Introduccion

This document presents an example of the design of a hitched (or slab keyed into rock) type of plug.
The approach presented follows the Bulkhead & Dams for Underground Mines Design Guidelines published by the
Ontario Ministry of Labour, Occupational Health and Safety Branch (1995).

Hypothetical Case:
A mine would like to build a hitched plug to close the access to the 130 haulage portal (Elev. 130 m) as part of the
general closure plan for the mine. The plug will be required to retain water after mine closure and the static
groundwater level is estimated to be at Elev. 465 m. For reference purposes,
Figure 1 shows a typical cross-section of a hitched plug.
Chemical analysis of the water indicated that it has a ph at approximately 7 and does not contain suspended solid.
Any leakage water from the plug will not be used for domestic purposes.
The drift is 3.7 m wide and 3.4 m high at the planned plug location and the rock mass of granite has been classified as
Fair quality through rock mass characterization.
The specifications for concrete and formwork presented in the course should be used.

BEARING CAPACITY OF ROCK

The Bulkhead Design Guidelines prepared by the Ontario Ministry of Labor (1995) includes estimation of bearing
capacity of rock, which is reproduced here in Sections 2.1 and 2.2. These guidelines are used to assess the rock
mass strength for incorporation into the plug design calculations of Section 4.0.

Homogneos Rock
The bearing capacity of rock that is homogeneous is dependent upon the geometry of the rock surface that is
undergoing loading, the unit weight of the rock, the cohesion of the rock and the internal angle of friction of the rock.
Ordinarily, homogeneous rock has a compressive strength that is higher than that of concrete. Consequently, the
bearing capacity of homogeneous rock in an anchor channel is not likely to be exceeded by the load transferred to it
from a concrete bulkhead.
For uniform loading on an area of rock having a width W, the bearing capacity is given as:
Where: = the unit weight of the rock
c = the cohesion of the rock
And
Nand Nc are bearing capacity factors
Nc = (Nq - 1) cot
N= 1.5 (Nq - 1) tan
Nq = e tantan2 (/4 + / 2)
= the angle of friction of the rock
Cohesion and friction angle values for commonly encountered rock types are:

Discontinuous Rock
Rock in mining environments is seldom homogeneous and is usually characterized by blast induced fractures and
geologic features such as joints, bedding planes or faults. Discontinuities ordinarily adversely influence the bearing
capacity of the rock. Notwithstanding its compressive strength, the bearing capacity of a rock mass that is personified
by discontinuities can be significantly lower than that of a homogeneous rock mass composed of the same rock type.
In discontinuous rock the potential failure mechanism from bearing stress can be somewhat different from that
resulting from excess bearing stress in homogeneous rock. The spacing, orientation and opening size of
discontinuities in a rock mass will dictate how it responds to bearing pressures. In rock masses that are typified by
discontinuities that are open, have a spacing that is less than the width over which the bearing load is applied and are
oriented sub-parallel to the direction of the applied load, the load is essentially supported by unconfined columns of
rock. The bearing capacity of such rock masses is approximately equal to the sum of the strengths of the individual
rock columns, provided that each column has the same strength and rigidity.

For bulkhead anchor channels that are excavated in jointed or fractured rock, it is crucial that the rock mass is
carefully mapped to assess what influences, if any, the rock mass discontinuities will have on its bearing capacity. The
outcome of such mapping endeavors may reveal the necessity to adjust the bearing capacity as presented before for
homogenous rock (Section 2.1).
For explanation on rock mass characterization and the derivation of rock strength parameters, refer to
Appendix B Rock Mass Characterization of the Plug Design Guidelines.

DESIGN CONSIDERATIONS
The Bulkhead Design Guidelines prepared by the Ontario Ministry of Labour (1995) includes a section on plug design
considerations, as presented in Sections 3.1 and 3.2. This outlines the basis for plug design requirements, design
criteria followed, typical layout of a plug, and coefficients used for design.
All are referenced to the design calculations of Section 4.0.

