Professional Documents
Culture Documents
DESIGN CRITERIA
STRUCTURAL DESIGN CRITERIA
25875-000-3DR-S01-00001 Rev 003
Bechtel Petrofac JV
003
22/02/2016
002
08/07/2015
001
11/06/2015
000
18/02/2015
REV
DATE
J Kudziela
K Lynch
J Bacon
M Barnham
Zayed
Shaat
M. Crosse
J Kudziela
K Lynch
J Bacon
M Barnham
M Crosse
S Hamida
J Kudziela
K Lynch
J Bacon
M Barnham
M Crosse
---
J Kudziela
M
Cordero
J Bacon
M Barnham
M Crosse
---
REASON FOR
REVISION
BY
CHECK
EGS
PEM
OWNER
OWNER
Page 1 of 46
DOCUMENT NO.
Confidential
Confidential 2016 Joint Venture between International Bechtel Co. Ltd (Abu Dhabi Branch) and Petrofac Emirates L.L.C. (BPJV). This
document, prepared under Contract EGA/SH-EPCM/27-016 between BPJV and Emirates Global Aluminium PJSC (EGA), contains
information confidential and/or proprietary to BPJV that is not to be used, disclosed, or reproduced in any form by any person or entity
other than BPJV or EGA without BPJVs prior written permission. All rights reserved.
Al Taweelah Alumina
TABLE OF CONTENTS
SECTIONS
DESCRIPTION
PAGE
1.
INTRODUCTION ....................................................................................................................... 5
2.
3.
4.
5.
GENERAL........................................................................................................................................ 9
PRE-ASSEMBLY .............................................................................................................................. 9
CALCULATIONS .............................................................................................................................. 9
COMPUTATIONAL MECHANICS METHODS (E.G. THE FINITE ELEMENT METHOD) ............................ 10
DESIGN DATA ......................................................................................................................... 11
5.1.
5.2.
6.
6.1.
6.2.
6.3.
6.3.1.
6.3.2.
6.3.3.
6.3.4.
6.4.
6.5.
6.5.1.
6.5.2.
6.5.3.
6.6.
6.6.1.
6.7.
6.7.1.
6.7.2.
6.7.3.
6.7.4.
6.7.5.
6.7.6.
6.7.7.
6.7.8.
6.7.9.
6.7.10.
6.8.
6.9.
6.10.
7.
GENERAL...................................................................................................................................... 11
DEAD LOADS ................................................................................................................................ 12
LIVE LOADS ................................................................................................................................. 12
Facilities and Buildings ............................................................................................................... 12
Conveyor Structures .................................................................................................................... 13
Retaining Walls ........................................................................................................................... 14
Slabs on Ground and Trafficable Culverts .................................................................................. 14
BLOCKED CHUTE LOADS .............................................................................................................. 14
EQUIPMENT LOADS ...................................................................................................................... 14
General ........................................................................................................................................ 14
Impact and Dynamic Loads ......................................................................................................... 14
Vibration Loads ........................................................................................................................... 15
WIND LOADS ................................................................................................................................ 15
Wind Loads for Special Structures .............................................................................................. 16
EARTHQUAKE LOADS ................................................................................................................... 16
Mapped Acceleration Parameters ............................................................................................... 16
Design Spectral Response Acceleration Parameters for Site Class C soils ................................ 17
Design Response Spectrum for Site Class C soils ....................................................................... 17
Liquefaction Considerations........................................................................................................ 18
Seismic Design Category ............................................................................................................. 19
Importance Factor ....................................................................................................................... 19
Seismic Force-Resisting System .................................................................................................. 19
Seismic Provisions for Vendor Equipment .................................................................................. 19
Earthquake Loads for Special Structures .................................................................................... 19
Soil-Structure Interaction ............................................................................................................ 20
TEMPERATURE EFFECTS ............................................................................................................... 20
PRE-ASSEMBLY LOADS................................................................................................................. 21
OPERATING MATERIAL LOAD ...................................................................................................... 21
LOAD COMBINATIONS ........................................................................................................ 21
7.1.
7.2.
GENERAL...................................................................................................................................... 21
NOMENCLATURE .......................................................................................................................... 21
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7.2.1.
7.2.2.
7.2.3.
7.2.4.
7.2.5.
7.2.6.
7.2.7.
7.3.
8.
Dead Loads.................................................................................................................................. 21
Live Load ..................................................................................................................................... 22
Spillage Load ............................................................................................................................... 22
Material Loads ............................................................................................................................ 22
Wind Loads .................................................................................................................................. 22
Seismic Load................................................................................................................................ 22
Belt Tension Loads ...................................................................................................................... 23
COMBINATIONS ............................................................................................................................ 23
SERVICEABILITY .................................................................................................................. 26
8.1.
8.2.
9.
9.1.
9.2.
9.2.1.
9.2.2.
9.2.3.
9.2.4.
9.2.5.
9.2.6.
9.2.7.
9.2.8.
9.3.
9.3.1.
9.3.2.
9.3.3.
9.3.4.
9.3.5.
9.3.6.
9.3.7.
9.3.8.
9.3.9.
9.3.10.
9.4.
9.4.1.
9.4.2.
9.4.3.
9.4.4.
9.4.5.
9.4.6.
9.4.7.
9.4.8.
9.4.9.
9.4.10.
9.4.11.
9.4.12.
9.4.13.
9.4.14.
9.5.
9.6.
9.7.
10.
10.1.
10.2.
EARTHWORKS .............................................................................................................................. 27
FOUNDATIONS .............................................................................................................................. 28
General ........................................................................................................................................ 28
Footings ....................................................................................................................................... 28
Holding Down Bolts .................................................................................................................... 28
Shear Keys ................................................................................................................................... 29
Piers / Piles ................................................................................................................................. 29
Raft Slabs..................................................................................................................................... 29
Ball Mill ....................................................................................................................................... 30
Tank Bases ................................................................................................................................... 30
CONCRETE STRUCTURES .............................................................................................................. 30
General ........................................................................................................................................ 30
Materials ..................................................................................................................................... 31
Concrete Cover for Reinforcement .............................................................................................. 32
Slabs on Grade ............................................................................................................................ 32
Earth Retaining Structures .......................................................................................................... 33
Bases to Pumps and Rotating Equipment .................................................................................... 33
Liquid Retaining Structures ......................................................................................................... 33
Suspended Floor Slabs ................................................................................................................ 34
Crack Control .............................................................................................................................. 34
One-Way Shear............................................................................................................................ 34
STEELWORK ................................................................................................................................. 34
General ........................................................................................................................................ 34
Materials and Preferred Steel Sections ....................................................................................... 35
Bolting ......................................................................................................................................... 35
Welding ........................................................................................................................................ 35
Connections ................................................................................................................................. 35
Bracing ........................................................................................................................................ 36
Corrosion Protection ................................................................................................................... 36
Flooring ....................................................................................................................................... 37
Stairs, Walkways and Landings ................................................................................................... 37
Handrails and Kick-Plates .......................................................................................................... 38
Ladders ........................................................................................................................................ 38
Crane Runway Beams and Monorails ......................................................................................... 38
Grouting of Baseplates ................................................................................................................ 39
Purlins and Girts ......................................................................................................................... 40
TIMBER ........................................................................................................................................ 40
CLADDING .................................................................................................................................... 40
CONCRETE MASONRY .................................................................................................................. 40
DESIGN OF FACILITIES ....................................................................................................... 40
CONVEYOR STRUCTURES ............................................................................................................. 40
TANKS AND VESSELS ................................................................................................................... 41
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Electronic documents, once printed, are uncontrolled and may become outdated.
