JSE Journal of Science and Engineering, Vol. 3, No.

1 (page: 40-49)
e-ISSN: 2723-3944 July 2024
DOI: https://doi.org/10.30650/jse.v3i1.4046

Safety Study of Steel Structure of Weighbridge I Girder Against

Hauling Trailer

Ryan Zulfikar1 , Rusandi Noor1*

1
Program Studi Teknik Sipil, Fakultas Sains dan Teknologi, Universitas Muhammadiyah Kalimantan Timur
Corresponding Email: [email protected]

Abstract – Weighbridges play a vital role in coal mining operations. This study aims to calculate
the stress range and fatigue life of steel bridge girder cross-sections. Using the numerical
simulation method with the CSI Bridge V22 application, the maximum axial force of 197 kN and
the minimum axial force of -74 kN were obtained. The axial force is determined from the first 3
spans of the bridge with a span length of 4 m. The span length of the weighbridge is 80 m. From
the calculation, the maximum stress of 40.11 MPa and the minimum stress of -15.06 MPa were
obtained, resulting in a stress range of 55.16 MPa. The nominal bending moment strength of the
beam was found to be 0.56. This modeling allows the simulation of dynamic loads from a 400-
tonne SDT truck (semi-trailer door tipper) passing over the bridge so that accurate stress range
data can be obtained. Fatigue analysis was carried out using the Basquin equation using the
constant C = 1x1012 and exponent m = 3, receiving a fatigue life of 0.006 (6.01x106) cycles
assuming 30-40 hauling trucks passing over the weighbridge. The results of calculations and
simulations obtained longitudinal and transverse profile dimensions of IWF 1000x520x18x31.

Keywords: Stress range, fatigue life, weighbridge

Submitted: 23 July 2024 - Revised: 26 July 2024 - Accepted: 29 July 2024

1. Introduction stresses from hauling trailer vehicles. Therefore, an in-

Weighbridges are heavyweight industrial scales depth understanding of its structural response to vehicle
installed with concrete foundations or placed on flat movements is important to ensure the structural integrity
ground and used to weigh the weight of trucks and their of the bridge [4].
cargo. By utilizing a weighbridge, the process of Hauling trailers or door-tipper semi-trailers (SDTs)
weighing vehicles and coal trucks either when they are often carry heavy loads and generate significant dynamic
empty or full of cargo, can be easily done [1]. forces when crossing weighbridges. Rapid movement,
The mention of the weighbridge is because the uneven loading, and vibration forces from the vehicle can
construction is in the form of a bridge consisting of 2 substantially affect the dynamic response of the bridge
(two) long I-Beam main girders and 6 (six) child girders [5].
with transverse beams along the beam that binds the right Understanding the parameters and characteristics of
and left girders and is covered with a plate on its surface. bridge dynamic modes based on the measured dynamic
The weighbridge rests on 42 (forty-two) load cells to response when the bridge is in operational condition is
function as load sensors [2]. very important information. This information can provide
Coal mining always strives to increase coal production an in-depth assessment of the bridge's condition and
every year. One of the efforts made is to increase the assist in making decisions regarding whether the bridge
carrying capacity of the Semi Trailer Door Tipper (SDT) is still suitable for optimal use [6].
or hauling trailer from 170 tons to 255 tons. The Before being operated, vehicle load tests need to be
weighbridge currently used is a permanent type carried out to ensure that the bridge can function
weighbridge with a maximum weighing capacity of 255 optimally and safely and deal with the loads that occur
tons [3]. during its use [7].
The existence of this bridge is very important for coal Bridge maintenance and repair has received
mining, so the feasibility and ability of this bridge need significant attention as its service life increases [8].
to be closely monitored. One way of monitoring can be Therefore, the use of CSI Bridge V22 software is
done by analyzing the fatigue life of the bridge. The 80- important in conducting structural analysis of
meter-long weighbridge may be subjected to various weighbridges. By inputting appropriate parameters, such

