Structure Calculation Report

Design Foundation for Melting

and Holding Furnace
Project
PT. Indonesia Smelting Technology
(IST Expantion Project Pase 2)
Pasuruan East Java
November 2007

Owner :

PT. Indonesia Smelting

Technology
Jl. Rembang Industri II/2-A
Pasuruan Jawa Timur
Main Contractor :

PT. INDONAKANO

Wisma Tamara 14 th FL. Room 1401

Jalan Jend. Sudirman Kav 24
Consultants :

KETIRA ENGINEERING
CONSULTANTS
Jl. Tanah Abang V no 56-56A
Jakarta Pusat 10160

Table of Contents
Table of Contents i
Executive Summary ii
CHAPTER 1 PRELIMINARY ...
Section
1. Purpose of Analysis ..............
2. Data Used .
3. Foundation System Used ..
4. Codes and Standards Used
5. Material Specification ..

CHAPTER 2 STRUCTURAL CALCULATION ..

Section
1. Loading Data .
2. Modeling Structure ...
3. Input Data .
4. Output Data ..
5. Analysis Structure ..
6. Analysis Slab Design .....

CHAPTER 3 SETTLEMENT ANALYSIS OF RAFT PILE FOUNDATION

Section
1. Introduction ...
2. Soil Investigation ...
3. Analysis Stage
3.1 Soil Profile and Parameter Design .
3.2 Foundation Data
3.3 Construction Stage
3.4 Summary Evaluation of Settlement ..

12

1
1
1
1
1

2
4
4
8
10
11

12
12
15
16
17
18
25

CHAPTER 4 CONCLUTION .. 26
Appendix A MACHINE DATA . 28

EXECUTIVE SUMMARY

In designing foundation for Melthing Furnice Machine and Holding Furnice there are stage to
design :
1. Collecting Data from Soil Investigation and Load for Machine
A. From Soil Investigation
Based on the soil investigation result, the bearing layer is found at a depth of 3 4 m
with N SPT value of 50. The allowable soil stress based on N SPT of 50 is 0.76 kg/cm2
and bearing capacity of bored pile 400mm is 60 ton
B. Load for Machine
Loading data for the building is divided into 2 types of load, e.g.:
- Uniform Load
Evaluated Life Load in the plan this building is 1200 tons (with 200 tons per
machine x 3 nos. x 2 as safety factor). The load is assumed as a uniform load by
dividing the load with the area so that the load carried by the machine foundation
= 1200 tons / area of foundation = 4500 kg/m2
- Point Load
Where the holding furnice machine works like a cup with the machine legs in at
rest condition (symbol c) that will result in a load of 70 ton per leg for 4 legs.
But when the liquid aluminum is to be poured, the load will be carried hydraulicly
by foundation a and b. Foundation leg a will receive a vertical load of 34
tons and a horizontail load of 29 tons, while both legs of foundation b will
receive a vertical load of 107 ton and a horizontal load of 29 tons
Note : for the analysis of burden is multiplying 2 as safety factor in calculation.
2. Structure Analysis
A. Foundation
- Bored Pile
In analysis got force reaction by design < force reaction of required permission
ok (see output data reaction for bored pile).
- Reinforcement
In modeling structure entered data thickness of slab is 75 cm with reinforcement
for top rebar D16-150 (2 ways) and bottom bar D19-150 (2 ways) according to
result design moment.
B. Displacement
- Analysis was made on vertical load of 34 ton x 2 to Point a. The result obtained
was that the structure is stable and the vertical deflection is 2,47 mm
- Analysis was made on horizontal load of 29 ton x 2 to Point a toward below in
Picture 1. The result obtained was that the structure is stable and the horizontal
deflection is 0,1 mm
- Analysis was made on vertical load of 107 ton x 2 to Point b. The result
obtained was that the structure is stable and the vertical deflection is 2,9 mm
- Analysis was made on horizontal load of 29 ton x 2 to Point b toward below in
Picture 1. The result obtained was that the structure is stable and the horizontal
deflection is 0,1 mm
3. Conclusions
It can be concluded based on the results of the analysis conducted are described below:

Use soil improvement with CBR value of 20 % in order to get a uniform soil
compaction up to the bearing layer at a depth between 3 4 m (readjusted with
excavation result on site).
For the melting furnice and holding furnice machines use bored pile with dia 400 mm
and raft foundation system with a thickness of 75 cm and each machine foundation is
unified to get a better rigidity.
The rebar used is D16150 for top rebar and D19150 for bottom rebar with belt
reinforcement of D10 in 2 layers.
To Reduce Settlement of Foundation
Foundation have design by taking load factor equal to 2 times plan burden, besides
foundation also have design with two system that is :
o Raft foundation with soil improvement
o Bored pile system
From result of calculation of settlement analyzing raft and piled foundation separately
the theoretically totalize settlement (consolidation and immediate settlemet) obtained
is 21,5 mm. However, considering that this foundation system employs both raft and
pile which shall support each other and that the foundation is connected to
surrounding floor slab which again shall support the foundation against any deflection
the actual settlement shall be less that 3 mm or practically nil.
The temperature at surface of the foundation shall always be lass than 80 degree C as,
higher temperature can degrade the reinforcement concrete.

Best regards

(Ir. Paul Retika, MSc.)

