In case no response
is received from the Tenderer concerned, or the response received is incomplete no
further information/clarification need be called and such tender may be evaluated on the
basis of available documents.
5. The decision to obtain clarifications from the tenderers concerned on the deficiencies
noticed in the documents/information can be taken by the Convenor of the Tender
Committee / Project Coordinator. Recommendation on satisfaction of qualification
criteria shall however be from full Tender Committee.”

Based on the decision of the Tender Accepting Authority, the Tenderers whose Technical Bids
have not been found acceptable will be advised by the Project Coordinator about this fact in writing
giving reasons for non-qualification and asked to take back the Earnest Money and the unopened
Financial Bid (in the case of a Two Packet System) Such intimation about rejection of their
Technical Bids should be sent before opening of Price Bids from Tenderers whose Technical Bids
have been found acceptable.

2.13 OPENING OF FINANCIAL BIDS

In Single Packet System, the Financial Bids are opened along with the Technical Bids. In the case
of a Two Packet System, after decision on recommendations of Tender Committee on the
Technical Bids, Financial Bids in respect of only those Tenderers whose Technical Bids are found
to be acceptable or provisionally acceptable shall be opened on a date to be fixed and advised in
writing to the Tenderers concerned. The Tenderers whose Bids have been provisionally accepted
should be clearly advised that their prequalification is only provisional and will be subject to
receipt of deficient documents/confirmation of credentials from past Clients/Bank.

2.14 PREPARATION AND SCRUTINY OF BRIEFING NOTE AND COMPARATIVE

NOTE FOR FINANCIAL BIDS

The Briefing Note, besides details mentioned earlier, shall include the following details: -

1. Discrepancies noticed in rates/amount quoted on BOQ Items: -

a) In case of the Item rate tender
• BOQ item numbers where rates in figures and words as well as the amount for
the item are given by the tenderer but the unit rates in figures and words don’t
agree with each other.
• BOQ item numbers where unit rates in figures and words have been given but
the amount for that item not given.
22
 • BOQ item numbers where rates in figures and words as well as the amount for
the item are given by the tenderer but the amount does not correspond with the
rate either in figures or in words.
• BOQ item number where unit rates in figures and words agree but they amount
for that item has been given wrongly.

b) In case of the Percentage Rate Tender

• Percentages are quoted in figures and words along with the total tender amount
by the tenderer but the percentages quoted in figures and words don’t agree with
each other.
• Percentages are quoted in figures and words but the total tender amount is not
quoted.
• Percentages are quoted in figures and words along with the total tender amount
but the total tender amount does not agree with the percentages quoted either in
figures or in words
• Percentages quoted in figures and words tally but the total tender amount has
been given wrongly.

2.15 PERFORMANCE GUARANTEE

Performance Guarantee is to be obtained from the successful tenderer at 5% of the tendered

amount. This is meant to ensure proper performance of the Contract and is to be deposited by the
Contractor within the period from date of issue of Letter of Acceptance the Performance Guarantee
shall be in the form of F.D. Receipts or Guarantee Bond / B.G.

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 2.16 TENDER OF PROJECT SAMBALPUR, ORISSA.

Setting up of Freight Train maintenance facility with ROH facility for Freight Wagons at Sarla
station yard, Sambalpur, Orissa. The work majorly includes supplying, laying and linking of track,
construction of ROH shed, wheel lathe shed, compressor house shed, RCC buildings, Box bridge,
Pipe culvert, Pathway, road works, Barbed wire Boundary wall, external development work,
Internal & External Electrical works, Supply and Commissioning of EOT cranes and other
Machinery and Plants etc.

1. Estimated Cost: INR 50.93 crores .

2. Type of Tender - Two Packets, Percentage rate wise, open tender.

3. Stipulated Period of Completion:

a. 18 months from the date of issue of LOA.

4. Names of News Papers and dates when NIT published: Hindustan Times (Eng) (All
Editions), Hindustan Hindi (Hindi) (All Editions), Mint (English) (All Editions), Dharitri
(Oriya) (All Orissa), Indian Express (English) (All Editions), Jansatta (Hindi) (All
Editions) and The Samaj (Oriya) (All Orissa) published on 13.07.2019 (NP-13)

5. Date of Pre-Bid Conference: 25.07.2019

6. Date and Time when tender opened: 06.08.2019 at 11:30 AM.

7. Date up-to which tender offers are valid: 90 days from due date of submission of bid.
8. Deadline for submission of bids: 1100 Hrs. on 05.08.2019

2.16.1 List of Documents to be scanned and uploaded within the period of bid submission: -

1. Banker’s Cheque/Pay Order/Demand Draft towards cost of Tender Document in

accordance with Clause 7.0 (f) hereinbefore.
OR
Document in support of exemption from payment of cost of Tender Document and
Udyog Aadhar Memorandum (UAM) number.
2. Banker’s Cheque/ Pay Order/ Demand Draft towards Earnest Money Deposit (EMD)
in accordance with Clause 9 hereinbefore.
OR
Document in support of exemption from payment of EMD and Udyog Aadhar
Memorandum (UAM) number.
3. Self-attested copy of Authority to Sign.
4. Self-attested copy of RTGS/NEFT.
5. Self-attested copy of Documents in support of meeting the criterion of Annual
Financial Turnover.

24
6. Self-attested copy of Certificates in support of meeting the criterion of Similar Work
Experience.
7. Self-attested copy of Details of Similar Works completed.
8. Self-attested copy of Certificates in support of meeting the criterion of Construction
Experience in key activities/specified components.
9. Self-attested copy of Documents (Audited Balance Sheets, Profit & Loss Statements
and Auditor’s Reports) in support of meeting the Profitability criterion.
10. Self-attested copy of Documents in support of meeting the criterion of Net Worth.
11. Self-attested copy of Declaration by the Bidder.
12. Self-attested copy of Integrity Pact.
13. Self-attested copy of Guidelines on Banning of Business Dealings.
14. Self-attested copy of Mandate form
15. Self-attested copy of a certificate, confirming that the applicant is working contractor
or has executed any work within the last five years reckoned from the date of opening
of tender, issued by Railways, CPWD, MES, DOT, RITES, State PWD or any other
Central/State Government Undertaking, Municipal Body of Central/State
Government or Public Limited Company listed in Stock Exchange in India &
Abroad.
16. Self-Attested Copy of Partnership Deed/Memorandum and Articles of Association
of the firm.
17. Self-Attested copy of Corrigendum(s), if any.
18. Self-attested copy of any other document if specified in the correction slips to the
Tender Document.
19. Self-certified copy of the Joint Venture Agreement/Memorandum of Understanding.
20. Self-attested copy of Power of Attorney in favour of Lead Member as the Lead
Member of JV executed by the authorized representatives of all the members of JV
(where Joint Venture is allowed).
21. Self-attested copy of a certificate, confirming that the Partners including Lead
Partner duly signed by the Authorized representative of each Partner/Member of
Joint Venture is a working contractor or has executed any work within the last five
years reckoned from the date of opening of Tender, issued by Railways, CPWD,
MES, DOT, RITES, State PWD or any other Central/State Government Undertaking,
Municipal Body, Autonomous Body of Central or State Government or Public
Limited Company listed on NSE/BSE (where Joint Venture is allowed)
22. Self-attested copy of GST Registration.

25
2.17 QUALIFYING CRITERIA FOR WORKS CONTRACTS

2.17.1 Pre-Qualification Criteria To Be Satisfied

1. Annual Financial Turn Over:

The bidder should have achieved a minimum annual financial turnover of Rs. 33.95 crores. in any
one of the last 3 Financial Years. In the case of Joint Venture is allowed Partner-in-charge/Lead
Member shall singly meet this criterion.

2. Work Experience:

a) Similar Work Experience:

The Bidder should have satisfactorily completed Similar Works in his own name or
proportionate share as a member of a Joint Venture, at least one similar work of
Minimum value of Rs.20.37 crores OR at least two similar works each of Minimum
value of Rs. 12.73 crores during the last 5 (five) years prior to the last stipulated date
for submission of the Bid. Works completed prior to the cutoff-date shall not be
considered.
“Similar Works shall mean the work of Engineering Project / work carried out in India,
which includes Construction of Factory Shed or buildings with related facilities
and/or Supply and Commissioning of Machine and Plant.

b) Construction Experience in Key Activities/Specified Components

To qualify for award of the contract, each bidder in his own name or as a member of
a Joint Venture should have, in the last five years prior to the last stipulated date for
submission of the bid, executed the following key activities in any one work
individually carried out in India.

i) Civil engineering work of at least Rs. 10.80 Crores (Rupees Ten crores and Eighty
Lakhs only), which shall include Construction of factory shed or building with
related facilities.
ii) Mechanical engineering works of Rs. 1.11 Crores (Rupees One Crores and Eleven
Lakhs only), which shall include Supply & Commissioning of Machine & Plant.

3. Servicing Of Loan/Credit Limit:

The bidder should furnish a declaration that he has not failed to service the principal
amount or interest or both of a loan amount / credit limit from any Bank or Financial
Institution during a period of one year prior to the deadline for submission of bids.
4. Profitability:
The Bidder should be a profit (net) making firm and should have made profit during
any two of the past 3 Financial Years immediately preceding the deadline for

26
 submission of bids. If the audited Balance Sheet for the immediately preceding year is
not available in case of tenders opened before 30th September, Audited Balance Sheets
of the three financial Years immediately preceding the previous Financial Year shall
be considered. The Bidder should furnish figures of net profit of last 3 years in a tabular
form and submit attested copies of Auditor’s Reports along with audited Balance
Sheets and Profit and Loss Statements for the last three Financial Years. Specific
reference with page no. of document which proves satisfaction of this Qualifying
Criterion should be indicated in the tabular statement.

5. Net Worth
The Bidder should have positive Net Worth of at least 15% of the estimated cost i.e.
Rs. 7.64 crore (Rupees seven core and Sixty Four lakhs only).

• Cost of Tender Document

Cost of Tender Document Rs. 15000/-(Rupees Fifteen Thousand Only) in the form of
Demand Draft/ Pay Order/ Banker’s cheque drawn on any Scheduled Commercial Bank
payable at Gurgaon/ Delhi in favour of RITES Ltd.

• Cost of EMD
Cost of EMD of Rs. Rs. 25,00,000/-(Rupees Twenty Five Lakhs Only) in the form of
Demand Draft/ Pay Order/ Banker’s cheque drawn on any Scheduled Commercial Bank
payable at Gurgaon/ Delhi in favour of RITES Ltd. as applicable and The bidder can also
submitted MSME certificate instead of the EMD. The MSME (Micro, Small and Medium
Enterprises.) certificate is for civil works which should be a part of the similar works
definition. This certificate is issued by government bodies to encourage the small scale
industries.
• MAINTENANCE PERIOD
The normal period of maintenance shall be twelve (12) calender months reckoned from
the date of issue of completion certificate by RITES/Railway for the completed work.
Also contractor shall provide and arrange throughout the maintenance period, sufficient
staff of each discipline , materials and Equipments etc for day to day maintenance to carry
out the repairs/ rectification’s immediately of the complex, buildings etc whenever
pointed out by RITES/ Railway free of cost.
However all running cost shall be directly paid by the client to various authorities.
90 % of the Security Deposit held by the authority will be refunded to the contractor
on satisfactory completion of the maintenance period on the recommendations of the
Engineer-in-Charge.

27
 50% of 10% security deposit after 3 years of completion and satisfactory performance
of the water proofing work.
50% of 10% security deposit after 6 years of completion and satisfactory performance
of the water proofing work.

6. COMPLETION REPORT
The following documents shall also be submitted by the Contractor in triplicate as part
of completion report:
1. Test certificate for materials supplied by the Contractor.
2. Certified records of field tests on materials/equipment, as applicable
including Welds, USFD etc.
3. Six sets of construction drawings showing therein the as built conditions of
the work duly approved by RITES along with CD.
4. Track geometry records as per railway manuals.
5. Records of welding of joints.
6. Assets handing over details.

2.18 NOTICE INVITING TENDER

It is explained earlier in general definition of the tender system.
The Notice inviting tender of this work was published in the following Newspapers:
(a) Hindustan Times English All Editions
(b) Mint English All Editions
(c) Hindustan Hindi All Editions
(d) Dharitri Oriya All Orissa
(e) Indian Express English All Editions
(f) Jansatta Hindi All Editions
(g) The Samaj Oriya All Orissa

28
2.19 TABLE OF MILESTONE(S): -
This Chart focuses on planned significant events scheduled to occur at specific times in the
program. … Like the Gantt chart, the milestone chart uses symbols imposed on a calendar to
provide information about planned and actual completion dates and any revisions to
the milestone schedule as shown in Table no. 2.1. This chart also includes the amount that is
held if contractor is not able to complete the activity in the time limit showed in the milestone
chart.
TABLE NO. 2.1

S. No. Description of Milestone Time allowed in Amount to be withheld in

(Physical) days (from date case of non-achievement
of start-D) of milestone
1. Submission of construction D+15 Rs.10 lakhs
programme, mobilization of all
resources, materials required for
execution of work in full pace
2. Starting of earthwork D+30 Rs. 20.0 lakhs
3. Submission of design drawings D+45 Rs. 20.0 lakhs
for construction of bridges and
pipe culverts
4. (i) Start of construction of bridge D+90 Rs. 20.0 lakhs
and pipe culverts
(ii) Submission of design
drawings for Transformers,
panels, DG set (GAD) and
substation (building as well as
cable route)
5. Finalization of PEB agency 6 D+120 Rs. 20.0 lakhs
6. Completion of earthwork D+180 Rs. 20.0 lakhs
7. (i) Start of construction of D+190 Rs. 20.0 lakhs
Barbed wire boundary wall.
(ii) Start of foundation work of
PEB buildings/RCC work of
other RCC buildings.
(iii) Preparation of GA drawing
of PEB sheds and getting
approval from RITES/Railways.