Refer to the electronic documents in the project electronic database for current revisions.
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10.3.
10.3.1.
10.3.2.
10.3.3.
10.3.4.
10.3.5.
10.3.6.
10.3.7.
10.4.
10.4.1.
10.4.2.
10.4.3.
10.4.4.
10.5.
10.6.
10.6.1.
10.7.
10.8.
10.9.
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1. INTRODUCTION
This design criteria defines the general and technical requirements for the structural design
of buildings, structures and foundations for the Shaheen Alumina Refinery Project located
in the Khalifa Port Industrial Zone (KPIZ) in Abu Dhabi, United Arab Emirates (UAE).
All design shall be in accordance with this Design Criteria, the Specifications and the
Standards and References set out in Section 2 and shall comply with the owners Safety
Guidelines. Alternative documents shall only be adopted with the owners approval.
for regulatory documents the local UAE requirements over the international
regulations,
The following are the principal standards, codes, guidelines and references to be used for
the structural design. In accordance with ADIBC 2013 American codes shall be considered
as govering codes, however, British and European codes may be used with project
approval.
2.1.
ASCE 37-02
AISC 360-05
AISC 341-05
ACI 318M-08
ACI 530-08
AA ADM 2010
AISI S100-07
North American Specification for the Design of ColdFormed Steel Structural Members, American Iron and
Steel Institute
BS 5395-1:2010
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BS EN 1990:2002
EN 1991-1-4:2005
EN 1991-3:2006
EN 1992-1-1:2004
EN 1992-3:2006
EN 1993-6:2007
EN 197-1:2011
EN 10080:2005
Refer to the technical specifications below for a list of relevant materials standards.
Alternative design codes may only be used with approval from the lead engineer.
Any conflicts between approved codes shall be brought to the lead engineers attention for
resolution.
2.2.
25875-070-V01-WA49-00011
25875-070-V01-WA49-00019
25875-070-V01-WA49-00020
Geotechnical Investigation
Changed Layout
25875-000-30R-K01-00001
25875-000-30R-K01-00002
25875-000-3DR-C01-00001
25875-000-3DR-P01-00002
25875-000-3DR-M01-00001
Additional
Works
Works
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25875-000-3DR-S01-00003
25875-000-3DR-S01-00004
25875-000-3DR-S01-00005
25875-000-3DR-V01-00001
25875-000-3PS-ATPS-00001
25875-000-3PS-AYFP-00001
25875-000-3PS-C000-00001
Site Conditions
25875-000-3PS-CE00-00002
25875-000-3PS-CE00-00003
25875-000-3PS-DB00-00001
25875-000-3PS-DB00-00002
25875-000-3PS-DB00-00003
25875-000-3PS-DB00-00004
25875-000-3PS-DB00-00005
25875-000-3PS-MT00-00001
25875-000-3PS-NX00-00001
25875-000-3PS-SS00-00002
Specification - Structural
Fabrication
25875-000-3PS-SS00-00003
25875-000-3PS-SS00-00004
25875-000-GPP-GES-00001
25875-000-GPP-GES-00002
25875-000-GPP-GES-00003
Steelwork
Supply
and
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2.3.
References
Design of Structures and Foundations for Vibrating Machines by Arya, ONeill and
Pincus
2.4.
All design, materials, workmanship and practises shall be in accordance with the local
agencies that have jurisdiction over the project and Abu Dhabi Municipality.
Relevant regulatory requirements on the project includes but not limited to the followings:
3. SITE CONDITIONS
The Shaheen Alumina Refinery will be located in the Khalifa Port and Industrial Zone
(KPIZ) in Abu Dhabi, United Arab Emirates (UAE). All equipment, components, and
materials shall be suitable for unprotected installation in the outdoors within a harsh
industrial environment that can be laden with alumina dust, and caustic liquors and
vapours.
General site information and climatic data are included in project specification 25875-0003PS-C000-00001 Site Conditions.
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4. DESIGN RESPONSIBILITIES
4.1.
General
The design engineer shall become familiar with the functions and operating conditions of
the plant such as the movement of materials and liquids, rotating masses, out of balance
forces, temperature changes, impact forces, spillage loads, and build up of scale.
The design engineer shall ascertain, in conjunction with the lead engineer and in
consultation with the process, mechanical, and electrical engineers, the loads created by
plant, equipment, operational conditions, and stacked materials during construction for
each facility.
All design input shall be authorised by the lead engineer prior to application.
Structures supporting plant and equipment should be designed with consideration for the
proposed function and the economical fabrication and erection of the structures.
Constructability and access for maintenance shall be considered. The bracing at ground
level should be kept to a minimum so that easy access is provided for maintenance and
operations.
Standard drawings have been produced for the project and these standards, where
appropriate, shall be referred to and used in preference to other, non-standard details.
All calculations and drawings shall be documented in SI units and the English language.
4.2.
Pre-Assembly
4.3.
Calculations
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A detailed introduction explaining the circumstances and basis for design and
the path chosen.
Copies of all inputs such as general arrangements, vendor data, geotech info,
data sheets, faxes , emails etc. Wherever possible these should be scanned
or copied as part of the calculations and not just referenced.
Ensure all electronic calculations and any other engineering package output is self
explanatory and easily followed without needing the software for interpretation.
Add an appendix for hard copy attachments, make the calculation a stand-alone
document where ever possible by attaching the nal IFC drawings to the
calculations.
Ensure there is a HOLDS list; all HOLDS should be cleared prior to nal check and
approval.
Ensure the checker signs each page unless a completely independent checkers
calculation is attached.
The DPPS Procedure Manual 2013 (refer Section 2.4) design checklist items should
all be addressed.
4.4.
Computational mechanics methods and analyses (including the finite element or finite
difference methods) shall only be used with the written approval of the lead engineer.
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Are there any schedule impacts associated with the proposed higher level analysis?
Are the goals and acceptance criteria of the analyses clearly defined?
Are the proposed personnel appropriately qualified and experienced in the particular
method of analysis?
Where approval is granted, such analyses must be documented in accordance with a preagreed procedure. The validation methodology shall be agreed with the lead engineer prior
to commencing any analysis.
5. DESIGN DATA
The plant shall be designed for a life of 30 years operating 24 hours a day and 365 days
per year.
For general design data related to temperature, humidity, rainfall and tide heights, refer to
specification 25875-000-3PS-C000-00001 Site Conditions.
Buildings and other structures are generally occupancy category II in accordance with the
ADIBC 2013 Table 1604.5. Facilities shall be occupancy category IV where listed as an
essential facility in Table 1604.5.
5.1.
5.2.
Material Properties
6. DESIGN LOADS
6.1.
