418200B00C1001R01 PDF

Sarcheshmeh Flash Smelting Project
Clients Document No.:
Contractors Document No.: Contract No. : Document Title: 4047 418/200-B00-C1-001 CIVIL DESIGN CRITERIA
Rev 01 Client Area No. : Date: 9 Nov 2011 200 Page 1 of 52
CIVIL DESIGN CRITERIA
01 00
REV.
28 Nov 2011 22 OCT 2011

DATE
Issued For Construction Issued for Review

DESCRIPTION
IFC IFR
PURPOSE OF ISSUE
B.GH B.GH
PREPARED
H.M H.M
CHECKED
A.A A.A
APPROVED

Revision Index
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Table of Contents
CIVIL DESIGN CRITERIA .................................................................................................................. 1 1 GENERAL............................................................................................................................................. 6 1.1 PROJECT OVERVIEW 6 6 1.2 DOCUMENT SCOPE 1.3 DEFINITIONS 6 6 1.4 CODES AND STANDARDS 1.4.1 REINFORCED CONCRETE STRUCTURES: ................................................................................................... 7 1.4.2 VIBRATING MACHINERY:...................................................................................................................... 8 1.4.3 STEEL STRUCTURES: ........................................................................................................................... 8 1.4.4 DESIGN LOADS: ................................................................................................................................. 9 1.4.5 AMERICAN SOCIETY FOR TESTING MATERIALS (ASTM) .............................................................................. 9 1.5 SITE GENERAL DATA 13 1.5.1 LOCATION ...................................................................................................................................... 13 1.5.2 TEMPERATURE ................................................................................................................................ 13 1.5.3 WINDS .......................................................................................................................................... 13 1.5.4 RAINS ........................................................................................................................................... 13 1.5.5 SOIL INVESTIGATIONS ....................................................................................................................... 14 1.5.6 ALLOWABLE BEARING CAPACITY ......................................................................................................... 14 1.5.7 EXPECTED SETTLEMENTS ................................................................................................................... 14 1.5.8 SOIL CHEMICAL PARAMETERS AND CEMENT TYPE ................................................................................... 14 14 1.6 IMPORTED FILL 2 LOADS AND LOAD COMBINATIONS .................................................................................................. 15 2.1 LOADS 15 2.1.1 DEAD LOAD (DL) ............................................................................................................................. 16 2.1.2 ERECTION LOAD (ER)........................................................................................................................ 16 2.1.3 SNOW LOAD (S) .............................................................................................................................. 16 2.1.4 LIVE LOAD (L) ................................................................................................................................. 16 2.1.5 TEST LOAD (TEST)............................................................................................................................ 18 2.1.6 OPERATING LOAD (OPER) ................................................................................................................. 18

2.1.7 THERMAL LOAD............................................................................................................................... 18 2.1.7.1 Equipment or piping thermal load ............................................................................................ 18 2.1.7.2 Ambient Thermal Load (Temp) ................................................................................................. 19 2.1.8 TRUCK LOADS .............................................................................................................................. 19 2.1.9 IMPACT LOAD (IL)............................................................................................................................ 20 2.1.10 MAINTENANCE LOAD (ML).............................................................................................................. 21 2.1.11 EXCHANGERS BUNDLE PULLING ........................................................................................................ 21 2.1.12 SURGE LOAD ................................................................................................................................ 21 2.1.13 WIND LOAD (W) ........................................................................................................................... 22 2.1.14 SEISMIC LOAD. (Q) ........................................................................................................................ 22 2.1.15 PIPE RACK AND PIPE SUPPORT DESIGN LOAD ....................................................................................... 23 2.1.15.1 Vertical Loads ......................................................................................................................... 23 2.1.16 VIBRATION LOAD (VL) .................................................................................................................... 24 2.1.17 CONSTRUCTION LOAD (CL) .............................................................................................................. 24 2.1.18 EARTH LOAD (HL).......................................................................................................................... 25 25 2.2 LOADING COMBINATIONS 2.2.1 FIXED EQUIPMENT ........................................................................................................................... 25 2.2.2 PIPE-RACKS, SHELTERS, STRUCTURES AND PIPE SUPPORTS ....................................................................... 27 2.2.3 LOAD COMBINATION FOR STEEL STRUCTURE DESIGN AND SOIL PRESSURE CHECK. .......................................... 28 2.2.4 LOAD COMBINATION FOR EQUIPMENT FOUNDATION DESIGN .................................................................... 29 3 GENERAL DESIGN CRITERIA .............................................................................................................. 30 3.1 ALLOWABLE VERTICAL DEFLECTION 30 31 3.2 ALLOWABLE HORIZONTAL DISPLACEMENT 32 3.3 REINFORCED CONCRETE WORKS 3.3.1 GENERAL ....................................................................................................................................... 32 3.3.2 CONCRETE GRADES .......................................................................................................................... 32 3.3.3 REINFORCING STEEL ......................................................................................................................... 33 3.3.4 ANCHOR BOLTS, PLATES AND STEEL INSERTS ......................................................................................... 33 3.3.4.1 Material ................................................................................................................................... 33 3.3.4.2 Design Requirement ................................................................................................................. 33 3.3.5 CONCRETE COVER............................................................................................................................ 34 35 3.4 STEEL STRUCTURE 3.4.1 MATERIAL...................................................................................................................................... 35 3.4.1.1 Structural Steel ......................................................................................................................... 35 3.4.1.2 Bolts, Nuts and Washers. .......................................................................................................... 35 3.4.2 CHEQUERED PLATES ......................................................................................................................... 36

3.4.3 STEEL GRATINGS ............................................................................................................................. 36 36 3.5 FOUNDATION DESIGN 3.5.1 GENERAL DESIGN CRITERIA AND DETAILS .............................................................................................. 36 3.5.2 TANK FOUNDATIONS ........................................................................................................................ 37 3.5.3 ELEVATIONS OF FOUNDATION PLINTHS ................................................................................................. 38 3.5.4 SOIL CHECK .................................................................................................................................... 38 3.5.5 ALLOWABLE SETTLEMENTS ................................................................................................................ 39 3.5.6 STABILITY RATIOS ............................................................................................................................ 40 3.5.7 SLIDING STABILITY ........................................................................................................................... 40 41 3.6 FOUNDATION AND STRUCTURES FOR HEAVY VIBRATING MACHINERY 3.6.1 DESIGN CRITERIA FOR RECIPROCATING MACHINERY ................................................................................ 44 3.6.2 DYNAMIC ANALYSIS SHALL BE CARRIED OUT AS FOLLOWS: ......................................................................... 44 3.6.3 DESIGN CRITERIA FOR ROTARY MACHINERY........................................................................................... 45 3.6.3.1 Dynamic Analysis...................................................................................................................... 45 3.6.3.2 Natural Frequencies ................................................................................................................. 45 3.6.4 ANALYSIS OF VIBRATIONS DUE TO UNBALANCED FORCES ......................................................................... 46 3.6.4.1 Exciting Forces.......................................................................................................................... 46 3.6.4.2 Allowable Displacements.......................................................................................................... 47 4 CIVIL WORKS .................................................................................................................................... 48 4.1 PAVING 48 4.1.1 TYPES OF PAVING............................................................................................................................. 48 4.1.1.1 Light duty paving ...................................................................................................................... 48 4.1.1.2 Medium Duty Paving ................................................................................................................ 48 4.1.1.3 Heavy duty paving .................................................................................................................... 48 4.1.2 PAVING ELEVATION .......................................................................................................................... 49 4.1.3 PAVING DESIGN .............................................................................................................................. 49 50 4.2 SIDEWALKS 4.2.1 WALKWAYS .................................................................................................................................... 50 4.2.2 LOCATION OF SIDEWALKS .................................................................................................................. 50 4.2.3 CROSS SLOPE .................................................................................................................................. 50 4.2.4 WIDTHS ........................................................................................................................................ 51 4.2.5 GRADES......................................................................................................................................... 51 4.2.6 DITCH CROSSINGS............................................................................................................................ 51 51 4.3 PIPE CROSSINGS 51 4.4 CABLE TRENCHES 52 4.5 SURFACE DRAINAGE SYSTEM