29
 (iv) Procurement of Rails and
Sleepers for p-way work
8. Completion of Bridges and pipe D+210 Rs. 20.0 lakhs
culverts
9. i) Start of p-way work D+220 Rs. 20.0 lakhs
ii) Preparation & submission of
Detailed drawing and design for
approval of RITES/Railways
and thereafter getting the design
/drawing proof checked from
reputed Institutes (like IIT/NIT
or any other Govt. Engineering
College)
10. Procurement of PEB steel D+250 Rs. 20.0 lakhs
material in the premises of
Contractor and getting raw
material Inspection of materials
11. Commissioning of substation in D+280 Rs. 20.0 lakhs
all respects (civil and electrical
combined)
(ii) Tapping from nearest grid,
laying of overhead lines for
charging of substation.
(iii)Erection and commissioning
of high mast
(iv) Completion of barbed wire
boundary wall
12. (i) Receipt of fabricated material D+295 Rs 20.0 lakhs
in good condition at site of work.
(ii) Completion of Foundation
work of all PEB sheds.
(iii) Start of erection of PEB
superstructure.
13. (i) On complete erection and D+400 Rs.20.0 lakhs
completion of riveting/ bolting/
welding of members and proper
line & level as per drawing of
fabricated members and
applying of final coat.

30
 (ii) Electrification of shed
(iii) Completion of RCC
buildings other than PEB sheds.
14. Completion of sheeting & D+440 Rs. 20.0 lakhs
cladding & other miscellaneous
works of PEB shed in all respect.
15. 15 Supply of M&Ps D+450 @1.5% per month
16. Completion of track work, road D+490 Rs. 20.0 lakhs
work, pathways and bulk
services (including all related
electrical works)
17. i) Completion of entire work of D+540 As per RITES rules
civil and electrical &
demobilization from site
(ii) Completion of supply,
installation and commissioning
of all M&Ps.

31
 CHAPTER-3
ESTIMATION OF PROJECT
The work is estimated to cost Rs. 50.93 Crores (Rs. Fifty Crores & Ninety Three Lakhs Only)
including all taxes except GST. The estimate is worked by applying DSR-2018, LARs and the
prevailing market rates of material cost, labour, sundries, POL and T&P charges without GST.

SUMMARY OF COST OF WORKS

NAME OF WORK: MANESWAR- FREIGHT TRAIN MAINTAINENCE FACILITY
WITH ROUTINE OVERHAULING FACILITIES FOR FREIGHT WAGONS
ESTIMATE
Sl. No. Subhead
Revised AMOUNT
A CIVIL WORKS
1 Area Filling Work & Tree cutting 108,335,628.60
2 New Boundary Wall 2,899,070.61
3 New Rail Track 122,005,568.13
4 Yard office 0.00
5 Service Station Building 21,030,635.82
6 Sub Station Building 5,741,431.75
7 Covering Shed (PEB) 67,298,173.73
8 Compressor House (PEB) 1,647,559.95
9 Lathe machine shed (PEB) 7,004,887.07
10
Residential quarters 0.00

11 Pathway 19,780,183.50
12 Water tank 88,000.00
13 Bitumen Road Work 20,973,136.30
14 Construction of Bridge; BR 62 (Lumpsum) 14,142,748.26
15 Construction of Bridge; BR 63 (Lumpsum) 4,807,490.88
16 Construction of Pipe Culverts 3,556,076.30
Siphon 0.00
Hostel 28,588,390.37
External Drainage 4,055,290.23
TOTAL COST OF CIVIL WORKS 431,954,271.51

The detailed estimation of the project is attached in the Appendix-2.

32
 CHAPTER-4

GEO-TECHNICAL INVESTIGATION
Geo-technical investigation work for setting up of workshop for refurbishing of LHB coaches at
NEW BONGAIGAON, ASSAM.

4.1 SCOPE OF WORK

1. Mobilizing required no. of boring/ drilling rigs with all necessary equipment's and
personnel.
2. Making boreholes with percussion drilling through all types of soil/rock.
3. Conducting SPT at regular depth intervals along with standard field & laboratory test.
4. Collecting disturbed and undisturbed soil samples along with standard field & laboratory
test.
5. The study & identification of suitable foundations system and assessment of safe bearing
capacity of the sub strata in according with standard engineering practice and I. S. Codes.

4.2 FIELD INVESTIGATION OBSERVATIONS & SAMPLING

According to our mentor during drilling they found that strata is normally consolidate, which
confirms the SPT results. We also observe some tree roots at a depth of 15 m while taking SPT at
that depth (BH-03). Water table and fine content of the soil gives an idea that it’s a deposited
material due to weathering of rock or transported due to floods.

6 No. of 150 mm. dia. bores were drilled down up to the depth of 15.00 m at proposed site of
construction by their skilled

Fig: -4.1 Location Plan of bore holes

33
and experienced site personnel by using percussion drilling in February 2018 as suggested by
client.

4.3 TEST PROCEDURES FOR FIELD TEST

1. Standard penetration test: - The standard penetration tests were carried out by split spoon
sampler confirming to IS 2131-1981. The split spoon sampler assembly is divided in three
parts. One is cutting shoe of 38 mm inside dia. and 51 mm outside diameter with 75 mm
length. The second is split body of same diameter and 508 mm in length. The third is
driving head with ball of same dia. meters and 180 mm in length. The drive weight
assembly consists of 63.5 kg. Weight hammer and 750 mm free fall guide rod. Before
conducting the Standard Penetration Test we had cleaned the bore by shell then lowered
the S.P.T. sampler with 'A' rod and conducted the Standard Penetration Test in accordance
with IS 2131-1981.
2. Undisturbed sample: - The undisturbed soil samples were collected in thin walled
sampling tubes. The thin wall sampling tubes confirming to IS 2132-1981 consist of cutting
shoe sampling tube and driving head with ball. The tests were conducted in accordance
with IS 2132- 1981.
3. Disturbed samples: - Disturbed samples were collected during boring and from the split
spoon sampler. The samples recovered were labeled and sent to Laboratory for testing. The
borehole was terminated when adequate depth of drilling was completed in consultation
with the Site-in-charge as per technical specification.
4. Laboratory testing: - The following laboratory tests were carried out on disturb and
undisturbed samples.
(a) Grain Size Analysis: - The Grain Size Analysis Tests were carried out in
accordance with IS 2720(Part IV)-1992.
(b) Atterberg Limit: - The Atterberg limit test apparatus is Casagrand in accordance
with IS 9259-1979.They have carry out the Test by using equipments with respect
to the soil behavior and as per the IS- 2720 (Part-V)-1991.
(c) Specific Gravity: - The specific gravity of the soil samples were carried out in
accordance with IS-2720 (Part- 3/Sec1)-1980 for fine grain soil and IS 2720 (Part-
3/ Sec- 2) - 1980 for medium and coarse grain soil.
(d) Field Density & Moisture Content: - Field density and moisture content were
carried out in accordance with IS 2720 (Part-2)-1973.
(e)Direct Shear Test: - The direct shear tests were carried out by small size box
shear test in accordance with IS- 2720 (Part-13 )-1986 and apparatus confirming
to IS- 11229- 1985.

34
4.4 SUB SOIL STRATIFICATION

The bore log data reveals the soil formation as under taken by the site engineer at that time.

a) Bore hole-1: - The first layer from 0.00mt.to 1.90mt. Consists of brownish medium to fine
grained non plastic sandy silt. The layer from 1.90mt.to 15.00mt. Consists of brownish
medium to fine grained non plastic silty sand mixed with kankkars. The water table was
encountered at 4.30mt in the borehole during the investigation in February 2018.
b) Bore hole-2: - The first layer from 0.00mt.to 1.70mt. Consists of brownish medium to fine
grained non plastic sandy silt. The layer from 1.70mt.to 15.00mt. Consists of brownish
medium to fine grained non plastic silty sand mixed with kankkars. The water table was
encountered at 3.50mt in the borehole during the investigation in February 2018.
c) Bore hole-3: - The first layer from 0.00mt.to 2.10mt. Consists of brownish medium to fine
grained non plastic sandy silt. The layer from 2.10 m to 13.70 m. Consists of brownish
medium to fine grained non plastic silty sand mixed with little kankkars. The layer from
13.70mt.to 15.00mt. Consists of brownish medium to fine grained non plastic sandy silt.
The water table was encountered at 4.50mt in the borehole during the investigation in
February 2018.
d) Bore hole-4: - The first layer from 0.00mt.to 5.20mt. Consists of brownish medium to fine
grained non plastic silty sand mixed with little kankkars. The layer from 5.20mt.to 6.90mt.
Consists of brownish medium to fine grained non plastic sandy silt. The layer from
6.90mt.to 15.00mt. Consists of brownish medium to fine grained non plastic silty sand
mixed with little kankkars. The water table was encountered at 2.50mt in the borehole
during the investigation in February 2018.
e) Bore hole-5: - The first layer from 0.00mt.to 8.20mt. Consists of brownish medium to fine
grained non plastic silty sand mixed with little kankkars. The layer from 8.20mt.to 10.10mt.
Consists of brownish medium to fine grained non plastic sandy silt. The layer from
10.10mt.to 15.00mt. Consists of brownish medium to fine grained non plastic silty sand
mixed with little kankkars. The water table was encountered at 4.80mt in the borehole
during the investigation in February 2018.
f) Bore hole-6: - The first layer from 0.00mt.to 15.00mt. Consists of brownish medium to
fine grained non plastic silty sand mixed with kankkars. The water table was encountered
at 2.10mt in the borehole during the investigation in February 2018.

35
Bore log details of bore hole-1

36
 Grain Size Analysis of soil in Bore hole-1

Fig:-4.2 Grain size distribution

Summary of lab test results of soil in Bore hole-1

Fig:-4.3 Lab test result

37
4.5 SAMPLE CALCULATION FOR GENERAL SHEAR FAILURE (BH-1) AS PER IS:
6403-1981

From the above lab results & graphs we got the values of soil shear strength parameters and type
of the soil like in bore hole-1 the soil is mainly sandy silty (SM) & Calculation of the Net-safe
bearing capacity of the soil if we assume the isolated footing of width 3m at a depth of 4m with
assuming general shear failure .

38
SAMPLE CALCULATION FOR GENERAL SHEAR FAILURE (BH-1) AS PER IS: 6403-
1981

Calculation of the Net-safe bearing capacity of the soil if we assume the isolated footing of width
3m at a depth of 4m with assuming local shear failure .

39
4.6 SAFE BEARING CAPACITY CALCULATION FOR RAFT

Calculation of the Net-safe bearing capacity of the soil if we assume the Raft footing of width 3m
at a depth of 4m.

40
4.8 Ultimate Bearing Capacity of Pile based on SPT N value Acc. to the (IS 2911 (Part 1/Sec
1): 2010 - Clause B-4)

Calculation of the ultimate bearing capacity of the soil if we assume the pile foundation of Dia.
450mm and length of pile 8m.

41
RECOMMENDATIONS & CONCLUSIONS: -

1. Water table was encountered in all of the boreholes during the investigation in
February 2018.
2. I have determined Safe Bearing Capacity as mentioned below for the proposed
structure. Suitable values may be used for design purpose.
3. We have determined the liquefaction potential as soil is fine sand and mixture of
silt with presence of ground water table.

4.9 SUMMARY OF SAFE BEARING CAPACITY

42
43
4.10 SUMMARY OF SAFE BEARING CAPACITY OF PILE FOUNDATION

Finally after the approval of the client and contractor and keeping in mind the condition of the site
we recommended the pile foundation of 450mm dia. and depth 7m details of the designed
foundation from the structure point of view done later.

44
 CHAPTER-5

INTRODUCTION OF THE PEB

Pre-engineered buildings (PEBs) use a predetermined inventory of raw materials that has proven
over time to satisfy a wide range of structural and aesthetic design requirements. This flexibility
allows PEBs to fulfill an almost unlimited range of building configurations, custom designs,
requirements and applications.

A pre-engineered steel building is a building shell utilizing three distinct product categories:

1. Built-up “I” shaped primary structural framing members (columns and rafters)
2. Cold-formed “Z” and “C” shaped secondary structural members (roof purlin, eave struts
and wall Girts)
3. Roll formed profiled sheeting (roof and wall panels).

5.1 THE MERITS OF PRE-ENGINEERED BUILDINGS

The advantages of pre-engineered steel buildings are numerous and are the major reason for the
spectacular growth of the PEB industry during the past 50 years. These advantages include:

1. Low Initial Cost: -

a. The use of tapered built-up primary structural members (columns and rafters)
usually results in up to a 40% weight advantage for the main rigid frames when
compared to the use of conventional hot rolled sections as primary members.
b. The use of “Z” shaped secondary structural members (roof purlins and wall girts),
particularly the overlapping of the “Z” shaped purlins at the frames, results in up to
a 30% weight saving for the secondary members when compared to the use of hot
rolled channels as purlins and girts. •
c. The manufacturing scrap from the production processes of built-up plate members
and cold formed “Z” sections is typically 75% less than the scrap costs generated
from the fabrication of hot rolled members.
2. Superior Quality
3. Fast Project Construction: -
a. Anchor bolt setting plans and anchor bolts can be delivered earlier than the building
supply to enable the construction of foundations prior to delivery of the steel
buildings.
b. Standard building(s) delivery is only 8 weeks (including engineering time) and may
be reduced to as low as 6 weeks for special “fast track” projects.
c. Fast erection of the steel building(s) because all structural members are field bolted
using clear user-friendly erection drawings. (The typical erection time per erection
crew is 1.0 man-hour per square meter).