General
The loads used in the design shall be in accordance with the loads given in this criteria, the
specific loadings as established for each item of equipment, and ASCE 7-05 Minimum
Design Loads for Buildings and Other Structures. The minimum or maximum dead loads
shall be combined in conjunction with other loads, so as to produce the most severe
combinations of load imposed on the structure.
The layout and design criteria for all equipment supported on the structure shall be
obtained in writing from the mechanical engineer before design commences.
The design engineer, in consultation with the lead engineer, shall determine the loads
imposed by electrical cables and services pipes.
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6.2.
Dead Loads
Superimposed dead loads shall be considered as the weight of all materials forming loads
on the structure that are not structural elements and which are likely to vary or be removed
during operation or construction of the structure.
Superimposed loads may include:
Piping contents.
The design engineer shall assess the possibility of the removal of these dead loads, which
will result in the most severe combination of stresses in the structure.
6.3.
Live Loads
Uniformly Distributed
Load
Concentrated
Load
(kPa)
(kN)
3.0
2.7
5.0
4.5
4.8
(100 psf)
4.5
2.5
2.0
2.5
2.0
1.2 kN/m
10.0
5.0
4.5
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Area
Uniformly Distributed
Load
Concentrated
Load
(kPa)
(kN)
10.0
To be determined
for specific
location
0.6 to 1.0
4.5
ADIBC 2013,
1607.11.2.1
Roof live load, for trafficable roofs
3.0
4.5
These loads are to be verified for the specific area and facility. The structural members are
to be designed for the load pattern (either uniformly distributed or concentrated), which has
the most adverse effect on the supporting member. Generally the concentrated loads in the
above table will be applied to short members that support only a small area of floor.
Where nominated by the lead engineer a concentrated load shall be applied to all major
floor and roof beams for lifting of equipment.
The magnitude of this load shall be determined in consultation with the lead engineer but
shall not be less than 10.0 kN applied at midspan. This load shall be considered as a
separate load condition not acting on the beam simultaneously with other live loads.
Areas of plant or support facilities not specified in this section shall have live loads
determined in accordance with the ADIBC 2013 and where uniformly distributed loads are
applied to a number of floors in a building, a live load reduction may be applied subject to
approval from the lead engineer.
Stair treads shall be designed for a concentrated vertical load of 1.35 kN (300 lb) in
accordance with the ADIBC 2013.
Handrails shall be designed for a load of 0.36 kN/m (25 lb/ft) applied in any direction to the
top rail and also 0.89 kN (200 lb) concentrated load applied in any direction (not applied at
the same time).
6.3.2. Conveyor Structures
The following loading to conveyor gantries shall be considered:
a)
Live to walkways:
b)
Spillage:
Open conveyors:
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6.4.
Loads from blocked chutes and blocked equipment shall be considered assuming the
equipment is filled to maximum capacity with material of maximum density.
6.5.
Equipment Loads
6.5.1. General
Layout and design criteria for the support of equipment items, together with Certified Seller
drawings, shall be provided by the relevant discipline engineer. Equipment reactions shall
be supplied by the Seller and shall indicate all possible loading combinations, dynamic
effects and allowable deflections of supporting structures.
6.5.2. Impact and Dynamic Loads
The static load of equipment shall be multiplied by the following factors to allow for impact:
3.0*
Rotating machinery
2.0*
Mobile equipment
1.2
Fork lifts
1.6
1.35
2.0
1.1
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* These values shall be used for preliminary design only. Actual certified dynamic load
values nominated by the equipment Seller shall be used in the final design.
6.5.3. Vibration Loads
Certified Seller drawings giving design parameters and operating frequencies shall be
obtained from the manufacturer for each piece of equipment. The dynamic effect on the
immediate supports and on the main structure shall be evaluated using un-factored actual
masses.
Areas subject to dynamic loading shall be checked for dynamic response against limits for
workers by ISO 2631-1:1997, Mechanical vibration and shock- Evaluation of human
exposure to whole-body vibration.
Wherever possible, vibrating equipment shall be isolated from the main structural framing.
However, where such equipment is supported on structural members, the following table
provides a guideline for the desired relationship between the frequency of the vibrating
loads and the frequency of the supporting members:
Length of Beam
Type of Supports
5 m or less
Directly connected to
column
1.5
Greater than 5 m
Directly connected to
column
2.0
5 m or less
1.5
Greater than 5 m
2.0
The natural frequency of bracing adjacent to the equipment shall also be checked. The
desired relationship between the natural frequency fn and the forcing frequency ff of the
brace shall be as follows: fn/ff is less than 0.75 or greater than 1.5.
The design engineer shall consider the effects of fatigue in the design of supporting
members and their connections. Fatigue shall be checked in accordance with EN 1993 and
shall be based on the relevant number of cycles applicable to the beam or to the detail
being designed and shall take into account the fabrication details of the beam and its
components.
6.6.
Wind Loads
The basic wind speed for the site is 40 m/s. The basic wind speed is the 3-second gust
speed at 10 m height in exposure category C with a 50 year return period.
The site exposure category for all wind directions shall be taken as exposure D. The design
wind speed is to be adjusted for the site exposure category and the building height above
ground in accordance with the procedures in ASCE 7-05.
The importance factor by ASCE 7-05 Table 6.1 shall be 1.0 for occupancy category II
facilities and 1.15 to occupancy category IV facilities.
The topographic factor in ASCE 7-05 shall be taken as 1.0.
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Wind forces, except for structures noted in Section 6.6.1, shall be determined in
accordance with ASCE 7-05. Drag coefficients may also be determined in accordance with
EN 1991-1-4.
The operating wind speed VO shall be taken as 20 m/s. This is the wind speed applicable
during shutdown of the plant and also during erection procedures.
The serviceability wind speed VS for serviceability deflection checks shall be based on a
10 year return period. It shall be taken as 27 m/s.
For structures subject to belt tension and/or blocked chute condition i.e. conveyor buildings,
head, tail, drive, take ups, cantilevered conveyor structures, a special case of wind speed
VOPERATING = VO = 20 m/s shall be used in combination with maximum belt tension or
blocked chute load.
Consideration shall be given to the effect on wind loads for closely spaced cylindrical
structures e.g. silos or tanks.
6.6.1. Wind Loads for Special Structures
Chimneys and stacks shall be designed for wind loads in accordance with document
25875-000-3DR-S01-00004 Stack/Chimney Structural Design Criteria.
6.7.
Earthquake Loads
Structures, except as noted in Section 6.7.9 of this Design Criteria, shall be designed for
earthquake loads as detailed in ADIBC 2013 and ASCE 7-05 using parameters as specified
below.
ASCE 7-05, Section 11.4.7, allows a site-specific ground motion evaluation to be performed
following the provisions of ASCE 7-05, Chapter 21. If such an analysis is performed,
Section 21.3 allows use of the site-specific results to develop the design response
spectrum except that it may not fall below 80% of a design spectrum developed directly
using regional maps, given in this case as part of the ADIBC 2013 (Figure 1613.5(1), Figure
1613.5(2), and Figure 1613.7). A site-specific probabilistic seismic hazard analysis (PSHA)
was undertaken by Bechtel Petrofac Joint Venture (BPJV). Refer to the Seismic Hazard
Study 25875-000-30R-K01-00001.