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 R. Zulfikar, R. Noor

as bridge geometry, construction materials, and vehicle Some studies may also lack attention to the
load profiles, simulations can provide valuable insights integration of the latest technologies, such as natural
into bridge stability and reliability [9]. frequency analysis, in the monitoring and maintenance
in planning a bridge construction, it is necessary to process. Recent data and facts show that the use of
consider vibration aspects to ensure user safety and natural frequency analysis can provide a deeper
comfort. Steel frame bridges are an attractive alternative understanding of the structural performance of bridges,
for bridges with long spans [10]. allowing the identification of previously overlooked
the fatigue life of the bridge to determine the limitations [20].
eligibility requirements of the bridge theoretically and
experimentally [11]. 2. Methodology
the natural frequency on the weighbridge refers to the
natural frequency of vibrations or oscillations that occur 2.1 Research Procedures
in the bridge structure when a load is applied to the This stage provides an overview of the initial steps to
bridge. This natural frequency is influenced by various the end of the preparation of the final project. The stages
factors such as the shape, size, material, and construction start from the starting stage, data collection, data
of the bridge [12]. analysis, bridge detail planning, CSI Bridge V22
the relationship between the natural frequency of the software planning, and design drawings.
weighbridge and the hauling trailer is that the vibration
generated by the trailer movement can cause the bridge Data Collection Techniques
to vibrate at a frequency that matches the natural In this case, data collection is carried out by taking
frequency of the bridge. If the vibration frequency of the data from the office of PT Ganda Alam Makmur in the
trailer is close to or matches the natural frequency of the form of images of existing data structures that have been
bridge, a phenomenon called resonance can occur [13]. processed again.
Resonance is a condition in which external vibrations The guidelines used in the preparation of the Final
(vibrations from the trailer) match the natural frequency Project entitled "Safety Study of the Weighbridge I
of the bridge, which can cause vibration amplification Girder Steel Structure Against Hauling Trailer" are:
and magnify adverse effects on the bridge structure [14]. 1. Data of 51 meters weighbridge of PT Ganda Alam
all objects that have mass and elasticity are capable of Makmur
vibrating. The magnitude of the natural frequency of a 2. SNI 03-1729-2002, on the Planning of Full-Walled
material that vibrates transversely is strongly influenced Plate Beams (Girder Plates).
by the modulus of elasticity of the material, Data collection is the first step taken in structural
dimensions/geometry (cross-sectional area, length), planning which generally consists of::
density, and the action force acting on the material [15]. 1. General description of the building
in one structural element there will be several different 2. Calculation analysis method and design of
frequency values, this is due to the difference in construction structures such as superstructure.
frequency values in each mode. The greater the mode 3. Determine the working load
number, the greater the natural frequency value [16].
In this study, the loading methods used did not follow Picture of Weighbridge
the standards set by the relevant authorities. This can Figures 2.1 and 2.2 show the design of the
include the use of loads that exceed or fall short of the weighbridge modeling results in AutoCAD 2021
regulated provisions, as well as the application of loading software.
techniques that do not comply with generally accepted
guidelines in construction.
SNI 03-1729-2002, This standard provides guidelines Figure 2. 1 Weighbridge longitudinal section
for the planning of full-walled plate beams (girder
plates), including structural design requirements,
dimensions, and calculation methods that must be
considered to ensure the safety and reliability of bridge
structures using girder plates [17].
The purpose of this study was to determine the
characteristics of fatigue fracture propagation rates in
structural components subjected to maximum forces on
steel arch bridges and to determine the fatigue life of
structural components subjected to excessive loads [18].
In recognizing the limitations of previous research, it
was found that most previous studies focused on bridge
supervision and maintenance, which may not fully
consider complex structural dynamics [19]. Figure 2. 2 Weighbridge cross-section

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 R. Zulfikar, R. Noor

Bridge Implementation Method

The implementation of this steel frame bridge
installation uses the Load Resistance Factor and Design
(L.R.F.D) method. The Load Resistance Factor and
Design (L.R.F.D) method is a method in building
planning that takes into account the load factor and
material resistance factor.
(c)
Design Modeling Stage
In the modeling process, the design of the weighbridge Figure 2.4 (a), (b), and (c) Hauling trailer size details
must comply with the applicable criteria and standards.
With a span of 80 meters and a bridge width of 5 meters, 4) At this stage, the CSI Bridge V22 user will
the structural modeling steps of the bridge will be create a live load model involving moving loads
analyzed in detail. from vehicle loads using the moving load
1) In this study, modeling was carried out using feature.
CSI Bridge V22 software. 5) The next step after entering the individual loads
into the bridge structure model in the CSI
Bridge V22 software is to determine the loading
combination.
6) Checking the bridge structure model in CSI
Bridge V22 software is an important stage in the
structural design and analysis process.
7) After checking and validating the bridge
structure model that has been made in the CSI
Bridge V22 software, the next step is to run the
structural analysis. This process is carried out by
performing a "Run Analysis" on the model that
Figure 2.4 CSI Bridge V22 display. has been prepared.
8) In the bridge retrofitting stage, CSI Bridge V22
2) After modeling the bridge structure using CSI users took various measures such as replacing
Bridge V22, the next step is to determine the weak structural elements and enlarging the
material and type of steel profile to be used for dimensions of certain elements by using
each part of the bridge. stronger steel.
3) After determining the material and type of steel 9) After performing the initial structural analysis on
profile for the bridge structure, the next step is the bridge model in CSI Bridge V22, the next
to enter the loads that have been capitalized into step is to re-run the analysis to obtain the
the CSI Bridge V22 software. structural reinforcement analysis results.
 Dead load
 Live load 3. Results and Discussion
3.1. Bridge Technical Data
1) Bridge general data
1) Bridge Type: Weighbridge
2) Bridge Width: 4.8 meters
3) Span: 80 meters
4) Floor Plate Thickness: 60 mm
(a) 2) Bridge Material Data
1) Steel Quality: BJ 50
3) Design Standard Reference
The following is a standard reference in the design
analysis of this weighbridge structure.
a. SNI 03-1729-2002, on ‘Planning of Full-Walled
Plate Beams (Girder Plates)’.
(b)
3.2. Bridge Steel Structure Design
Data-data:
Mu max = 4078331000 kN/m
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Vu max = 8560000000 kN/m