Plug Design Requirements

The design of the plug should account for the dimensions of the plug, the depth to which the plug will be hitched
(keyed) into the rock, as well as the following components relevant to design:
Factored Loads
Factored Shear Loads
Factored Moments (and reinforcement requirements)
Bar Spacing & Slab Thickness
Anchorage into Rock
Bearing on Concrete

3.2 Plug Design Criteria

The Ontario guidelines consider:

1. The bulkhead is designed in accordance with the CSA, CAN3-A23.3-M84, "Design of

Concrete Structures for Buildings", requiring that:
Factored Resistance Effect of Factored Loads
2. The Bulkhead is considered to be a two-way slab that is simply supported on four sides.
3. Tectonic pressure is not considered
4. Deep beam flexure "analysis" does not apply.
5. The potential of hydraulic fracturing within the rock around the bulkhead has not been considered in the
design of the Ontario guidelines.
6. The bulkhead design has been designed to withstand static hydrostatic pressure with specific gravity
equal to one.
3.3 Typical Plug Layout
The following is the layout of a typical plug for illustration purposes:

Notes:
1. Anchorage distance of h/2 is based on anchorage in sound rock with an allowable bearing pressure of 3800 kPa. If
rock is fractured or allowable bearing is less than 3800 kPa, then appropriate adjustment to anchorage depth is
required.
2. Concrete cover = 75 mm 12 mm.
3. For rectangular bulkheads, place reinforcement parallel to short dimension (l a) on the outermost layer.
4. For bulkheads that may be loaded from either side, place reinforcement, as indicated in tables, on both sides.
5. Minimum bar spacing s = Bar dia. (db) + largest of:

- 25 mm; or
- db; or
- 1.33 x max. size aggregate.
3.4 Coefficients and Notations Used in Design
The following are notations used in the design calculations of Section 4.0:
An Effective tension area of concrete surrounding the flexural tension.
Reinforcement and having the same centroid as that.
Reinforcement, divided by number of bars, mm2h.
As
D
L
Q
T

Area of tension reinforcement, square mm

Load factor on dead load (Clause 9.2.3)*
Load factor on live load (see Clause 9.2.3)*
Load factor on wind or earthquake load (see Clause 9.2.3)*
Load factor in T-load (see Clause 9.2.3)*

