PT. PUPUK SRIWIDJAJA PT. WIJAYA KARYA (Persero) Tbk.

PROYEK PEMBANGUNAN PABRIK NPK FUSION II

KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

NPKII-01-A1-CS-401-W
 PREP'D CHECK'D APPR'D CHECKED APPROVED
REV. DATE STATUS CODE
PT.WIJAYA KARYA PT. PUPUK SRIWIDJAJA
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

NO OWNER COMMENT NAME & CONTRACTOR RESPONSE NAME &

TITLE TITLE
NPKII-01-A1-CS-401-W 2 of 4 REV.0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

1. GENERAL
1.1 Objective
This document present calculation for Raw Material Storage Slab for NPK Fusion II 2x100.000 MTPY Project of PT PUPUK SRIWIDJAJA Palembang, South Sumatera,
Indonesia.

1.2 Code and References

1.2.1 International Code
a. ACI 318-05 : Building Code Requirements for Structural Concrete
b. ASCE 7-02 : Minimum Design Loads for Buildings and other structures.
c. IBC 2003 : International Building Code

1.2.2 Indonesia National Standards (SNI)

SNI 07-2052-2002 : Concrete Reinforcement Steel Bar

1.2.3 Company Rerefence

XXX : Soil Investigation Report, Pusri NPK FUSION II Project

1.3 Unit
All units are in SI system (metric) unit unless otherwise noted.

2. GENERAL REQUIREMENT
2.1 Material Specification

a. Concrete :
- Concrete design strength fc' = 250 kg/cm2
- Cement : SNI 15-2049-2004, ASTM C150 Type I or equivalent
- Aggregate : ASTM C33 or equivalent
b. Rebar :
- Deformed high yield steel bar : ASTM A615 Gr. 60 or equal ; fy = 4200 kg/cm2
- Plain round steel bar : ASTM A615 Gr. 40 or equal ; fy = 2400 kg/cm2
c. Piles :
- Concrete Pile : JIS A 5335 or equivalent.

2.1 Unit Weight

- Raw Material
Di-Ammonium Phospate (DAP) = 960 kg/m3
Rock Phosphate (RP) = 1360 kg/m3
Potassium Chloride (KCL) = 988 kg/m3
Urea = 730 kg/m3
- Reinforcement Concrete = 2400 kg/m3
- Plain Concrete = 2200 kg/m3
- Soil = 1850 kg/m3
- Sand gravel = 1800 kg/m3

3. ANALYSIS
Unfactored loading combination is used for checking the axial and horizontal capacity of pile foundation. Factored loading combination is subsequently used
for reinforced concrete design.

NPKII-01-A1-CS-401-W 3 of 4 REV.0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

1. GENERAL
1.1 Objective
This document present calculation for Raw Material Storage Slab for NPK Fusion II 2x100.000 MTPY Project of
PT PUPUK SRIWIDJAJA Palembang, South Sumatera, Indonesia.

1.2 Code and References

1.2.1 International Code
a. ACI 318-11 : Building Code Requirements for Structural Concrete and Commentary
b. ASCE 7-10 : Minimum Design Loads for Buildings and Other Structures

1.2.2 Indonesia National Standards (SNI)

SNI 07-2052-2002 : Concrete Reinforcement Steel Bar

1.2.3 Company Rerefence

NPKII-00-A0-IS-412-W : Soil Investigation Report, Pusri NPK FUSION II Project

1.3 Unit
All units are in SI system (metric) unit unless otherwise noted.

2. GENERAL REQUIREMENT
2.1 Material Specification

a. Concrete :
- Concrete design strength fc' = 250 kg/cm2
- Cement : SNI 15-2049-2004, ASTM C150 Type I or equivalent
- Aggregate : ASTM C33 or equivalent
b. Rebar :
- Deformed high yield steel bar : ASTM A615 Gr. 60 or equal ; fy = 4200 kg/cm2
- Plain round steel bar : ASTM A615 Gr. 40 or equal ; fy = 2400 kg/cm2
c. Piles :
- Concrete Pile : JIS A 5335 or equivalent.

2.1 Unit Weight

- Raw Material
Di-Ammonium Phospate (DAP) = 960 kg/m3
Rock Phosphate (RP) = 1360 kg/m3
Potassium Chloride (KCL) = 988 kg/m3
Urea = 730 kg/m3
- Reinforcement Concrete = 2400 kg/m3
- Plain Concrete = 2200 kg/m3
- Soil = 1850 kg/m3
- Sand gravel = 1800 kg/m3
- Clay = 1800 kg/m3

3. ANALYSIS
Unfactored loading combination is used for checking the axial and horizontal capacity of pile foundation.
Factored loading combination is subsequently used for reinforced concrete design.