6.7.1. Mapped Acceleration Parameters
Abu Dhabi International Building Code (ADIBC) 2013 has specified, using regional maps for
the United Arab Emirates (Figure 1613.5(1), Figure 1613.5(2), and Figure 1613.7), for
determination of the earthquake loads:
SS = 0.71 g
S1 = 0.21 g
TL = 8 s
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6.7.2. Design Spectral Response Acceleration Parameters for Site Class C soils
Site Class C soils are typical for the project site (Refer 25875-070-V01-WA49-00011 and
25875-000-30R-K01-00002) except where liquefaction considerations detailed in Section
6.7.4 identify Site Class F soils.
Site coefficients for Site Class C soils shall be taken as specified below:
Fa = 1.116
Fv = 1.590
0 to 1 second
1.000
> 1 to 2 seconds
0.913 + 0.088 x T
> 2 to 8 seconds
1.088
> 8 to 10 seconds
1.363
Note that in calculating Cs values to ASCE 7-05 Section 12.8, the Cs values are equal to
Sa / (R/I). Note also that Cs values by ASCE 7-05 Equation 12.8.2 are constant from a
period of 0.0 seconds up to the period Ts i.e. they do not reduce for periods less than T0.
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Facility
Number
Thickness of
Liquefiable Soil
Post-Liquefaction
Settlement
Change House
035
2-3m
50 60 mm
Crushing
210
1-2m
20 60 mm
Grinding
220
1-3m
50 60 mm
Pre-Desilication
230
2-4m
80 100 mm
Digestion
240
2-4m
100 140 mm
Clarification
250
1-2m
30 60 mm
Evaporation
350
1-3m
50 60 mm
Hydrate Transfer
470
1-3m
40 60 mm
Calcination
490
2-3m
40 60 mm
A site response soil model has been developed based on low-strain shear wave velocities,
nonlinear, or equivalent linear, shear stress-strain relationships and unit weights in
accordance with ASCE 7-05, Section 21.1. The design spectral response acceleration Sa
values developed from this model are below 80% of the design spectra for Site Class E for
all periods. Hence by ASCE 7-05, Section 21.3, the design spectral response acceleration
at all periods shall be taken as 80% of the Sa values for Site Class E calculated in
accordance with ASCE 7-05, Section 11.4.5.
Structures in the facility areas identified above shall be designed for earthquake loads
based on the design spectral response acceleration for Site Class F soils, using parameters
specified in 6.7.4.1 and 6.7.4.2, unless suitable ground improvement treatments are
adopted to prevent liquefaction.
Design Spectral Response Acceleration Parameters for Site Class F soils
As noted above parameters for Site Class F soils shall be calculated for Site Class E soils
and factored by 0.80.
Fa = 1.28
Fv = 3.16
Page 18 of 46
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Silos, bins and bunkers shall be designed for additional earthquake requirements in
accordance with document 25875-000-3DR-S01-00005 Silos, Bins and Bunkers Structural
Design Criteria.
Silos and tanks shall also consider the earthquake requirements of ASCE 7-05 Chapter 15
and relevant seismic design references of ASCE 7-05 Chapter 23.
6.7.10. Soil-Structure Interaction
Soil-structure interaction may be considered for non-building structures. Typically this will
involve modelling the combined structure, foundation and soil support to accurately access
the fundamental period of the structure.
The values of the total lateral force and total base overturning moment shall not be less
than 80% of the values calculated using ASCE 7-05, as detailed in ASCE 7-05, Section
15.4.1, 6b.
6.8.
Temperature Effects
Other Locations
65
50
Foundations and structures, which are subject to temperature effects, shall be designed for
any temperature difference, which may occur in parts of structural members.
For stresses arising in structures due to variation in atmospheric temperature, the following
temperature differences shall be considered.
Maximum rise in temperature:
T = + 40 (oC)
Maximum fall in temperature:
T = - 40 (oC)
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6.9.
Pre-assembly Loads
Pre-assembly units and associated temporary erection and transportation steelwork and
concrete supports shall be designed for the loads induced during transportation and crane
lifts, especially road and sea transport and shall be in accordance with
25875-000-3DR-S01-00003 Pre-Assembly Structural Design Criteria.
The method of transport / lifting and the location of transport support / lifting points shall be
agreed with the Pre-assembly and Construction teams.
The design engineer shall be responsible for nominating the location of such points and
designing the connections at the lifting points and shall also consider the effects of forces
induced in the structure due to the lifting arrangement.
Impact factors shall be in accordance with 25875-000-3DR-S01-00003 Pre-Assembly
Structural Design Criteria.
The pre-assembly structural engineer shall prepare a sketch or arrange for a drawing of the
pre-assembly showing the location of the lifting points, the angle of slings and the
disposition of spreader beams as applicable.
The WLL (Working Load Limit) or Safe Working Load (SWL) for the slings shall be
calculated in accordance with the relevant British/European/International Standards.
6.10.
Operating material load (other than for a conveyor as per Section 7.2) shall be considered
to be a superimposed (removable) dead load Gsup as per Section 7.2.1 provided the
material density and the maximum operating volume of material contained is clearly
defined. Where this is not possible the operating material load shall be added to the load
MN in Load Combination Tables in Section 7.3.
7. LOAD COMBINATIONS
7.1.
General
Loading combinations shall be in accordance with the ADIBC 2013 and ASCE 7-05 and the
combinations shown in this Section. Where these combinations are not applicable, the
engineer shall submit new combinations to the lead engineer for approval.
Reliance on friction for stability should be avoided, where economically possible. The
possibility of a reduction in friction due to dynamic loads shall be carefully considered.
Friction shall not be considered in resisting earthquake loads.
7.2.
Nomenclature
ID
= idler weight
BL
= belt weight
EQUIP
PIPING SW
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EL DEAD
OML
PIPING SW + PIPING CONTENTS to equal total pipe loading allowance. Refer 10.3.1
EL DEAD + EL SUP to equal the total cable tray load allowance. Refer 10.3.7
7.2.2. Live Load
Q
= Live load on floors, platforms and walkways, including stairs.
7.2.3. Spillage Load
SP
= Spillage allowance.
The full spillage load in combined with maximum wind and seismic loads. If a lesser, most
likely value of spillage is more appropriate in combination with wind and seismic loads,
spillage should be considered as a floor live load.
7.2.4. Material Loads
MN
= Maximum operating material load on a conveyor belt where MN is based on
maximum operating material load at the upper limit of the material design bulk density. MN
shall be applied over the length of conveyor to create the worst effect.
MF
= Flooded belt load (i.e. belt profile with material at angle of repose from edge of
belt at the upper limit of the material design bulk density). MF shall be applied over the
length of conveyor to create the worst effect.
BC
= Chute totally full (i.e. to top of chute) using the upper limit of the material design
bulk density
7.2.5. Wind Loads
WO
= Operating wind load, calculated using wind speed VO (Refer Section 6.6).
WS
= Serviceability wind load, calculated using wind speed VS (Refer Section 6.6).
= Wind load, calculated using 50 year return period (Refer Section 6.6).