 Ratio of clear spans in long to short direction of two-way slabs

1 Ratio of depth of rectangular compression block of depth of the neutral axis (see clause 10.2.7)*
c Ratio of the long side to short side of the concentrated load or reaction area
b With of compression face of member, mm
bo Perimeter of critical section for slabs and footings, mm
bw Web width, mm
c Distance from extreme compression fibre to neutral axis, mm
Cad,Cbd Moment coefficients for positive dead load moments in short and long spans respectively
Cal, Cbl Moment coefficients for positive live load moments in short and long spans respectively
D Dead load, N
D Distance from extreme compression fibre to centroid of tension reinforcement, mm
db Nominal diameter of bar, wire or prestressing strand, mm
dc Thickness of concrete cover measured from extreme tension fibre to the centre of the longitudinal bar or
wire located closest to it, mm
Es Modulus of elasticity of reinforcement, MPa (see clause 8.5.2 or 8.5.3)*
s Strain in reinforcing
fs Calculated stress in reinforcement at specified loads, MPa
fy Specified yield strength of nonprestressed reinforcement, MPa
NOTE: For Clause numbers refer to CAN-A23.3-M84 Standard
fc Specified compressive strength of concrete, MPa
f c Square root of specified compressive strength of concrete, MPa
g Gravitational acceleration, 9.81 m/s2
H Head of water in metres
h Overall thickness of member, mm
hs Overall depth of slab, mm
L Live load N
I Span length of one-way slab as defined in clauses 8.7.1 and 8.7.2;* clear projection of cantilever, mm
Ia Clear span of a two-way slab in short direction, mm
Ib Clear span of a two-way slab in long direction, mm
Ma Maximum moment in member at load stage at which deflection is computed, Nmm
MadPos, Positive dead load moments in short and and long spans respectively, N.mm/m
Mf Factored moment at section, N mm
Mr Factored moment resistance, calculated using the assumption in clauses 10.2 and 10.3,* and the
resistance factors given in clause 9.3,* N mm
m = 1a Ratio of short to long span of a two-way slab
1b
Ratio of nonprestressed tension reinforcement = As/bd
Q Live load due to wind or earthquake, whichever produces the more unfavorable effect
s Spacing between layers of reinforcement, mm
T Cumulative effects of temperature, creep, shrinkage and differential settlement
Vc Factored shear resistance provided by tensile stresses in the concrete, N
Vf Factored shear force at section, N
Vr Factored shear resistance, N
Vs Factored shear resistance provided by shear reinforcement, N
Wdf Factored dead load per unit area, kPa
Wf Factored load per unit area,, kPa
Wlf Factored live load per unit area, kPa (kN/m2)
For Clause numbers refer to CAN-A23.3-M84 Standard
z Quantity limiting distribution of flexural reinforcement kN/mm (see clause 10.6)*
Importance factor (see Clause 9.2.6)*
Factor to account for low density of concrete (see clause 11.2.3)*
c Density of concrete, kg/m3
c Resistance factor for concrete (see Clause 9.3.2)*
s Resistance factor for reinforcing bars (see Clause 9.3.3)*
Load combination factor (see Clause 9.2.4)*
* Note: For Clause numbers refer to CAN-A23.3-M84 Standard
Table E-2 of the Ontario Ministry of Labour Guidelines (1995) is provided for reference purposes which presents the
coefficients for live and dead load positive moments. These coefficients will be utilized in Section 4.0.

4.0 DESIGN CALCULATIONS

The following section provides details related to the calculation of factored loads, and the ultimate requirements for
plug design, using the hypothetical case presented in Section 1.0. These calculations are based on the Bulkhead
Design Guidelines from the Ontario Ministry of Labour (1995).
Refer to Section 3.4 for an itemized list of notations used in the following calculations.

4.1 Initial Conditions

The following presents initial conditions related to data input such as geometries, material strengths, etc.
Opening (long side x short side), la x lb = 3400 mm x 3700 mm
Head of Water, H = 335 m (Elev. 465 m Elev. 130 m)
Concrete Compressive Strength, fc = 30 MPa
Reinforcing Yield Strength, fy = 400 MPa
Live load due to hydrostatic pressure, (w):

w = H x rw x g = 3287 kN/m2
Where, g = 9.81 m/s2
rw = 1000 kg/m3, (density of water)
4.2 Design Coefficients
The following are design coefficients related to the bulkhead geometrical requirements, and design layout:

Moment coefficient, Cal (See Table E-2 Case 1) = 0.0431

Moment coefficient, Cbl (See Table E-2 Case 1) = 0.0305
4.3 Total Factored Load, Wf
The total factored load (W f) incorporates the various loads acting on the bulkhead including; dead loads, live loads,
wind and earthquake loads, and temperature loads. A factor is applied to the loads to weight the loads accordingly.
Total Factored Load (W f):

Wf = aDD + gc(aLL + aQQ +aTT) (CSA 9.2.2)

Where, D = Dead load
L = Live load
Q = Wind, Earthquake
T = Temp
Load Factors (a):
aD = 1.25, aL = 1.50, aQ = 1.50, aT = 1.25 (CSA 9.2.3)
Load Combination Factor (c):
c = 1.0 one of L, Q, T
c = 0.7 two of L, Q, T
c = 0.6 three of L, Q, T
Since only a live load is considered in this design, c = 1.0 is considered.
Importance Factor (g):
g = 1.0 (CSA 9.2.6)
For vertical bulkheads (load acting horizontally across bulkhead), such as in the hypothetical case
analyzed, D = 0.00. For horizontal bulkheads (e.g., built in vertical shafts, the load would be acting vertically
across bulkhead), the dead load should be estimated based on the plug volume and density of the
concrete. For this example, D = 0.
Wf = 0 + 1.50 x 3287 kN/m2
= 4931 kN/m2
4.4 Factored Shear Resistance, Vc
The following series of equations consider the bulkheads resistance to shear failure.
Factored shear resistance (Vc):