Director

CHAPTER 1

PRELIMINARY
This report contains additional machine foundation calculation for Melting Furnice dan
Holding Furnice of PT. Indonesia Smelthing Technology located in Jalan Rembang Industri
II/2-A, Pasuruan East Java. The foundation used is raft pile foundation calculated with finite
element analysis utilizing computer program - ETABS version 8.5.
The analysis was based on data provided by Owner, e.g. loading data and other supporting
data such as soil investigation result conducted on site.
2. Purpose of Analysis
The purpose of analysis is to review structurallly the thickness of foundation, the
foundation system used, and the reinforcement design based on the data provided. In the
analysis, the above data was input to determine the foundation to be used.
3. Data Used
Data used as input are as follows:
A. Soil data from PT. Data Persada
Based on the soil investigation result, the bearing layer is found at a depth of 3 4 m
with N SPT value of 50. The allowable soil stress based on N SPT of 50 is 0.76 kg/cm2
and bearing capacity of bored pile 400mm is 60 ton.
B. Loading Data
Loading data for the building is divided into 2 types of load, e.g.:
- Load data for melting furnice and holding machine for design Live Load
- Load data for holding furnice machine (see Appendix A) for design Point Load as
Live Load
4. Foundation System Used
The foundation system used is combination bored pile (dia. 400mm until hard layer) with
raft foundation with soil improvement by replacing the clay layer with compacted sand up
to the rock layer with a depth of 3 4 m (will be readjusted based on the rock layer found
at excavation). Compaction was conducted per layer with thickness of 20 cm until CBR
value of 20% is obtained for each layer. Thus, it is assumed the soil has a uniform rigidity
to result in a uniform deformation.
5. Codes and Standards Used
A. Indonesian Reinforced Concrete Code 1971 (NI-2)
B. Methods Of Concrete Structure Calculation for Buildings (SNI-03-2847-2002)
C. Standards and Methods of Structural Calculation for Buildings, SKSNI T-15-1991-03
D. Indonesian Guide for Steel Building Design (PPBBI-1987)
6. Material Specification
A. Concrete Grade
K-300
B. Steel Reinforcement Grade
- Undeformed rebar U-24 (fy = 240 MPa) for dia. < 13 mm
Deformed rebar U-40 (fy = 400 MPa) for dia. D 13 mm and D 10 mm

CHAPTER 2

STRUCTURAL ANALYSIS

Picture 1. Picture for Melting Furnice and Holding Furnice

1. Loading Data
A. Dead Load
Dead Load which calculated consist of weight alone structure that is plate of and
concrete of finishing building alone.
B. Live Load
Evaluated Life Load in the plan this building is 1200 tons (with 200 tons per machine
x 3 nos. x 2 as safety factor). The load is assumed as a uniform load by dividing the
load with the area so that the load carried by the machine foundation = 1200 tons /
area of foundation = 4500 kg/m2
C. Point Load (from Holding Furnice see. Appendix A for machine picture)
Arragement Point Load

Where the holding furnice machine

works like a cup with the machine legs in
at rest condition (symbol c) that will
result in a load of 70 ton per leg for 4
legs. But when the liquid aluminum is to
be poured, the load will be carried
hydraulicly by foundation a and b.
Foundation leg a will receive a vertical
load of 34 tons and a horizontail load of
29 tons, while both legs of foundation
b will receive a vertical load of 107 ton

and a horizontal load of 29 tons

Typical Section for Vertical Force and Horizontal Force

REST CONDITION
Note : Vc = 70 ton / legs

LIQUID ALUMUNIUM TO BE POURED

Note : Va = 34 ton
Ha = 29 ton
Vb = 107 ton Hb = 29 ton

2. Modeling Structure
For modelling with combination bore pile and raft foundation which implematation with
spring constant, with made model by 3 dimension and also reckoned element finete in one
model of analysis.
P Machine Load = 4500 kg/m

Raft Foundation with

thickness 75 cm

Ks2
Ks1

Ks2

Ks2

Ks2
Ks1

Ks2

Ks2
Ks1

NOTE :
Ks1 : Spring Constant forBore Pile
Ks2 : Spring Constant for Soil
P
: Load for holding furnice machine, is vertical load and horizontal load
where :
Ks1 =
Bearing Capacity of bore pile
actual
Ks2 =
Allowable soil stress
actual
actual earn from result of settlement analysis (see enclosure), by using program of
Plaxis. Of calculation got that degradation of slab after structure burden work full on a
long term, total settlement maximum happened ata raft and bored pile = 2.15 cm.
3. Input Data
A. Material Properties and Loading Data
- Concrete Grade K 300 kg/cm2 or fc = 24.9 Mpa
- Spring Constant for Ks1
Knowns Bearing Capacity of bore pile = 60 ton
Ks1

60000kg
2790697 kg / m'
0.0215m

Spring Constant for Ks2

Knowns Allowable Soil Stress = 0.76 kg/cm2 or 7600 kg/m2
Ks1

7600kg / m 2
353488kg / m 2
0.0215m

B. Modeling Structure with 3D

C. Loading Uniform Live Load = 4500 kg/m2

D. Loading Live Load for Point Load C

E.