Page 22 of 46
Al Taweelah Alumina
Vertical seismic acceleration effects shall be considered in accordance with ASCE 7-05
Section 12.4.2.2. Vertical accelerations shall be added and subtracted from the seismic
load combinations in accordance with ASCE 7-05 Section12.4.2.3.
7.2.7. Belt Tension Loads
BTTU = Belt tension at take up
BTN = Normal operating belt tension
BTA = Accelerating belt tension (i.e. at start-up)
BTE = Extreme stalling or belt pull out tensions (i.e. belt jammed)
(Note: Substitute 1.5BTA for BTE if BTE < 1.5BTA)
7.3.
Combinations
Where applicable, loads shall be combined in accordance with but not limited to the
following two tables.
Departure from combinations listed shall be allowed if approved by the lead engineer.
When determining load combination factors for design of vessels and support structures
including foundations, the vertical and lateral pressures of liquid product shall be treated as
an operating material load in accordance with Section 6.10.
For load combinations with minimum vertical load, product load shall be excluded from
dead load unless directed otherwise by the lead engineer.
On open structures, consideration may be given to reducing the floor live load (Q) in
serviceability wind (W S) and maximum wind (W) load combinations. Loads shall only be
reduced if approved by the lead engineer.
The following philosophy for checking the capacity of the foundation material shall be
adopted:
Serviceability wind loads (from Section 6.6) shall be used to check that maximum
absolute and differential settlements (elastic and long-term) are within acceptable
limits.
Maximum wind and earthquake loads (from Sections 6.6 & 6.7) shall be used to
check that bearing failure (i.e. rupture) does not occur under ultimate loads. Ultimate
wind load is 1.6W, as per the following load combinations. If an ultimate bearing
capacity is not explicitly stated in the geotechnical report(s) then the ultimate
bearing capacity may be taken as 1.5 x the allowable (permissible) bearing
capacity.
Ultimate load combinations include maximum wind and earthquake loads with
minimum vertical loads. Bearing capacity shall be checked for this condition as well
as checking overturning stability.
The potential for soil liquefaction in an earthquake shall be checked using ultimate
earthquake loads (from Section 6.7).
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It is not normally required to check deflections under earthquake loads, unless pounding
can occur between closely spaced structures.
Load Combinations For all Structures
Dead only
Dead and Live
Operating wind
operating
material load
flooded belt
load and
blocked chute
Maximum wind
maximum
vertical load
G + Gsup
1.4(G + Gsup)
G + Gsup + 1.0Q + SP + MN
minimum.
vertical load
Seismic
maximum
vertical load
minimum
vertical load
0.9G + 1.6W
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Additional Load Combinations For all structures subject to belt tension (BT)
i.e. conveyor buildings, head, tail, take ups, cantilever conveyor structures
Dead only
Dead and Live
Operating wind
operating
material load
flooded belt
load and
blocked chute
flooded belt
load, blocked
chute &
extreme belt
tension.
Empty belt and
extreme belt
tension
Maximum wind
maximum
vertical load
G + Gsup
1.4(G + Gsup)
G + Gsup + 0.5Q + SP + MN +
BTA + W O
minimum
vertical load
Seismic
maximum
vertical load
minimum
vertical load
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8. SERVICEABILITY
8.1.
Acceptable Deflections
The following table shall be used as a guide to determine acceptable deflections that satisfy
the requirements of Section 1604.3 of ADIBC 2013. Unless noted otherwise, deflection is
for the serviceability limit state load combination.
Element
Floor beam
Refer ISO 2631-1:1997, Mechanical vibration and shock Evaluation of human exposure to whole-body vibration
(per EN 1991-3)
Note: For cantilevers with
a backspan allow for
rotation of the beam at
supports
Lateral deflections to be
based on the top or bottom
flange mobilization, as
applicable.
Lateral
deflection
of
supports at level of crane
rail (per EN 1991-3)
Lesser of 10 mm and Hc
500
Height
150
Height
250
Roof beam
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Element
8.2.
Conveyor trusses
Span Vertical
300
Span Lateral
300
Relative horizontal
deflection between floors
Pipe Racks
Limits for the slenderness as a minimum shall be in accordance with code AISC 360-05 and
AISC 341-05 when applicable.
Item
100
180
180
200
Earthworks
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95% for a minimum depth of 300 mm immediately under concrete slabs and
footings placed on fill or the in-situ subgrade
Embankments composed of engineered fill and cuts in existing site material shall be to a
slope of 1 vertical to 2 horizontal unless otherwise approved by the lead engineer.
9.2.
Foundations
9.2.1. General
Foundations shall be designed in accordance with the Geotechnical Report for the specific
facility.
Where over excavation has occurred backfill shall be either mass concrete or selected
graded granular material from an approved source in accordance with
specification 25875-000-3PS-CE00-00003 Earthworks, Structural Excavation and Backfill
and shall be compacted in layers of 150 mm maximum compacted thickness to the required
standard of compaction.
9.2.2. Footings
Foundations shall be designed for the applicable load combinations.
Maximum total settlements, differential settlements and interaction between foundations
and structures shall be considered during design.
Liquefaction Analysis 25875-000-30R-K01-00002 shall be used to calculate the total and
differential liquefaction settlements applicable to a foundation. These settlements are
additional to the calculated settlements due to loading.
In checking uplift stability, only the soil directly above the footing shall be taken into account
unless approved by the lead engineer.
The effect of groundwater level shall be considered for footing stability.
Footings shall be cast on a 50 mm layer of blinding concrete.
The top of footing bases shall be a minimum of 450 mm below the finished grade or
450 below the slab on grade low point.
The minimum height from top of concrete to finished grade shall generally be:
Exposed column pedestals
300mm
300mm
The minimum height from top of concrete to paving high point shall generally be:
Exposed column pedestals
150mm
150mm
Refer Section 7.3 for details on checking footing bearing capacity, uplift and sliding stability.
9.2.3. Holding Down Bolts
All columns with a mass of more than 140 kg shall have a minimum of four holding down
bolts per base plate unless erected as part of a stable self-supporting structure.
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The capacity of holding down bolts for shear and tension shall be in accordance with
ACI 318M-08, Appendix D or approved equivalent. The total design shear load shall be
considered as applied to a maximum of two front bolts (the bolts closest to the potential
concrete breakout edge). Where a shear key is required, refer Section 9.2.4.
All holding down bolts, nuts and washers shall be hot dip galvanised. Material shall be
Grade 36 to ASTM F1554 or Grade S275JR to EN 10025 (or approved equivalent). Bolts
shall be painted following installation of nuts and approval of the erected steelwork. The
paint system shall be in accordance with 25875-000-3PS-NX00-00001 Painting and
Protective Coatings.
Small items (such as ladders and stair stringers) may be fixed to concrete using mechanical
or chemical anchors where approved. These items shall be stainless steel or hot
galvanised unless otherwise approved by the lead engineer.
Minimum sizes of bolts shall be as follows:
Holding down bolts
20mm dia.
16mm dia.
When designing holding down bolts to a baseplate, the contribution of friction between the
baseplate and the supporting concrete under compression loading may be taken into
account subject to the approval of the lead engineer. The friction force mobilised, using a
coefficient of friction = 0.40 can be deducted from the applied shear to calculate the
resultant shear on the holding down bolts. If the resultant applied ultimate shear load to the
holding down bolts is greater than 75 kN, a shear key shall be provided.