Primary Load : - (D) Dead Load is selfweigh of foundation (Dead Load Type)
- (L) Live Load is (Live Load Type)
- (O) Operating Load is Material on slab (Dead Load Type)
- (W) Wind on slab (ignore)
- (E) Sesimic on slanb (ignore)

Load Comb: : -D+O+L

NPKII-01-A1-CS-401-W 14 OF 10 REV 0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

NPKII-01-A1-CS-401-W 14 OF 10 REV 0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

4. LOAD CALCULATION
4.1 Dead Load
Dead Load automaticly calculated by STAAD (Y = -1.1)

Dimension of Foundation :
Slab 78 x 150 meter
Thickness of Slab = 0.20 m
Pile Cap
Thickness of Pilecap = 0.60 m
Length = 1.35 m
Width = 1.35 m
Tie Beam -1
Height of Tie Beam = 0.40 m
Width of Tie Beam = 0.30 m
Tie Beam -2
Height of Tie Beam = 0.40 m
Width of Tie Beam = 0.25 m

4.1 Operating Load

Di-Ammonium Phospate (DAP)
Storage Area, W = 42.00 m
L design = 49.00 m
L actual = 34.21 m
Height of reinforced concrete partition = 4m
Angle of repose = 35 °
Maximum height of material (h2) = 12 m
h1 = 5.02 m
Total load for A1 & A3 = 4814.59 Ton/m2
Total load for A2 = 8167.30 Ton/m2

h1 h2

L actual
L design

Rock Phosphate (RP)

Storage Area, W = 35.00 m
L design = 49.00 m
Y L actual = 30.66 m
Z X
Height of reinforced concrete partition = 4.00 m Load 1
Angle of repose = 38.00 °
Maximum height of raw material (h2) = 12.00 m
h1 = 5.91 m
Total load for A1 & A3 = 8035.56 kg/m2 (For Design)
Total load for A2 = 12177.78 kg/m2 (For Design)

h1 h2

L actual
NPKII-01-A1-CS-401-W 14 OF 10 REV 0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

L design

Potasium YChloride (KCL)

Storage Area,
Z XW = 67.00 m Load 1
L design = 49.00 m
L actual = 29.64 m
Height of reinforced concrete partition = 4.00 m
Angle of repose = 39.00 °
Maximum height of raw material (h2) = 12.00 m
h1 = 4.05 m
Total load for A1 = 4000.31 kg/m2
Total load for A2 = 11856.00 kg/m2

L actual

L design

Conclusion

- Loading For Design Slab 49 m x 150 m using : Rock Phosphate (RP)

Y
Z X
Load 1

Urea
Storage Area, W = 17 m
L actual = 30 m
L design
Height of reinforced concrete partition = 4 m
Angle of repose = 28 °
Maximum height of raw material (h2) = 7.9756415 m
h1 = 3.9878207 m
Total load for A1 = 2911.1091 kg/m2
Total load for A2 = 5822.2183 kg/m2

NPKII-01-A1-CS-401-W 14 OF 10 REV 0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

Clay
Storage Area, W = 29 m
L = 57 m
Height of reinforced concrete partition = 4 m
Angle of repose = 35 °
Maximum height of raw material (h2) = 19.955915 m
h1 = 10.503113 m
h3 = 10.503113 m
Total load for A1 = 18905.604 kg/m2
Total load for A2 = 35920.647 kg/m2
Total load for A3 = 18905.604 kg/m2

Other Y
Storage Area, W
Z X = 29 m
Load 1
L = 47 m
Height of reinforced concrete partition = 4 m
Angle of repose = 40 °
Maximum height of raw material (h2) = 19.718841 m
h1 = 12.586494 m
h3 = 12.586494 m
Total load for A1 = 18879.742 kg/m2
Total load for A2 = 29578.262 kg/m2
Total load for A3 = 18879.742 kg/m2

Y
NPKII-01-A1-CS-401-W
Z X 14 OF 10 REV 0
Load 1
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

NPKII-01-A1-CS-401-W 14 OF 10 REV 0
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
PT. PUPUK SRIWIDJAJA PALEMBANG

CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

5. CONCRETE PILECAP REINFORCEMENT DESIGN

5.1. Foundation Specification

Concrete
fc' Compressive strength for structural concrete = 24.5 MPa
fc' Compressive strength for leveling concrete = 11.8 MPa
ɣc Unit weight for structural concrete = 23.5 kN/m3
ɣpc Unit weight for leveling concrete = 21.6 kN/m3
Reinforcing Steel Bar
ASTM A615 or JIS G3112 SR 390/40 or SII 0136-84 BJTD 40
Fy Yield strength of deformed reinforcement bar = 412 MPa
Fyv Yield strength of plain bar = 235 MPa
Soil
ɣs Unit weight of soil = 18.14 kN/m3