Loading Live Load for Point Load A and Point B

F. Arrangment Joint for Bore Pile Reaction

4. Output Data
A. Reaction for Bore Pile
Story

Point

Load

FZ

Story

Point

Load

FZ

BASE

23

COMB2

23424.77

BASE

1051

COMB2

24020.21

BASE

26

BASE

29

COMB2

24962.7

BASE

1054

COMB2

27000.61

COMB2

26125.73

BASE

1057

COMB2

BASE

28512.5

32

COMB2

26562.52

BASE

1060

COMB2

28765.09

BASE

35

COMB2

26518.26

BASE

1063

COMB2

28552.98

BASE

38

COMB2

25823.78

BASE

1066

COMB2

27039.1

BASE

131

COMB2

23644.28

BASE

1069

COMB2

23999.44

BASE

134

COMB2

26512.85

BASE

1072

COMB2

20873.01

BASE

137

COMB2

28390.61

BASE

1075

COMB2

18538.83

BASE

140

COMB2

28402.56

BASE

1078

COMB2

16991.26

BASE

143

COMB2

28627.18

BASE

1081

COMB2

16089.55

BASE

146

COMB2

26945.32

BASE

1087

COMB2

15678.9

BASE

147

COMB2

23658.14

BASE

1090

COMB2

15549.16

BASE

188

COMB2

15438.21

BASE

1374

COMB2

16542.93

BASE

191

COMB2

15616.7

BASE

1377

COMB2

17348.96

BASE

194

COMB2

16610.35

BASE

1380

COMB2

18852.96

BASE

197

COMB2

18285.25

BASE

1383

COMB2

21176.84

BASE

200

COMB2

20713.67

BASE

1386

COMB2

24301.99

BASE

224

COMB2

20435.06

BASE

1389

COMB2

27511.31

BASE

227

COMB2

18080.77

BASE

1392

COMB2

29267.34

BASE

230

COMB2

16498.31

BASE

1395

COMB2

29279.41

BASE

233

COMB2

15587.73

BASE

1398

COMB2

29287.46

BASE

236

COMB2

15449.93

BASE

1401

COMB2

27525.7

BASE

524

COMB2

15491.69

BASE

1404

COMB2

24278.72

BASE

527

COMB2

15461.84

BASE

1407

COMB2

21109.07

BASE

609

COMB2

15796.43

BASE

1410

COMB2

18758.3

BASE

612

COMB2

16787.28

BASE

1413

COMB2

17238.19

BASE

615

COMB2

18410.84

BASE

1416

COMB2

16406.71

BASE

618

COMB2

20728.06

BASE

1560

COMB2

15999.42

BASE

621

COMB2

23661.86

BASE

1620

COMB2

15783.84

BASE

624

COMB2

26667.71

BASE

627

COMB2

28458.49

BASE

630

COMB2

28668.81

BASE

633

COMB2

28570.78

BASE

636

COMB2

26812.09

BASE

639

COMB2

23654.07

BASE

642

COMB2

20568.23

BASE

645

COMB2

18253.8

BASE

648

COMB2

16678.49

BASE

651

COMB2

15733.01

BASE

657

COMB2

15471.41

BASE

660

COMB2

15516.96

BASE

739

COMB2

15625.34

BASE

740

COMB2

15564.31

BASE

960

COMB2

15649.86

BASE

963

COMB2

15754.27

BASE

1039

COMB2

16198.33

BASE

1042

COMB2

17099.15

BASE

1045

COMB2

18648.27

BASE

1048

COMB2

20959

B. Contour Moment M11

Result
P design < P allowable -- ok

Mu max = 32629,29 kgm

Mu min = 22345,627 kgm

C. Contour Moment M22

Mu max = 40764,65 kgm

D. Contour Displacement

Mu min = 21640,288 kgm

5. Analysis Structure
A. Punching shear analysis
The punching shear stress of the slab around the concentrated loads or restraint
reactions (on raft foundation) is determined by the concrete tension strength in the
critical section of pyramid or cut cone shape around the concentrated load or restraint
reaction according to the following formula:
Pu

bpm
,u
2 a b 2ht ht

300 = 16,8 kg/cm2.

where bpm
,u = 0,97

bp ,u

a and b are the length and width of the column or base plate (cm)
Ht is the the foundation thickness subtracted by the concrete cover.
Control of foundation legs
Leg
Pu

ht

bp ,u (kg/cm

Description

a
34 ton x 1.5 = 51 ton
b
107 ton x 1,5 = 160,5 ton
c
70 ton x 1,5 =105 ton
Case
If the column leg is not on the slab
becomes

75
75
120

75
75
50

70
70
70

1,26
3,96
2,21

Ok
Ok
Ok

but on the wall, e.g. on load b, the formula

Pu
bpm , u
2 a b ht

300 = 16,8 kg/cm2.

where bpm
,u = 0,97
bp , u

a and b are the length and width of the column or base plate (cm)
Ht is the the foundation thickness subtracted by the concrete cover.
Analysis
Foundation leg b

Pu = 160,5 ton

a = 75 cm and b = 75 cm
ht = 100 cm

thus the actual stress obtained is 5,35 kg/cm2 < bpm,

u = 0,97
ok

300 =

16,8 kg/cm2.

B. Analysis of lateral force causing moment on cantilever wall

Known

Mu = 73.950 kg m
t
= 100 cm
deff = 90 cm (concrete cover assumed = 10 cm)
Mu/bd2 = 913
Rho = 0.0026
As = 0.0026 x 900 mm x 1000 mm = 2340 mm2.
using D22 100 with As = 3800 mm2.