Holding down bolt type A (refer to standard concrete drawings) is typically used with
templates, and as such a sleeve is not required. For assemblies with numerous bolts, such
as vessels, a king bolt with an extra 100 mm projection shall be provided for ease of vessel
erection.
Where a sleeve is required, Type B is typically used for sizes up to 36 mm diameter as
larger sizes are too stiff to move and for diameters greater than 36 mm Type D shall be
used with a match-drilled template.
Type C shall only be used where requested by field engineering. This is typically required
where pre-assembly trailers traverse over or near existing pedestals.
9.2.4. Shear Keys
Shear keys shall be used where the applied ultimate shear load to the baseplate exceeds
75 kN and shall be designed to resist all the shear unless the contribution from friction
under compression loading is taken into account, subject to the approval of the lead
engineer.
Shear keys shall be single or cruciform plates in preference to an open H section. They
shall be full penetration butt welded to the baseplate unless otherwise approved. Refer to
standard drawings for preferred details.
9.2.5. Piers / Piles
The design parameters for piers shall be in accordance with the Geotechnical Report for
the specific facility.
9.2.6. Raft Slabs
Raft slabs shall be designed in accordance with the Geotechnical Report for the specific
facility.
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Design of Structures and Foundations for Vibrating Machines by Arya, ONeill and
Pincus
9.3.
Concrete Structures
9.3.1. General
Concrete design shall be in accordance with ACI 318M-08. For typical details refer to
Concrete Standards commencing at drawing no. 25875-000-D0-0000-10001.
Site soils are generally corrosive. Concrete surfaces below ground shall receive surface
protection as per 25875-000-3PS-DB00-00002 Concrete Works.
Concrete surfaces above ground shall receive surface protection where noted in
25875-000-3PS-NX00-00001 Painting and Protective Coatings.
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9.3.2. Materials
Concrete strength grade designations as per EN 1992 and corresponding usage, shall be
as follows:
Application
Strength
Grade
Designation
Maximum
Aggregate
Size
Characteristic
Compressive
Cylinder Strength fck
at 28 days [MPa]
C40/50
20
40
C40/50
20
40
Piles
C40/50
20
40
Silo walls
C40/50
20
40
Blinding
C12/15
20
12
Marine facilities
C40/50
20
40
Miscellaneous Concrete
e.g. Drainage Structures, Road
Signage and Fencing Footings
C25/30
20
25
C40/50
10
40
C20/25
10
20
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Minimum Protective
Cover to Reinforcement
[mm]
Applications
Blinding
X0
XC3
XS1
XS3
N/A
40
50
50
XA3
Foundations
75
For specific structural elements, U.N.O., a concrete protective cover (mm) for reinforcement
shall be as follows:
(A) Sealed interior environments
40
Formed
50
50
Precast footings
50
Precast piles
50
75
Tops of footings
75
Formed
75
Bored piers
100
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Slab design, including joint selection and spacing, shall be guided by reference Guide to
Industrial Floors and Pavements by Cement Concrete and Aggregates Australia or
approved equivalent. Joint detailing is to be approved by the lead engineer. The design
engineer shall take account of any loading, both during construction and plant operations,
from mobile equipment, cranes and scaffolding.
As a minimum, provide a 150mm thick slab reinforced with SL82 fabric (8 mm bars at
200 mm centres) throughout to top face.
9.3.5. Earth Retaining Structures
Refer to geotechnical reports for more accurate information on earth pressures loads and
backfill material to earth retaining structures.
For flexible structures such as retaining walls, the lateral earth pressure coefficient shall be
taken as the active condition.
For more rigid construction the at-rest pressure shall be used. Retaining structures subject
to repeated traffic loading, shall take into account the effect of long term compaction that
may lead to a pressure approaching the at-rest pressure.
Passive pressures shall not be assumed to resist lateral forces unless substantial
movement of the structure can be accommodated.
The upper 500 mm of soil below finished grade shall be ignored for passive resistance to
the front of retaining walls.
Free standing cantilever retaining walls shall have a factor of safety against overturning and
sliding of at least 1.5.
The calculation of lateral seismic pressures to retaining walls in accordance with ASCE 705 11.8.3 to be agreed with the lead engineer.
9.3.6. Bases to Pumps and Rotating Equipment
Individual bases shall be sized to weigh 3 times the weight of pumps and small equipment.
This ratio can be reduced to 2 where the base is integral with a slab on grade.
A dynamic analysis of machine foundations shall be performed where directed by the
lead engineer. This analysis would typically be a hand method of analysis and would
typically apply to machines that are out of balance by design.
For large rotating equipment the lead engineer may direct that the design is performed
using a nite element analysis.
Dynamic deections and velocities shall be no greater than the vendor requirements and
approved by the lead engineer.
As a guide, to avoid resonant response problems, the operating frequency should be less
than 0.7 times the base natural frequency or more than 1.4 times the base natural
frequency.
Refer to Section 9.2.7 for design references.
9.3.7. Liquid Retaining Structures
All liquid retaining/storage structures shall be designed assuming maximum height of
containment.
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9.4.
Steelwork
9.4.1. General
Steelwork design shall be to the limit state design method in accordance with the
ADIBC 2013 and AISC 360-05 and AISC 341-05 where required.
For typical details refer
25875-000-S0-0000-10001.
to Steelwork
Standards
commencing
at
drawing
no.
Where floor plate is adequately welded to its support beam, it can be considered as
restraining the top flange of the beam. Floor grating fixed by any method shall not be
considered as restraining the top flange of its supporting beam.
3D welded steel frames shall not be used. The use of 3D welded steel frames shall be
approved (by exception) by the lead engineer. 2D welded steel frames are acceptable,
subject to transportation size limits.
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Page 35 of 46
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provide the necessary load capacity. Alternatively a new connection shall be designed.
Non-standard connections shall be approved by the lead engineer.
Connections shall be checked for the minimum loads derived from AISC 360-05.
Where a number of members come together at a joint, the path of load transfer from one
member to another shall be evaluated before accepting the standard connection.
When selecting a connection, due consideration shall be given to ease of connection and
reducing labour costs in fabrication and particularly on site. To achieve this, preference
shall be given to extended cleat connections supporting un-coped members that are saw
cut and drilled only, as shown on the standard drawings.
Design of extended cleat connections shall be in accordance with AISC Steel Construction
Manual, 13th Edition (or later) or otherwise approved method.
Column splices shall be located so that they are readily accessible during erection of the
steelwork, preferably without the use of ladders or scaffolding. Note should be taken of
those splices labelled non-preferred on the standard drawings.
Temporary bolted lifting lugs shall be rationalised and preferably located so that they can
be readily attached and detached without special access.
Where necessary, slotted holes shall be used to allow for thermal expansion and
contraction for minor connections in lightly loaded situations i.e. conveyor stringers. Bolts to
slotted holes shall be finger tight and have a lock nut. Generally, slotted or oversize holes
should not be used if the member or assemblage is to provide stability to another structure
or part of a structure.
All connections shall have a minimum of 2 bolts except for minor connections such as fly
bracing.