GENERAL
1.1 PROJECT OVERV IEW

Sarcheshmeh Copper Complex is located at 50 km west of Sarcheshmeh and 30 km east from Shahr-e-Babak city at Kerman Province, Iran. The copper production facilities at the complex comprise the mine, the concentrator, the smelter and the refinery, together with the required utilities. The complex was constructed during the 1970's. The current smelting technology is conventional, based on Reverbratory furnace smelting of concentrates, followed by Peirce-Smith converting of matte, copper fire refining and anode casting. The target of this project is to replace the conventional smelting technology with new FSF technology. The scope of the project is construction on EPC basis of Flash Smelter Furnace with the steady production capacity of 875 ton per day Cathodic copper including of basic engineering review, detail engineering, site engineering, Material supply (Foreign/local), manufacturing / inspection, packing, insurance covering, site fabrication, all construction activities including of Civil works, Equipment erections & test, pre-commissioning, test performance, EMPLOYER personnel training, 2 years spare parts supply for operation, consumable material supply for 12 month operation, supervision on operation for 6 month.
1.2 DOCUMENT SCOPE

This specification covers general design criteria for foundations, concrete& steel structures and civil works for the Project Flash Smelter Furnace Sarcheshme Copper Complex.
1.3 DEFIN ITIONS

Employer: National Iranian Copper Industries Co.(NICICO) Consultant: NIPEC Company / HAK consortium Contractor: Sadid Jahan Sanat, Bam Rah, Fakoor Sanat Teharn, Sanayea-E-Madani Mobina Tekjoo
1.4
CODES AND STANDARDS
All work shall be completed in accordance with engineering codes and standards listed in this

document unless otherwise stipulated, the International Standards referenced as applicable or their version of these documents, including relevant appendices and supplements. Where there are national regulations, their particular requirements, and those of the standards and codes to which they refer, must be applied, supplementing or amending the provisions of this document.
1.4.1

Reinforced Concrete Structures:

ACI 318-2005 ACI 201-2R ACI 211-1 Concrete. ACI 212-3R ACI 214-3R Chemical Admixture For Concrete Simplified Version of the Recommended Practice for Evaluation of Strength Building Code Requirements for Reinforced Concrete Guide to Durable Concrete Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass
Test Results of Concrete ACI 221-R ACI 222-R ACI 224-R ACI 224-1R ACI 224-2R ACI-225-R ACI 301 ACI 302-1R ACI 304-R ACI 305-R ACI 308 ACI 309-R ACI 309-2R Surface. ACI 311-4R ACI 313 Guide for Concrete Inspection Standard Practice For Design And Construction Of Concrete Silos And Stacking Guide for Use of Normal Weight and Heavyweight Aggregates in Concrete Protection of Metals in Concrete against Corrosion Control of Cracking in Concrete Structures Causes, Evaluation and Repair of Cracks in Concrete Structures Cracking Of Concrete Members in Direct Tension Guide to the Selection And Use Of Hydraulic Cements Specifications for Structural Concrete Guide for Concrete Floor and Slab Construction Guide for Measuring, Mixing, Transporting and Placing Concrete Hot Weather Concreting Standard Practice For Curing Concrete Guide for the Consolidation of Concrete Identification and Control of Visible Effects of Consolidation on Formed Concrete
Tubes For Storage Of Granular Materials.

ACI 315 ACI 318-2005 ACI 347 ACI 350M ACI 352
Details & Detailing of Concrete Reinforcement Building code requirements for structural concrete and commentary. Guide to Formwork for Concrete Code Concrete Sanitary Structures. Recommendations for Design of Beam-Column Connections in Monolithic
Reinforced Concrete Structures. ACI 408 -R Suggested Development, Splice and Standard Hook Provisions for Deformed
Bars in Tension. ACI 442-R ACI 504-R ACI 530 Response of Concrete Buildings to Lateral Forces Guide to Sealing Joints in Concrete Structures Building Code Requirements for Masonry Structures and Commentary
INBC-Part9-1388 Iranian Building code requirements for Concrete Structures. INBC-Part 123-1374 Iranian Building code for Under Ground reservoirs. BS CP 110& CP 114 The Structural use of Reinforced Concrete in Buildings.
BS CP 2012-1 Code of Practice for Foundations for Machinery. Foundations for Reciprocating Machines. DIN 1045 DIN 4024-1 Elements. DIN 4024-2 Machine Foundations, Rigid Foundations for Machinery with Periodic Excitation Concrete, Reinforced and Pre-stressed Concrete Structures. Machine Foundations, Flexible Structures that Support Machines with Rotating
1.4.2

Vibrating machinery:
DIN 4024 Machines Foundations VDI 2056 Evaluating the Mechanical Vibrations of Machines. VDI 2060 Evaluating the Balanced Condition of Vibrating Rigid bodies.
1.4.3

Steel S tructu res:

Specification for Structural Steel Building ANSI/AISC 360-2005. Seismic Provision for Structural Steel Buildings ANSI/AISC 341-2005.

Prequalified Connections for Special and Intermediate Steel Moment Frames for Seismic Applications ANSI/AISC 358 Steel Construction Manual 13th Edition. Code of Standard Practice for Steel Buildings and Bridges AISC 303. Iranian national building code for Structural Steel Building -Part 10-1387 Iranian national building code for Industrial Structural Steel Building -Part 325. AWS: American Welding Society ANSI/ASCE, American Society of Civil Engineers,
1.4.4

Design Loads:
Uniform Building code, UBC 1997. ASCE, American Society of Civil Engineers for Minimum Design Loads for Buildings and Other Structures, Rev7. Iranian Code for seismic resistant design of buildings, standard No.2800-03R-05. Iranian national building code for Building Design Loads -Part 6-1385.
1.4.5

American Society for Testing Mate rials (ASTM)

ASTM A6/6M Standard Specification for General Requirements for Rolled Structured
Steel Bars, Plates, Shapes and Sheet Piling. ASTM A36/36M ASTM A53/A53 M Standard Specification for Carbon Structural Steel Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-
Coated, Welded and Seamless. ASTM A108 ASTM A123 Steel Products ASTM A135 ASTM A139/139M and over). ASTM A153 Hardware Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Standard Specification for Electric-Resistance-Welded Steel Pipe. Standard Specification for Electric Fusion (Arc)-Welded Steel Pipe (NPS4 Standard Specification for Steel Bars, Carbon and Alloy Cold Finished. Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and

ASTM A185 Concrete. ASTM A193/193M
Standard Specification for Steel Welded Wire Reinforcement, Plain, for
Standard Specification for Alloy Steel and Stainless Steel Bolting
Materials for High Temperature Service ASTM A194/194M Standard Specification for Carbon and Alloy-Steel Nuts for Bolts for High
Pressure or High Temperature Service, or Both. ASTM A307 Tensile Strength ASTM A320 Temperature Service. ASTM A325 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 Standard Specification for Alloy Steel Bolting Materials for Low Standard Specification for Carbon Steel Bolts and Studs, 60 000 psi,
Ksi Minimum Tensile Strength. ASTM A-392 ASTM A 490 Ksi tensile strength ASTM A497 Standard Specification for Steel Welded Wire Fabric, Deformed, for Standard Specification for Zinc-Coated Steel Chain-Link Fence Fabric Standard Specification for Structural bolts, alloy steel, heat treated, 150
Concrete Reinforcement ASTM A500 Standard Specification for Cold-Formed, Welded and Seamless Carbon
Steel Structural Tubing in Round and Shapes. ASTM A501 Steel Structural Tubing ASTM A563 ASTM A572 Structural Steel. ASTM A615 Standard Specification for Deformed and Plain Carbon Steel Bars for Specification for Carbon and Alloy Steel Nuts. Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Standard Specification for Hot-Formed Welded and Seamless Carbon
Concrete Reinforcement. ASTM A706 Standard Specification for Low-Alloy Steel Deformed and Plain Bars for
Concrete Reinforcement. ASTM A759 ASTM A775 Standard Specification for Carbon Steel Crane Rails Standard Specification for Epoxy-Coated Steel Reinforcing Bars

ASTM A820 ASTM A884 Reinforcement. ASTM B695 Iron and Steel. ASTM C31 Field ASTM C 33 ASTM C 39 Specimen ASTM C 40 Concrete. ASTM C 88
Standard Specification for Steel Fibers for Fiber-Reinforced Concrete Standard Specification for Epoxy-Coated Steel Wire and Welded Wire
Standard Specification for Coatings of Zinc Mechanically Deposited on
Standard Practice for Making and Curing Concrete Test Specimens in the
Standard Specification for Concrete Aggregates Standard Test Method for Compressive Strength of Cylindrical Concrete
Standard Test Method for Organic Impurities in Fine Aggregates for
Standard Test Method for Soundness of Aggregates by Use of Sodium
Sulphate or Magnesium Sulphate ASTM C90 ASTM C94 ASTM C 109 Standard Specification for Load bearing Concrete Masonry Units Standard Specification for Ready-Mix Concrete Standard Test Method for Compressive Strength of Hydraulic Cement
Mortars (Using 2-in. or (50-mm) Cube Specimens). ASTM C 114 ASTM C 117 Standard Test Methods for Chemical Analysis of Hydraulic Cement Standard Test Method for Material Finer than 75-m Micrometers
(No.200) Sieve in Mineral Aggregates by Washing ASTM C 127 Standard Test Method for Density, Relative Density (Specific Gravity) and
Absorption of Course Aggregate ASTM C 128 Standard Test Method for Density, Relative Density (Specific Gravity) and
Absorption of Fine Aggregate ASTM C 131 Standard Test Method for Resistance to Degradation of Small-Size
Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine ASTM C 136 ASTM C 138 Concrete Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates Standard Test Method for Density, Yield and Air Content (Gravimetric) of