Used BJ – 50, fu = 500 MPa
fy = 290 MPa
Calculations (The numbers listed in brackets on the moment and
Determine the height of a full-walled plate beam: latitude plane images indicate the magnitude of the
h = L/10 lateral force and bending moment which includes the
= 1000/10 self-weight of the beam).
After recalculating the bending moment, the flange area
= 100 cm
is calculated once again :
h = L/12
= 1000/12
= 83,33 cm
A maximum height of 100 cm is used If the flange thickness remains 3.1 cm as before, then the
Suppose a flange thickness of 3.1 cm is taken, then the flange width will be :
height of the web is:
h = h – 2 tf
= 100 - 2 ( 3,1 )
= 93,8 cm
To determine the thickness of the web, the limit values Tried flange size 3,1 cm x 52 cm
h/tw can be used: Calculate the moment of inertia of the cross-section
1. To fulfill the requirements of a full-walled plate beam, concerning the bending axis:
the

2. To a/h ≤ 1,5:
= 2213026,651 cm4
And cross-sectional modulus:

3. To a/h > 1,5:

= 26824,57 cm3
Since the beam is continuously laterally restrained, it is
not necessary to check the lateral torsional buckling
stress to limit the local buckling stress at the compressive
flange :
Using a web size of 1.8 cm x 93.8 cm to determine the
flange size:

The self-weight of the beam can now be calculated: Furthermore, the coefficient Kg for beams with full-
2 walled plates was also calculated :
Extensive web = 1,8 x 93,8 = 168,8 cm
Extensive flens = 2 (154,1) = 308,2 cm2
Total = 477 cm2 By:

Self weight of the beam = ton/m =

0,37 ton/m

The value of the bending moment caused by the beam's

weight is:

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should be divided equally. In this example, 2 panels are

planned as shown in the figure below:

Hence the nominal bending moment strength of the

beam:
Mn = Kg.S.fcr = 1,0675 (26824,103) (290) = 830,4 ton/m
. Mn = 0,9 (830,4) = 747,4 ton m > 425,81 ton/m OK

Count the distance between vertical stiffeners!

Shear resistance at the end of the panel (does not take
into account the influence of tensile forces):

 Vn =  (0,6.Aw.fyw.Cv)

From Equation. 10.25: (assume Cv is within the elastic

region)

a = 0,61.h = 0,34 (93,8) = 31,89 cm = 32 cm from the

end of the beam

Confirm again the sliding stability of the end panels with

the corresponding numbers.

a = 32 cm:

Nominal shear strength for end panels:

ɸ.Vn = 0,9 (954,28) = 858,85 ton > 8,536 ton OK

For center panels, the influence of the tensile field can be

calculated if:

a/h = 1,6 → a = 1,6 (93,8) = 150,1 cm (max)

To obtain uniform spacing of the vertical stiffeners, the
remaining length between the end vertical stiffeners and
the center of the span of the full-walled plate beam

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Ratio a/h = 184 / 93,8 = 1,9616

Then Cv is taken from equation 10.25:

Nominal shear strength of full-walled plate beams

considering the influence of tensile field:

= 127,41 ton
ɸVn = 0,9 (127,41) = 114,669 ton > 8,560 ton OK

The next step is to design the vertical stiffeners. The

cross-section of the vertical stiffener is determined based
on three criteria:
1. Minimum area
1. Minimum moment of inertia
2. Maximum width to thickness ratio to thickness
ratio.