Vc = (1 + 2 / bc) 0.2 l fc (fc)0.5 bo d Formula (1) (CSA 11.10.2.2)

But not greater than, Vc = 0.4 l fc (fc)0.5 bo d Formula (2) (CSA 11.10.1.3)

Where, bo = perimeter of critical section

d = effective depth, mm
bo = 2 (la + lb 2d)
= 2 (3400+3700-2d)
= 14200 4d (mm)

Importance factor (l ):
l = 1.0 (CSA g.2.6)
Resistance factor (fc):
fc = 0.60 (CAN g.3.2)
Design coefficient (bc):
bc = 1.088 (Section 4.2)
Strength of concrete (fc):
(fc)0.5 = (30)0.5 = 5.477
where fc is expressed in MPa
Evaluating Formula (1):
Vc = (1 + 2 / bc) 0.2 l fc (fc)0.5 bo d,
= (1+2 / 1.088) 0.2 x 1.0 x 0.60 x 5.477 x bo d
= 1.8654 bo d
Formula (1) cannot be greater than Formula (2).
4.5 Evaluating Formula (2):
Vc = 0.4 l fc (fc)0.5 bo d
= 0.4 x 1.0 x 0.6 x 5.477 bo d
= 1.3145 bo d
Which is less than Vc in Formula (1)
Therefore, use Vc in Formula (2) & substitute (14200 4d) for bo:
Vc = 1.3145 (14200 4d) d
= 18665.9 d 5.258 d2 (N)
= 18.6659 d - 0.005258 d2 (kN) Formula (3)
4.6 Factored Shear Loads, Vf
The following equations consider the applied shear loads on the bulkhead:
Factored shear load (Vf) :

Vf = Wf (la d) (lb d)
= 4931 (3.400 0.001 d) (3.700 0.001 d) (kN)
= 4931 (12.58 0.0034 d 0.0037 d + 0.000001 d2) (kN)
= 0.004931 d2 35.0101 d + 62031.98 (kN)
Where, Wf = total factored load = 4931 (kN) (Section 4.3)
4.7 Factored Thickness of Bulkhead, d
The following equations consider the factored thickness of the bulkhead based on the factored shear resistance and
factored shear load.
Let:

Factored Shear Resistance (Vc) = Factored Shear Load (Vf)

18.6588 d - 0.005256 d2 = 0.004931 d2 35.0101 d + 62031.98
0.010187 d2 53.6689 d + 62031.98 = 0
Solving quadratic equation for d:
ad2 + bd + c = 0
d = (-b 6 (b2 4ac)0.5) / (2a)
= (53.6689 6 (2880.350827 2527.679121)0.5) / 0.020374
= (53.6689 6 18.77955554) / 0.020374
= 1713 mm
Use d = 1800 mm
4.8 Factored Moment (Short Side), Mf
The following equation considers the moment acting along the short side of the bulkhead. Factored moment, short
side, (Mf):

Mf = Mal + Mad (CSA E2.8)

Where, live load positive moment, (Mal):
Mal = Cal Wlf la2
= 0.0431 x 4931 x (3.40)2
= 2457 kN.m per metre width
And, dead load positive moment, (Mad):
Mad = Cad wdf la2
=0