ASTM C 142 ASTM C ASTM C 150 ASTM C172 ASTM C 227
Standard Test Method for Clay Lumps and Friable Particles in Aggregates Standard Test Method for Slump of Hydraulic Cement Concrete Standard Specification for Portland Cement Standard Practice for Sampling Freshly Mixed Concrete Standard Test Method for Potential Alkali Reactivity of Cement-Aggregate
Combinations (Mortar-Bar Method). ASTM C 260 ASTM C270 ASTM C289 (Chemical Method) ASTM C309 Curing Concrete ASTM C494 ASTM C535 Standard Specification for Chemical Admixtures in Concrete Standard Test Method for Resistance to Degradation of Large-Size Standard Specification for Liquid Membrane-Forming Compounds for Standard Specification for Air-Entraining Admixtures in Concrete Standard Specification for Mortar for Unit Masonry Standard Test Method for Potential Alkali-Silica Reactivity of Aggregates
Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine. ASTM C566 Aggregate by Drying ASTM C579 Standard Test Methods for Compressive Strength of Chemical-Resistant Standard Test Method for Total Evaporable Moisture Content of
Mortars, Grouts, Monolithic Surfacing and Polymer Concretes ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete. ASTM C1017 Flowing Concrete. ASTM C1064 Cement Concrete. ASTM D512 ASTM D516 ASTM F436 ASTM F606 Standard Test Methods for Chloride Ion in Water.. Standard Test Method for Sulfate Ion in Water. Standard Specification for Hardened Steel Washers. Standard Test Methods for Determining the Mechanical Properties of Standard Test Method for Temperature of Freshly Mixed HydraulicStandard Specification for Chemical Admixtures for Use in Producing
Externally and Internally Threaded Fasteners, Washers and Rivets.

ASTM F959
Standard Specification for Compressible-Washer-Type Direct Tension
Indicators for Use with Structural Fasteners.
1.5 SITE GENER AL DATA

1.5.1 Location
The plant is located in Latitude & Longitude N 29.95 E 55.85 and Elevation about 2450 m above sea level, according to seismology studies the earthquake zone is as per UBC Zone 3 or high risk zone according to Iranian national standard no 2800 (acceleration 0.3 g).
1.5.2 Temperature
The minimum & maximum temperature is between -25 C / 35 C and design Min / Max temperature is between: -17.7 C / 32.5 C
1.5.3
Winds
Prevailing wind directions in winter is between South and South-West and in summer is between North and North-East. Annual mean wind velocity is 3.5 m/s, mean minimum velocity is 2.3 m/s. Maximum wind velocity recorded: 28 m/s (100 km/h) Stormy days per annum are 10 days.
1.5.4 Rains
Annual average rainfall: 400 mm / a Design rainfall: 400 mm / a Rainfall intensity: 76 mm / h Annual average snowfall: 80 mm / a (as water) Design snowfall intensity: 150 mm / a (as water)

Frost line: 1200 mm below grade
1.5.5 Soil Inves tigations

Design of foundations, structures, earthworks and other concrete works shall be carried out in accordance with the prescriptions included in the Soil Investigation Reports by PEY KAV Consulting Engineers for Sarcheshmeh Flash Smelting plant.
1.5.6 Allowable Bearing Capacity

Allowable bearing capacity of soil relate to allowable settlements, dimensions and depth of foundations. For allowable bearing capacity of soil, refer to Soil Consulting Engineers Reports with doc No 418/200000-C5-001.
1.5.7 Expected Settlements

The settlements shall be limited to 25 mm up to 40 mm (according to type of structure and manufacturer instructions), based on curves given in the Soil Consulting Engineers Reports.
1.5.8 Soil Chemical Parameters and Cement Type

According to soil report issued by PEYKAV Consulting Engineers, type of used cement is cement type I but according to environmental consideration cement type IV shall be used.
1.6 Imported Fill

In case of substantial fill needs to be imported then until such time as the imported fill is tested it may be assumed that it may have the following properties: Cohesion c = 0 Internal angle of friction = 320-340 Unit weight = 18-21 kN/m
3

LOADS AND LOAD COMBINA TIO NS
2.1 Loads
All civil works including buildings, equipment structures, pipe racks, shelters, process equipment and foundations shall be designed for the following loads: Dead load (DL) Erection Load (Er) Live (imposed) load (LL) Test load (Test) Operating Load (Oper) Thermal loads (Fric,TH, Temp) Truck Load Impact load Maintenance Load(ML) Surge Load (Surge) Wind load (W) Seismic load(Q) Vibration Load(VL) Construction Load (CL) Earth Load (HL) Fluid Load (FL)

2.1.1 Dead Load (DL)

Dead load for buildings includes the weight of walls, foundations, floors and roofs, partitions, ceiling finishes, partitions, stairways and fixed service installations. Dead load for equipment structures, pipe-racks and process equipment includes the weight of structure, vessels including internals, pipes, valves and accessories, electrical and lighting conduits, switch-gear, instrumentation, fireproofing, insulation, ladders, platforms, davits etc. Equipment and piping shall be considered empty of product load when calculating dead load. The weight of soil overburden shall be considered as dead load in the design of foundations.
2.1.2 Erection Load (Er)

The erection load is the weight of empty equipment and structure at the time of erection plus the weight of foundation.
2.1.3 Snow Load (S)

Design snow load shall be: 150 Kg/ m2 uniformly distributed over the horizontal projection of the loaded area. Snow on grating shall not be taken into account.
2.1.4 Live load (L)

Live load is defined as the weight superimposed by the use and occupancy of the building or other structure, but not permanently attached to it. For industrial plant, live load is defined as additional load produced by personnel, moveable equipment, tools, etc. placed on the structure but not permanently attached to it. The Live Loads shall be considered as uniformly distributed over the horizontal projection of the loaded areas, except for the loads with a concentrated nature Minimum recommended live loads for buildings shall be in accordance with IRANIAN NATIONAL BUILDING CODE-part6, except otherwise stated in this Design Criteria.

Table 2-1: Minimum Live Load TYPE OF STRUCTURE Stairs to equipment structures (excluding buildings) Walkways / access platforms Operating platforms, Laboratory, operating and maintenance areas: 250 Kg/m2 or 450 Kg point load
2 500 Kg/m or 900 Kg point load
MINIMUM LIVE LOAD 250 Kg/m or 500 Kg point load

2
Hand railing
360 kg/m applied horizontally to the top rail 740 Kg applied horizontally to the top of handrail post
Cover plates and Slabs &Concrete paving with no vehicular access (positioned to produce maximum stress) Concrete trench covers in off-site and unpaved areas with no vehicular access Control Rooms, Switch Gear Rooms, Battery Rooms and Compressor Buildings, Pump Houses Platform in Storage Areas
1000 Kg point load or 500 Kg/m2
500 Kg/m2
Uniformly distributed load of 1000 Kg/m (These live loads shall be checked against Manufacturers documents.) Uniformly distributed load of 600 kg/m2 for light and 1200 2 kg/m for heavy storage areas or a concentrated load of 900 kg at any point over the platform, whichever is critical.
For operating platforms, floor grating and slabs subject to concentrated load during the installation or removal of equipment known to be greater than the above values, the greater load shall be used in design. For design against seismic conditions, 25% of live load shall be considered. In case of multi story buildings/structures above figure may be reduced for columns and foundations design.