45
 4. Functional Versatility: -
a. Buildings are easily expandable on all sides (allowing for future expansion).
b. Building shell is designed to accept stocked (custom manufactured) standard
accessories (personnel doors, sliding doors, roof ventilators, louvers, windows,
skylights, etc.)
c. Building design can incorporate additional standard structural subsystems such as
mezzanines, cranes, roof platforms, etc.
5. Low Maintenance and Operating Costs: -
a. Virtually no maintenance required for wall panels.
b. Roof panels require only periodic cleaning.
c. Annual washing of eave gutters.
d. Watertight roofs
e. Energy efficient roof and wall systems
5.2 Basic Terms used in the PEB structure
1. Anchor Bolts: Bolts used to anchor structural members to a concrete floor, foundation or
other support. Usually refers to the bolts at the bottom of all columns and door jambs.

Fig-5.1 Anchor bolts

2. Assembly: Two or more components bolted together.
3. Anchor Bolt Plan: A plan view of a building(s) foundations showing all dimensions and
sections required to properly locate the anchor bolts, including the projections of the bolts
above the concrete surface, required recess, etc. Column reactions (magnitude and
direction), and base plate dimensions are also included.
4. Auxiliary Loads: All specified dynamic live loads, other than the basic design loads,
which the building must safely withstand.
Examples are loads imposed by crane systems,
material handling systems and impact loads.
5. Base Angle: A continuous angle fixed to the
floor slab or to the grade beam to enable the
attachment of wall panels.
6. Base Plate: The endplate of a column which
rests on the supporting substructure surface.
Fig:-5.2 Base plate & base angle

46
7. Bay: The space between the center lines of frames or primary supporting members in the
longitudinal direction of the building. Also called Bay Spacing or Bay Length.

Fig:-5.3 Bay spacing

8. Beam: A horizontal structural member designed primarily to resist moment.
9. Brace Rods/Cables: Rods or cables placed diagonally in the roof and walls for the purpose
of transferring wind loads to the foundations and longitudinally stabilizing the building.
10. Braced Bay: The bay where bracing is provided.
11. Bracket: A structural support projecting from a column or rafter to which another
structural member is fastened. Example: Brackets supporting crane runway beams.

Fig:-5.4 Bracket
12. Bridge Crane: Overhead traveling crane supported by rails which are in turn supported by
crane runway beams.
13. Building Width: The lateral width of the building
measured from out to out of sidewall steel lines.
14. Built-up Section: A structural member, usually an
“I” shape, made from individual flat plates welded
together.
15. “C” Section: A member formed into a “C” shaped
profile by cold roll-forming from coils. Fig:-5.5 Building width

47
16. Catwalk: A narrow walkway used to provide access to mechanical equipment normally
supported on roof platforms.
17. Channel (Hot Rolled): A member formed, while in a semi molten state at the steel mill,
into a “C” shaped profile having standard dimensions and properties specified by a relevant
standard specification.
18. Clear Height: The vertical dimension from the finished floor level to the lowest underside
point of the rafter.
19. Clear Span: A building without internal columns.
20. Clip: A plate or angle used to fasten two or more members together.

Fig:-5.6 Clear span

21. Coil: A roll of steel sheet or wire.
22. Cold-Formed Member: A light gauge structural member produced from coiled steel stock
running through a series of rolls at normal room temperatures.
23. Collateral Load: The static load other than the basic design loads such as sprinklers,
mechanical and electrical systems, ceilings, etc.
24. Column: A vertical structural member used in a building to transfer loads from the main
roof beams, trusses or rafters to the foundation.
25. Crane: A machine designed to lift and/or move material by means of a hoist.
26. Crane Beam: A beam that supports an overhead traveling bridge crane. On under hung
bridge cranes, it also acts as a crane rail. Also known as a Crane Runway Beam.
27. Crane Bracket: Structural support welded to the primary building frame to permit
attachment of a crane runway beam. See also Bracket.
28. Crane Bridge: One or two girders or box sections supported on end carriages.
29. Crane Capacity: The maximum weight a crane can safely lift. Crane capacity depends on
the standard design of the crane components and their supports.
30. Crane Rail: Rail welded or bolted to a crane beam forming the track on which the bridge
crane wheels travel.
31. Crane Stopper: A small vertical member welded to the top of the crane beam to stop the
crane bridge at the end of the crane run area.
32. Eave: A line along the sidewall formed by the intersection of the inside faces or planes of
the roof and the sidewall panels.
33. Eave Height: The vertical dimension from the finished floor level to the top of the eave
strut.

48
34. End Bay: The first or last bay in the building, as opposed to interior bay. It is the spacing
between the outside face of the outer flange of the endwall columns and the center line of
the first interior column.
35. Endwall: A term used to describe the entire
composition of a building end. See Post & Beam
Endwall or Rigid Frame Endwall.
36. End Wall Framing: Framing located at the
endwall of a building which supports the loads
acting on a portion of the end bay.
Fig:-5.7 End wall
37. Erection Drawings: Drawings and erection instructions which identify all the individual
components in sufficient detail to permit the proper assembly of all parts of the metal
building system furnished by the seller..
38. Fixed Base: A column base that is designed to resist
rotation as well as horizontal or vertical movement
39. Footing: Reinforced concrete base that provides
support for a column.

Fig:-5.8 Fixed base

40. Framing: Primary and secondary members (columns, rafters, girts, purlins, brace cables,
etc.) which when connected together make up the skeleton of a structure to which the
covering can be fastened.
41. Girt: Secondary horizontal member attached to the main frame columns. Girts normally
support wall panels.

Fig:- 5.9 Grit

42. Gusset Plate: Steel stiffener plate used to help distribute load at a connection.
43. Impact Load: A dynamic load resulting from the motion of machinery, crane ways,
elevators and other similar moving forces.
44. Interior Bay: The distance between the center lines of two adjacent interior rigid frames.
45. Jack Beam: A primary horizontal member used to support another beam, truss or rafter.
46. Lean-To: A structure dependent upon another structure for partial support and having only
one slope or pitch.

49
47. Live load: Any variable load that results from intended use of the structure during its life
time.
48. Mezzanine: An intermediate floor within a building above the ground floor that occupies
all or part of the building floor area and consists of columns, beams, joists, deck panels and
edge trims to receive reinforced concrete.
49. Multi-Gable Buildings: Buildings consisting of one or more gables across the width of
the building.

Fig:-5.10 Multi-gable building

50. Moment Connection: A connection designed to transfer moment, as well as axial and
shear forces, between connecting members
51. Pitch (Roof): Slope of the roof.
52. Portal Frame: Column and beam bracing used in lieu of standard diagonal cable bracing
to provide clear access.

Fig:-5.11 Pitch (Roof) Fig:-5.12 Portal frame

53. Primary Framing: The main load carrying members of a structural system, generally the
columns, rafters, and/or other main support members.
54. Purlin: A horizontal secondary structural member, bolted to the rafters, which transfers
the roof loads from the roof covering to the primary frames.
55. Rafter: A primary beam member supported on columns.

50
 Fig:-5.13 Purlins Fig:-5.14 Rafters
56. Reactions: The resisting forces, at the column bases of a frame, holding the frame in
equilibrium under a given loading condition.
57. Ridge: The peak, or highest point of a gabled building, which describes a horizontal line
running the length of the building.
58. Ridge Connection: A connection, between two rafter members, which transfers the
moment from one side of the connection to the other and maintains, under application of
load, the same angle between the connected members that exists prior to the loading. See
also Moment Connection.
59. Rigid Frame: A structural frame consisting of members joined together with rigid (or
moment) connections so as to render the frame stable with respect to imposed loads,
without the need for bracing in its plane.
60. Sag Rod: A tension member used to limit the movement of a girt or purlin in the direction
of its weak axis before the installation of sheeting.
61. Seismic Load: The assumed lateral load acting in any horizontal direction on the structural
system due to earthquakes.
62. Sheeting: Profiled metal panels.
63. Sidewall: A term used to describe the entire composition of a building side which is
parallel to the ridge.
64. Stiffener: Plate welded to a member to increase strength of the web or to provide continuity
at connections.
65. Under Hung Crane: Bridge crane hanging from beams, rather than supported on beams.
66. Wheel Base: The distance between the two wheels of a crane along the crane beam.

Fig:-5.15 Wheel base

67. Wheel Load: The maximum load which is transferred through the wheels of a crane to a
crane beam.

51
68. Wind Load: A loading representing the pressure exerted on a structure by a given wind
velocity. A load caused by the wind blowing from any
horizontal direction.
69. “Z” Section: A member formed from coiled steel stock
into the shape of a block “Z”. Usually used for purlins and
girts.
Fig:-5.16 “Z”-section

Fig:-5.17 General Pre-engineered building

52
5.3 STANDARD STRUCTURAL SYSTEMS

1. Bay Length: - A bay length of 7.5 m is used is the most economical in most PEB
applications. However, 9 m bay lengths are gaining popularity and acceptance because
longer bays often result in savings to the overall project cost as their use results in lower
foundation costs (fewer rigid frames translates into fewer footings). When bay lengths
greater than 9 m are required, jack beams or open web joists are used. These permit bay
lengths of up to 18 m.
2. Eave Height: - Eave heights as high as 30 m can be accommodated.

5.3.1 Some Of The Structural Systems Most Used Are Shown Below

1. Single Slope (SS) buildings

2. Multi-Gable (MG) buildings
3. Roof System (RS) buildings
4. Flat Roof (FR) buildings
5. Low Rise (LR) buildings.

1. Single Slope (SS) buildings: - Buildings are economical in spans that are less than 12
meters. The most common conditions for using Single Slope buildings are:-
a. Whenever rain water drainage is required to be along one sidewall of the building
only.
b. When a new Single Slope building is added directly adjacent to an existing building
2. Multi-Gable (MG) buildings: - Multi-Gable (MG) buildings consist of two or more gable
buildings sharing common sidewall columns. Multi-Gable buildings have the advantage of
reducing the height of the building ridge (peak) for very wide buildings. Multi-Gable
buildings may be either Clear Spans or Multi-Spans.

Fig:-5.18 Multi-Gable building (used in our project)

3. Roof System (RS) buildings: - A Roof System consists of roof rafters, purlins and
sheeting specifically designed to install onto a planned or an existing substructure. The
substructure is normally made of concrete or masonry.
4. Flat Roof (FR) buildings: - A Flat Roof system provides the convenience of easy roof
accessibility and is usually specified when the support of heavy unit loads, such as HVAC

53
 equipment, is a requirement. Flat Roofs, particularly popular in low rise buildings,
comprise of horizontal main frame rafters (beams) supporting joists (built-up or open web)
and a structural steel deck.
5. Low Rise (LR) buildings: - Low rise buildings are ideal for offices and other commercial
uses. Low rise buildings, utilizing the PEB approach, are not only more economical than
traditional methods of construction but are often constructed in half the “normal” time
especially when complemented with the following subsystems.

5.4 SECONDARY STRUCTURAL FRAMING

Purlins, girts and eave struts are

secondary structural members used to
support the wall and roof panels. Purlins
are used on the roof; girts are used on the
walls and eave struts are used at the
intersection of the sidewall and the roof.
Secondary members have two other
functions: they act as struts that help in
resisting part of the longitudinal loads
that are applied on the building such as
wind and earthquake loads, and they
provide lateral bracing to the
compression flanges of the main frame
members thereby increasing frame
capacity.

BASIC STRUCTURAL SUBSYSTEMS Fig:-5.19 Sub-Structure

The strength of the pre-engineered building system lies in its ability to incorporate a large number
of structural subsystems that use standard components and standard design approaches to satisfy a
wide range of custom requirements.

The structural subsystems that form a basic pre-engineered building consists: -

1. Bracing Systems
2. Post & Beam End-walls

1. Bracing: - Lateral stability along the width of pre-engineered steel buildings is provided by
designing the frames to resist the imposed lateral loads. Bracing systems are furnished along
the length of the buildings to provide longitudinal stability due to the weakness of the building
structure in that direction. The main purpose of a bracing system is the transmission of lateral

54
 forces due to wind, cranes, earthquakes, etc. from their point of application on the structure to
the column bases and eventually into the foundations.
Standard bracing systems are Diagonal X-Bracing, Portal Bracing and Minor Axis Bending.
a. Diagonal X-Bracing: - This is the standard bracing system commonly used in the roof and
sidewalls of pre-engineered steel buildings. Members used for the diagonals are galvanized
cable strands solid smooth rods, flat bars or angles.
b. Portal Bracing: - This form of bracing is usually provided between exterior columns at
the exterior sidewalls, or between interior columns in very wide Multi-Span and Multi-
Gable buildings, in bays where diagonal X-bracing is not permitted due to a desire to have
clear non-obstructed deep space through these bays. Portal frames are made from built-up
columns and rafters. Portal frame columns are commonly stitch bolted to the web of the
Rigid Frame columns as an alternative to anchoring the portal frame columns to the
foundation substructure.

Fig:-5.20 Portal bracing Fig:-5.21 Cross-bracing

2. End-walls: - The End-wall Frame of a pre-engineered building may be designed as a main

Rigid Frame (R.F.), i.e., similar to an interior frame, or as a Post-and Beam (P&B) frame.
• Post-and-Beam End-wall Post-and-Beam End-wall: - The Post-and-Beam end-wall
system of framing consists of columns (posts), with pinned ends, supporting end-wall
rafters. Girts are flush-framed between posts to provide lateral stability and a neat
appearance. Post-and-Beam end-walls are assumed to be laterally stiff due to the flush-
framed girts and the diaphragm effect of the wall sheeting. The diaphragm action is proven
to be sufficient enough to resist the transverse wind force acting on the small tributary area
of the sidewall. Where a block wall is required in place of the wall sheeting, angle clips are
provided at certain locations along the posts to tie them to the block wall in order to ensure
the frame’s stability. End-wall posts are designed to carry both vertical loads and horizontal
wind loads.
• Rigid Frame: - End wall Rigid Frame End wall A Rigid Frame end wall is typically used
when a building is designed for a future expansion along the length of the building, when
a crane system (runway beam) extends to the end of the building or when large
55
 unobstructed openings are required in the end wall. This type of frame is usually designed
to withstand a full bay load and is normally identical to an interior main rigid frame.