9.4.6. Bracing
Vertical bracing shall generally be tube sections. Vertical braces are often long, heavily
loaded members and the fabrication effort required on the end connection is outweighed by
the structural efficiency of the tube section. Horizontal floor bracing shall generally be angle
sections. Open H section bracing is typically not used.
The flexural stiffness of tube bracing end connections shall be considered in determining
the effective length of compression tube braces.
Note should be taken of those bracing connections that are indicated as non-preferred on
the standard drawings.
9.4.7. Corrosion Protection
Corrosion protection is required for all steelwork.
Specification 25875-000-3PS-NX00-00001 Painting and Protective Coatings Table 1 gives
a schedule of Paint Systems relating to the Area Number.
The steelwork shall incorporate the following minimum requirements:
The minimum thickness of structural hollow sections shall be 4.8 mm and shall be
sealed unless galvanised.
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Arrangements of steel that prevent access for inspection and maintenance shall not
be used, for example back-to-back angle members
9.4.8. Flooring
The minimum clear head height between top of floor and the underside of overhead
services and beam soffits for all buildings, structures and conveyor galleries shall be 2200.
Unless noted otherwise, floor grating shall be hot dipped galvanised and fabricated from
32mm x 5mm bars at 40mm centres with 6mm square twisted cross bars at 100mm
centres. Load bars shall preferably be at right angles to the direction of predominant
pedestrian travel. All edges, ends and penetrations shall be fully banded.
The grating shall be fixed to the support members by hot galvanised bolts and proprietary
bent clip fasteners spaced at a maximum of 1000 mm intervals at all supports, but with a
minimum of four clips per panel. An alternative fixing system may be used subject to
approval. Where approved, floor grating may be welded to the supporting steelwork.
The standard floor plate thickness is 6 mm, exclusive of the raised angular pattern.
Floor plate shall have a raised angular pattern and shall be used selectively to prevent
spillage flowing to lower levels and shall be fully seal welded or sealed by another approval
method. Plate shall be welded to support beams or an alternative fixing system may be
used subject to approval, however it may not be sufficient to provide lateral restraint. Where
floor plate is assumed to provide lateral beam restraint, this shall be demonstrated by
calculation.
9.4.9. Stairs, Walkways and Landings
The clear nominal width between handrails for maintenance walkways and stairs (including
spiral stairs surrounding vessels), other than in conveyor gantries, shall be:
900 mm
The clear nominal width between handrails for maintenance walkways and stairs in
conveyor gantries shall be 750mm.
Where possible, at the end of stairs, grating shall be aligned such that the load bars are
perpendicular to the direction of the stair.
For stairs up to 1200 wide, grating treads shall be fabricated from 32mm x 5mm load bars
at 30mm c/c with 6mm square twisted cross bars at 100mm c/c or approved alternative.
The stair treads shall be bolted to the stair stringers. Stair treads shall be T6 Webgrate
treads or an approved alternative and nosing shall be non-slip, coloured and removable.
The geometry of stair flights and handrails is detailed on the standard drawings and shall
conform to the ADIBC 2013. The loading on stairs and handrails is detailed in Section 6.3
of this document.
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20 mm square ladder rungs turned on edge where advised by the lead engineer.
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The horizontal actions arising from above eccentricities shall by analysed by the Twin
Beam Analogy assumption calculated by deriving horizontal forces acting at the centre of
gravity of the upper and lower beam flanges.
Horizontal loads derived from dynamic actions shall be applied at top of rail level and the
resulting horizontal design action on the beam also analysed by the Twin Beam Analogy
Method outlined above.
To allow for the above vertical and horizontal eccentric effects the following shall be
adopted to derive total stresses in the beam top and bottom flanges:
a)
Basic Case: Stresses due to vertical and lateral loads with no allowance for vertical
and lateral load eccentricity.
b)
c)
Grout may be extended by aggregate addition where recommended by the grout supplier
and approved by the lead engineer.
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9.5.
Timber
Timber engineering design shall comply with ANSI/AWC NDS 2012 National Design
Specification for Wood Construction.
Timber shall be resistant to moderate acid and alkaline conditions.
Timber shall be anti-fungal treated, using material approved in the UAE, as appropriate to
the species.
9.6.
Cladding
9.7.
Concrete Masonry
Concrete masonry (i.e. blockwork) shall be designed in accordance with ACI 530-08
Building Code Requirements for Masonry Structures.
Infill blockwork shall typically cantilever from the base and shall not incorporate metal ties to
the surrounding structure. Metal ties are not rated for seismic loads nor capable of
sustaining high seismic deflections.
Walls shall be detailed in accordance with the standard drawings.
10.
DESIGN OF FACILITIES
10.1.
Conveyor Structures
Structures are to be arranged such that belt tensions are not applied to conveyor gantries
except for cantilevered situations.
Where required, Teflon slide bearings shall be incorporated in sliding joints to gantries to
allow movement under thermal effects. Movements can be calculated using a thermal
coefficient for steel of 12 x 10-6 with an additional allowance for installation tolerance of +/25mm. Frictional loads generated by thermal movement shall be based on a coefficient of
friction for Teflon of 0.10.
When calculating total wind loads on open truss conveyors, a drag coefficient of 2.2 shall
be adopted and shall be applied to the full projected front face area of the conveyor.
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However, the total wind load on an open conveyor may be reduced provided that the loads
on every individual conveyor element are calculated.
When calculating total wind loads on fully enclosed conveyors, the drag coefficient may be
determined in accordance with ASCE 7-05.
Longitudinal effects from wind load on the conveyor and any anchorage points shall be
calculated on a 45 degree wind.
Frames supporting head, tail and bend pulleys shall be designed for a lateral load of 2.5%
of the applied belt tensions for each load combination.
Fatigue shall be checked in accordance with AISC 360-05 and shall be based on the
relevant number of cycles applicable to the structure or to the detail being designed and
shall take into account the fabrication details of the structure and its components.
10.2.
Tanks and vessels containing liquids at atmospheric pressure shall generally be designed
in accordance with API 650 and document 25875-000-3PS-MT00-00001 Technical
Specification for Steel Tanks.
Tanks and vessels shall be designed for the loading produced by the contained material or
fluid filled to the top. The design engineer shall check whether the hydro-test load condition
results in the worst load combination for design of support structures and foundations for
vessels and tanks.
When designing supports for tankage and pipe work, the design engineer shall obtain
information relating to the process fluid (S.G., temperature, etc.) and the likelihood of scale
formation.
In determining the weight of insulation, a density of 200 kg/m3 shall be adopted unless
noted otherwise. Maximum coefficient of friction to tank bases shall be 0.40 on concrete or
asphalt and 0.30 on an HDPE membrane.
10.3.
Pipe Racks
In consultation with the piping engineer, the design engineer shall determine the magnitude
and application of the loads listed below.
A pipe stress analysis shall be completed and all forces shall be provided before structural
design on pipe racks is finalised. Seismic loads, if provided by piping engineer, shall be
confirmed by the structural engineer.
Pipe rack lateral and vertical deflections shall be limited as required by the piping engineer.
Thermal loads shall be considered as dead loads and included in the appropriate load
combinations. Pipe anchor point forces shall be added in wind or seismic load combinations
where applicable. Pipe friction loads shall not be combined with wind or seismic loads.