2.1.5 Test Load (Test)

Test load is defined as the gravity load imposed during hydrostatic test of vessels, tanks, equipment or piping. In test conditions 20% increase in allowable stress is permitted. In case a hydrotest is required, in static calculation the weight of water shall be considered as a live load.
2.1.6 Operating Load (Oper)

Product load is defined as the gravity load imposed by liquid, solid or viscous materials in vessels, tanks, equipment or piping during operation. In static calculation this load shall be considered as a dead load.
2.1.7 Thermal Load

Thermal loads are those forces caused by temperature variations. Two different types of thermal loads shall be considered in design of structures and foundations: 2. 1. 7. 1 Eq u i p men t o r p ip i ng th ermal l o ad The primary source of thermal load in an industrial plant is the expansion and contraction of vessels and piping. This force is exerted to structure in two ways:
2.1.7.1.1
F ri cti o n force (Fric)
The Forces caused by equipment or piping expansion or contraction shall be defined as those required to overcome the static friction between two surfaces in contact and one liable to sliding over the other, and shall be termed as friction forces. These can take place only during operation and must be considered as live loads. These loads shall not be combined with earthquake load. Friction forces are used only for local design of main supports. Columns and foundation shall not be designed for this load.To calculate friction loads caused by equipment and single pipes, the following friction coefficient f shall be used: Teflon to teflon Teflon to stainless steel Steel to steel f = 0.10 f = 0.10 f = 0.30

Steel to concrete
f = 0.50
On pipe racks and pipe supports with 4 or more lines the friction force shall be taken as10% of the total pipe weight tributary to the pipe rack or pipe support, under operating conditions. On pipe racks and pipe supports with 3 or less lines the friction force shall be taken as 20% of the total pipe weight tributary to the pipe rack or pipe support, under operating conditions. The transversal (perpendicular to the pipe ) friction force shall be taken as 5% of the total tributary pipes weight. The thermal load caused by the expansion contraction of the structure shall be computed based on the coefficients of expansion specified in AISC manual of steel construction. 2. 1. 7. 1. 2 O p erati n g th ermal l o ad s (T H) Operating thermal loads are the forces caused by equipment or piping expansion or contraction shall be defined as those resisted by anchors or guide supports and are calculated with appropriate software by other departments, These loads can take place only during operation and must be considered as live loads. These loads shall be combined with other instantaneous loads such as wind and earthquake. 2. 1. 7. 2 Amb i en t T h ermal L o ad (T emp ) Thermal loads are also generated due to the expansion or contraction of the entire structure or individual structural components. Regarding the design criteria for thermal load due to change in ambient temperature, the recommendation is =25c should be considered, in order to minimize temperature effect on structure expansion joints shall be provided in steel structures which are 45 m long or greater considering the centre of structural elements. This load is considered as dead load but shall not be assumed to act with earthquake simultaneously.
2.1.8 TRUCK LOADS

All pavements, slabs, bridges, trenches, trench covers and underground installations accessible to truck loading shall be designed to withstand the worst of the following loading cases. HS 15-44 wheel loading or its equivalent lane loading as defined by the American Association of State Highway and

Transportation Officials (AASHTO) under Standard Specifications for highway bridges. For the design of paving the following axle load should be considered. Light duty paving: Medium duty paving: Heavy duty paving : Maximum axle load is equal to 10 kN. Maximum load of 60 kN per axle. Maximum load per axle of120 kN (4 tyres)
2.1.9 Impact Load (IL)

Any live load that can produce a dynamic effect (such as a moving load) shall be increase by an impact factor, impact factors are applied to crane vertical wheel loads and should be applied to crane runway beams and their connections and connection elements including brackets but excluding columns and foundation. Loads applied by cranes, runway beams, jib cranes, davits, hoists and other lifting appliances shall be calculated in accordance with AISC and UBC codes but shall not be less than the following: Table2-2: Dynamic Impact Load
STRUCTURE LOAD DIRECTION DYNAMIC INCREASE Take into account manufacturer loading data if any or the following requirements : a) Vertical b) Horizontal (longitudinal) Bridge-crane runways c) Transversal 25% of lifted load 20% of maximum wheel load applied at top of runway 20% of the sum of the lifted load and the weight of the crane trolley applied at top of runway, one half on each side. This force shall be considered acting in either directions normal to runway rail.

a) Vertical Monorails runway b) Horizontal (longitudinal) c) Transversal a) Vertical Davits (1) b) Horizontal Elevator Supports Vertical Hangers supporting floors and Balconies Machinery Supports
25% of lifted load 20% of wheel load 20% of lifted load 50% of lifted load 20% of equipment weight 100% of elevator weight 33% off vertical load
Vertical 50% off vertical load
Transverse and longitudinal impact forces shall not be assumed to act simultaneously.
2.1.10
Maintenance Load (ML)
Maintenance loads are temporary forces due to dismantling, repair or painting of equipment. In static calculations they shall be considered as live loads.
2.1.11
Exchangers Bundle Pulling
Structures and foundations supporting heat exchangers shall be designed to withstand a longitudinal force applied at the centre of the tube bundle. The fixed saddle only shall support such force. It shall be equal to 0.5 of the weight of the bundle or to 10 kN, whichever is bigger. In case of stacked equipment it shall be assumed that the bundle pulling of equipment shall not be contemporary. Above figures may be reduced if only special extraction devices are provided. This maintenance load shall be considered as a live load
2.1.12
Surge Load
Supporting structures and foundations shall be designed for surge loads occurring in vessels or equipment. The magnitude and direction of the load shall be given in the Equipment Specification.

2.1.13
Wind Load (W)
Wind pressure shall be calculated according to INBC Part: 6, based on the following: Basic Wind Speed: V should be considered as 100 km/h Ce: Cq: Accordance to Section 6.6.6-INBC Part: 6 Accordance to Section 6.6.7 to 6.6.9-INBC Part: 6
Wind loads on structures and foundations will be evaluated according to INBC Part: 6. Wind loads and Earthquake loads shall not be considered simultaneously. Wind loads shall be assumed from any direction. For towers, stacks and slender equipment the phenomena of wind induced vortex shedding and natural frequency induced instability shall be assessed and appropriate measures taken to avoid such instabilities.
2.1.14
Seismic Load. (Q)
Earthquake load on structures and foundations shall be calculated according to INBC Part: 6, or UBC97 based on the following: Seismic Zone: Zone 3
Peak ground horizontal acceleration: PGA = 0.30g. Peak ground vertical acceleration 2/3 x 0.30g Seismic Importance Factor I: 1 Soil profile type: Type II, According to Soil Investigation Report
Total weight contributed in seismic load is combination of dead load or operating load in addition 25% of live load, for other buildings following loads should be considered concurrent with dead loads.

Buildings: as per INBC Part: 6 Vibration equipment: 150 % of total static weight Pipe racks: operating loads Industrial buildings with crane: Total weight of the cranes, but excluding the lifted loads shall be considered as a dead load. Storage tanks : 75% of snow load
The distribution of the total lateral earthquake load over the height of the building and other structures shall be based on the following procedures: Buildings: as per INBC Part: 6 Vertical vessels, stacks, storage tanks, Horizontal vessels, Heat exchangers (single & Multi level) and the other Equipment: as per UBC 97.
Flat-bottomed, vertically orientated storage tanks and their foundation shall be in accordance with Appendix E of API 650, with an importance factor I = 1.0.
2.1.15
Pipe Rack and Pipe Support Design Load
For design of pipe racks and pipe supports in the absence of definite loading provided by Piping Department, the following minimum loads can be used. 2. 1. 15. 1 Verti cal L o ad s
The following vertical loads shall be considered in design: Pipe Bundle:
For pipes diameter < 12 inches, a uniformly distributed load shall be applied to the considered pipe rack level on the total area including free space for future use. For minimum values see table below:

Average Diameter (Inches) 2 3 4 6 8 10 12
Empty Weight (Kg/m2) 40 70 80 110 120 140 150
Full of Water Weight (Kg/m2) 60 100 120 180 220 280 320
For pipes diameter > 12 inches, piping load shall be considered as concentrated loads. In static calculation, fluid loads shall be considered as dead loads. Single Pipe:
Piping loads shall be considered as concentrated loads.
2.1.16
Vibration Load (VL)
Vibration loads are those forces and moments caused by rotating or reciprocating machinery such as compressors, turbines, fan, blowers, and pumps. The evaluation of such loads shall be done on the base of Manufacturers documents and as indicated in the following paragraph 5 "Foundations and Structures for Vibrating Machines".
2.1.17
Construction load (CL)
Construction loads are temporary forces due to the erection of structures or equipment. In static calculations it shall be considered as live loads.