5.5 CATWALKS & WALKWAYS

Catwalks and walkways which are used primarily by maintenance crews to provide access to
mechanical equipment:
• Catwalks that are normally located inside the building alongside crane beams or suspended
underneath rigid frame rafters.
• Elevated walkways that are placed directly above the building roof, whenever very
frequent access is required between several roof platforms.
• Flush walkways that are also placed above the building roof, whenever less frequent
access is required for maintenance.

56
 CHAPTER-6

DESIGN OF BOGIE REPAIR SHED

6.1 BUILDING DESCRIPTION

Bogie Repair Shop is the Second main workshops of the LHB Project where the Bogies are sent after
the processing work done in the LHB Workshops. Here the bogies and its components are Shot Blasted
and then Painted at the paint booth. The Detailed description of shed in given in Table no. 6.1.

TABLE NO. 6.1

Building Parameters
1 Type Multi span type
2 Crane description 2 NOS of 10 MT O.H CRANE IN EACH SPAN
3 Width Module (m) 3 @ 10 m C/C
4 Width (m) 31.24 Out to Out of Steel Sheeting
5 Length (m) 160.4 Out to Out of Steel Sheeting
6 Roof Slope 1:5
7 Exterior Columns Base Fixed
8 Interior Columns Base Fixed
9 Height (m) from FFL (0.00m) 11.0 Clear Height under the knee
10 Bay Spacing (m) As per G.A. Drawings
Frame Type: Rigid Frame Girts: Bypass
Left End wall
Column Spaces(m):N.A.
11 End walls
Frame Type: Rigid Frame Girts: Bypass
Right End wall
Column Spaces(m):N.A.
At Exterior Walls Cross Pipe Bracing
Bracing
12 On Interior Walls Cross pipe bracing
Type
On Roof Diagonal (Cross Pipe Bracing)
Minimum Built up Section
13 Web: 6mm Flange: 6mmall Built up sections.
Thickness
Minimum Cold Formed
14 2.0
Member Thickness (mm)

Open Wall Conditions.

1 Front Side Wall Open upto2.4m height above wall cladding.
2 Back Side Wall Openupto2.4m height above wall cladding.
3 Left End wall Openupto2.4m height above wall cladding.
4 Right End wall Open upto6.65m height and above cladding.

The Plan and Elevation of the Shed in attached in Appendix-3.

57
 6.2 DESIGN LOADS

The Detailed description of Loads in given in Table no. 6.2.

TABLE NO. 6.2

Design Loads
1 Design Dead Load ( KN/m2 ) on roof 0.15
2 Design Live Load ( KN/m2 ) on frame 0.75
3 Additional Collateral Load ( KN/m2 ) 0.20
4 Wind Speed (m/sec) 50 m/sec
5 Seismic Zone Zone 5

Crane Loads
1 Crane Capacity M.H/A.H 10.0/5.0 MT
2 Crane Span 10 m
3 Top of Crane Rail 7.5 m
4 Bridge Weight 12.0 MT
5 Trolley Weight 3.0 MT
6 Wheel Load 8.0 MT
7 Wheel Base 3.0 m

6.3 DESIGN CODES

All buildings included in this proposal are designed in accordance with the following codes:

APPLICABLE INDIAN CODES

1. Hot rolled sections and built up members have been designed with:
• IS: 800:2007: General Construction in Steel-Code of Practice. (Limit State Method)
• IS: 2062: Specification for structural steel.
2. Loads have been applied on structure in accordance with :
• IS: 875 (Part-1, 2 & 3): Code of Practice for design loads for building & structures.
• IS: 1893-2002: Criteria for Earthquake resistant design and structures.
3. Cold formed members have been designed with:
• IS: 801 Code of practice for use of cold formed light Gauge steel structural members
in general Building construction
• IS: 811 Cold form sections
4. Welding has been applied in accordance with:
• IS: 816 Code of practice for use of metal arc welding for general construction in mild
steel.

58
Only in absence of design criteria not available in mentioned IS codes, reference can be made to
other international codes/manuals as applicable.

6.4 DESIGN ASSUMPTIONS

• The main frame rafters and exterior columns are rigidly connected to each other (using
moment type connections).

• The lateral stability of the building is provided through the frame action of the main frames.

• The longitudinal stability of the building is provided through the truss action in the cross
braced bays of the building.

• The Rigid frame is provided at the end walls too.

• Building is designed with internal wind coefficient +/-0.7 (openings >20%).

• The roof purlins are continuous beams supported at rigid frame locations and span the bay
spacing of the building.

• The Side Wall girts are continuous beams supported at rigid frame location and span the bay
spacing of the building.

• The roof and wall sheeting provide lateral support for purlins and girts.

Limitations of Assumptions on Design: -

1. Purlin & side-cladding Runners

a) If purlin/runners are assumed to be continuous over supports, continuity shall
have to be developed at supports through proper connections to be absorb the
continuity moments.
b) In case of continuous purlins/runners temperature effects need to be considered
and such force need to be transferred down to the foundation through the main
structure and appropriate bracing or other force transfer-system.
c) Sag rod / or sag struts may be provided as per requirements of economic design.
2. Columns/Portal frames
a. The portal frame shall be analyzed for semi fixed base and hinge base the
combination of load cases which gives maximum force shall be considered for
design of foundation holding down bolts, column main rafters and connections.
b. All columns shall be of solid web sections. These can be standard hot rolled
sections or built up sections. Profiling of the sections is permissible if so desired
by the suppliers.

59
3. Roof rafters
a. Roof rafters shall also be solid web sections, either standard hot rolled or built-
up. Depending on suppliers design. Truss and castellated sections will not be
acceptable.
b. Connections of rafters to columns shall be through rigid welded/bolted joints
only.

Fig:-6.1 Proposed Bogie Repair Shop Sectional View

60
6.5 DEFLECTION LIMITATION

61
 6.6 LOAD COMBINATIONS

Load Combinations: (AS PER IS-800-2007)

Limit states design shall, Section 5.2.2, shall satisfy these two design requirements:

i) Limit state of Strength,

ii) Limit state of Serviceability.

Strength state is satisfied when the anticipated loads are less than the calculated strengths.
Serviceability is satisfied when the deflections at working loads are within the limiting values.

62
 6.7 STAAD MODELING OF FRAME

The frame analysis of any PEB structure is done in the STAAD or MBS but as per RITES
guidelines it can only be done in the STAAD because it is more reliable and widely used software
then MBS. If we talk only about the design of the industrial shed only then they are designing
frame and columns with rafters and the bracing is design in the STAAD itself but the secondary
members like Purlins, Base plate & anchor blot, Connection plate design of the members is
designed manually or in by M.S EXCEL for time shortage. The Gantry girder for the EOT crane
is designed in the STAAD or by M.S EXCEL (Manually).

For the purpose of preparing the Design calculation report & drawings, I follow the general &
special requirements of design criteria and material specifications as laid down below STAAD
model with detailed calculations for all the members. I am submitting all design calculations along
with anchor bolt and general arrangement drawings.

Fig:-6.2 Geometric Model of the Structure

The Geometric model of the structure is only for the half of the length because it is 160m long
shed with equal bay spacing due to this the other bay frames are same as other half.

63
 6.8 PROPERTIES OF THE MEMBERS

The Tapered I-section is provided for the frame members and pipe section for the bracing details
showing in the figure below:-

Fig:-6.3 Properties of the Frame

The Detailed description of Properties in given in Table no. 6.3

TABLE NO. 6.3

Properties of Frame members

S.No. Designation Properties
Depth of Flange Width & Thickness of web
section Thickness
1. R1 483mm 225mm & 12mm 8mm
2. R2 450mm 200mm & 16mm 10mm
3. R3 732mm 225mm & 12mm 8mm
4. R4 524mm 200mm & 10mm 8mm
5. R5 524mm 200mm & 12mm 8mm
6. R6 740mm 325mm & 12mm 8mm
7. R7 316mm 150mm & 10mm 6mm
8. R8 524mm 250mm & 12mm 8mm

64
Properties of the Pipe for bracing: - Outer dia. of 139.7mm & thickness of 4.80mm.

Fig:-6.4 Properties of bracing

6.8.1 Material Specification of members: - The material provided for structure is steel
only with details below in Table No. 6.4: -

TABLE NO. 6.4

Material Specification
S.No. Materials Specification Steel Yields
1. Built-up Member ASTM A572 Gr50 Fy= 345Mpa
2. Hot Rolled Secondary Members IS: 2062 Fy= 240Mpa
3. Gantry beam ASTM A572 Gr50 Fy= 250Mpa
4. X-Bracing Members IS: 2062/1732 Fy= 240Mpa
5. High strength Bolts for Primary IS: 1367(Part-3) Gr 8.8
Connection
6. Machine Bolts for secondary IS: 1367 & 1363 (Part-
Connection 3)

Cold form/Z- sections are pre galvanized (120 GSM) AS PER ASTM A653M OF Gr. 50(345
MPa) steel.
65
 6.9 SUPPORT CONDITION OF THE STRUCTURE

The supports provided in the structure are fixed butt joint in which Mx & My are released because
frame is restraint at base by bolts in Mz direction.

Fig:-6.5 Supports at columns

Fig:-6.6 Support condition

66
 6.10 LOADING ON THE STRUCTURE

1. Seismic parameters: - seismic load parameters are applied on the structure because the
zone-5 of the area in which project is going on.
2. Dead load: - Self-weight and the sheeting load is applied on the structure.
3. Live load: - the live load acc. to the IS: 875-Part-2 is applied on the structure of 0.75
KN/m2 is applied on the structure.
4. Wind load: - wind loads are applied on the structure due to zone-5 of wind and calculation
is acc. to the IS: 875-Part-3 and the load is find in every direction and applied to the
structure.
5. Crane load: - Reaction of the crane on the each column max. & min. is applied on the
structure.

6.10.1 Calculation of load: -

1. DEAD LOAD: - 0.15 KN/M2 X7.33 =1.099 KN/RMT
2. LIVE LOAD: - 0.75 KN/M2 X7.33 =5.497 KN/RMT
3. COLLETRAL LOAD: -0.2 KN/M2 X7.33 =1.466 KN/RMT
4. Wind Load Calculation IS 875 (Part 3):2015: -
a. Building Width W = 30.0 m
b. Building Length L = 160.0 m
c. Eave Height H = 11.0 m
d. Roof Slope (1:10) 5.87
e. Openings in buildings > 20% (Internal Pressure Coefficient 0.7 Refer clause 7.3.2,
page 11)
f. Bay Spacing BS = 7.33 m
g. Purlin & Girts Spacing GS = 1.2 m
h. Basic Wind Speed Vb = 50 m/sec (Refer ANNEX A, page 51)
i. Probability Factor (Risk coefficient) k1 = 1.08 (Refer Table 1, page 7).
j. Terrain Category = 2 (Refer clause 6.3.2.1, page 5).
k. Terrain Roughness & Height Factor k2= 1.05 (Refer Table 2, page 8).
l. Topography Factor k3 = 1 (Refer clause 6.3.3, page 8)
m. Importance Factor for Cyclone Region k4 = 1 (Refer clause 6.3.4, page 8).
n. Design Wind Speed Vz = 50 x 1.07 x 1.05 x 1 = 56.175 m/sec (Refer clause 6.3,
page 5).
o. Wind Pressure at Height H Pz = 0.6 x 56.175^2 = 1.8933 kN/m2 (Refer clause 7.2,
page 9).
p. Wind Directionality Factor Kd = 0.9 ( Refer clause 7.2.1, page 9).
q. Tributary Area Rafters A = 30 x 7.33 = 219.9 sqm ( Refer Table 4, page 10).
r. Tributary Area Columns A = 11 x 7.33 = 80.63 sqm (Refer Table 4, page 10).
s. Tributary Area Purlins/Girts A = 1 x 7.33 = 7.33 sqm (Refer Table 4, page 10).
t. Area Averaging Factor for Rafters Ka = 0.9 (Refer Table 4, page 10).