10.3.1. Vertical Loads
The design engineer shall obtain information relating to the process fluid and the likelihood
of scale formation from the lead engineer.
The vertical loads shall include the weight of pipes, fittings, valves, insulation and the fluid
contents of piping, as well as loads due to scaling and sanding. In determining the weight of
insulation, a density of 200 kg/m3 shall be adopted. A minimum vertical load (including self
weight of pipes) of 2.5 kPa shall be used for each level of pipe rack.
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The procedure for hydro-testing and the resultant loads shall be evaluated to determine the
worst load case acting on supports.
10.3.2. Transverse Loads
Transverse loads include those from thermal expansion and the transverse component of
wind load.
In determining wind loads, the projected height per level of pipe rack used shall be obtained
from the following:
Width of pipe rack B
Metres
Metres
B<4
1.2
4 <= B < 6
1.5
6 <= B <= 10
2.0
A drag coefficient Cd of 1.3 shall be adopted. Wind on structural steel is included in the
above.
For congested pipe racks, loads shall be explicitly calculated for all pipes (with due
allowance for future expansions) but shall not be less than calculated using the above
simplified method unless approved by the lead engineer.
10.3.3. Longitudinal Loads
Longitudinal loads include those from thermal expansion and the longitudinal component of
wind load.
Thermal forces are those forces caused by temperature changes during operations and
maintenance conditions over the life of the plant. Thermal forces shall be considered for the
following conditions:
Sliding friction forces due to the thermal expansion and contraction of the piping and
equipment.
Horizontal loads due to thermal expansion shall be a minimum of 15% of the vertical pipe
loads attributed to a transverse frame and shall be applied to each transverse frame.
Where anchor loads are higher (and available) they shall be adopted for design. In case of
pipe rack components being individually analysed (e.g. transverse frames, longitudinal
braced bays, strut beams, etc.), a minimum longitudinal load of 10% of vertical pipe loads
shall be accumulated at longitudinal braced bays and carried down to the foundations. In
case of a pipe rack being analysed as a whole system, longitudinal loads on transverse
frames, as specified earlier, are considered adequate to meet the above requirement.
Longitudinal thermal forces shall be considered as uniformly distributed loads over the
entire span of the beam applied to the top flange of the pipe support beam.
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uniformly distributed vertical load of 10% of the vertical load applied on the beams of
the transverse frame or
whichever produces the most adverse condition (e.g. shear, bending, deflection).
Horizontal load applied at mid-span shall be a minimum of 15% of the vertical load from
pipe off-takes (pipes coming on and off the side of the pipe rack) but shall not be less than
3 kN.
Loads from monorails and platforms etc. shall be considered to act simultaneously with
these loads.
10.3.5. Intermediate beams at tier levels
When determining distribution of load between main pipe rack beams and intermediate
transverse beams at tier levels, consideration of the relative stiffnesss of the beams and
supported pipes shall be taken into account.
10.3.6. Transverse restraint guides
Loadings on restraint guides shall be determined in consultation with the piping engineer.
10.3.7. Cable Trays
Loadings from cable trays shall be determined in consultation with instrument and electrical
engineers. As a minimum, the following loads shall be used:
300 wide tray
60 kg/m
90 kg/m
120 kg/m
180 kg/m
10.4.
Caustic Areas
Caustic areas can be found in facilities 180, 220, 230, 240, 250, 260, 270, 321, 322, 330,
350, 410, 420, 452, 453, 470, 510, 530 and 660. The extent of caustic area in a facility can
be confirmed by the facility engineer.
The standard drawings give typical details of the required construction.
Concrete structures, including slabs in caustic areas shall be designed, detailed and
specified as liquid retaining structures to EN 1992-3. For surfaces exposed to caustic,
crack control shall be achieved by applying Section 7.3.3 of EN 1992-3 for a crack width of
0.20 mm.
10.4.1. Materials
The following materials shall be used:
Concrete
Concrete Grade Designation:
C40/50
20 mm
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Cement:
360 kg / m3
0.42
Centre bulb:
Backstop water-stops:
Joint fillers:
150 mm minimum thickness with SL81 fabric (8 mm bars at 100 centres) throughout
to top face and 50 mm minimum cover. In locations where spillage of strong
solutions of caustic and liquor heated above 100 degree centigrade occur, an
approved equivalent or SL81 fabric shall be placed throughout to top and bottom
faces with 50 cover.
Select fill under slabs on grade shall be selected for its lack of reaction to caustic
spillage. This applies especially to any clay content of the fill material
50 mm thick blinding concrete under all slabs and backstop support footing.
0.2 mm thick polyethylene membrane placed prior to monitor drain insertion. All
joints to be overlapped 100 mm and taped using polythene adhesive tape.
Membrane joints should not occur beneath a slab joint.
Provide building paper above monitor drains and lap 100mm with membrane.
Vertical water stop in combination with backstop water stop at all joints. Joint
intersections should be at or near 90 degrees.
Bases for all small equipment, pump discharge and suction supports, piping
supports, cable ladders, hose stations, field instrument housing, etc. shall preferably
be cast integrally with the slab. Locate bases and plinths to avoid obstruction to
drainage.
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Where column pedestals, pump bases, etc. penetrate the slab, construct a kerb
around the perimeter of these foundations and provide an isolation joint. The kerb
shall preferably be cast integrally with the slab.
The maximum and minimum floor slopes considered as desirable are tabulated
below:
Absolute
Min.
1 : 20
Desirable
Min.
1 : 10
Max.
1 : 30
1 : 20
1:6
1 : 50
1 : 30
1:6
1:5
Joints should be arranged so that slab areas are rectangular with side ratio in the
range of 1:1 to 2:1 and intersect at approximately at right angles.
Intersection of joints should be located away from column, pump or pipe support
foundations and sumps.
Joints should be positioned at the high points of slabs, across 'vee' drains and not
parallel to the bed of the drain and at right angles to the direction of surface flow
over the slab.
Monitor drains shall be installed under the full length of each joint above the
waterproof membrane. These shall fall to a low point discharging to an observation
drain at the perimeter of the slab.
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10.5.
Acid preparation and storage areas shall be designed to isolate and minimise the area over
which spills, leaks, or discharge can occur. Protection to areas of contact should be as
follows:
Concrete: Protective coating system for acid areas in accordance
specification 25875-000-3PS-NX00-00001 Painting and Protective Coatings.
with
Steelwork: For all discontinuous welds, provide seal weld to fully seal the joint. All welds
and heat-affected areas shall be de-scaled and passivated.
10.6.
All buildings shall have a roof pitch of 50, complying with the minimum requirements of
Section 1507.4.2 of ADIBC 2013, unless noted otherwise on the drawings and other
documents.
10.6.1. Calcination Building
Floors temporarily supporting refractory during construction shall be designed for a stacking
load of 17 kPa. The lead engineer shall confirm the extent of floor areas required to support
refractory.
10.7.
Steel Tanks
10.8.
with
document
NOTE: Wind loads for chimneys and stacks shall be calculated using internationally
accepted, chimney/stack design codes published by ACI, ASME, CICIND or otherwise
approved publication.
10.9.
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