2.1.18
Earth Load (HL)
Earth loads are those loads due to soil, and ground water pressure when necessary, against structures and foundations.
2.2 Loading Com binations

All loading combinations shall be done in accordance with the referenced design codes. For loads not specified in ACI 318-05, but referred to in this Design Criteria, the load factor shall be taken as 1.4. Combination of loads and forces shown in the following table shall be considered to determine the critical loading condition for the design of the structural elements (columns, beams, slabs, bracings, anchor bolts, foundations) and to check the stability of the structure. when inclusion of fluid loads, live loads or snow load results in a less critical loading condition, these loads shall be excluded. However safety of persons and structures shall be assured during all transient phases of construction. All civil works including equipment structures, pipe racks, shelters, process equipment and foundations shall be designed for the following scenarios:
2.2.1 Fixed Equipment

Supports and foundations for vertical and horizontal heat exchangers and vessels shall be designed on the basis of UBC chapter 16 requirements summarised in 14.3.4 and the following specific conditions:

Table2-3: Load Combination for Equipment Structure Design ERECTION Vessels dead weight Internals weight Platforms and ladders Piping, valves Cables Insulation Fire proofing Live loads Operating Ambient Thermal loads Impact loads Vibration loads Surge loads Wind 100 % 0% 0% 0% 0% 0% 0% 100 % 0% 0% 0% 0% 0% 100 % TEST 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % (test) 0% 0% 0% 0% 33 % *** 0% OPERATION 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % (operating) 100 % 100 % 100 % 0% 100 %* SHUTDOWN 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % 100 % 0% 100 % 100****% BUNDLE PULL 100 % 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% ACCIDENTAL 100 % 100 % 100 % 100 % 100 % 100 % 100 % 25 % 100 % (operating) 0% 0% 0% 0% 0%
Bundle pull 0% 0% 0% 100% 0% load Seismic 0 % ** 0 % *** 100 %* 100****% 0% 100 % * Wind and Earthquake are not considered simultaneously. Refer to UBC 97 section 1612 for applicable load combinations. ** *** It is assumed that erection of equipment is too short a period to take into account seismic loads. It is assumed that the testing of equipment or pipes is too short a period to take into account seismic loads or the full wind loads. Design for whichever the greater, 100% wind or 100% seismic.
****

2.2.2 Pipe-Racks, Shelte rs, Structures a nd Pipe Supports

Pipe-racks, structures and pipe supports and their foundations shall be designed on the basis of UBC chapter 16 requirements summarised in 14.3.4 and the following specific conditions: Table2-4: Load Combination for Pipe Rack ERECTION 100 % 100 % 0% 0% 100 % 100 %**** 0% 100 % 0 % ** 0% 0% 0% 0% 0% TEST 100 % 0% 100 % 0% 100 % 25 % 100 % (test) 33 % *** 0 % *** 0% 0% 0% 0% 0% OPERATION 100 % 0% 100 % 100 % 100 % 100% 100 % (operating) 100 % * 0% - 100 % * 100 % 100 % 100 % 100 % 100 % ACCIDENTAL 100 % 0% 100 % 100 % 100 % 25% 100 % (operating) 0% 100 % 0% 0% 0% 0% 0%
Structural Piping weight Cables Fireproofing Equipment Live loads Operating Load Wind loads Seismic loads Anchor loads Friction loads Ambient Thermal Load Impact Load Crane/Lifting Hoists
Wind and Earthquake are not considered simultaneously. Refer to UBC 97 section 1612 for applicable load combinations.
** ***
It is assumed that erection of equipment is too short a period to take into account seismic loads. It is assumed that the testing of equipment or pipes is too short a period to take into account seismic loads or the full wind loads.
****
Consideration shall also be given to the erection case without live loading.

2.2.3 Load Combination for Steel S tructure design and Soil pressure Check.
Table2-5: Load Combination for soil pressure check
Item 1 2 3 4 5 6
Load Description Structural dead weight Piping weight Cables Fireproofing Equipment Live loads
Erection Test Normal Wind Normal Wind (%) (%) (%) (%) 100 100 100 100 100 100 100 100 100 100 100 100 100 25 100 (test) 100 25 100 (test) 33
Operation Normal Tempera Wind ture(%) (%) (%) 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 (OP) 100 100 100 100 100 1.333 100 1.333
Seismic (%) 100 100 100 100 25 100 (OP) 72 90 90 90 90 90 (OP) 72
Operating loads 7 8 Wind loads () 9 Seismic loads () 10 Piping Thermal loads() Ambient Thermal load() 12 13 Impact loads 14 Bundle Pull load Allowable increase factor
100 (OP) 100 (OP)
100
100
100 1.000 1.333 1.200 1.333 1.000 1.333 1.333

2.2.4 Load Combination for Equipment Foundation Design
Table2-6: Load Combination for equipment foundation design
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Load Description Structural dead weight Piping weight Cables Fireproofing Equipment Live loads Operating loads Wind loads () Seismic loads () Piping Thermal loads() Piping Friction loads(Local design) Ambient Thermal load() Impact loads Bundle Pull load
Erection Test Normal Normal Wind (%) (%) (%) 140 120 120 90 140 120 140 120 120 90 140 120 140 120 120 90 160 100 130 130 140 120 40 140 120
Operation Wind (%) 120 120 120 25 120 53 Normal Wind (%) (%) 140 120 120 90 140 120 120 90 140 120 120 90 140 120 120 90 160 100 140 120 120 90 130 130 140 120 120 140 120 120 140 120 120 160 100 Seismic (%) 120 90 120 120 120 25 120 100 90 90 90 90 100
160

GENERAL DESIGN CRITERIA
3.1 Allowable vertical deflection

Design deflections of structural steel members shall not exceed the following values: Purlins, building floor joists and girders not supporting plastered ceilings Floor beams without equipment Building floor joists and girders supporting plastered ceilings Pipe rack Main supporting beams Combined deflection of intermediate beams and longitudinal tie-beams (L = span of intermediate. beam) Floor beams supporting equipment Operating state Hydraulic test Crane runways and monorails (vertical) For class services SA,SB&SC For class services SD For class services SE &SF Crane runways and monorails (horizontal) Crane runways and monorails (horizontal) L/500 L/250 L/400 L/800 L/1000 L/400 L/400 L/400 L/200 L/200 L/300 L/300
Conveyer support for pulleys and drive units under live load + belt tension L/800 Conveyer support under dead + live load Relative lateral deflection of runway rails due to gravity loads Where: L = theoretical span of beam. L/400 25mm

3.2 Allowable horizontal displacement

Maximum horizontal displacements of structures shall not exceed the following values: Single floor walkways and shelters without bridge-cranes Frames without equipment Pipe-racks Frames with equipment o o Total Displacement Displacement between floors H/200 h/300 H/150 H/200 H/200
Shelters with bridge-cranes at runway beam elevation o o for structural classes of services SA&SB&SC for structural classes of services SD&SE H/240 Max 50mm H/400 Max 50mm
where H = total height of structure For allowable horizontal displacement of building due to earthquake loads, refer to the INBC Part: 6 and UBC provisions of section 1630.

3.3 REINFORCED CONCRETE WORKS

3.3.1 General
All concrete design shall be in accordance with the requirements of ACI standards and guides and project specification 418/200-B00-C1-002, Specification for Concrete Works . All bar arrangement such as spacing, lapping, anchorage, and concrete cover shall be carried out according to ACI requirements. Reinforcement details not shown on standard and design drawings shall be carried out in accordance with the requirements of ACI 315 "Details and Detailing of concrete Reinforcement".
3.3.2 Concrete Grades

Concrete works shall be designed using following minimum compressive strength at 28 days age for cylindrical specimen (ASTM C39): Cement = 150 Kg/m3 fc = 150 Kg/cm2 fc = 280 Kg/cm
2 2
Lean concrete Concrete for duct bank and anchor blocks Foundation concrete Machine foundation concrete Elevation concrete (cast in situ) Prefabricated concrete Paving Basins and water retaining structures Fireproofing concrete ( density :20 kN/m3)
fc = 350 Kg/cm fc = 250 Kg/cm
fc = 280 Kg/cm2 fc = 210 Kg/cm

2 2
fc = 250 Kg/cm
fc = 210 Kg/cm2

3.3.3 Reinforcing Steel

Deformed High Tensile Strength Steel Bars, Grade III, in accordance with DIN 488 Specification with a minimum yield stress of 4000 Kg/cm2 or approved equivalent. Diameters to use are : 8, 10,12, 16 ,20, 22, 25, 28 & 32mm. Reinforcing Fabric Mesh in accordance with BS 4483 or approved equivalent as follow:
100 100 6 6 mm 200 100 8 8 mm 200 200 8 8 mm 150 150 8 8 mm
3.3.4 Anchor Bolts, P lates and S teel Ins erts