67
 u. Area Averaging Factor for Columns Ka = 0.9 (Refer Table 4, page 10).
v. Area Averaging Factor for Purlins/Girts Ka = 1.0 (Refer Table 4, page 10).
w. Combination Factor Kc = 0.9 (Refer clause 7.3.3.13, page 16).
x. Minimum Design Wind Pressure Pdmin = 0.7 x 1.899 = 1.3293 kN/m2 , (Refer
clause 7.2, page 9).
y. Design Wind Pressure for Rafter Pd = 1.89 x 0.9 x 0.9 x 0.9 = 1.377 kN/m2,
(Refer clause 7.2, page 9)
z. Design Wind Pressure for Columns Pd = 1.89 x 0.9 x 0.9 x 0.9 = 1.377 kN/m2,
(Refer clause 7.2, page 9)
aa. Design Wind Pressure for Purlins/Girts Pd = 1.89 x 1.0 x 0.9 x 0.9 = 1.53 kN/m2,
(Refer clause 7.2, page 9)
bb. Building Height Ratio= 0.366 ( Refer Table 5, page 13)
cc. Building Plan Ratio= 5.33 (Refer Table 5, page 13)

1. WLP (WIND PRESSURE LEFT TO RIGHT): -

• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.0 = 0 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M XX 1.90 = 19.07 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 1.10 = 11.040 KN/M
• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.95 = 9.535 KN/M
• GABLE ENDWALL WIND LOADS
• WIND LOAD = 1.370 KN/SQM X 10M X 1.15 = 15.81 KN/M
• WIND LOAD = 1.370 KN/SQM X 10M X 1.15 = 15.81 KN/M

2. WRP (WIND PRESSURE RIGHT TO LEFT): -

• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.95 = 9.535 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 1.10 = 11.04 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 1.90 = 19.07 KN/M
• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0 = 0 KN/M
• GABLE ENDWALL WIND LOADS
• WIND LOAD = 1.370 KN/SQM X 10M X 1.15 = 15.81 KN/M
• WIND LOAD = 1.370 KN/SQM X 10M X 1.15 = 15.81 KN/M

3 WLS (WIND SUCTION LEFT TO RIGHT): -

• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 1.4 = 14.05 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 0.50 = 5.05 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 0.30 = 3.012 KN/M
• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.45 = 4.518 KN/M
• GABLE ENDWALL WIND LOADS
• WIND LOAD = 1.370 KN/SQM X 10M X 0.1 = 1.37 KN/M

68
 • WIND LOAD = 1.370 KN/SQM X 10M X 1.3 = 1.37 KN/M

4 WRS (WIND SUCTION RIGHT TO LEFT): -

• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.45 = 4.518 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 0.30 = 3.012 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 0.50 = 5.05 KN/M
• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 1.4 = 14.05 KN/M
• GABLE ENDWALL WIND LOADS
• WIND LOAD = 1.370 KN/SQM X 10M X 0.1 = 1.37 KN/M
• WIND LOAD = 1.370 KN/SQM X 10M X 1.3 = 1.37 KN/M

5 WPP (WIND PARALLEL PRESSURE): -

• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 1.2 = 12.048 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 1.5 = 15.06 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 1.5 = 15.06 KN/M
• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 1.2 = 12.048 KN/M

6 WPS (WIND PARALLEL SUCTION): -

• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.20 = 2.008 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 0.10 = 1.004 KN/M
• FOR RAFTER = 1.370 KN/SQM X 7.33M X 0.10 = 1.004 KN/M
• FOR COLUMNS = 1.370 KN/SQM X 7.33M X 0.20 = 2.008 KN/M

Fig:-6.7 Loads on the structure

69
 6.11 DESIGN METHODOLOGY OF THE BASE PLATE

Base Plate:- The end plate of a column which rests on the supporting substructure surface. Column
bases should have sufficient stiffness and strength to transmit axial force, bending moments and
shear forces at the base of the columns to their foundation without exceeding the load carrying
capacity of the supports.

Fig:-6.8 3-D view of base plate at foundation Fig:-6.9 Detail of the anchor bolts

Anchor Bolts: - Bolts used to anchor structural members to a concrete floor, foundation or other
support. Usually refers to the bolts at the bottom of all columns and door jambs. Anchor bolts and
shear keys should be provided wherever necessary; Shear resistance at the proper contact surface
between steel base and concrete/grout may be calculated using a friction coefficient of 0.45. The
nominal bearing pressure between the base plate and the support below may be determined on the
basis of linearly varying distribution of pressure. The maximum bearing pressure should not
exceed the bearing strength equal to 0.6fck, where fck , is the smaller of characteristic cube strength
of concrete or bedding.

The hole diameter in base plates shall not exceed the anchor bolt diameter by more than 6 mm.

Column and base plate connections

Where the end of the column is connected directly to the base plate by means of full penetration
butt welds, the connection shall be deemed to transmit to the base all the forces and moments to
which the column is subjected.

70
 Fig:-6.10 Forces acted on the base plate

6.11.1 General design procedure of the base plate in industries acc. to the IS: 800-2007:-

1. In our case we have divided base footing design in 2-parts like:-

i) Inner grids base plates because the moments & axial load in these grid columns are
more than as compared to the outer grids.
ii) Outer grids base plates because the moments & axial load in these grid columns are
less than as compared to the outer grids.
2. We have considered different load cases acc to the IS: 800-2007 acc. to the table-4 as
shown.

3. From these loads combination we have to find critical one like in our case there are 2
critical load combination:-
i) One which have higher moment.
ii) Other which have higher axial load.
Upper both 2 load cases contain a little amount of horizontal shear.
4. Calculate the shear load from the bracing bay.
5. Calculate the resultant shear load from the bracing and the shear comes from the load
combination by (fx2+ fy2 )0.5.
6. Assume the size of the base plate acc to the size of the column.
7. Allowable compressive strength of concrete (fc) is 0.45fck.

71
8. Assume the dia. & no. of the anchor bolt and size of the hole is (dia.+ 6mm) acc. to IS:
800-2007 cl.17.2.2.1
9. Find the Net & Gross area of the bolt (net area is cross-sectional area of the bolt at the
threads).
10. Find the edge distance and the pitch of the bolts acc to IS: 800-2007 cl. 10.2.3.2..
11. Assume the grade of the material used like grade of the anchor bolts and the grade of the
base plate.
12. Find the maximum and the minimum stress at the extreme fibers of the plate by the axial
load and the moment transferred at the base plate form the load combination for both the
cases.
13. Also find the tension in all anchor bolts in one side of the bolt group by simple linear stress
theory and find the load coming on the bolt group by stress*area of the plate
14. Calculate the tension in each bolt by total load/no. of the bolts on one side.
15. Calculate the tension capacity of the one bolt acc. to IS: 800-2007 cl.10.3.5
16. Find the shear in each bolt from resultant shear/Total no. of the bolts.
17. Find the shear capacity of the bolts acc. to the IS: 800-2007 cl.10.3.3.
18. Find the bearing capacity of the bolts acc. to the IS: 800-2007 cl. 10.3.4
19. Check for the combined shear and the tension acc. to the IS: 800-2007 cl. 10.3.6.
20. Find the thickness of the base plate acc. to the
21. Check for length of anchor bolt.
22. Assume Bond stress of the concrete acc to the fck.
23. Required Length of the bolt is (tension per bolt/bond stress*circumference of the bolt).

72
Final output comes from the design given to the client or at the site.
(1) Length of base plate ( l ).
(2) Width of base plate ( w ).
(3) Thickness of base plate ( w ).
(4) Diameter of anchor bolt ( d ).
(5) Total number of anchor bolts ( n ).
(6) Length of anchor bolt (l).

Fig:-6.11 General Base plate details

73
 CUSTOMER M/S ISGEC-BONGAIGAON DESIGN BY MK

PROJECT BOGIE REPAIR SHED FOR M/S RITES BONGAIGAON CHECK BY AGM

DESIGN OF BASE PLATE & ANCHOR BOLT AS PER IS 800-2007(LSD)

6.12 DESIGN OF BASE PLATE & ANCHOR BOLT AS PER IS 800-2007(LSD)

DETAIL A &A1

INPUT DATA :

1 LOCATION : LEAN TO COLUMN @ GL D1

NODE:

2 LOAD COMBINATION : 105 1.5 DL1+1.5 LL1+1.5 CL1+1.05 CR3 CASE I 1

108 1.5 DL1+1.5 LL1+1.5 CL1+1.05 CR4 CASE II 1

3 TYPE OF BASE : FIXED BASE

4 LOADINGS : CASE I CASE II

FACTORED MOMENT @ Z AXIS ( Mz ) = 286 KN/M 473 KN/M

FACTORED MOMENT @ Y AXIS ( My ) = 0 KN/M 0 KN/M

FACTORED AXIAL LOAD ( P ) = 414 KN Thrust 444 KN

FACTORED TRANSVERSE SHEAR ( Hz ) = 60 KN

FORCE FROM BRACED BAY( Hy ) = 145 KN

RESULTANT SHEAR FORCE ( H ) = 156.92 KN

5 SIZE OF BASE PLATE :

1040

LENGTH OF BASE PLATE ( L ) = 1040 MM

590

WIDTH OF BASE PLATE ( B ) = 590 MM

74
6 COLUMN DETAILS :

DEPTH OF COLUMN (D) = 740 MM

7 FOUNDATION DETAILS :

ALLOWABLE COMPRESSIVE STRENGTH

OF CONCRETE (fc) = 11.25 Mpa FOR M25 GRADE OF CONCRETE

8 ANCHOR BOLT DETAILS :

DIAMETER OF ANCHOR BOLT (D) = 32 MM

HOLE DIAMETER OF ANCHOR BOLT (do) = 38 MM

NET AREA (An) = 660.52 MM2

GROSS AREA (Ag) = 804.248 MM2

NO. OF ANCHOR BOLT ON EACH SIDE ( N ) = 8

C/C DISTANCE OF BOLT GROUP (Lb) = 700 MM

EDGE DISTANCE (e) = 70 MM

PITCH (p) = 150 MM

NUMBER OF SHEAR PLANES WITH

THREADS INTERCEPTING THE SHEAR = 0
PLANE (nn)

NUMBER OF SHEAR PLANES WITHOUT

THREADS INTERCEPTING THE SHEAR = 1
PLANE (ns )

75
9 MATERIAL :

ULTIMATE
YIELD STRESS PARTIAL SAFETY
GRADE TENSILE
(Mpa) FACTOR (ϒ)
STRESS(Mpa)

BOLT A307 240 400 1.25

PLATE A572GR.50 345 450 1.10

76
ANALYSIS & DESIGN :

AREA OF BASE PLATE (Ab) = L x B

= 1040 x 590

= 613600 MM2

P + 6M
σcon-max = =
A BL2

414000 6 x 286000000 6 x 0
= + +
613600 590 x 1081600 1040 x 348100

= 3.36 Mpa <fc O.K. CASE I

= 5.171 Mpa < fc O.K. CASE II

P - 6M
σcon-min = =
A BL2

414000 6 x 286000000 6 x 0
= - -
613600 590 x 1081600 1040 x 348100

= -2.02 Mpa

L x σcon-max
c= =
(σcon-max + σcon-min)

1040 x 3.36
=
( 3.364 +2.015)

= 650.411 MM

77
 L c
a= = -
2 3

1040 650.411
= -
2 3

= 303.20 MM

L - Lb
e= =
2

1040 - 700
=
2

= 170 MM

c
y= = L - - e
3
650.411
= 1040 - - 170
3

= 653.2 MM

TENSION IN ALL ANCHOR BOLT LOCATED AT ONE SIDE OF BASE PLATE (F T)

M - (Pxa)
FT =
y

286000 - ( 414 x 303.197)

=
653.2

= 245.679 KN

78
CHECK 1 : CHECK FOR TENSION

ACTUAL TENSION PER BOLT ( Tb )

FT
Tb =
N

245.68
= = 30.71 KN
8

ALLOWABLE TENSION PER BOLT (Tdb)

Tnb
Tdb = = 190.23 KN > 30.71 KN OK
ϒmb

WHERE, Tnb = 0.9 x fub x An

= 237.79 KN

CHECK 2 : CHECK FOR SHEAR

ACTUAL SHEAR PER BOLT ( V sb )

H
Vsb = = 9.81 KN
2xN

CAPACITY OF BOLT IN SHEAR ( V dsb )

Vnsb
Vdsb = = 148.59 KN
ϒmb

WHERE, fub
Vnsb = (nn x Anb + ns x Asb)
√3

= 185.73 KN

79
 CAPACITY OF BOLT IN BEARING (V dpb)

Vnpb
Vdpb = = 222.26 KN
ϒmb

WHERE, Vnpb = 2.5 Kb d t fub = 277.828 KN

Kb = SMALLER OF FOLLOWING = 0.61

e
i) = 0.61
3do

p
ii) - 0.25 = 1.07
3do

fub
iii) = 0.89
fu

iv) 1.0

DESIGN STRENGTH OF BOLT IS MINIMUM OF STRENGTH OF BOLT IN SHAR AND STRENGTH OF BOLT IN BEARING

DESIGN STRENGTH OF BOLT (V db) = 148.59 KN > 9.81 KN O.K.

CHECK 3 : CHECK FOR COMBINED SHEAR AND TENSION

= 0.030 < 1 O.K.

80
THICKNESS OF BASE PLATE :

CONDITION 1:- THREE EDGES FIXED CONDITION 2:- TWO EDGES FIXED

a a

b b

a = 150 MM a = 100 MM

b = 150 MM b = 100 MM

a a
= 1.00 = 1.00
b b

β3 = 0.511 β2 = 0.632

 2   con− max  b 2
Treqd =  3   con − max  b 2 Treqd =
(1.2 / 1.1) f y
(1 . 2 / 1 . 1) f y

= 10.14 MM = 7.52 MM

CONDITION 3:- THICKNESS REQUIRED FOR MAXIMUM DOWNWARD FORCE

Treqd =
 3   con − max  b 2

(1 . 2 / 1 . 1 ) f y

= 12.57 MM (For Case 1)

81
 Treqd =
 2   con − max  b 2

(1 . 2 / 1 . 1 ) f y

= 9.32 MM (For Case 2)

MAXIMUM THICKNESS OF BASE PLATE ( T ) = 12.57 MM

CHECK 4 : CHECK FOR LENGTH OF ANCHOR BOLT

BOND STRESS OF ANCHOR BOLT = 1.4 N/mm2

LENGTH OF EACH BOLT REQUIRED (L) = T/(p *d*Tbd )

= 218.31 MM

LENGTH OF EACH BOLT PROVIDED = 900.00 MM > 218.31 O.K.

82
SUMMARY : DETAIL A &A1

LENGTH OF BASE PLATE ( L ) = 1040 MM

WIDTH OF BASE PLATE ( W ) = 590 MM

THICKNESS OF BASE PLATE ( W ) = 32 MM

DIAMETER OF ANCHOR BOLT ( D ) = 32 MM

TOTALNUMBER OF ANCHOR BOLTS ( N ) = 16 Nos.