= 32,15 cm2
From equation 10.70

= 560,54 cm4

The maximum value of bs/ts is:

It was tried to use vertical stiffeners with a size of 1.8 cm

x 12 cm, so that:

OK

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OK or performance degradation. The steps to apply vehicle

lane input can be found in Figures 3.3, 3.4, and 3.5.
OK

3.3. Weighbridge Design Modeling

Dimensions of the Upper Structure of the Bridge
The dimensions of the superstructure of the
weighbridge using IWF 1000x520x18x31 profiles were Figure 3. 3 Input Preferences
selected for their strength and stability in withstanding
loads. These profile size inputs were entered in the CSI
Bridge V22 program.

Bridge Floor Plate Dimensions

The weighbridge floor plate uses a 60 mm thick steel
plate to ensure strength and resistance to the load of
hauling trailers that often pass by. Details of the floor
plate size were entered in the CSI Bridge V22 program.

Support/Restraint Figure 3. 4 Input bridge layout line data

A bridge uses roller-joint support to transmit load
forces and improve measurement accuracy by allowing
horizontal movement of the vehicle. Meanwhile, roll
pedestals on weighbridges are emphasized more than
joint pedestals because the lateral tilt allowed by the roll
allows the vehicle to move horizontally without
compromising measurement accuracy.

Vehicle Load Input

At this stage is the input of vehicle loads that include
dynamic loads generated by hauling SDT-type trailers
(semi-trailer door tipper) across the bridge. This includes
analyzing the weight of different vehicles, and the load
Figure 3. 5 Input bridge lane data
distribution that affects the performance of the bridge
during normal use. The following application of vehicle Vehicle Speed Input on Load Pattern
load input is shown in Figures 3.1 and 3.2 below. The speed of haulage vehicles crossing the bridge has
been set at 5 km/h or equivalent to 1.4 m/s. This speed
was chosen based on special considerations related to
operational conditions at the study site. The use of this
speed allows for the collection of accurate data regarding
the impact of vehicle speed on the bridge structure and
overall system performance. The procedure for inputting
Figure 3. 1 Vehicle data vehicle speeds can be found in Figure 3.6.

Figure 3. 6 Vehicle speed input

Figure 3. 2 vehicle load input
Vehicle Design Hauling Trailer Across the Bridge
Vehicle Lane Input Modeling hauling trailers in the CSI Bridge V22
The lane or traffic lane on a bridge determines the program must consider various factors such as dynamic
load borne by the bridge from passing vehicles, including loads, proper load distribution, and structural interaction
their weight and speed. This definition is crucial in the with the bridge to produce accurate and representative
design and analysis of bridge structures to ensure safety simulations. Here are some views of the vehicle shown in
and efficiency in bearing vehicle loads without damage Figures 3.7, 3.8, and 3.9 below.
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Figure 3. 7 A hauling trailer crosses the weighbridge

Figure 3. 8 Side view of hauling trailer crossing the weighbridge

Figure 3. 9 Top views of hauling trailer crossing the weighbridge

3.4. Bridge Structure Analysis Results with CSI Bridge

V22.
In this section, we will briefly describe the forces
arising from the applied plan loads.
Moment Force
From the results of the analyses carried out using the
CSI Bridge V22 software, data were obtained regarding
the magnitude of the maximum moment that occurred on
span 1 (one) and span 2 (two) of the weighbridge. This
data is illustrated in detail in Figures 3.10, 3.11, 3.12,
3.13, 3.14, and 3.15 below. The figures show the moment
distribution at various points along the span, providing a
clear visual representation of the areas experiencing the
highest moments.
1. Moment at span 1

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Figure 3. 10 Maximum moments of span 1 at the left end

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Figure 3. 11 Maximum moment of span 1 at span center

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Figure 3. 12 Maximum moments of span 1 at the right end

Based on the analyses conducted, it was found that the

maximum moment forces arising due to the maximum
load were -96.2667 kN at the left end of span 1,
407.8331 kN at the center of the span, and -210.9252 kN
at the right end.

2. Moment at span 2

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Figure 3. 13 Maximum moments of span 2 at the left end

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Figure 3. 14 Maximum moment of span 2 at span center

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Figure 3. 15 Maximum moments of span 2 at the right end

The analysis results show that the maximum moment

forces arising from the maximum load on span 2 are -
194.485 kN at the left end, 352.0961 kN at the center of
the span, and -220.1584 kN at the right end.