3. 3. 4. 1 Materi al Material for steel plates and steel shapes for inserts shall be: A36 according to ASTM, or approved equivalent with minimum yield strength of 235 N/mm2 or ST-37-2 in accordance with DIN 1025, 1050 and 17100 Specifications or approved equivalent with a minimum yield stress of 2400 Kg/cm2. Material standard anchor bolts shall conform or be equal to the following: ASTM A 307 Grade C or DIN ST-37-2 for Anchor bolts or approved equivalent. Minimum anchor bolts diameter for structural steel foundations shall be 20 mm. Hexagonal nuts shall be in accordance with DIN 555 or ASTM A 563M or approved equivalent for anchor bolts in foundations. Circular washers shall be in accordance with DIN 7989 specification or ASTM F 436M .
3. 3. 4. 2 Desi g n Req u i remen t Allowable stress for anchor bolts shall be the following (ASD Part. 5, Table J3.2): Tensile stress Ft, all = N/A =110 N/mm2 (1)
Shear stress Fv, all = T/A = 70 N/mm2(1) Where:

A = Gross (nominal) area of bolt N = axial force on bolt; T = shear force on bolt. All anchor bolts shall be hot dip galvanized 1. Allowable stresses may be increased 1/3 if loading conditions includes wind or earthquake. In principle shear stress should not be transferred on foundation by anchor bolts. Shear design of Steel structure base-plates shall meet the following criteria: _ Shear-keys shall be provided under columns which transfer important shear loads (such as Braced frames, shelters with bridge-crane and pipe rack braced bays). Shear-key consists of steel profile welded under column base-plate. _ Shear can be transferred to foundation by friction for minor structures, such as walkways, shelters without bridge-crane, pipe-racks, etc. In these cases the effective compressed area shall be calculated based on actual vertical load and moment. If the effective shear load exceeds the maximum shear transferred by friction, shear-key shall be foreseen.
3.3.5 Concrete Cover

Minimum net cover shall be as follows:
Formed concrete cast against and permanently exposed to ground and sea water, for all diameter Formed concrete exposed to weather and underside of foundation for all diameters Concrete not exposed to weather or not in contact with ground : Walls, slabs Concrete not exposed to weather or not in contact with ground : Beams, Columns
70 mm
60 mm
40 mm
40 mm
The net cover is the distance from the outer edge of any reinforcement or other metal items to the concrete external face.

Minimum distance of reinforcing bars shall be 2 times the maximum diameter of bars. Above mentioned figures for concrete cover and bar distance shall be checked against maximum size of available aggregate and enough free space for vibrator.
3.4 Steel Structure

3.4.1 Material
3. 4. 1. 1 Stru ctu ral Steel Material for structural steel shall be Mild Steel Grade ST 37-2 in accordance with DIN 1025, 1050 and 17100 with a minimum yield stress of 2400 kg/cm2 or approved equivalent. Single or double sections of European profiles such as I-sections (IPE), channels and angles shall be used in the design. In the case of buildings, application of built-up sections is allowed. Structural steelworks fabrication and erection shall be in accordance with project specification 418/D00-200-T1-001, Specification for Fabrication & Erection of Steelwork. 3. 4. 1. 2 Bo l ts, Nu ts an d Wash ers. The following types of bolts may be used for design of connections. Hexagonal head bolts grade 4.6 or 5.6 or A307 in accordance with DIN 7990, hexagonal nuts in accordance with DIN 555, and circular washers in accordance with DIN 7989, square taper washers in accordance with DIN 434 for connections of steel channels and DIN 435 for connection of steel Isections or approved equivalent. Bolts grade 4.6 or 5.6 or A307 may be used only for walkways, joists, girts, stair stringers, handrails and other secondary steel connections. The minimum diameter of bolt for these secondary members shall be 12 mm. Hexagonal head bolts grade 8.8 in accordance with DIN 6914, hexagonal nuts in accordance with DIN 6915, circular washers in accordance with DIN 6916, square taper washers in accordance with DIN

6918 for connections of steel channels and DIN 6917 for connection of steel I-sections or approved equivalent. High strength bolts grade 8.8 or 10.9 shall be used for structural steel connections. The minimum diameter of bolts for structural steel connections and main members shall be 16 mm and for secondary members shall be 12 mm. Not less than two bolts shall be used in end connections.
3.4.2 Chequered Plates

Steel for chequered plates shall be ST 37-2 or approved equivalent. Minimum thickness shall be 6 mm for plate plus 2 mm for raised pattern height. Chequered plates shall be welded unless otherwise specified in related drawings.
3.4.3 Steel G ratings

Steel grating shall be a 30 x 50 mm mesh, with 30 x 3 mm bearing and 6X6 mm twisted transverse bars or deformed 8 mm. Steel shall be in compliance with ST-37-2 or approved equivalent. Gratings shall be hot dip galvanized as per ASTM A 123. Maximum span between supports of the gratings is 1.5 m.
3.5
Foundati on D esign
3.5.1 General Design Cri teria and Detail s

The following design criteria shall be applied: The depth of foundation with respect to adjacent foundation has to be determined so that the ground slope between the foundations is not steeper than 45. This may require a lean concrete fill below the higher foundation. Foundations next to pipe lines are to be founded at the bottom of pipe level. This applies up to a distance of 1.5 m between foundation and pipe. In case of bigger distances, the slope of 45 has to be kept at distance of 1.0 m from the foundation.

Foundations shall be cast on a minimum 60 mm thick lean concrete layer. Top of concrete pedestals shall be at least 150 mm (including grout thickness of 25 mm) above the high point of paving or finished grade level, unless noted otherwise in related drawings. In order to facilitate the adjustment of equipment and steel structure, top of concrete level in foundations shall be set at least 25 mm below the final level. Possible gap shall be filled by grout after installation. Underside surface of the base plates of equipment and structures shall be rough enough to increase grout bonding.
Foundation pedestal for structural columns and equipment legs shall extend at least 50 mm from edges of the base plates. Foundation for equipment such as pump and compressors shall extend at least 100 mm from the edges of the base plates, unless otherwise specified on manufacturers drawings. Anchor bolts shall be positioned within the reinforcing bar cage. As a general rule, anchor bolts shall be installed before concrete casting. If necessary, adequate pockets shall be provided in the foundation when anchor bolts will be installed later. Pockets shall be filled using nonshrinking grout.
Foundation for vertical equipment on skirt shall have the top surface sloped for drainage purposes. Accordingly, an embedded drain pipe shall be provided in the foundation.
3.5.2 Tank foundations

Tank Diameter (D) Foundation Type D > 3 m Reinforced Concrete Slab Foundation D <3m Solid octagon or solid square reinforced concrete foundation The design of ring wall ( if any ) shall conform to requirement of paragraph 4 of this specification, or as required by tank vendor. Minimum width of ring wall = 300 mm

3.5.3 Elevations of foundation pl inths

The minimum elevation of foundation plinths (top of grout) above high point of paving / finishing floor level for steel structures and equipment shall be as follows: Structural steel columns : 200 mm Stairs and ladders : 150 mm Equipment (general) : 150 mm Equipment (pumps) : 300 mm
3.5.4 Soil Check

Foundations shall be designed according to the following criteria: Maximum soil pressure which shall be lower than the allowable figure (as determined from the complimentary geotechnical investigation) for all non-factored loading combinations. Allowable soil pressure may be increased by 33 % for any loading combination that includes wind or earthquake loads. Total and differential settlements due to dead and live loads shall be lower than the maximum values described in this specification (as detailed in 3.5.5). Minimum factor of safety against overturning (as detailed in 3.5.6). Minimum factor of safety against sliding (as detailed in 3.5.7)
Friction coefficients between soil and foundation shall be based on the soil report recommendations. Should this information be unavailable it shall be assumed equal to tan (where is the soils angle of friction) and shall not exceed the following values: 0.6 in the case of course or gravel soils. 0.45 in the case of fine to medium sand or stiff clay soils. 0.35 in the case of clay soils.