Thus, for the wall it is used D22 100 rebar (2 directions & 2 layers)
C. Result of the heat produced
Based on the description provided that the heat produced on the concrete surface less
than 800C, we recommend the use of an isolator material to dissipate the heat, e.g.
using fire resistance bricks.
6. Analysis Slab Design
Based on the given data of uniform load of 4500 kg/m2 and column legs load on holding
furnace in the form of vertical and horizontal load, an analysis using finite element method
with ETABS version 8.5 was conducted. The results obtained can be seen in output design
at contour moment result which in turns results in rebar area of D16-150 (2 ways) for top
rebar and D19-150 (2 ways) for bottom rebar.
Known from contour moment
Moment ultimate max. = 40764,65 kgm
Thickness slab = 750 mm and d effective = 700 mm
Mu/bd2 =
1039,9
Rho = 0.0026
As = 0.0026 x 700 mm x 1000 mm = 1866 mm2.
using D19 150 with As = 1867 mm2.

CHAPTER 3

SETTLEMENT ANALYISIS OF RAFT PILE FOUNDATION

1. INTRODUCTION
This report to analysis behavior of raft pile foundation settlement for Project Extention of Phase II PT.
Indonesia Smelting Technology at Pasuruan Industrial Estate Rembang
2. SOIL INVESTIGATION
Soil investigation data use Laporan Penyelidikan Tanah by PT. Testana Engineering Inc (November
2003), the data consist of 3 (three) deep boring BH-1 - BH-3 with SPT test and laboratory test. Other
data use soil investigation by PT. Data Persada (February 2005) in which consist 2 (two) deep boring in
which consist deep boring B-1 dan B-2 and SPT test also laboratory test
On site, depth of boring consist depth 10.0 m (B-1 and B-2) and also 15.0 m (BH-1 BH-3). Scope of
soil investigation included the following phases Standard Penetration Test (SPT) with interval test 2.00
m. Groundwater observation at deep bore B-1 dan B-2, in which the groundwater depth at -3.00 m from
eksisting level soil investigation.
Picture 1 : Value of NSPT versus depth

Silty Clay, firm

N=5-9

Sandy Silt,stiff
N = 10 - 50

Sand, very dense

N = 50 - 60

Besides field test, intake of undisturbed sampel (UDS) as examination of laboratory. Laboratory test
to know the nature of physical and mechanical of the soil. Test type which cover index properties test,

direct shear test, triaksial test and consolidation test. Following the tables of data result of test of
properties and and strength of soil at laboratory.
Tabel 1: Data of Soil Parameter from laboratory test
Tester by PT. Data Persada
Deep Boring No.
Sample Depth, m
Sub. Unit Weight, wet ton/m
Natural Void Ratio, e
Spesific Gravity, Gs
Saturated Unit Weight sat ton/m
Degree of Saturation, Sr %
water content, wn
Liquid Limit, %
Atterberg Limits
Plastic Limit, %
Plasticity Index
(D)
cu, kg/cm
UCT
(R)
cu, kg/cm
Strength
c, kg/cm
UU Test Total
Test

c', kg/cm
CU Test Eff
'
Cc
Cr
Consolidation Test Pc kg/cm2
Cv (cm2/sec)
OCR

BI
0.50 - 1.00 1.50 -2.00
1.70
1.78
1.35
1.28
2.75
2.75
1.40
1.85
58.00
120.00
50.20
69.80

0.58
0.035
22
6

B - II
0.50 - 1.00
1.50 -2.00
1.734
1.68
1.43
1.53
2.75
2.54
1.80
1.75

42.50
105.00
42.00
63.00

75.40
108.00
48.00
60.00

0.6
15

0.28
25

0.34
0.05
23
5

0.50
0.05
10.5
6

56.00
98.00
52.80
45.20
0.
565

0.50
0.05
12
1.6

Note : pursuant to test of swelling sample Bore B-1 and of B-2, known that at deepness
0.50 - 1.00 m nothing swelling potential. Potential of swelling meet at deepness
1.50 - 2.00 m equal to 1.5 kgf/cm2.
Tester by PT. Testana Engineering
Deep Boring No.

BH-1
Sample Depth, m 0.50 - 1.0 7.50 - 8.0
Sub. Unit Weight, wet ton/m
Natural Void Ratio, e
Spesific Gravity, Gs
2.62
2.70
Saturated Unit Weight sat ton/m
Degree of Saturation, Sr %
water content, wn
Liquid Limit, %
98
31
Atterberg Limits
Plastic Limit, %
37
26
Plasticity Index
61
5
(U)
cu, kg/cm
UCT
(R)
cu, kg/cm
Strength DS Test/ Total c, kg/cm

Test
c', kg/cm
UU Test Eff
'
Cc
Cr
Consolidation Test Pc kg/cm2
Cv (cm2/sec)
OCR

BH-2
3.50 - 4.00 9.50 - 10.00

2.66

2.68

46
29
17

29
24
5

BH-3
1.50 - 2.00 11.50 - 12.0
1.69
1.23
2.60
2.66

45
48
30
18

45
29
16

0.10
26

Pursuant to curve of plastisitas (chart plasticity) proposed by Casagrande, known that soil type until
deepness - 4.00 predominated by clayey silt of low to high plasticity or ML - MH (picture 2).

