Cover sheet

CLIENT : NMDC Limited

3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR
CHHATTISGARH
RAW MATERIAL HANDLING SYSTEM
CONSULTANT:

MECON LIMITED
EPC CONTRACTOR :
BHARATH HEAVY ELECTRICALS LIMITED
ISG, BANGALORE

CIVIL CONTRACTOR PRASAD AND CO (PROJECT WORKS) LIMITED

SNEHALATH , GREENLANDS, HYDERABAD

CIVIL CONSULTANTS HBS INFRA ENGINEERS INDIA PVT LIMITED

HYDERABAD

SUBJECT : DESIGN OF STACKER CUM RECLAIMER FOUNDATIONS

design code date revision remarks

IS-4-DC-669-508-C1812 Nov-11 0 1 ST submission
 PROJECT 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Rev Date
RAW MATERIAL HANDLING SYSTEM

SUBJECT DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER 0 30.11.11

CONTENTS

1 INTRODUCTION

2 DESIGN PHILOSOPHY

3 DATA AND GENERAL ARRANGEMENT

INTRODUCTION

This Document contains design calculations pertaining to Stacker Reclaimer foundation system for the
proposed RMHS for 3.0 MTPY integrated steel plant Nagarnar.

DESIGN PHILOSOPHY

The foundation system is envisaged to consist of a series of transverse frames tied by long beams at top. The
frame has expansion joints approximately at every 39 m intervals. The analysis is done in the following
steps as explained below :

A typical frame between expansion joints having 39 m length is modeled in StaadPro software and the
series of wheel loads corresponding to Zmax ( 30 t vertical ), Xmax = 3.0t Horizontal, simultaneously on
either side as indicated in the Mechanical drawing no. NMDC/BHEL/01/01/BE/--/489 , Rev-0 entitled
Wheel Load Diagram for Stacker Reclaimer(Coal) causing the worst effect on the supporting structure
are applied on the frame. The footing is modelled as flat shell elements along with foundation beam is also
modeled in the frame and the effect of soil structure interaction is simulated by applying the supports as
springs at every 750 mm intervals on the foundation.

To produce longitudinal moments in the foundation beam the moments Mz at the supports are released and
springs are applied in the vertical direction . The Modulus of subgrade reaction has considered as 800t/cum

The foundation system

The frame is spaced at 3.0m clc spaced and suported continuous strip footing with foundation beam .
Zone-1 As recommended by Soil report, the Allowable bearing capacity at foundation considered
as 20 t/sq.m at 3.0 m depth from Original ground level.

1
 PROJECT 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Rev Date
RAW MATERIAL HANDLING SYSTEM

SUBJECT DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER 0 30.11.11

DESIGN DATA & GENERAL ARRANGEMENT

Loading ** Dead load selfweight of structure with unit weight of concrete at 2.5 t/cum
For load data
Equip. load As per system suppliers load data Ref drg. No
NMDC/BHEL/01/01/BE/--/489 , Rev-0

Effective length = 6.5 m 5 2.7 (enclosed)

0.8+1.1+0.8+1.1+0.8+1.1+0.8 0.8+1.1+0.8
critical zone for design

Critical Load case

30 t 30 t

=3.0 t Self wt of Rail = 60 kg/m (assumed)

0.5
M = 3.0*0.5 =1.5tm
8.0 m c/c

cross section
Load data Ref drg. No NMDC/BHEL/01/01/BE/--/489 , Rev-0
 PROJECT 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Rev Date
RAW MATERIAL HANDLING SYSTEM

SUBJECT DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER 0 30.11.11

Overburden Soil Pressure

Dry Density of Soil =1.8 t/m3
OverBurden Pressure = 1.8x2.5=4.5t/m2

Materials Concrete M 25 gr
Reinf. Fe 500
Cover to reinf. Beams 40 mm
columns 40 mm
footings 75 mm

Design Is done using Limit state method of design - IS 456

REFERENCES 2
a) IS 456 2000 - Code of practice - Plain & Reinforced concrete.
b) SP 16 - Design Aids for Reinforced concrete.
c) NMDC/BHEL/01/01/BE/--/489 , Rev-0 Wheel load diagram
 Project 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Des chd REV 0

Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

1.0 DESIGN OF STACKER CUM RECLAIMER STRUCTURE

Following are the various parts of a stacker cum reclaimer structure:
a) Beam connecting the portal frames,i.e longitudinal beam. (Rail supporting)
b) Portal frame consists of portal beam and column.
c) continuous Footing for supporting portal

1.1 DESIGN OF LONGITUDINAL RAIL BEAM

This beam is designed for horizontal&vertical bending moment , vertical shear force ,horizontal shear (axial force)
and torsion in the beam. Maximum bending moment ,shear force and axial force are evaluated considering
wheel load drg furnishe by vendor .