In sandy soils (without cohesion) foundations of vertical equipment higher than 30 m and have a total height/diameter ratio of greater than 10 shall be designed as follows: 85 % of the soil under the foundation shall be under compression for all load combinations in erection. 100 % of the soil under the foundation shall be under compression for all loading combinations in operation. Minimum factor of safety against flotation shall be 1.2 in all loading conditions/combinations.
3.5.5 Allowable Settlements

Allowable settlements, due to permanent loads are shown in the following table: Maximum differential settlement between two adjacent equipment shall not exceed 15 mm. Special care shall be taken for heavy permanent loads (storage tanks and storage buildings) with regard to long term settlements. Table 3-1: Foundation Allowable Settlement FOUNDATION TYPE Towers and vertical equipment Horizontal equipment Vibrating machinery Process structures Buildings Mat Foundation MAXIMUM SETTLEMENT 25 mm 25 mm 10 mm 25 mm 25 mm 50mm TOTAL MAXIMUM DIFFERENTIAL SETTLEMENT Deviation from vertical line due to differential settlement shall not exceed 0.2% 15 mm 5 mm 10 mm 15 mm 15 mm

3.5.6 Stabil ity Ratios

The following minimum factors of safety against overturning shall be applied in the design of foundations: Table 3-2: Overturning Safety Factor Design Condition Erection condition Test condition Operating condition Shutdown condition Accidental condition Stability Ratio 1.5 1.5 2 2 1.5
3.5.7 Sliding S tabil ity

The minimum factor of safety against sliding shall be 1.5 in all loading conditions/combinations except the accidental condition when the factor may be reduced to 1.2. Passive soil resistance may be used in calculating the factor of safety against sliding. The coefficient of friction of concrete on soil shall be in accordance with clause 3.5.3 of this specification. The resisting force against sliding shall be taken as either the full frictional force between foundation and the sub-soil strata plus 50% of the earth's passive resistance or 50% of the frictional force plus 100% of the earth's passive resistance, whichever is greater. The weight of the earth superimposed over the foundations may be included in the loads causing the resisting frictional force.

3.6 Foundati on and Structures for H eavy Vibrating Machinery

Heavy vibrating machinery is any equipment having reciprocating or rotary masses as the major moving parts (such as reciprocating or rotary compressors, pumps, turbines) and having a gross plan area exceeding 2.5 m, or a total weight of greater than 25 kN. Light vibrating machinery is any equipment having reciprocating or rotary masses as the major moving parts (such as reciprocating or rotary compressors, pumps, turbines) and having a gross plan area less than 2.5 m and total weight of less than 25 kN. For light vibrating machinery dynamic design is not required. Static design shall be carried out
according to the criteria of sections 8. In addition it shall be checked that the foundation weight shall not be less than 3 times the total rotary machine or 5 times the total reciprocating machine weight. The dynamic modulus of elasticity (E) of concrete to be used in the dynamic analysis is indicated in the following table: Table 3-3: Module of Elasticity
Characteristic Compressive Strength, F c (N/mm2) 25 35 45 55
Dynamic Modulus Elasticity, E (kN/mm2) 30.0 34.0 37.0 39.0
of
Soil pressure, considering dead and live loads, shall not exceed 50% of the allowable figure. The effects of shrinkage and thermal expansion shall be taken into account. In order to prevent cracking

the minimum amount of reinforcement shall be 50 kg/m.
The minimum diameter of the main
reinforcing bars shall be 16 mm. All reinforcement shall be triaxially arranged. The following rules shall be considered in foundation design: Foundation shall consist of clean, simple lines. Pockets where vapour could accumulate are not permitted. The shape of beams and columns shall be uniform and rectangular. All parts of the machine supports shall be independent from the adjacent foundations and buildings. Concrete floor slabs, adjacent to machine foundations, shall be spaced a minimum of 20 mm from the foundation. The space between slab and foundation shall be filled with a flexible joint filler and sealer. Thickness of foundation slab, in meters, shall not less than: Thk = 0.6 + L/30 where: for one machinery train: L = longest dimension of the foundation slab (m); For two or more machinery trains supported on a common foundation (only where cannot be avoided): L = greater of: Width of the common slab; Maximum slab segment length assigned to any train.
The minimum thickness of the foundation base slab shall not be less than 1/10 of its maximum dimension. Foundations and supporting structures for heavy vibrating machinery shall be designed as per CP2012 such that the natural frequency of the supporting structure including soil/structure interaction is either less than 0.7 or greater than 1.3 times the operating frequency of the machine.

The factor of safety against overturning shall be greater than or equal to 3. The manufacturer of the machine shall provide the following basic information: An arrangement drawing showing overall dimensions of the required concrete support specification for the machines, with location and size of opening, holes and grooves; location of base plate, pads, anchor bolts and relevant pocket sizes. A layout showing location of auxiliary equipment and miscellaneous, such as condenser, piping supports and service platform legs A drawing showing distribution lines to be connected to the footing or passing through it. Maximum operating temperature at the machine-foundation contact surface The operating speed range of each machine. The shaft position, both in plane and in elevation. Weight and centre of gravity for every machine and base plate and the static load acting on each support Weight and centre of gravity of each rotating mass (for rotating machinery only) For each machine, the standard dynamic forces and moments with relevant point of application and phase angle. Indication of supports where dynamic load acts Full load torque and force produced upon each support. Short circuit moment and force produced upon each support Depression on the condenser and type of connection (rigid or flexible) Permissible amplitudes of vibration, allowable settlements and any other information, according to the supplier, is to be taken into account.

3.6.1 Design Crite ria for Reciprocating Machinery

Design of foundations for reciprocating machinery shall be carried out in accordance with the following criteria: The total foundation weight shall be at least 5 times the total weight of the machine. The horizontal eccentricity in any direction between the centroid of the machine + foundation system and the centroid of the base contact area shall not exceed 5 % of the respective base dimension. The centre of gravity of the machine-foundation system should be as close as possible to the lines of action of unbalanced forces. Groups of reciprocating machinery could be tied together with a common foundation slab when allowed by their location and service and the combined foundation results in reduced amplitudes.
3.6.2 Dynamic analysis shall be carried out as follows:

Natural frequencies in the modes being exited shall preferably be out of 0.7 to 1.3 times the disturbing frequencies of any machine on the foundation. If it is not possible to meet this requirement, frequencies within the above mentioned range may be accepted if the maximum calculated amplitudes are within the limits listed in the following point e). Damping shall not be higher than 3 %. Primary forces, couples and moments shall be applied at machine speed for calculation of primary amplitudes. Secondary forces, couples and moments shall be applied at twice the machine speed for calculation of secondary amplitudes. Total amplitude shall be calculated by combining, in the worst conditions, primary and secondary amplitudes. Exciting forces arising under fault condition shall also be considered Total peak to peak amplitudes on foundation shall not exceed 0.05 mm, unless specified otherwise by the manufacturer.

3.6.3 Design Crite ria for Rotary Machinery

Rotary machines may be supported either on a direct foundation or on an elevated structure. Weight of basement (foundation and elevated structure) shall be at least three times the weight of the machinery. If evaluation of damping of concrete is not carried out, the damping factor of system machine + foundation shall be assumed as 0.02. Higher values of damping factor shall be considered in loading condition in which the loads are significantly higher than that during normal operation. 3. 6. 3. 1 Dyn ami c An al ysi s Dynamic analysis may be dispensed if the mass of rotating elements is less than 1/100 of the mass of the whole system (machine + foundation). Model shall be defined in such a way to correctly describe the foundation behaviour up to 1.5 fmax, where fmax is the maximum operating speed. 3. 6. 3. 2 Natu ral F req u en ci es Natural frequencies of the system, machine + foundation, shall be calculated in accordance with the following criteria: Number of natural frequencies to be calculated shall be defined so that the highest natural frequency calculated is at least 10 % higher than the operating frequencies. This prescription may be neglected in the case of machines having operating frequency higher than 75 Hz. However, depending on the analysis model, the number of natural frequencies to be calculated, n, shall meet the following: n = 10 for two dimensional models in which only displacements out of the plane are considered and in which vibration in one direction has influence in other directions.

n = 6 for two dimensional models in which only displacements out of the plane are considered and in which vibration in one direction has only secondary influence in other directions ( the system may be represented by independent models). The assessment of vibration behaviour shall be checked as follows: First order natural frequency (lowest frequency): f1 1.25 fm or f1 0.8 fm where fm is the lowest service frequency. Higher order natural frequencies: a) b) fn 0.9 fm and fn+1 1.1 fm If condition a) is not met it shall be suffice that fn is less than fm where n is equal to 6 or 10.
3.6.4 Analysis of Vib rations Due to Unbalanced Forces

3. 6. 4. 1 Exci ti n g Fo rces Unbalanced forces are provided by the machine manufacturer and shall be used for the dynamic response of the foundation. In case of absence of such information unbalanced forces may be calculated on the basis of nominal quality of balance of machine as follows: a) Operating state
The balanced quality of machine shall be assumed one grade lower than that for the relevant machine group.

Contractors Document No.: Contract No. : Document Title: F = M e = F( e) Where: = speed in rad/sec ( e) = quality of balance of machine All forces shall be considered applied at the bearings. b) Malfunctioning state. 4047 418/200-B00-C1-001 CIVIL DESIGN CRITERIA
Forces due to malfunctioning shall be assumed 6 times the values for operating state and shall be used for the static design and stability checks of the structure. 3. 6. 4. 2 Al l o w ab l e Di sp l acemen ts If allowable displacements are given by the machine manufacturer they shall be used for the check of the structure. In the absence of such information the maximum amplitudes, effective at the bearings, may be assumed for the particular machine group as follows: a) Operating state
The value associated with the operating frequency which is one grade higher than that guaranteed by the manufacturer shall be taken as the amplitude under service conditions. b) Malfunctioning state
The amplitude in case of malfunctioning shall be assumed to be 6 times the values used for the operating state.