CH

MH & OH

CL & ML

ML & OL

Figure 2 : Curve of Placticity Index againts Liquid Index

Rate water value range from 40 - 60 % with boundary value of plastis index ( Wp) range from 24 - 50
% and liquid index ( WL) = 30 - 120 % ( picture 3)

Picture 3 : Water nature, plasticity index and liquid index against deepness

3. ANALYSIS STAGES
Behavioral, analysis of raft foundation by using finite element method constructively Program of
Plaxis version 8.2. Analysis to know pressure and deformation of land under raft foundation. Data
which used in this analysis :
Report Investigation of Land;Ground by PT. Testana Engineering Inc. ( November 2003) and PT.
Data of Persada (February 2005)
Layout drawing cutting structure of raft foundation

Plant drawing replacement of ground surface with compacted sand in which CBR 20 %
Layout planning of structure slab & bore pile layout

Analysis which cover deformation analysis to short-range (immediate settlement) in which under raft
foundation consist of sand layer
Analysis by using model of plane strain hence structure modeled to have same section as long as
cutting with condition of same surcharge and same pressure also. Switchover in vertical direction
drawing assumed nothing.
In this report, construction step sequence modeled in 2 the following phase are :
1. Slope stability
Execution of replacement of soil surface which in the form of silt clay and clay silt until deepness 4.00 m with compacted sand gravel

2. Immdeiate settlement analysis

a. Soil replacement with compacted sand gravel
b. Construction of bore pile & raft foundation
c. Surcharge (upper structure construction)
Some assumption which used in analysis is :

For slope analysis, ground water level at deepness - 3.00 m modeled as according to
perception of borehole taken as as reference

Dig system of basement use open cut system with inclination of level 45

Elevasi culminate dig taken pursuant to layout cutting dig plant

Elementary Elevasi of dig at + 0.00 in which taken from dig plant
Slope stability of dig bevel for the construction of basemen reckoned is separate
Laboring burden at plate of raft thickly 0.75 m
Surcharge load above land existing is 0.8 t / m2 widely 10 m
Laboring burden as surcharge load
Slab raft Elevation is same
Thickness of slab raft is same
Soil profile of soil follow boring data.
Dephtness of bored pile penetration until hard layer + 2.00. Using bored pile
400 mm

3.1 SOIL PROFIL AND PARAMETER DESIGN

Soil parameter use data result of field test and laboratory test. Election of parameter adapted by
location investigation on site. Figure 4 and tables 2, showing modal of soil profile where subgrade
modulus value ( Es) taken away from :
Es = 766 NSPT kN / m2 ( for sand)
Es = 250 - 500 kg / cm2 ( for silt and clay)

SECTION 4
SECTION 3
SECTION 2
SECTION 1

Picture 4 : Layout Foundation

Structure Load
1.91 t/m

Surcharge Load
0.8 t/m
A
A
0

4
6

y
A

Surcharge Load
0.8 t/m
A

A
93

A
9

14
x
15
12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 13

Compacted Sand Gravel

19 23 27 31 35 39 43 47 51 55 59 63 67 71 75 79 83 87 91
18 22 26 30 34 38 42 46 50 54 58 62 66 70 74 78 82 86 90

10

A
11

94

Silty Clay
Sandy Silt

5
7

17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89
92

Sand

Picture 5 : Soil Profile Section 1 & 4

Structure Load
2.22 t/m

Surcharge Load
0.8 t/m
A
A
0

Surcharge Load
0.8 t/m

y
A

A
93

A
9

14
12 16

20

24 28

32 36 40 44 48

52

56 60

64

68 72 76 80 84

55 59 63 Sand
67 71 Gravel
75 79 83
Compacted

15
88 13

A
11

94

Silty Clay

19

23

27 31

35 39 43 47 51

87

91

18

22

26 30

34 38 42 46 50

54

58 62

66

70 74 78 82 86

90

17

21

25 29

33 37 41 45 49

53

57 61

65

69 73 77 81 85

89
92

10

Sandy Silt

Sand

Type of Soil Layer

(Depth)

Picture 6 : Soil Profile Section 2 & 3

Table 2 : Soil Parameter

wet
(kN/m3)

sat
(kN/
m3)

Undrained Strength

c
(kN/m2)

Sirtu, stiff
(0.00 0.50)
Compacted Sand Gravel, very
dense
(0.50 4.00)
Silty Clay, stiff
(0.00 4.00)
Sandy Silt, stiff
(4.00 6.00)
Sand, very dense
(6.00 15.00)

()

Drained Strength
(Long term Analysis)

E
(kN/m2)

c
(kN/m2)

()

E
(kN/m2)

Concrete Slab

1.85

1.85

0.30

30

75000

30

75000

15.0

15.5

0.35

60

18000

10

27

12000

15.5

16.0

0.35

125

10

43750

25

25

29000

17.5

17.5

0.3

40

34470

40

34470

3.2 FOUNDATION DATA

Raft Data
- raft thickness
= 0.75 m
- Concrete modulus, E = 2.1 E + 5 kg/cm2
= 2.1 E + 7 kN/m2
- Inertia, I
= 1/12 bh3
= 1/12 (1)(0.75) 3
= 0.035 m4
- Luas, A
= 0.75 m2
- EA/ m
= 1.575 E + 7 kN/m
- EI / m
= 7.350 E + 5 kNm
Bored Pile Data
- Diameter
= 0.40 m
- Concrete modulus, E = 2.1 E + 5 kg/cm2
= 2.1 E + 7 kN/m2
- Inertia, I
= /64 D4
= /64 0.44