Therefore, Mf = 2457 kN.m per metre width

4.9 Reinforcement Steel Area for Preliminary Calculations (Short Side)
The following formulae consider the reinforcement steel area which is required for preliminary calculations regarding
the bulkhead reinforcing steel requirements. These formulae refer to the CPCA Concrete Design Handbook 2.9. Steel

area, (As):
As = (Mf x 106) / (0.90 fs fy d) (CSA 9.3.3)
Where, Mf = 2457 kN.m per metre width
d = 1800 mm
For fs = 0.85, fy = 400 MPa
Therefore, As = (2457 x 106) / (306 x 1800)
= 4461 mm2 / m
Consider two steel layers of 30M at 200 mm:
As = 2 [(30/2)2] / 0.200
= 7068 mm2 / m
Ratio of non-prestressed tension reinforcement, (r):
r = As / (b d)
Where b = 1000 mm unit width
r = 7068 / (1000 x 1800),
= 0.003927
4.10 Factored Moment Resistance (Short Side), Mr
The following formulae consider the factored moment resistance acting across the short side of the bulkhead. Refer to
CPCA Concrete Design Handbook 2.7 and CSA Appendix B3.
Factored moment resistance, (Mr):

Mr = r fs fy [1 (r fs fy) / (1.7 fc fc)] bd2

= 0.003927 x 0.85 x 400 [1 (0.003927 x 0.85 x 400) / (1.7 x 0.60 x 30)] 1000 x 18002
= 4137 kN.m
Since Mr $ Mf , OK.
4.11 Ratio of Tension Reinforcement (Short Side),
The following formulae consider the ratio of tension reinforcement of the bulkhead. Three criteria are to be met:

Preliminary:
= 0.003927 (Section 4.8)
1. Temp. & shrinkage reinforcing.
min = 0.0020,
Since min, OK
2. Max. Allowable steel ratio max
(to ensure ductile failure)
max = (c / s) [(0.85 x fc x 1 x 600) / fy (600 + fy)]
Where, fc = 30, 1 = 0.85
max = (0.60 / 0.85) [(0.85 x 30 x 0.85 x 600) / 400 (600 + 400)]
= 0.02295,
Since max, OK
3. Minimum Reinforcing for Flexure
min = 1.4 / fy or 1.33 x reqd for flexure (CSA 10.5)
= 1.4 / 400 = 0.0035,
Since min, OK
Therefore initial reinforcing steel area estimation (Section 4.8) of two layers of 30 M at 200
4.13 Reinforcement Steel Area for Preliminary Calculations (Long Side)
The following formulae are the second iteration for considering the reinforcement steel area which is required for
preliminary calculations. The bulkhead reinforcing steel requirements for moments acting along the long side of the
bulkhead are considered. These formulae refer to the CPCA Concrete
Design Handbook 2.9.

Steel area, (As):

As = (Mf x 106) / (0.90 fs fy d) (CSA 9.3.3)

Where, Mf = 2059 kN.m per metre width (long side)

d = 1800 mm
For fs = 0.85, fy = 400 MPa
Therefore, As = (2059x 106) / (306 x 1800)
= 3738 mm2 / m
Consider two steel layers of 30M at 250 mm:
As = 2 [(30/2)2] / 0.250
= 5655 mm2 / m
Ratio of non-prestressed tension reinforcement, (r):
r = As / (b d)
Where b = 1000 mm unit width
r = 5655 / (1000 x 1800),
= 0.00314mm are satisfactory. (As = 7068 mm2 / m)
4.12 12. Factored Moment (Long Side), Mf
Factored moment, long side, (Mf):

Mf = Mbl + Mbd (CSA E2.8)

Where Mbd = 0 (dead load, D = 0)
Mbl = Cbl Wlf lb
2

= 0.0305 x 4931 x (3.70)2

= 2059 kN.m per metre width
Mf = 2059 kN.m per metre width
4.14 Factored Moment Resistance (Long Side), Mr
The following formula considers the factored moment resistance acting across the long side of the bulkhead. Refer to
CPCA Concrete Design Handbook 2.7 and CSA Appendix B3.
Factored moment resistance, (Mr):

Mr = r fs fy [1 (r fs fy) / (1.7 fc fc)] bd2

= 0.002618 x 0.85 x 400 [1 (0.002618 x 0.85 x 400) / (1.7 x 0.60 x 30)] 1000 x 18002
= 2800 kN.m
Since Mr $ Mf, OK.
4.15 Ratio of Tension Reinforcement (Long Side),
The following formulae consider the ratio of tension reinforcement of the bulkhead. Three criteria are to be met:

Preliminary:
= 0.00314 (Section 4.12)
1. Temp. & shrinkage reinforcing.
min = 0.0020,
Since min, OK
2. Max. Allowable steel ratio max
(To ensure ductile failure)
max = (c / s) [(0.85 x fc x 1 x 600) / fy (600 + fy)]
Where, fc = 30, 1 = 0.85

max = (0.60 / 0.85) [(0.85 x 30 x 0.85 x 600) / 400 (600 + 400)]

= 0.02295
Since max, OK
3. Minimum Reinforcing for Flexure
min = 1.4 / fy or 1.33 x reqd for flexure (CSA 10.5)
= 1.33x As/ (b x d)
= 1.33 x 3738/ (1000 x 1800)
= 0.0028
Since min, OK
Therefore initial reinforcing steel area estimation (Section 4.8) of two layers of 30 M at 250 mm are satisfactory. (A s =
5655 mm2 /m)

4.16 Bar Layer Spacing and Slab Thickness

The following formulae consider the spacing of reinforcement steel bar layers, as well as the thickness of the bulkhead
concrete slab.

Bar Layer Spacing, (s):

s = db + 1.33 x 35 mm (max. aggregate size)

Where, db = diameter of the reinforcing bar (30 mm)

s = 30 mm + 46.55 mm
= 76.55 mm, use 80 mm
Slab Thickness, (h):
h = d + s / 2 + dc + db / 2
Where, d = 1800 mm (effective depth)
dc = 75 mm (concrete cover to bar)
h = 1800 + 80 / 2 + 75 + 30 / 2
= 1930 mm
4.17 Anchorage in Rock
The following formulae consider the anchorage depth of the bulkhead into the rock based on the bulkhead geometry
and allowable bearing capacity of the rock.

Total bulkhead area, (A):

A = A2 A1
Where, A2 = outside area of bulkhead (including anchorage in rock)
A1 = inside area of bulkhead (not including anchorage in rock)
A = (la + h) (lb + h) (la x lb)
= lalb + lbh + lah + h2 lalb
= (h2 + lbh + lah)
Where, h / 2 = Anchorage in Rock
Hydrostatic Pressure = 3287 kN / m2
Allowable Bearing Pressure = 3800 kN / m2
3287 A1 = 3800 A
A1 / A = 3800 / 3287 = 1.156
Where, la = 3.40 m
lb = 3.70 m
(3.4 x 3.7) / (h2 + 3.7h + 3.4h) = 1.156
12.58 = 1.156 h2 + 8.2076 h
h2 + 7.1 h 10.8824 = 0
Solving quadratic equation:

ah2 + bh + c = 0
h = (-b 6 (b2 4ac)0.5) / (2a)
= (-7.1 6 (50.41 + 43.5296)0.5) / 2
= (-7.1 6 9.6922) / 2
= 1.30 m
Therefore, anchorage required = h/2 = 1.30 / 2 = 0.65 m
For additional factor of safety:
Anchorage required = h / 2, let h = d, 1800 / 2 = 900 mm = 0.90 m
4.18 Bearing on Concrete
The following formulae consider the allowable bearing pressure of the concrete slab compared to the bearing pressure
of the live load.
At support:

Pressure = 3800 kN / m2 x 1.5 (live load factor)

= 5700 kN / m2
= 5.70 MPa
On Face = 3287 kN / m2 x 1.5
= 4931 kN / m2
= 4.93 MPa
Allowable Bearing Pressure on Concrete:
= 0.85 c fc (CSA 10.15.1.1)
= 0.85 x 0.60 x 30
= 15.3 MPa
Since Allowable Bearing Pressure on Concrete>Pressure on Face (due to live load), OK
Bulkhead Design Example

Figure D2 Results of the bulkhead design calculations for an opening 3400mm x 3700mm.