Axial Force
From the results of the analyses carried out with the
CSI Bridge V22 software, data were obtained on the
magnitude of the maximum axial force that occurred due
to the hauling trailer on span 1 (one) and span 2 (two) of
the weighbridge. This data is illustrated in detail in
Figures 3.16, 3.17, 3.18, 3.19, 3.20, and 3.21 below. The
figures show the axial forces at three points along the
span, providing a clear visual representation of the areas
experiencing the highest axial forces.
1. Axial Force at span 1

Figure 3. 16 Maximum axial force of span 1 at left end

Figure 3. 17 Maximum axial force of span 1 at span center

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Figure 3. 18 Maximum axial force of span 1 at right end

Based on the analyses conducted, it was found that the

maximum axial forces arising from the maximum load
were 197.268 kN at the left end of span 1, 197.268 kN at
the center of the span, and 130.938 kN at the right end.

2. Axial Force at span 2

Figure 3. 19 Maximum axial force of span 2 at left end

Figure 3. 20 Maximum axial force of span 2 at span center

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Figure 3. 21 Maximum axial force of span 2 at right end

Based on the analyses conducted, the results show that

the maximum axial forces that occur due to the
maximum load are 100.66 kN at the left end of span 2,
100.66 kN at the center of the span, and 87.247 kN at the
right end.

Mid-span Maximum Deflection

The maximum deflection of the weighbridge was
found to be 0.6 mm at the center of the span, indicating
the highest load point that affects the stability and overall
strength of the weighbridge. This phenomenon occurs
because the hauling trailer-type SDT (semi-trailer door
tipper) vehicle crossing the weighbridge produces the
largest deflection, resulting in maximum deformation.
The following are the results of the deflection analysis
displayed in the CSI Bridge V22 program as shown in
Figure 3.22 below.

Figure 3. 22 Maximum deflection result of the bridge

Shear Force
The results of the analysis using CSI Bridge V22
software showed that the maximum shear force generated
by the SDT (semi-trailer door tipper) hauling trailer when
crossing the weighbridge was 315.764 kN. This detail is
presented in illustration figure 3.23 below.

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Figure 3. 23 Maximum shear force results in the CSI Bridge program

Check the Safety of the Bridge Structure

After a thorough inspection using the CSI Bridge V22
software, the weighbridge was found to be safe against
the hauling load of a 400-tonne SDT (semi-trailer door
tipper) type trailer. Analyses performed with the software
included a detailed evaluation of the material strength,
load capacity, and pressure distribution on the bridge.
The load difference on the floor plate occurs due to the
repeated movement of the wheels. Each time the wheels
move and pass over the floor plates, the dynamic load
received by the plates changes, causing stress variations
at various points.

Figure 3. 24 Check the safety of the structure

Bridge Floor Plate Safety Check

Initially assuming an 18 mm thick steel plate with a
yield stress (fy) of 290 MPa, it was found that the
stresses exceeded the yield limit and the specified
allowable stress. To solve this problem, the floor plate
was reinforced by thickening it to 60 mm. The aim is to
ensure that the steel plate can safely withstand the
hauling load of a 400-tonne SDT (semi-trailer door
tipper) type trailer, without exceeding the allowable
stress limit. The safety results of the floor plate from the
simulation using CSI Bridge V22 software can be seen in
Figure 3.25 below.

Figure 3. 25 Check floor plate safety

Check Stress Areas

1. Area Stress Step 100
Based on the results of the analysis that has been
carried out, it is obtained that the largest floor plate
stress value at Step 100 is -275.92 Mpa with object
area 1 fulfilling 95%. It can be concluded that at
Step 100, the floor plate is safe because the floor
plate does not exceed the yield limit and allowable
stress of 290 MPa.

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2. The results of the calculation obtained the dimensions

of the IWF 1000x520x18x31 longitudinal profile and
IWF 1000x520x18x31 transverse girder.
4.2. Suggestion
1. For future research, it is necessary to conduct more
Figure 3. 26 Area stress step 100
in-depth planning related to the lower structure of
weighbridges that use steel frames. This includes
1. Area Stress Step 500 detailed analyses of the foundations and the most
Based on the results of the analysis that has been suitable materials to ensure the strength and
carried out, it is found that the largest floor plate durability of the structure. In addition, it is also
stress value at Step 500 is -212.65 Mpa with an important to consider environmental and
object area of 7 fulfilling 73%. It can be concluded geographical aspects that may affect the performance
that at Step 500, the floor plate is safe because the of the weighbridge.
floor plate does not exceed the yield limit and 2. It is necessary to perform analyses using Midas Civil
allowable stress of 290 MPa. Software to obtain accurate data on the distribution
and amount of loads acting on the bridge. This
analysis will provide a detailed comparison so that we
can better understand how loads are distributed and
affect the bridge structure.

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