Grade of concrete = M 25
Grade of steel = Fe 500
Size of beam = 500 mm x 650 mm = 0.5 m x 0.65 m
Depth of rail = 150 mm = 0.15 m ( Assumed)
Span of beam = 3 m = 3000 mm
Elastic modulus of concrete = 25000 N/Sqmm
1.1.2 MOMENT CALCULATION
Maximum bending moment due to vertical load are arrived from staad pro .
This beam will be subjected to torsion due to the horizontal thrust at top of the rail. So,
equivalent vertical moment due to torsion is calculated.Sum of these two moments will give the total vertical
moment. Horizontal bending moment is due to horizontal thrust is also taken into consideration

Equivalent vertical moment due to torsion (M t) = Tu x [(1+D/b)/1.7] [Ref (a) cl 41.4.2]

1.1.3 SHEAR FORCE CALCULATION
Maximum shear force due to vertical load are taken from STAAD PRO analysis. But this beam will be
subjected to torsion,so, equivalent vertical shear force due to torsion is calculated from the following equation.
Equivalent shear force due to torsion(Ve) = V + 1 .6 Tu [Ref (a) cl 41.3.1]
u
b
150
d

650

Analysis and results

Mtspan
Span Support
LOAD COMBINATION Torsion, T Shear (Mt+Ms Mtsup Vt
Moment Moment, M
)

Critical case 1001 27.00 23.00 4.00 57.00 34.06 30.06 69.80

Maximum Span Moment (factored) = 51.09 tm

Maximum Sup Moment (factored) = 45.09 tm 3
 Project 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Des chd REV 0

Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

Horizontal Bending Moment = 13.50 tm

Maximum Vertical Shear Force (Ve) (factored) = 69.80 tm
Total depth of beam (D) = 650 mm
cover (d') = 30 mm table 16 of IS 456
Assuming 25 mm dia bar,
Effective depth (d) = 607.5 mm = 0.6075 m
2
Mulim = 0.133fckbd
2
= (0.133X25X0.5X0.6075 )
= 61.35560156 tm > 51.09 tm
1.2 Reinforcement calculation
Mu/bd2 = (51.09X10^7/500X607.5 2)
= 2.77
Percentage of reinforcement (Pt) = 0.7490
100Ast/bd = 0.749
Ast reqd. = 2274.98 mm2
provide 4 - 20 dia bars
through bars' + 2 - 25 extra
2
Ast provd. = 1256.64 mm + 981.75 2238.38
Side face reinforcement
As the depth of beam < 750mm, Side face reinforcement is not reqd [Ref (a) clause 26.5.1.3]
However provide
Side reinforcement = 0.1% of web area
= (0.1X500X650/100) mm2
2
= 325 mm
Assume 12 mm dia bars for side reinforcement,
Area of each bar = 113.04 mm2
Nos of bars required = 2.87509
Nos of bars to be provided = 6
Provide 10 mm dia 3 bars at each side of beam as side reinforcement,
Ast provd. = 678.24 mm2
Percentage of provided side reinforcement = 0.2233

1.4 Shear reinforcement

Nominal shear stress ( ve ) = (Ve/bd) [Ref (a),clause 40.1]

3
= (69.8X10 500X607.5)
= 2.30 N/Sqmm < c max = 3.1 N/Sqmm[Ref (a),table 20]

Total Ast provd. = 2238.38 mm2

Percentage of provided steel = 0.74
Shear strength of the section ( c ) = 0.571 N/Sqmm < 2.30 N/Sqmm [Ref (a),table 19]
Shear reinforcement shall be provided to carry the following shear

Vus = [Vu- ( c bd ) ]
= [69.8-(0.570849631893825X500X607.5)] kN
= 698.00 - 173.395576 Kn
= 524.60 Kn
Assume 4 legged 10 mm dia stirrup
Spacing of stirrup = 0.87*fy*Asv*d/Vus [Ref (a),cl 40.4 a]
= 158.25 mm
Provide 4 legged 10 mm dia stirrup @ 150 mm c/c
 Project 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Des chd REV 0

Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

1.6 Check for horizontal bending moment

2
Mu/db2 = (13.5X10^7/607.5X500 )
= 0.89 Pt = 0.185 %
Hence 0.240 % reinforcement which is provided as side face reinforcement is sufficient
1.7 Check for combined stress
As the beam is subjected to axial load , it should be checked for combined stress also.
Maximum bending moment due to wheel load Z direc(Mz) = 51.09 tm
Maximum axial load (Pu) = 5.07 t
Maximum bending moment due to wheel load in Y direc(My) = 13.50 tm
Axial load is very less. hence checking for combined stress is not required.
2.0 DESIGN OF PORTAL FRAME
2.1 DESIGN OF COLUMN OF PORTAL
GIVEN DATA
Grade of concrete = M 25
Grade of steel = Fe 500

Size of column = 400 mm x 500 mm = 0.4 m x 0.5 m

Height of rail = 150 mm = 0.15 m
Length of column = 3.65 m = 3650 mm
Moment of inertia of the section = 4,16,666.7 cm4
Elastic modulus of concrete = 25000.0 N/Sqmm
Mz value is taken from results of STAAD PRO analysis
Ref. STAAD PRO files
Maximum bending moment due to wheel load Z direc(Mz) 20.68 tm
= +
Muz = 31.020 t\m
Muy = 12.612 t\m
Maximum axial load (Pu)
Pu = 165.00 t

Maximum bending moment due to wheel load in Y direc(My) = 12.61 tm

(Refer staad analysis results) Muy = 18.92 tm

Total depth of col section (D) = 500 mm

Thictess of cover (d') = 40 mm
Assuming 20 mm dia bar,
Effective depth (d) = 450 mm = 0.45 m
Effective width (b') = 350 mm = 0.35 m
Assume For Z direction,
Percentage of reinforcement (Pt) = 1.75
Pt/fck = 1.75/25 = 0.070
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Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

Uniaxial moment capacity of the section about zz axis :

d'/D = 0.080
Chart for d'/D =0.1 will be used
Pu/fckbD = 165X10^4/25X400X500
= 0.330
Mu/fckbD2 = 0.142 [Ref (c),chart 44]
2
Muz1 = 0.142X25X400X500
= 35.50 tm 0.142* 25* 400* 500^2/10^7

Assume For Y direction,

Percentage of reinforcement (Pt) = 1.75
Pt/fck = 1.75/25 = 0.070
Uniaxial moment capacity of the section about YY axis :
d'/D = 0.100

Chart for d'/D =0.10 will be used

Pu/fckbD = 165X10^4/25X500X400
= 0.330
Mu/fckbD2 = 0.142 [Ref (c),chart 44]
2
Muy1 = 0.142X25X500X400
= 28.40 tm

(Muz/Muz1)act = 0.87
(Muy/Muy1)act = 0.67
Calculation of Puz :
Ag = 0.2 m2
Puz/Ag = 16 [Ref (c),chart 63]
Puz = 320 t
Pu/Puz = 0.515625

(Muz/Muz1)lim = 0.600 > 0.87 [Ref ( a),chart 64]

Area of reinforcement = 1.75X400X500/100

= 3500 mm2

Assume 20 dia bars

Area of each bar = 314.00 mm2
Nos of bars reqd = 11.15
Provide 20 mm dia 12 bars

Spacing required for 8 dia ties = 300mm [Ref (a),cl 26.5.3.2( c) ]

For ductile detailing as per IS:13920:1993,

Provide 8 dia lateral ties 200 mm c/c at midspan & Provide 8 dia lateral ties 100 mm c/c
over a length 1000 mm from joint face. [Ref (d),cl 7.3.3&7.4 ]
Hence, the section is safe.
 Project 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Des chd REV 0

Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

2.2 DESIGN OF BEAM B1 OF PORTAL FRAME (Cross beam)

GIVEN DATA
Grade of concrete = M 25
Grade of steel = Fe 500
Size of beam = 300 mm x 700 mm = 0.3 m x 0.7 m
Height of rail = 150 mm = 0.15 m
Span of beam = 8.5 m = 8500 mm
Moment of inertia of the section = 857500 cm4
Elastic modulus of concrete = 25000 N/Sqmm
Maximum vertical bending moment due to wheel load (Mv) = 19.20 tm
Maximum vertical shear force due to wheel load (Vu) = 7.78 t

Total depth of beam (D) = 700 mm

Thictess of cover (d') = 30 mm
Assuming 16 mm dia bar,
Effective depth (d)
f c c = 2
= 662 mm = 0.662 m