Moment occurred is very small and can be neglected so that flexural

reinforcement design is used minimum reinforcement. However, in this case is
used minimum eccentricity = 50 mm considering the worst case due to
wrongness in construction

5.2. Flexural Reinforcement Design

The followings are maximum factored load combination for flexural design

Horizontal VerticalHorizontal
Node Load Combination
Fx kN Fy kN Fz kN
22 201 1.4 (D+O) 2.68 553.46 0.00
23 201 1.4 (D+O) -2.68 553.46 0.00
27 201 1.4 (D+O) -0.04 1160.00 0.00
105 200 1.2D + 1.2O + 1.6L -0.16 295.43 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
22 200 1.2D + 1.2O + 1.6L 2.34 556.76 0.00
Minimum -2.681 295 0
Maximum 2.68 1160 0.00

Max Span, L = bwx = 3m

Minimum Eccentricity, e = 0.5*D = 0.23 m
Max Compression Force, P = 1160 kN
Max Factored Moment, M = P*e = 260.999 kN.m
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
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CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

Concrete Cover, c = 0.05 m

D rebar, db = 16 mm
Pile Cap Thickness, h = 0.6 m
Footing Effective Thickness, d = 0.526 m
Block stress depth factor, β1 = 0.85
Coefficient of resistance, Ru = Mu/(ø *L*d2) = 0.34938 where ø = 0.9
m fy / ( 0.85 * fc' ) = 19.7647
Required reinforcement ratio, ρreq
= (1/m) * [1 - √(1 - 2m * Ru / Fy)] = 0.09 %
Balanced reinforcement ratio, ρb
= (β1 * 0.85 * fc' / Fy) * (600 / (600 + Fy)) = 2.55006 %
Maximum reinforcement ratio, ρmax= 0.75 * ρb = 1.91255 %
Minimum reinforcement ratio, ρmin
= 1.4 / Fy if 1.33 * ρreq > 1.4 / Fy or
= 0.18 % if 1.33 * ρreq < 1.4 / Fy = 0.18 %
ρused = 0.18 %
Total area of rebar required, A =sreq
ρused * L * d = 2840.4 mm2
Total area of rebar, As
= 0.25 * π * ørebar2 = 201.062 mm2
Number of rebar, n = 15 ea
Rebar spacing, s = (L - 2 * c) / (nr - 1) = 200 mm
Rebar spacing used = 200.00 mm
Use D16 - 200 mm or 15-D16 for top and bottom flexural reinforcement.

5.3 Shear Reinforcement Design

Vu Shear ultimate forces = 1160 kN
d footing effective thickness = 0.526 m
Vc = 0.17 √fc' bo d = 1460.51 kN
Ø Shear capacity reduction factor = 0.75
ØVc Shear ultimate capacity = 1095.38 kN
ØVc = 1095.38 kN > Vu = 1160.00 kN Not OK 547.691
0.5ØV = 547.69 kN > Vu = 1160.00 kN
---> shear reinforcement required

note :
Vu<0.5*ØVc No reinforcement required
0.5*ØVc<Vu<ØVc use minimum reinforcement
(Vu - ØVc )< 0.67*bw*d*√fc' use shear reinforcement required
PROYEK PEMBANGUNAN PABRIK NPK FUSION II
KAPASITAS 2 X 100,000 MTPY
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CALCULATION SHEET FOR RAW MATERIAL SLAB FOUNDATION

5.4 Punching Shear of Pile

At the corner pile, critical section of punching shear is figured below :
bwx
d/2 = 0.30 m
hf

Dp = 0.45 m
bwy hp

bo = 3.30 m

D Pile
L

Vup Punching shear ultimate forces = 1159.997 kN

Dp Width of pile = 0.45 m
d footing effective thickness = 0.60 m
Pseudocritical section for shear design (bo)
D Diameter =Dp + d = 1.05 m
bo Pseudocritical section =πxD = 3.298672 m

Two way shear capacity

βc Ratio of length and width of pile = Dp/ Dp = 1
as Pile position factor = for corner column 20
Vc shall be smallest of
= (2+4/ βc) fc'1/2 bo d/12 = 4899.94 kN
= ((as d/ bo) +2) fc'1/2 bo d/ 12 = 4604.169 kN
= 4 fc'1/2 bo d/ 12 = 3266.627 kN
Vc Two way shear capacity of concrete = 3266.627 kN
Ø Shear capacity reduction factor = 0.75
ØVc Punching shear ultimate capacity w/o reinf. = 2449.97 kN

ØVc = 2449.97 kN > Vu = 1160.00 kN ..OK!

0.5ØV = 1224.99 kN > Vu = 1160.00 kN
No reinforcement required
Because Vu < 0.5 Ø Vc, so no reinforcement required