LENGTH OF ANCHOR BOLT (L) = 900 MM

1040

590 BASE PLATE THK. = 32.00

83
 6.13 DESIGN METHODOLOGY OF CONNECTION PLATE

Moment Connection: A connection designed to transfer moment, as well as axial and shear
forces, between connecting members.

Pin Connection: A connection designed to transfer the axial and shear forces between connecting
members, but not moment forces.

A structural frame consisting of members joined together with rigid (or moment) connections so
as to render the frame stable with respect to imposed loads, without the need for bracing in its
plane. The connection plates used in the industrial building to join two members like column with
the rafter are used to transfer shear, tension & moment (they are sort of bracket type connection
type-2).

Gusset Plate: Steel stiffener plate used to help distribute load at a connection.

Fig:-6.12 Gusset Plate

6.13.1 General design procedure of the connection plate in the industry acc. to the IS: 800-
2007:

1. Determine the size of the connection plate (width*depth) Approx. (pitch+ 2*min. edge
distance in case 2 bolts per row)
2. Determine the Size & grade of the bolt as well as the size of the fillet weld to be used for
the joining the member with the connection plate.
3. No. of the bolts approx. by experience.
4. Shear, tension & moment at the connection by STAAD pro.
5. Stiffeners provided at the connection.
6. Determine the edge distance Acc. to cl. 10.2.4.2.
7. Determine distance from the bolt centre line to the toe of the fillet weld or to half the root
radius for a rolled section (lv), distance between prying force and bolt centre line and is the
minimum of either the end distance or the value given by cl. 10.4.7. (le).
8. Check for the Tension of the bolt.
i) Determine the Tension created by the moment couple (M/d, Tension Above N.A &
compression below N.A) & Direct Tension transmitted at bolts (Above the N.A only).

84
 ii) Determine the Prying force is the additional tensile force which is developed in the
bolts. When connections subjected to tension forces the connected part can leads to
deformation that increases the tension applied to the bolt so that the additional force is
generated in the blots due to joint plates Acc. to cl. 10.4.7.
iii) Determine the tension capacity of the one bolt Acc. to the cl. 10.4.5.
iv) If the tension in the bolt is less than its capacity Hence Ok.
9. Check the shear capacity of the bolt.
i) Determine the shear per bolt (shear/total no. of bolts).
ii) Determine the shear capacity of bolt Acc. to cl. 10.3.3.
iii) Determine the bearing capacity of bolt Acc. to cl. 10.3.4.
iv) The shear acting must be less than capacity of bolt (min. of Shear & Bearing).Hence
Ok.
10. Check for the combined action Acc. to the cl. 10.4.6.
11. Check for the fillet weld around the section
i) Find the Ixx & Ymax of the fillet weld about X-X according to the stiffeners provided for
ex. In our case the 2 stiffeners one above NA & other below NA is provided along the
web.
ii) Find shear stress on the weld (Shear force/(length of weld * Throat thickness) ) Fd.
iii) Find the Bearing stress in the weld (Moment*Ymax/Ixx) Fm.
iv) Find resultant stress in the weld by two stress Fd & Fm.
v) Determine the design shear strength of the weld Acc. to cl. 10.5.7.1.1. & design stress
from Table-1 of IS: 800-2007.
vi) If Resultant stress is less than the design shear strength of weld then OK.
12. Final Dimensions of the plate is given as follows:
i) Depth of plate ( depth of web + clear distance)
ii) Width of plate Max. (Width of flange, Pitch + 2* edge distance).
iii) Thickness of plate is provided by moment at the edge of plate by tension of bolts
(Tension in bolts * Edge distance) & Thickness of plate is (moment= Yield Stress *
Section modulus (b*t2)).

85
 6.14 DESIGN OF THE CONNECTION PLATE FRAME IS: 800-2007
APEX BUILIDSYS LTD
Design
JOB NO. of the connection
: ISGEC plate is done after the Rev.
design
No. of the main frame
R0 in our shed. the general
OWNER : INDIAN RAILWAY Date 18/04/19
procedure of the design of the shed is given above here I am attaching the full design of the purlin
CONSULTANT RITES Designed By MK
MAIN CONTRACTOR APEX BUILDSYS Checked By AGM
in done excel acc.: toBOGIE
BUILDING the REPAIR
IS: 800-2007.
SHED Approved By

CONNECTION PLATE FOR RAFTER-SP1

FOUR/EIGHT BOLT MOMENT CONNECTION IS PROVISION AS PER LSD FOR 8.8 GRADE BOLT UTS 800MPa
Frame No. MAIN FRAME NODE 121
SI units Beam No. 193
Nominal Dia. Of Bolt 'db' = 27 mm Beam No. 224
Fillet weld size in flange 'w1' = 5 Load Case 400
Throat Size t1 = 4
Fillet weld size in web 'w2' = 5 mm
Throat Size t2= 4
Number of bolt near one flange 'N' = 4 N A y mf 1.25
Depth of connected beam 'd' = 574 mm y m1 1.25
Width of beam flange 'bf' = 250 mm ym 1.1
thickness of beam flange 'tf' = 12 mm y mw 1.25
thickness of beam web 'tw' = 8 mm
Shear Force 'V' = 173 kN
Bending Moment 'M' = 87 kN-m
Tension Force 'T' = 15 kN
Stiffner Condition = 2 PLEASE REFER STIFFNER CONDITION TABLE & G.A -02 (Sheet 4 of 5)
Yield stress of material 'Fy'= 345
β= 2 (2-for Non pre tensioned bolt & 1-for pre tensioned bolt)
Proof Stressf0=0.7X fu 'f0'=0.7x800= 560 REFER TABLE 1 SNO (iv) ULTIMATE STRENGTH (fu) & clause 10.4.3 for proof stress
Clause 10.2.4.2 End distance 'Ed'= 50 mm > 1.5x D 40.5 For Machine Flame cut, sawn & Planed edge
le=1.1xt (provided)x √(βf0/fy)= 49.55 mm IS 800:2007 Cl 10.4.7
lv= 43.00 mm Distacnce b/w centre of bolt to fillet weld of flange.

Check For Tension:

Flange Force 'Ff' = M / (d+tf) +T/2 155.96 kN
Tension per bolt 'Tb' =Flange Force/N = 38.99 kN
Prying Force=Q
Q= (lv/(2le))x(Te-βγf0bet^4/(27le^2xlv^2) -6.11 kN IS 800:2007 Cl 10.4.7
Total Tension in the bolt = Tb+Q= 32.88 kN
Nominal Tension Capacity of the Bolt (Tnf )= 330.8 kN 0.9xFub x An IS 800:2007 Cl 10.4.5
Nominal Tension Capacity of the Bolt (Tnf )= 334.1 kN fyb x Asb x ym1/ym IS 800:2007 Cl 10.4.5
Hence Tnf = Min of above two value 330.8
Capacity of Bolt (Tdf )= Tnf /y mf 264.6 kN Hence OK IS 800:2007 Cl 10.4.5

Check For Shear:

Shear per Bolt 'Tsb'=Shear Force/2N = 21.6 kN
No. of Shear Plane with thread intercepting = n n= 0.0
No. of Shear Plane without thred intercepting= n s = 1.0
Distance b/w extreme rows of bolt(l j)= 694.0 > 15db Reduction for Long Joint required IS 800:2007 Cl 10.3.3.1
Reduction Factor for shear (βij) = 0.95 where 0.75≤ βij ≤ 1.0
Design Shear Strength of the Bolt = Vdsb= 200.24 kN (fu/√3)x(nn x Anb +nsx Asb )xβij IS 800:2007 Cl 10.3.3
Reduction Factor for Bearing 'K b'= 0.57 kb=min of e/3d0,p/3d0-0.25,fub /fu ,1 As Per IS 800:2007 Cl 10.3.4
Design Bearing Strength of the Bolt =Vdpb= 349.14 kN (2.5 kb d t fu )/ymb As Per IS 800:2007 Cl 10.3.4
Design Shear Strength of Bolt=V db= 200.24 kN Min of V dpb & V dsb Hence OK

Check For Combined Shear & Tension:

Tension Forc e per Bolt (Tf)= 32.88 kN

Design Tensile Strength of the Bolt (Tdf)= 264.62 kN

Factored Shear Force per Bolt = Vsf= 21.62 kN

Design shear Strength of the bolt = Vdf= 200.24 kN

Combined Stress Ratio (Shear+ Tension) = (Vsf / Vdf )2 + (Tf / Tdf )2<1 IS 800:2007 Cl 10.4.6

= (21.62/200.24)^2+(32.88/264.62)^2 = 0.03 OK

B. Top flange with stiffner to end plate weld :

FD= SHEAR STRESSES

FM= BENDING STRESSES
FD= SHEAR FOECE 'V'
∑LENGTH OF WELD(L)x3.535

FD= 19.48 N/mm2

FM= M X Ymax
PROVIDE FILLET WELD AROUND WEB AND
Ix FLANGE

Y max= (794-20)/2

Y max= 387 mm

86
 Ix= (((250x3.535^3/12)+((250x3.535)(293^2)))X4)+((3.535x750^3/12)x2)

Ix= 552034583.7 mm4

FM= 60.99 N/mm2

RESULTANT= (FM2+FD2)^0.5 Please Refer Page no 490 6.11.4 End Plate Connection N.Subriminum

RESULTANT= 64.03 N/mm2.

Design Shear Strength of weld 'fs' =(fu/√3)/y mw 281.75 N/mm2 As per Cl 10.5.7.1.1 . We are using 70xx electrode but using the property
of 56xx as per Table 1 800-2007 designing on conservative side
64.03 < 281.75 SAFE

PROVIDE FILLET WELD AROUND WEB AND FLANGE

C. End Plate Design :

Tension in extreme bolt 'Tb' = 38.99 KN

Factored Moment due to tension at Flange top = (38.99x48xmm)/1000 = 1.87 KN-m

Factored Design Moment Md = 1.87 KN-m

1/2
t= 1.1xMdx 4 Please Refer Page no 1097 Point No 5 N.Subriminum
fy x b

t= 9.8 mm

Provide Connection Plate 794 x 250 x 25

Provide Weld size of 5 mm in flange 5 mm in web
Provide Bolts 8 nos @ 27 mm Dia Bolts

Fig:-6.13 General detail drawing of the connection

87
 6.15 DESIGN METHODOLOGY OF THE PURLIN

Purlin is a horizontal secondary structural member, bolted to the rafters, which transfers the roof
loads from the roof covering to the primary frames.

Fig: - 6.14 Purlins

All purlins shall be designed in accordance with the requirements for uncased beams as the
limitations of bending stress based on lateral instability of the compression flange. In calculating
the bending moment, advantage may be taken of the continuity of the purlin over supports. The
purlin is subjected to the bi-axial bending (Mzz & Myy) due to gravity load & due to wind load.
Therefore check for bi-axial bending is done Acc. to the Section-9 of the IS: 800-2007. Deflection
of the purlin should be less than (l/180).

We design the purlin Acc. To IS:801-1975 (code of practice for use of cold-formed light gauge steel
structural members in general building construction) because purlin used in our case are cold rolled
means they are rolled at the room temperature but also some clauses of the IS: 800-2007 are used.

6.15.1 General design procedure of the Purlin in the industry acc. to the IS: 800-2007: -

1. Note down all the geometric specification like building Width, length, height, roof slope,
purlin spacing etc. with all material properties used in the construction of the purlin.
2. Calculate the dead load, live load, collateral load & wind pressure.
i) Dead load:- The load of the sheeting on the roof
ii) Live load: - Can be taken as 0.75KN/m2 for inaccessible roof.
iii) Collateral load: - load of the Non-permanent structure on the roof but act as a dead load
like load of the fans, lighting etc.
iv) Wind load: - Calculated Acc. to IS: 875-part-3 (2015). In this following steps can be
followed.
a. The design wind speed is calculated on the basis of risk factor, terrain height&
topography factor Acc. to the cl. 6.3. (Our structure is taken as important structure
due to large life of about 50yrs, terrain category-2 & topography factor is 1

88
 because terrain slope is less than 3 degree also our structure does not lies in
cyclonic region).
b. Compute design wind pressure (0.6*Vz2).
c. Calculate Tributary Area of (Rafters, columns, grits) it is the area on one member
under wind pressure. Also find area averaging factors Acc. to Table-4 & Acc. to
cl.7.3.3.13.
d. Calculate Minimum Design Wind Pressure Acc. to clause 7.2 & design wind
pressure on rafters, columns & grits or purlins etc. (Design wind pressure * Area
avg. factors of all members).
e. Also find wind pressure co-efficient by opening area acc. to cl.7.3.2
f. How they find load in directions.
3. Calculate load in running meter on purlin in X-X axis (Load*spacing*Cos (roof slope)) &
in Y-Y axis (Load*spacing*Sin (roof slope)).
4. Draw shear force & bending moment diagram for (D.L+L.L & W.L) taken as UDL as
loading.
5. Find maximum moments in the different spans (left lap, right lap & mid span). Lap is the
connection between
6. Find allowable bending stress of the member from IS: 801-1975, Cl. 6 which is 0.6*fy and
also find Mall which is equal to allowable stress*section modulus.
7. At location of maximum positive moment the section is assumed to be fully braced due to
the sheeting but at the location of the maximum negative moment the flange is assumed to
be un-braced.
8. In case of the maximum positive moment the moment can directly compare to the Mall but
it cannot be done in case of maximum negative moment because the flange is not braced.
9. For the maximum negative moment case the Mall is find by IS 801-CL.6.3 this clause is
self explanatory but the un-braced length of the Purlin is length between Sag Rods in case
we are finding for normal span check but in case of lap check (left or right) the un-braced
length is (inflection point length from support – lap length). Check can be applied for
maximum negative moment.
10. The allowable moment is doubled at the joints where 2 grits are joined but this cannot be
done in case of lap check.
11. Check for shear strength (Cl.no.6.4 – IS: 801-1975) shear stress on the section is equal to
shear force/depth*thickness. Allowable shear stress can be found by code provisions
accordingly.
12. Check for combined bending and shear in web (cl.no.6.4.2 and 6.4.3 of IS: 801 -1975).
13. Check for combined axial and bending stress (cl.no.6.7.2 IS: 801-1975) as there is no axial
force in purlin so, this check can be ignored.