- Luas, A

= 0.001256 m4
= 0.1256 m2

- EA/ m

= 1.12 E + 6 kN/m (for section 1 & 4, span of bored pile 2.350 m)

= 1.30 E + 6 kN/m (for section 2 & 3, span of bored pile 2.025 m)

- EI / m

= 1.12 E + 4 kNm (for section 1 & 4, span of bored pile 2.350 m)

= 1.30 E + 4 kN/m (for section 2 & 3, span of bored pile 2.025 m)

3.3 CONSTRUCTION STAGES

1. Slope Analysis
a. Contour deformation of soi, stage surcharge load 0.8 ton/m1.

Picture 7 : Contour Deformation (Stage Surcharge Load)

b. Contour deformation of soil, stage work Of Dig, Dig until - 4.00 m.

Picture 8 : Contour Deformation (Stage Cut until 4.00)

Picture 9 : Soil Movement of Slope at Momen Work of Dig

Chart 1
Sum-Msf

Chart 1
Sum-Msf

Curve 1

Curve 1

1
0

20

40

60

80

100

30

60

90

120

150

|U| [m]

|U| [m]

Graph Safety Factor of Point A

Graph Safety Factor of Point C

Picture 10 : Graphic Safety Factor of Slope

Chart 1

Chart 1
Sum-Msf
6
Curve 1

Sum-Msf
6

Curve 1

5
3

4
1
0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

|U| [m]

1
0

0.01

0.02

0.03

0.04

|U| [m]

Graph Safety Factor of Point F

2. Total Settlement
a. Section 1 & 4

Graph Safety Factor of Point H

0.05

-3

*10 m
20.000
19.000
18.000
17.000
16.000
15.000
14.000
13.000
12.000

P1

P9

11.000

P19

10.000
9.000
8.000
7.000
6.000
5.000
4.000
3.000
2.000
1.000
0.000
-1.000

Picture 11 : Contour Deformation

Total displacements
-3
Extreme total displacement 19.52*10 m

Total displacements
-3
Extreme total displacement 19.52*10 m

Picture 12 : Raft Vertical Deformation ( max = 1.95 cm)

Table 2 : Two Dimension Total Settlement of Raft
SECTION
1&4
1

Element
1
RAFT

2
RAFT

3
RAFT

4
RAFT

5
RAFT

Node
503
507
508
509
513
517
518
519
846
847
848
849
856
860
861
862
1185
1186
1187
1188
1195

X
[m]
-20.00
-19.50
-19.00
-18.50
-18.00
-17.50
-17.00
-16.50
-16.00
-15.50
-15.00
-14.50
-14.00
-13.50
-13.00
-12.50
-12.00
-11.50
-11.00
-10.50
-10.00

Y
[m]
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50

Ux
[cm]
0.026
0.026
0.026
0.026
0.026
0.026
0.026
0.025
0.025
0.025
0.025
0.025
0.024
0.024
0.024
0.024
0.023
0.023
0.023
0.022
0.022

Uy
[cm]
-1.442
-1.452
-1.461
-1.471
-1.483
-1.500
-1.520
-1.540
-1.562
-1.587
-1.612
-1.636
-1.660
-1.685
-1.708
-1.730
-1.750
-1.771
-1.790
-1.808
-1.823

RAFT

7
RAFT

8
RAFT

9
RAFT

10
RAFT

11
RAFT

12
RAFT

13
RAFT

14
RAFT

15
RAFT

16
RAFT

17
RAFT

18
RAFT

19
RAFT

20
RAFT

1199
1200
1201
1205
1209
1210
1211
1515
1516
1517
1518
1525
1529
1530
1531
1535
1539
1540
1541
1858
1859
1860
1861
1868
1872
1873
1874
2180
2181
2182
2183
2190
2196
2195
2194
2200
2204
2205
2206
2377
2378
2379
2380
2387
2391
2392
2393
2397
2401
2402
2403
2407
2411
2412
2413
2567
2571
2572
2573
2687

-9.50
-9.00
-8.50
-8.00
-7.50
-7.00
-6.50
-6.00
-5.50
-5.00
-4.50
-4.00
-3.50
-3.00
-2.50
-2.00
-1.50
-1.00
-0.50
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
10.50
11.00
11.50
12.00
12.50
13.00
13.50
14.00
14.50
15.00
15.50
16.00
16.50
17.00
17.50
18.00
18.50
19.00
19.50
20.00

Total displacements
-3
Extreme total displacement 19.48*10 m

-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50

0.022
0.021
0.021
0.021
0.020
0.020
0.020
0.020
0.019
0.019
0.019
0.018
0.018
0.018
0.017
0.017
0.016
0.016
0.016
0.015
0.015
0.015
0.014
0.014
0.014
0.013
0.013
0.013
0.012
0.012
0.012
0.012
0.011
0.011
0.011
0.010
0.010
0.010
0.009
0.009
0.009
0.009
0.008
0.008
0.008
0.008
No.
0.007
Pile
0.007
0.007
P1
0.007
P2
0.006
P3
0.006
P4
0.006
P5
0.006
0.006
P6
0.006
P7
0.006
P8
0.006
P9
0.006
P10
0.006