CIVIL WORKS
4.1 Paving
4.1.1 Types of paving
4. 1. 1. 1 L i g h t d u ty p avi n g Light duty paving will be used in areas not subjected to vehicle traffic, or occasionally subjected to transit of light movable equipment with maximum axial load equal to 10 kN. Concrete slab shall be of uniform thickness of 100 mm and shall be designed to withstand a maximum axial load of 10 kN plus impact. Reinforcement consists of single welded wire mesh or equivalent reinforcement. 4. 1. 1. 2 Med i u m Du ty Pavi n g Medium duty paving is provided for areas subjected to light and medium traffic and to transit of maintenance vehicles. Concrete slab shall be 150 mm thickness with thicken edges and designed to withstand a maximum load of 60 kN per axle. Reinforcement consists of single welded wire mesh or equivalent reinforcement 4. 1. 1. 3 Heav y d u ty p avi n g Heavy duty paving is provided for areas subjected to heavy vehicle traffic including the areas from loading arms to outlet road. Paving shall be designed to withstand a maximum load per axle of 120 kN (4 tyres) Concrete heavy duty paving shall be 250 mm thickness in central area and 300 mm along the edges. Reinforcement consists of double welded wire mesh or equivalent reinforcement

4.1.2 Paving Elevation

High point of the paving shall be near the center if the process operation areas and it shall be sloped a minimum of 1% to drain. Paving shall slope away from all equipment foundations to prevent water damage to foundation and preserve bearing capacity. Cable Trenches shall be located on high point of paving as much as possible to prevent water damage.
4.1.3 Paving Design
Static design of reinforced concrete paving shall be carried out according the criteria indicated in manual PCA-Portland Cement Association-Concrete Pavement Design.Final design thickness of pavements shall be appropriate to vehicular or other acted loadings.
Paving slabs adjacent to foundation pedestals columns. Etc. shall be separated by joint filler and sealer. In the case of large areas covered by pavement slabs, the slabs shall be subdivided into square, rectangle or other convenient shapes by use of expansion joint. Such expansion joint should be placed at the high points of the slab in order to discourage infiltration of water below the slab Other Kinds if joints such as contraction construction, control and etc. should be used as necessary.
The contraction joints in reinforced paving shall be not more than 6m apart and expansion joints not more than 24 m apart. A maximum allowable difference in elevation of paving 150mm shall be limited for slope paving. Concrete paving may support minor equipment (small pumps, staircase, and light skid mounted packages) provided that the local strengthening results in max 10 kN/m2 soil pressure.
In correspondence of expansion joints shall be foreseen dowel bars for transferring at least

20% of the load across the joint. Generally these dowel bars consist of smooth steel bar 20 mm diameter,500 mm long every at a spacing of 500 mm. Half dowel bar shall be oiled to prevent bond between two section of r. c. slab.
Construction joints shall extent to the full depth of concrete paving. Construction joints shall be 8 mm width and shall be filled with hot bitumen or with suitable material hydrocarbon resistant. Lower part of joint shall be filled with polystyrene or with suitable non extruding material.
4.2 Sidewalks
Justification of sidewalks in rural areas depends upon the volume of pedestrian and vehicular traffic, their relative timing, and the speed of vehicular traffic. Sidewalks are accepted as integral part of streets, but few are provided in roads.
Sidewalks shall be laid parallel to streets and as walkways to building entrances, and shall be provided in accordance with operational and/or pedestrian traffic requirements. Walkways adjacent to and between buildings, and other facilities in built-up areas, generally are accepted as integral parts of these areas.
4.2.1 Walkways
Walkways along roads in open areas, between certain isolated locations, can be as necessary as in built-up areas.
4.2.2 Location of sidewalks

Sidewalks shall be placed adjacent to the curb, and widened as necessary to satisfy operational requirements.
4.2.3 Cross slope

Allow 2 percent in the direction of natural drainage.

4.2.4 Widths
Sidewalks shall be having minimum 1.0 m width. The width of a planted strip between the sidewalk and travel way, if provided, should be a minimum of 0.60 m to allow maintenance activities.
4.2.5 Grades
The use of steps in walkways shall be avoided, if possible. Single risers, in particular, are hazardous and are prohibited. When steps are required they should have a minimum of three risers. Grade limitations are:
Minimum allowable: Maximum allowable:

4.2.6 Ditch Crossings
none, flat grades are permissible 6 percent, however, 5 percent maximum is preferred. Build steps for steeper grade.
Where sidewalks cross open drainage channel hold the underside of the walkway above the design high water surface.
4.3 Pipe Crossings

Piping below roads shall be run in sleeves or culverts, as applicable direct burial for non-process lines is usually the rule. Pipe crossings shall be installed so that the angle between the road way axis and the axis of the crossing is as near 90 degrees as is practicable. After pipe has been installed the trench shall be backfield with approved material and compacted to the base course and surface coat shall be installed according to the original road specifications.
4.4 Cable Trenches

The main cables are placed in covered reinforced concrete trenches. There will be a layer of fine sand on top of the cables in the trenches.

Smaller cables, lighting cables and off sticks from the main trenches that width is smaller than 60 Cm, can be put directly in excavated trenches Roughly a half of the depth a concrete warning slab shall be put wherever needed. The cable trenches will have a certain slope for dewatering.
4.5 SURFACE DRA INAGE SYSTEM

The surface drainage system of the Plant shall be based mainly on open drainage ditches and nullah drains. The use of catch basins, storm drains and culverts shall be minimized. The system shall be designed for rainfall intensity as per specific Site conditions. In special process areas sewer system with catch basin and manholes shall be used, as required. The surface storm water runoff shall be determined by rational method from the following equation. Q = 2.778 C.I.A. Where Q = Rate of runoff (liters/sec) C = Runoff coefficient I = Design rainfall intensity (mm/hr) A = Area of the drained surface (hectares) The design rainfall intensity " I " shall be taken as per specific site conditions. The runoff coefficient C shall be taken as follows: Paved areas and roof surfaces, C=1.00 Graveled areas, C = 0.50 Landscaped areas, C = 0.40 Unpaved areas, C = 0.50

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Sarcheshmeh Flash Smelting Project

Clients Document No.:

Rev 01 Client Area No. : Date: 9 Nov 2011 200 Page 1 of 52

CIVIL DESIGN CRITERIA

28 Nov 2011 22 OCT 2011

Issued For Construction Issued for Review

Sarcheshmeh Flash Smelting Project

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Sarcheshmeh Flash Smelting Project

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Sarcheshmeh Flash Smelting Project

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Sarcheshmeh Flash Smelting Project

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Sarcheshmeh Flash Smelting Project

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1.1 PROJECT OVERV IEW

1.2 DOCUMENT SCOPE

1.3 DEFIN ITIONS

CODES AND STANDARDS

Sarcheshmeh Flash Smelting Project

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Reinforced Concrete Structures:

Tubes For Storage Of Granular Materials.

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Steel S tructu res:

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American Society for Testing Mate rials (ASTM)

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ASTM A185 Concrete. ASTM A193/193M

Standard Specification for Steel Welded Wire Reinforcement, Plain, for

Standard Specification for Alloy Steel and Stainless Steel Bolting

Sarcheshmeh Flash Smelting Project

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Standard Specification for Coatings of Zinc Mechanically Deposited on

Standard Test Method for Organic Impurities in Fine Aggregates for

Standard Test Method for Soundness of Aggregates by Use of Sodium

Sarcheshmeh Flash Smelting Project

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ASTM C 142 ASTM C ASTM C 150 ASTM C172 ASTM C 227

Externally and Internally Threaded Fasteners, Washers and Rivets.

Sarcheshmeh Flash Smelting Project

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Standard Specification for Compressible-Washer-Type Direct Tension

Indicators for Use with Structural Fasteners.

1.5 SITE GENER AL DATA

Sarcheshmeh Flash Smelting Project

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Frost line: 1200 mm below grade

1.5.5 Soil Inves tigations

1.5.6 Allowable Bearing Capacity

1.5.7 Expected Settlements

1.5.8 Soil Chemical Parameters and Cement Type

1.6 Imported Fill

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LOADS AND LOAD COMBINA TIO NS

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2.1.1 Dead Load (DL)