89
 6.16 DESIGN OF THE PURLIN IN THE BRS SHED, NBQ ACC. TO THE IS: 801

Design of the purling is done just after the design of the main frame in our shed. the general
procedure of the design of the shedDESIGN
is given aboveAShere
OF PURLIN PER I am attaching the full design of the purlin
IS801-1975
in done excel acc.JOB
to NO.
the IS:801 because purlins are cold formed
J#1006 members
DESIGN BY which
MK isREV.
are coldDATE
rolled
not hot rolled likeJOB
theNAME
structure
BOGIEsteel they
REPAIR made by the G.I coils
SHED CHECKat BY
site or at
AGMfabrication
0 site18.4.19
where
CLIENT INDIAN RAILWAY
all cutting and welding of PEB material is done. BLDG. NO. 2 1
LOCATION BONGAIGAON AREA. NO. 1 1

BUILDING PARAMETERS MATERIAL PROPERTIES

BUILDING WIDTH = 30.0 M YIELD STRENGTH (F y) = 345 N/MM 2

BUILDING LENGTH = 160.0 M YOUNG'S MODULUS (E) = 2.01E+05 N/MM 2

BUILDING HEIGHT = 12.0 M GIRT SPACING

ROOF SLOPE = 1:10 END BAY = 1200 MM

ROOF ANGLE = 5.72 O INTERMEDIATE BAY = 1200 MM

LOAD DATA DEFLECTION LIMITS

DEAD LOAD+COLLAT. LOAD = 0.35 KN/M 2 DEAD LOAD + LIVE LOAD = SPAN/ 150

LIVE LOAD = 0.75 KN/M 2 DEAD LOAD + WIND LOAD = SPAN/ 150

AXIAL LOAD = 0 KN

Y
WIND LOAD :-

Bbottom
DESIGN WIND PRESSURE = 1.53 KN/M 2

INTERNAL PRESS. COEFFT. = 0.70

X
X

EXTERNAL PRESS. COEFFT. = 1.20

Btop

THK.
LOCAL PRESS. COEFFT. = 0.00

LOAD CALCULATIONS
Y

DEPTH
→ DEAD LOAD+COLLT. LOAD

@ X-X AXIS = 0.35 x 1.2 = 0.418 KN/m

@ Y-Y AXIS = 0.35 x 1.2 = 0.042 KN/m

→ LIVE LOAD

@ X-X AXIS = 0.75 x 1.2 = 0.896 KN/m

@ Y-Y AXIS = 0.75 x 1.2 = 0.090 KN/m

→ WIND LOAD

@ X-X AXIS = 1.53 x (0.7 + 1.2) x 1.2 = 3.489 KN/m FOR END BAY

= 1.53 x (0.7 + 1.2) x 1.2 = 3.489 KN/m FOR INTERMEDIATE BAYS

90
LOAD COMBINATIONS

→ DEAD LOAD + LIVE LOAD

@ X-X AXIS = 0.418+0.896 = 1.314 KN/m

@ Y-Y AXIS = 0.042+0.09 = 0.132 KN/m

→ WIND LOAD

@ X-X AXIS = 3.489 = 3.489 KN/m

@ Y-Y AXIS = 0 = 0.000 KN/m

SPAN CONDITION

SPAN 1 SPAN 2 SPAN 3 SPAN 4

7333 7333 7333 7333

SAG ROD 3 3 3 3

740 740 740

LAP
740 740 740

GIRT Z250x2.5 Z250x2.5 Z250x2.5 Z250x2.5

PROPPERTIES OF SECTION

SECTION Z250x2.5 Z250x2.5 Z250x2.5 Z250x2.5

Depth 25.00 cm 25.00 cm 25.00 cm 25.00 cm

Thk. 0.25 cm 0.25 cm 0.25 cm 0.25 cm

Area 10.89 cm 2 10.89 cm 2 10.89 cm 2 10.89 cm2

Ixx 1016.58 cm4 1016.58 cm4 1016.58 cm4 1016.58 cm4
Sx 81.33 cm3 81.33 cm3 81.33 cm3 81.33 cm3
Rx 9.66 cm 9.66 cm 9.66 cm 9.66 cm

Iyy 144.89 cm 4 144.89 cm 4 144.89 cm 4 144.89 cm4

Sy 15.97 cm3 15.97 cm3 15.97 cm3 15.97 cm3
Ry 3.65 cm 3.65 cm 3.65 cm 3.65 cm

BTop 7.50 cm 7.50 cm 7.50 cm 7.50 cm

BBottom 8.20 cm 8.20 cm 8.20 cm 8.20 cm

91
LOADING DIAGRAMS

CASE 1 : DL + LL

1.314 KN/m

7333 7333 7333 7333

5.06444 4.738876 4.89331

3.83

-5.8056 -4.57112 -4.8967 -4.7422

SHEAR FORCE DIAGRAM

7.26

-5.50 -6.08 -6.08

2.52 3.11 3.10

5.59

BENDING MOMENT DIAGRAM

FOLLOWING INTERNAL FORCES ARE OBTAINED USING MOMENT DISTRIBUTION METHOD

DL+LL SPAN 1 SPAN 2 SPAN 3 SPAN 4

MOMENT (KNM)

LEFT SUPPORT 0.00 7.26 -5.50 -6.08

LEFT LAP 0.00 -3.86 -2.29 -2.75

MAXIMUM 5.59 2.52 3.11 3.10

RIGHT LAP -3.31 -2.41 -2.75 -2.31

SHEAR (KN)

LEFT LAP 3.83 4.09 3.77 3.92

RIGHT LAP -4.83 -3.60 -3.92 -3.77

92
CASE 2 : WL

3.489 KN/m

7333 7333 7333 7333

13.4252 12.58033 13.0055

12.1607

10.17

-15.415 -12.1597 -13.005

SHEAR FORCE DIAGRAM

14.83

6.60 8.09 8.09

-14.59 -16.16 -16.16

19.28

BENDING MOMENT DIAGRAM

FOLLOWING INTERNAL FORCES ARE OBTAINED USING MOMENT DISTRIBUTION METHOD

WL SPAN 1 SPAN 2 SPAN 3 SPAN 4

MOMENT (KNM)

LEFT SUPPORT 0.00 19.28 -14.59 -16.16

LEFT LAP 0.00 -10.25 -6.24 -7.48

MAXIMUM 14.83 6.60 8.09 8.09

RIGHT LAP -8.78 -6.55 -7.48 -6.23

SHEAR (KN)

LEFT LAP 10.17 10.84 10.00 10.42

RIGHT LAP -12.83 -9.58 -10.42 -10.00

93
 MOMENT AT LEFT SUPPORT
MOMENT AT LEFT LAP MOMENT AT RIGHT LAP

LAP LAP

MOMENT AT MID SPAN

NOTATIONAL BENDING MOMENT DIAGRAM

SHEAR AT LEFT LAP

SHEAR AT RIGHT LAP

NOTATIONAL SHEAR FORCE DIAGRAM

UNITY CHECKS

DL+LL SPAN 1 SPAN 2 SPAN 3 SPAN 4

MOMENT

LEFT SUPPORT -- 0.22 OK 0.16 OK 0.18 OK

LEFT LAP -- 0.24 OK 0.14 OK 0.17 OK

MAXIMUM 0.33 OK 0.15 OK 0.18 OK 0.18 OK

RIGHT LAP 0.20 OK 0.15 OK 0.17 OK 0.14 OK

DEFLECTION

CALCULATED 12.83 5.58 5.58 5.58

OK OK OK OK
ALLOWABLE 48.89 48.89 48.89 48.89

WL SPAN 1 SPAN 2 SPAN 3 SPAN 4

MOMENT

LEFT SUPPORT -- 0.57 OK 0.43 OK 0.48 OK

LEFT LAP -- 0.80 OK 0.37 OK 0.44 OK

MAXIMUM 0.93 OK 0.41 OK 0.51 OK 0.51 OK

RIGHT LAP 0.52 OK 0.39 OK 0.44 OK 0.37 OK

DEFLECTION

CALCULATED 34.56 14.81 14.81 14.81

OK OK OK OK
ALLOWABLE 48.89 48.89 48.89 48.89
94
 CHECK FOR BENDING STRENGTH (CL.NO.6.1 - IS801-1975)

ACTUAL MOMENT :

SPAN 1

MAXIMUM MIDSPAN MOMENT Mxx = 5.59 KNM DL +LL

Mxx = 14.83 KNM WL

MOMENT AT THE END OF RIGHT LAP Mxx = -3.31 KNM DL +LL

Mxx = -8.78 KNM WL

SPAN 2

MOMENT AT LEFT SUPPORT Mxx = 7.26 KNM DL +LL

Mxx = 19.28 KNM WL

MOMENT AT THE END OF LEFT LAP Mxx = -3.86 KNM DL +LL

Mxx = -10.25 KNM WL

MAXIMUM MIDSPAN MOMENT Mxx = 2.52 KNM DL +LL

Mxx = 6.60 KNM WL

MOMENT AT THE END OF RIGHT LAP Mxx = -2.41 KNM DL +LL

Mxx = -6.55 KNM WL

ALLOWABLE BENDING STRESS :- (IS801-1975 Clause 6,Page 11)

SPAN 1

MID SPAN

CASE 1 :- DL+LL

AT LOCATION OF MAXIMUM POSITIVE MOMENT THE SECTION IS ASSUMED TO BE FULLY BRACED

(At maximum positive moment the top flange is under compression which is considered as fully restrained due to sheeting.)

BASIC DESIGN STRESS (Fb)

Fb = 0.6 x Fy

= 207 N/mm2

ALLOWABLE BENDING MOMENT (M allow )

Mallow = Fb x Sxc

= 16834482 Nmm

= 16.834 KNm

95
 UNITY CHECK

Mactual 5.59
= = 0.332 <1 OK
Mallow 16.83

CASE 2 :- WL

AT LOCATION OF MAXIMUM NEGATIVE MOMENT THE SECTION IS ASSUMED TO BE UNBRACED

(At maximum Negative moment the Bottom flange is under compression which is considered as Unbraced)

UNSUPPORTED LENGTH = SPAN - POINT OF CONTRA FLEXURE

= 5.78574 m

UNSUPPORTED LENGTH
SAG ROD SPACING =
(NO. OF SAG ROD + 1)

= 1.834 m

UNBRACED LENGTH (L) = 183.4 cm

AS PER IS 801-CL.6.3 THE ALLOWABLE BENDING STRESS (F bx) IS GIVEN AS,

PARAMETERS:-

2
 M1   M1 
COEFFICIENT OF BENDING (C b) = 1 . 75 + 1 . 05   + 0 . 3 
 M 2  M2

= 1.00 FOR COMBINED AXIAL AND BENDING

Iyy
MOMENT OF INERTIA ( Iyc) = = 72.4425 cm4
2

L2Sxc 183.4^2 x 81.326

= = 1510.41
d Iyc 25 x 72.4425

0.18 π2 ECb 0.18 x π^2 x 201000 x 1

= = 1035.02
Fy 345

0.90 π2 ECb 0.9 x π^2 x 201000 x 1

= = 5175.11
Fy 345

96
 0.90 π2 ECb L2Sxc 0.18 π2 ECb
i)
Fy › d Iyc
› Fy

2 Fy2 L2Sxc
Fbx = Fy - x
3 2.7 π2 ECb d Iyc

= 196.44 N/mm2

0.90 π2 ECb L2Sxc

ii)
Fy ‹ d Iyc

d Iyc
Fbx = 0.3 π2 ECb
L2Sxc

= 394.02 N/mm2

0.90 π2 ECb L2Sxc 0.18 π2 ECb

SINCE, > >
Fy d Iyc Fy

Fbx = 196.44 N/mm2

ALLOWABLE BENDING MOMENT (M allow )

Mallow = Fbx x Sxc

= 15975356.98 Nmm

= 15.975 KNm

UNITY CHECK

Mactual 14.83
= = 0.928 <1 OK
Mallow 15.98

97
 RIGHT LAP

CASE 1 :- DL+LL

IN THE REGION OF NEGATIVE MOMENT BETWEEN END OF LAP AND THE INFLECTION POINT

(In the region between end of lap and the inflection point the moment is negative which creates compression

in bottom flange,due to which this region is considered as Unbraced.)

UNBRACED LENGTH = INFLECTION POINT - END OF LAP

= 0.80726 m

2
 M1   M1 
COEFFICIENT OF BENDING (C b) = 1 .75 + 1 .05   + 0 . 3 
M2 M2

= 1.00 FOR COMBINED AXIAL AND BENDING

AS PER IS 801-1975 CL.6.2,COMPRESSION ON IUNSTIFFENED ELEMENT IS,

FLAT WIDTH RATIO w/t = 32.8

w 530
i)
t ‹ √Fy
= 28.53

Fc = 0.6 x Fy = 207 N/mm2

530 w 1210
ii)
√Fy ‹ t ‹ √Fy
= 65.14

Fc = Fy [0.767-(3.15/10 4) (w/t) √Fy ]

= 198.41 N/mm2

w 1210
iii)
t › √Fy ‹ 25

Fc = 562000/(w/t) 2

= 522.38 N/mm2

98
 HERE , 1210/√Fy > w/t > 530/√Fy

Fc = 198.41 N/mm2

ALLOWABLE BENDING MOMENT (M allow )

Mallow = Fc x Sxc

= 16135615.8 Nmm

= 16.136 KNm

UNITY CHECK

Mactual 3.31
= = 0.205 <1 OK
Mallow 16.14

CASE 2 :- WL

AT LOCATION OF MAXIMUM POSITIVE MOMENT THE SECTION IS ASSUMED TO BE FULLY BRACED

(In the region of Positive moment betw een the end of lap and the inflection point the section is assumed to be fully braced.)