-1.839
-1.853
-1.865
-1.876
-1.888
-1.898
-1.906
-1.913
-1.921
-1.927
-1.931
-1.935
-1.940
-1.944
-1.946
-1.948
-1.950
-1.952
-1.952
-1.951
-1.952
-1.951
-1.950
-1.947
-1.945
-1.942
-1.937
-1.931
-1.927
-1.922
-1.914
-1.906
-1.899
-1.890
-1.880
-1.868
-1.858
-1.847
-1.834
-1.820
-1.807
-1.794
-1.779
-1.765
-1.753
Total Deformation
-1.742
(cm)
-1.732
Raft
Bore Pile
-1.723
-1.720
1.483
1.483
-1.719
1.562
1.562
-1.721
1.660
1.660
-1.727
1.750
1.750
-1.740
1.823
1.823
-1.756
-1.776
1.876
1.876
-1.797
1.973
1.973
-1.822
1.935
1.935
-1.848
1.948
1.948
-1.874
1.951
1.951
-1.899

P11
1.947
1.947
Table 3P12
: Raft & Bored Pile
Vertical Deformation
1.931
1.931
P13
P14
P15
P16
P17
P18
P19

1.906
1.868
1.820
1.765
1.723
1.727
1.797

1.906
1.868
1.820
1.765
1.723
1.727
1.797

Total displacements
-3
Extreme total displacement 14.83*10 m

(a) P1

(a) P9

Picture 13 : Vertical Deformation of Bored Pile

a. Section 2 & 3

-3

*10 m

2.000

-0.000

-2.000

-4.000

-6.000

-8.000

P1

P9

P19
-10.000

-12.000

-14.000

-16.000

-18.000

-20.000

-22.000

Picture 14 : Contour Deformation

Vertical displacements
-3
Extreme vertical displacement -21.53*10 m

Total displacements
-3
Extreme total displacement 21.53*10 m

Picture 15 : Raft Vertical Deformation ( max = 2.15 cm)

Table 4 : Two Dimension Total Settlement of Raft

Beam

Element

Node

Ux

Uy

[m]
SECTION
B

1
RAFT

2
RAFT

3
RAFT

4
RAFT

5
RAFT

6
RAFT

7
RAFT

8
RAFT

9
RAFT

10
RAFT

11
RAFT

12
RAFT

13
RAFT

14
RAFT

15
RAFT

16
RAFT

503
507
508
509
513
517
518
519
846
847
848
849
856
860
861
862
1185
1186
1187
1188
1195
1199
1200
1201
1205
1209
1210
1211
1515
1516
1517
1518
1525
1529
1530
1531
1535
1539
1540
1541
1858
1859
1860
1861
1868
1872
1873
1874
2180
2181
2182
2183
2190
2196
2195
2194
2200
2204
2205
2206
2377
2378
2379

-20.00
-19.50
-19.00
-18.50
-18.00
-17.50
-17.00
-16.50
-16.00
-15.50
-15.00
-14.50
-14.00
-13.50
-13.00
-12.50
-12.00
-11.50
-11.00
-10.50
-10.00
-9.50
-9.00
-8.50
-8.00
-7.50
-7.00
-6.50
-6.00
-5.50
-5.00
-4.50
-4.00
-3.50
-3.00
-2.50
-2.00
-1.50
-1.00
-0.50
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
10.50
11.00

[m]
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50

[cm]
0.028
0.028
0.028
0.027
0.027
0.027
0.027
0.027
0.027
0.026
0.026
0.026
0.026
0.025
0.025
0.025
0.025
0.024
0.024
0.024
0.023
0.023
0.023
0.022
0.022
0.022
0.021
0.021
0.021
0.020
0.020
0.020
0.019
0.019
0.018
0.018
0.018
0.017
0.017
0.017
0.016
0.016
0.016
0.015
0.015
0.015
0.014
0.014
0.013
0.013
0.013
0.012
0.012
0.012
0.011
0.011
0.011
0.010
0.010
0.010
0.010
0.009
0.009

[cm]
-1.626
-1.633
-1.640
-1.648
-1.658
-1.674
-1.693
-1.713
-1.735
-1.760
-1.786
-1.811
-1.836
-1.862
-1.887
-1.910
-1.932
-1.955
-1.976
-1.994
-2.011
-2.028
-2.044
-2.058
-2.069
-2.082
-2.093
-2.103
-2.110
-2.118
-2.125
-2.130
-2.134
-2.140
-2.144
-2.147
-2.148
-2.151
-2.153
-2.153
-2.152
-2.153
-2.153
-2.151
-2.147
-2.145
-2.142
-2.136
-2.130
-2.125
-2.119
-2.111
-2.102
-2.094
-2.084
-2.072
-2.060
-2.048
-2.036
-2.022
-2.006
-1.993
-1.979

17
RAFT

18
RAFT

19
RAFT

20
RAFT

2380
2387
2391
2392
2393
2397
2401
2402
2403
2407
2411
2412
2413
2567
2571
2572
2573
2687

11.50
12.00
12.50
13.00
13.50
14.00
14.50
15.00
15.50
16.00
16.50
17.00
17.50
18.00
18.50
19.00
19.50
20.00

-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50
-0.50

0.009
0.008
0.008
0.008
0.008
0.007
0.007
0.007
0.007
0.007
0.006
0.006
0.006
0.006
0.006
0.006
0.006
0.006