Mulim = 0.133fckbd2
2
= (0.133X25X0.3X0.662 )
= 43.714839 tm > 19.20 tm

Reinforcement calculation

Mu/bd2 = (19.2X10^7/300X662 2
)
= 1.46
Percentage of reinforcement (Pt) = 0.3621 [Ref (c) Table 3]
100Ast/bd = 0.362
Ast reqd. = 719.0707731 mm2
Area of each bar = 200.96 mm2
Nos of bars required = 3.57818
Nos of bars to be provided = 4
Provide 4 nos 16 mm dia bars.
Ast provd. = 803.84 mm2
Shear reinforcement

Nominal shear stress ( ve ) = (Vu/bd) [Ref (a),cl.40.1]

= (7.79X10 4 300X662)
= 0.39 N/Sqmm < c max = 3.1 N/Sqmm [Ref (a),Table 20]

Percentage of provided steel = 0.40 [Ref (a),Table 19]

Shear strength of the section ( c ) = 0.448 N/Sqmm > 0.39 N/Sqmm
Minimum shear reinforcement shall be provided.

Provide 2 legged 8mm dia stirrups at 150mm c/c at 1500mm from supports & [Ref (d),clause 6.3.5]
provide 2 legged 8mm dia stirrups at 250mm c/c at midspan.
 Project 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Des chd REV 0

Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

2.4 DESIGN OF FOUNDATION ( Strip Footing)

Size of footing ( Refer Staad anslysis results)

Thickness of footing at edge 0.3 m
Thickness of foot. at face of Ped. 0.60 m
Width of footing(across rail) 2.25 m
Max base pressure 20.00 t/sq.m ( Refer staad analysis for both the cases )
Min Base Pressure 1.54 t/sq.m
No Tension
Net SBC 15.50 t/sq.m < 20 t/sq.m (allowable )
Maximum bending Moment in footing (along width) 13.7 tm/m (element no 628)
Mxy 2.7 tm/m
Mx * = [Mx+Mxy] 16.4 tm/m
Maximum bending Moment in footing (along rail)) My = 11.3
Mxy 2.7
My * = [My+Mxy] 14 tm/m
( from wood's criteria)
Mx* /bd^2 (across rail) 0.80 (deff = 555mm)
My* /bd^2 (along rail) 0.68 (deff = 555mm)
Pt x 0.1910 %
Pt y 0.1621 %
Ast x 1059.9 sq.mm
Ast y 899.4 sq.mm
Provide Y16-150 mm c/c along shorter direction
Provide Y16-150 mm c/c along longitudinal direction
Shear stress at deff 0.28 N/sq.mm
Provided pt 0.290 %
Shear stress , Tc 0.389 N/sq.mm > Tv Hence OK
( IS 456)
Check for Settlements ( under service condition)
(refer staad analysis and results)
Maximum displacement 25.00 mm < Allowable settlement ( 75mm for continuous raft)

2.5 Foundation Beam Design ( refere staad output results)

Moment at column face = 41 tm

Shear force = 27 t
Torsion = 3.5 tm
Equivalent Moment due to torsion = 4.3 tm
Total Moment = 45.3 tm V + 1 . 6 Tu
u
Equivalent Shear due to torsion = 30.5 t b
Shear stress = 1.066 N/sq.mm
Beam size = 650 x 700 d = 660 mm
Mu/bd2 = 2.40 N/mm2 . => pt = 0.6314 %
Ast reqd = 2708.8 mm2
Provide 6 - Y25 top and bottom = 2940 mm2
 Project 3.0 MTPY INTERGRATED STEEL PLANT , NAGARNAR Des chd REV 0

Doc Title DESIGN OF FOUNDATION SYSTEM OF STACKER CUM RECLAIMER AHM Krishna DT 30.11.11

Shear check
% of reinf. Provided , pt = 0.69 %
shear stress tc = 0.555 N/mm22
shear capacity (tcbd) = 23.80 t
Vus = [ Vu- ( c bd ) ]
= 305.00 - 238.024048 Kn
= 66.98 kN
Assume 4 legged 8 mm dia stirrup
Spacing of stirrup = 0.87*fy*Asv*d/Vus [Ref (a),cl 40.4 a]
= 861.87 mm
Provide 4 legged 8 mm dia stirrup @ 200 mm c/c
Modelling of Stacker reclaimer

Y
X
Z
Load 1000

11