BASIC DESIGN STRESS (Fb)

Fb = 0.6 x Fy

= 207 N/mm2

ALLOWABLE BENDING MOMENT (M allow )

Mallow = Fb x Sxc

= 16834482 Nmm

= 16.834 KNm

UNITY CHECK

Mactual 8.78
= = 0.521 <1 OK
Mallow 16.83

99
 6.17 DESIGN METHODOLOGY OF THE CRANE BEAM

Crane systems in factories and warehouses are being appreciated by more and more of our end-
users. A crane system greatly improves material handling productivity within a building, promotes
safety and allows more efficient utilization of space by reducing or eliminating traffic due to
forklifts and side loaders.

Crane systems design rules & assumption:

1. Crane beam is assumed to be simply supported.

2. No two fully loaded cranes can accommodate in the single at the same time.
3. Generally 2 wheels are considered on each side of the crane.
4. The EOT cranes have the Impact factor of the 1.25.
5. All top running cranes runway beams are build-up section with cap section
6. The cap channel shall be directly welded on both sides to the web of the runway beam,
without the top flange.
7. If a shop splice is needed on runway beam it shall be located at a distance not to exceed
1/4 span from either end of beam.

Stepped Column

The use of a separate crane column shall be limited

to eave heights less or equal to 15m beyond which
a stepped crane column becomes the only option.
Note that the stepped crane column should always
require a fixed base In our project we use stepped
column.

Fig:-6.15 Stepped Column

100
The complete design of a gantry girder consists of the following elements:

1) Calculation of external loads and estimation of self-weight.

2) Calculation of shear force and bending moment.
3) Selection of girder section by trial and error.
4) Design of girder section.
5) Design of web and flange.
6) Design of connection.

Most of the steel gantry girders are made of Composite section because it has following
advantages:
1) High capacity in shear, tension and compression,
2) Light weight,
3) Members are visible and thinner, factory made, which manner.

6.18 DESIGN OF GANTRY GIRDER IN STAAD The Design loads are in table no. 6.5.
TABLE NO. 6.5

Crane Loads
Crane Capacity M.H/A.H 10.0/5.0 MT
Crane Span 10 m
Top of Crane Rail 7.5 m
Bridge Weight 12.0 MT
Trolley Weight 3.0 MT
Wheel Load 8.0 MT
Wheel Base 3.0 m

6.18.1 Modeling of the Crane Beam in STAAD: -

Fig:-6.16 Crane beam

101
6.18.2 Load combination used in the design of the structure: -

1. 1.5D.L + 1.5 C.R + 1.5 C.L

2. D.L + L.L + C.L

6.18.3 Properties of the members: - The Properties of member are in Table no. 6.6

Fig:-6.17 Properties of Member

TABLE NO. 6.6

Properties of Crane members

S.No. Designation Properties
Depth of Flange Width Thickness of web
section
1. R1 320mm 200mm 6mm
2. R2 740mm 300mm 8mm
3. R3 ISA 65*65*6

6.18.4 Loading on the crane Beam: -

Fig:-6.18 Loading on the crane beam.

Detail drawings of superstructure are attached in the Appendix-3.

102
 6.19 COLUMN REACTIONS FROM THE STAAD FOR FOUNDATION DESIGN

The column reaction from the STAAD is shown below in the tabular form below with the position
of the load node points in the figure below: -

Fig:-6.19 Reaction node Position

Reactions at node-2 used for design PC1 is in Table No. 6.7.

TABLE NO. 6.7

Load Type Fx Fy Fz Mz
EQ+X -19.4 -5.6 -0.4 128.5
EQ-X 19.4 5.6 0.4 -128.5
EQ+Z -0.1 -63.5 -32.6 0.6
EQ-Z 0.1 63.5 32.6 -0.6
DEAD LOAD 0.8 5.4 0.3 -4.4
LIVE LOAD 4.2 27.2 1.5 -22.0
COLL LOAD 0.0 0.0 0.0 0.0
WIND LOAD 1 -19.4 -114.5 -9.1 115.4
WIND LOAD 2 63.1 -76.8 -6.9 -162.6
WIND LOAD 3 -101.8 -8.7 -0.7 261.4
WIND LOAD 4 -19.3 29.1 1.4 -16.5
WIND LOAD 5 68.8 -96.4 -5.6 -118.4

103
WIND LOAD 6 -13.5 -1.5 -0.1 28.4
WIND LOAD 7 0.0 0.0 0.0 0.0
WIND LOAD 8 0.0 0.0 0.0 0.0
CRANE LOAD 1 -12.7 285.0 14.9 157.8
CRANE LOAD 2 -14.4 51.5 2.7 87.8
CRANE LOAD 3 -20.3 46.2 2.4 136.6
CRANE LOAD 4 -12.7 285.0 14.9 157.8
CRANE LOAD 5 33.3 293.7 15.5 -129.1
CRANE LOAD 6 31.6 60.2 3.3 -199.2
CRANE LOAD 7 25.7 54.9 3.0 -150.3
CRANE LOAD 8 33.3 293.7 15.5 -129.1

104
 CHAPTER-7

DESIGN OF THE PILE CAP FOR FOUNDATION

The foundation system is designed for the actual safe bearing capacity available at site. A net
allowable bearing pressure of 100 Tone for Pile foundation is considered as per soil report. Water
table is also considered in the design.

7.1 MATERIAL TO BE USED SHALL BE AS FOLLOWS

1. Concrete grade for Footing pile structures shall be M25 in footing.

2. Reinforcement steel grade Fe 500 High Yield strength deformed bars conforming
to IS- 1786.

7.1.1 Construction materials and durability considerations

From the aspects of durability due consideration will be given to the choice of construction materials
and methodology. The factors influencing durability of a concrete structure are:

• The environment
• The cover to embedded steel
• The type and quality of constituent materials
• The cement content and water cement ratio of the concrete
• Workmanship to obtain full compaction and efficient curing.
Considering the above factors, durability of the proposed structure will be ensured through
controlling the quality of the concrete in accordance with Clause 8 of IS: 456-2000.
As per Table 3 of IS 456: 2000 the environment can be classified as “mild” and the concrete surface
protected against weather or aggressive conditions. Hence as per Table 5, for mild exposure
condition, minimum cement content shall be 300-320- kg/m3, maximum free water cement ratio
shall be 0.45-0.55 and Grade of concrete shall be M-25. Reinforcement used shall be high yield
strength TMT bars of grade Fe 500.
Nominal clear cover in various structural elements as given below shall be such that durability
consideration in Clause 26.4.2 of IS: 456: 2000 are satisfied.

• For foundation- 50mm.

• For columns- 40mm.
7.2 DESIGN OF PILE CAP- PC1 (PEDESTALSIZE = 750X1250)
Data: -
1) Pile diameter: 450 mm
2) Spacing of piles 3 times dia. f pile = 3 x 450= 1350 mm
3) Pedestal dimension b x d= 750 x 1250 mm
4) Concrete mix: M25 , Steel grade= Fe 500

105
 5) Load data from STAAD at Node number 2 due to max. in that row of columns
• Vertical load Fy= 480 KN,
• Horizontal force Fx = 67 KN
• Bending moment Mz = 320 KN-m
6) Cut-off level of pile cap = 1 m from NGL & 2.0 From cut off level of pile.
7) Weight of backfill = 2.25x2.25x18x0.8 =72.9 KN.
8) Weight of footing= 2.25x2.25x25x0.8=101.25 KN.
9) Weight of pedestal = 0.75x1.25 x25x0.8= 19 KN.
10) Weight of plinth beam = 0.3x0.6x25x7.333= 32.99 KN.
Hence, final calculation of total load,
1. Total vertical load (P) = STAAD vertical load+ footing+ backfill load+ weight of plinth beam
P = 480 + 101.25 +72.9 + 32.99 = 687.14 KN
2. Moment due to horizontal force = 67x 2 = 134 KN-m
3. Hence total moment = 320+ 134 = 454 KN-m
Design: -
1. Pile cap dimension:

• Breadth of pile cap = 2.25m

• Length of pile cap = 2.25m
2. Check for pile load capacity:-
Total axial compressive load on single pile p= P / n ± Mxy/∑y2 ± Mxx /∑x2
Where, P = total downward load, n= no of pile,
Load from column P = 687 KN.
Total moment = 454 KN –m.
No. of piles along one side of axis = 2
Y coordinate of pile cap = 0.675 m
Max. Compressive load due to (axial load + moment)
= 687/4 ± 454x1.35/ (2x1.35x1.35)
= 172 ± 168
=340 KN or 4 KN
P = 340 KN < safe load on Pile i.e. 1003 KN. Ok
3. Bending moment: -
Reaction on each pile= 340 KN

106
 Bending moment at face of column, Le= 0.225 m
Total moment = 0.225x2x340= 153 KN-m
4. Check for effective depth: -
Mu = 0.133 Fck b d²= 153x1.5x10^6 = .133x 25x 2250xd²
D required = √ (153x1.5 x10^6) / .133x25x2250 =175 mm
Let us provide overall depth d = 800 mm
Provide 16 φ, cover = 60 mm
‘D’ available = 800 – 60-8 = 732 mm > d required i.e. 175 mm
5. Check for punching shear (two way shear): -
Punching shear at a distance d/2 (i.e.732/2= 366mm) from face of column = 687 KN.
Factored load Pu= 687x1.5= 1030.5 KN.
The critical section of punching comes the centre of pile. Hence the net load is to be taken.
However the depth is checked for factored.
Axial factored load from column = 1030.5 KN.
Min. size of pedestal = 750x1250 mm
Width of punching plan = 750 +d, 750+366 = 1116 mm
Length of punching plan = 1250+d, 1250+366 = 1616 mm
Perimeter= 2(L x W) = 2(1616+1116) = 5464 mm
Punching stress= .25√25 = 1.25 n/mm²
D= load/ (perimeter x stress), = 687x1000/5464x1.25 = 100 mm < 732 mm ok,
Punching shear stress = p/perimeter x d
= 687x1000/5464x732,
= 0.17 n/mm2
Allowable shear stress for M25
= 0.25 √Fck = 0.25 √25 = 1.25 N/mm2 > 0.17 N/mm2, hence safe.
6. Check the depth for one way shear:-
The critical section z-z is considered at d from face of column
K= Mu/bd2 = 454x1.5x10^6/2250x732², =0.56
107
 Value of Pt= 0.1, hence provide minimum Pt= 0.20%
Vc from table = 0.33 N/mm2
Total vertical reaction= 340x2= 680 KN
Shear stress Vv= Pu/bd
Vv= 680x1.5x1000/2250x732, = 0.6 n/mm2
Again Vv > Vc hence shear Stripps are required.
Balance shear taken by stirrups- Vus = 680x1.5 – (.33x2250x732/1000) =477 KN.
Provide 12 φ 2 legged stirrups
Spacing Sv= .87fy.asv.d/Vus = .87x500x2x113x732/477x1000=151 mm.
Provide 12 φ 2 legged stirrups @ 150mm c/c.
7. Main reinforcement: -
Mu = 454x1.5 KN-m
K= 454x1.5x10^6/2250x732², =0.56
Value of Pt= 0. 1, hence provide minimum Pt= 0.20%
Minimum Ast /m= 0.2 x 1000 x 732/100 = 1464 mm2
Provide 16 φ @ 100 c/c bottom
Reinforcement at top:-
Minimum Ast = 0.12 x 1000 x 800/100 =960 mm2
Each face = 960/2 = 480 mm2
Provide 12 φ @ 100 c/c.

Detailed drawings of Foundation are attached in the Appendix-4

108
 CHAPTER-8

INSPECTION OF RAW MATERIAL

Checking and inspection of fabricated structural steel work by the Engineer shall be done at various
stages of completion of fabrication work & all joints of all members are either visible or accessible
for inspection at all stages of inspection like work source inspection, incoming raw material
inspection, verification of material purchases is as per approved QAP. The contractor shall
arrange for conducting tests, specified in Quality Assurance Plan (QAP), in the presence of an
officer, authorized by the Engineer-in-Charge. Full records of all tests conducted shall be
maintained by the contractor in the format approved by Engineer- in-Charge which will be made
available to the Engineer-in-Charge or to any officer authorized by him
After checking and inspection, all members shall be marked for identification during
erection. This mark shall correspond to distinguishing marks on approved erection drawings and
shall be legibly painted and stamped on it. The erection mark shall be stamped with a metal dye
with figures at least 20 mm high and to such optimum depth as to be clearly visible, even after a
member is galvanized.

All rejected material shall be promptly removed from the shop and replaced with new
material for the Engineer’s approval/ inspection.

8.1 Suggestive QAP details:

All the inspection in future is done accordingly to QAP only. However QAP can be different for
each project as well as sometimes it can be vary from inspection to inspection for same project. In
QAP all tests and inspection for the all materials and type of record to be maintained for the
specified type of material. Amount of samples (sample size) to be taken for the particular material
and at which stage which type of test to be performed.
When the tests have been satisfactorily completed at the contractor’s or sub- contractor’s
premises, the RITES shall forthwith issue an Inspection Certificate to that effect. No item is
shipped or otherwise dispatched before such certificates have been issued.

The Suggestive QAP used for testing raw material is attached in Appendix-5

109