-1.963
-1.948
-1.936
-1.925
-1.915
-1.906
-1.904
-1.905
-1.909
-1.917
-1.933
-1.954
-1.977
-2.003
-2.032
-2.063
-2.094
-2.125

Table 3 : Raft & Bored Pile Vertical Deformation

No.
Pile

Vertical displacements
-3
Extreme vertical displacement -16.58*10 m

(a) P1

Vertical displacements
-3
Extreme vertical displacement -21.48*10 m

(a) P9

Picture 16 : Vertical Deformation of Bored Pile

3.4 SUMMARY EVALUTION OF SETTLEMENT

P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
P19

Total Deformation
(cm)
Raft
1.658
1.735
1.836
1.932
2.011
2.069
2.110
2.134
2.148
2.152
2.147
2.130
2.102
2.060
2.060
1.948
1.906
1.917
2.002

Bore Pile
1.658
1.735
1.836
1.932
2.011
2.069
2.110
2.134
2.148
2.152
2.147
2.130
2.102
2.060
2.060
1.948
1.906
1.917
2.002

From Program of PLAXIS obtained strain value and laboring tension at slab evaluated to every
construction phase. Result of Program output of PLAXIS can be seen at enclosure. For settlement
analysis, positive value show to aim to up (heave) and negative value show to aim to down.
At a period of dig work in - 4.00 m, result of analysis stability of bevel by using Program of Plaxis
version 8.2. assigning value Safety Factor (SF) = 5 > SF allowable = 1.25 for the temporally of slope
stability while at a period of construction where structure burden not yet employed at dig area of
heaving can be disregarded because form of the land in dig base of very solid sand. Degradation of
slab after structure burden work full on a long term, total settlement maximum happened at raft and
bored pile = 2.15 cm.

CHAPTER 4

CONCLUSION
In designing foundation for Melthing Furnice Machine and Holding Furnice there are stage to
design :
1.
Collecting Data from Soil Investigation and Load for Machine
A. From Soil Investigation
Based on the soil investigation result, the bearing layer is found at a depth of 3 4 m
with N SPT value of 50. The allowable soil stress based on N SPT of 50 is 0.76 kg/cm2
and bearing capacity of bored pile 400mm is 60 ton
B. Load for Machine
Loading data for the building is divided into 2 types of load, e.g.:
- Uniform Load
Evaluated Life Load in the plan this building is 1200 tons (with 200 tons per
machine x 3 nos. x 2 as safety factor). The load is assumed as a uniform load by
dividing the load with the area so that the load carried by the machine foundation
= 1200 tons / area of foundation = 4500 kg/m2
- Point Load
Where the holding furnice machine works like a cup with the machine legs in at
rest condition (symbol c) that will result in a load of 70 ton per leg for 4 legs.
But when the liquid aluminum is to be poured, the load will be carried hydraulicly
by foundation a and b. Foundation leg a will receive a vertical load of 34
tons and a horizontail load of 29 tons, while both legs of foundation b will
receive a vertical load of 107 ton and a horizontal load of 29 tons
Note : for the analysis of burden is multiplying 2 as safety factor in calculation.
2.Structure Analysis
C. Foundation
- Bored Pile
In analysis got force reaction by design < force reaction of required permission
ok (see output data reaction for bored pile).
- Reinforcement
In modeling structure entered data thickness of slab is 75 cm with reinforcement
for top rebar D16-150 (2 ways) and bottom bar D19-150 (2 ways) according to
result design moment.
D. Displacement
- Analysis was made on vertical load of 34 ton x 2 to Point a. The result obtained
was that the structure is stable and the vertical deflection is 2,47 mm
- Analysis was made on horizontal load of 29 ton x 2 to Point a toward below in
Picture 1. The result obtained was that the structure is stable and the horizontal
deflection is 0,1 mm
- Analysis was made on vertical load of 107 ton x 2 to Point b. The result
obtained was that the structure is stable and the vertical deflection is 2,9 mm
- Analysis was made on horizontal load of 29 ton x 2 to Point b toward below in
Picture 1. The result obtained was that the structure is stable and the horizontal
deflection is 0,1 mm
2. Conclusions
It can be concluded based on the results of the analysis conducted are described below:

Use soil improvement with CBR value of 20 % in order to get a uniform soil
compaction up to the bearing layer at a depth between 3 4 m (readjusted with
excavation result on site).
For the melting furnice and holding furnice machines use bored pile with dia 400 mm
and raft foundation system with a thickness of 75 cm and each machine foundation is
unified to get a better rigidity.
The rebar used is D16150 for top rebar and D19150 for bottom rebar with belt
reinforcement of D10 in 2 layers.
To Reduce Settlement of Foundation
Foundation have design by taking load factor equal to 2 times plan burden, besides
foundation also have design with two system that is :
o Raft foundation with soil improvement
o Bored pile system
From result of calculation of settlement analyzing raft and piled foundation separately
the theoretically totalize settlement (consolidation and immediate settlemet) obtained
is 21,5 mm. However, considering that this foundation system employs both raft and
pile which shall support each other and that the foundation is connected to
surrounding floor slab which again shall support the foundation against any deflection
the actual settlement shall be less that 3 mm or practically nil.
The temperature at surface of the foundation shall always be lass than 80 degree C as,
higher temperature can degrade the reinforcement concrete.