80m TALL STEEL CHIMNEY

ANALYSIS AND DESIGN CHECK REPORT

FOR STACK COMPONENTS
FOR INCREASED LOAD DUE TO STRAKES
 Invictus Consultancy Services A-401, Sai Leela Apts.
Sector 16, New Panvel,
Dist. Raigad – 410206

OWNER
THAI RAYON PCL

OWNER’S ENGINEER

CONTRACTOR

PROJECT
80m TALL STEEL CHIMNEY

TITLE
ANALYSIS AND DESIGN CHECK REPORT
FOR STACK COMPONENTS
FOR INCREASED LOAD DUE TO STRAKES

DATE Rev. MODIFICATIONS/ PREPARED CHECKED APPROVED

No. PURPOSE OF ISSUE Name Signature Name Signature Name Signature

31/05/2018 0 Initial issue MDB ASO ASO

This note is the property of REV.No.

Invictus Consultancy Services. It DATE PAGES NOTE No.
may not be used, copied or
reproduced without their written 31/05/18 17 230/E/DN-02 R0
permission.
 DATE: 31.05.18 NOTE NO. : 230/E/DN-02 (R0)

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ANALYSIS AND DESIGN CHECK REPORT

FOR STACK COMPONENTS
FOR INCREASED LOADS DUE TO STRAKES
List of Contents Page No

1 Introduction 4

2 Analysis – STAAD model 4

2.1 Geometry 4
2.2 Boundary conditions 5
2.3 Element properties 6
2.4 Material properties 6
2.5 Other masses 7

3 Static wind load 9

4 Dynamic wind 10

5 Analysis results 11

6 Design checks 11
6.1 Deflection check 11
6.2 Deflection check 12
6.3 Stress check 12
6.4 Check for base plate/ foundation bolts 12
6.5 Check for piles 13
6.6 Check for pile cap 14

7 Conclusion 14

8 References 15

Annex. A – STAAD input file 16

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ANALYSIS AND DESIGN CHECK REPORT

FOR STACK COMPONENTS
FOR INCREASED LOADS DUE TO STRAKES

1 Introduction
In order to suppress across-wind oscillation of the chimney, it is decided to provide helical steel strakes.
However, addition of strakes leads to increase in effective diameter of the chimney and corresponding
wind load over the top portion of the chimney. In this design report, the chimney section, holding down
bolts and foundation are checked for wind loads with the addition of strakes.

2 Analysis – STAAD model

A stick model of the stack is produced, which is analysed in order to estimate lateral force and moment
due to wind.

2.1 Geometry
The stack is modelled using 1-dimensional beam elements as shown below.

Nodes are located at every 5m in height.

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Node numbers

Element numbers

2.2 Boundary conditions

The stack is modelled as being fixed at the base.
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2.3 Element properties

The stack tapers from 6m outside diameter at the base to 0.9m outside diameter at the top, with constant
thickness of 15mm. Element bottom and top diameters are calculated and corresponding properties are
assigned to the elements in STAAD.

2.4 Material properties

Material for the stack wall is taken as steel.
8 2
Modulus of elasticity is taken as 2 x 10 kN/m .

The density of the material is adjusted so as to account for the insulation and aluminium cladding around
the stack as well.
3
For 15mm thick MS wall, 50mm thick resin bonded rock wool insulation (density 100 kg/m ) and 0.8mm
3
thick aluminium cladding (density 2700 kg/m ) are provided.

Hence, the mass of (stack wall + insulation + cladding) = 78.5 x 0.015 + 0.98 x 0.05 + 27 x 0.0008
2
= 1.248 kN/m .
3
Equivalent density = 1.28/0.015 = 83.21 kN/m .
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2.5 Other masses

a) Mass of ladder :-

Ladder elements weight per unit meter

Member Nos./ meter L Total L Wt/m Total wt/Ldr Total wt/Ldr

(m) (m) Kg kN kN
DB20 3.33 1 3.333 2.47 0.08
Pipe 60.5x3.2 3.33 2.4 8.000 4.52 0.35 0.55
Pipe 76.3x3.2 2 1 2 5.77 0.11

We assign the ladder weight as 0.55 kN/m to the whole chimney

b) Mass of stiffeners:-

Sample calculation of stiffeners at level of 1m from the base =

(6 − 0.9)
Outside diameter of chimney at level 1m from base = 6 − x1 = 5.936m
80

Inner diameter of chimney = 5.936-(2x0.015) = 5.906m

Size of wall stiffener at 1m level = 250mm x 10mm thick

Inside diameter of ring = 5.906 – (2x0.25) =5.406m

No. of stiffener plate at that level = (π x 5.906)/1 =19 nos.

π 3
Volume of ring = (5.906 2 - 5.406 2 ) x 0.01 =0.0444 m
4
3
Total volume of stiffener plate = ½ x 0.25 x 0.25 x0.01 =0.00312 m

Total weight of stiffeners + ring = (78.5 x0.044) + (78.5 x 0.00312) = 3.69 kN

Similarly we calculate the weight of stiffeners at each level and take the average for each element of height
5m and assign the same in the STAAD model.
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Stiffener weight distribution

b) Mass of platforms:-

We calculate the weight of platforms by considering that each panel of every platform is similar and
consists of the same elements, as shown in table below

Level Pl No Pipe Tl Length Wt wt/panel Checkered Plate Plate wt Total wt per panel Panel Total wt
m (m) Kg/m volume /panel m3 Kg Kg Nos. KN
42.7x3.2mm 1.75 2.29 4.0075
10 1 60.5x3.2mm 7.24 4.25 30.77 0.00304 23.864 65.57 19 12.510
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
20 2 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 17 8.537
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
30 3 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 14 7.040
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
40 4 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 12 6.042
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
50 5 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 10 5.043
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
60 6 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 8 4.045
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
70 7 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 6 3.047
76.3x3.2mm 1.2 5.77 6.924
42.7x3.2mm 1.75 2.29 4.0075
80 8 60.5x3.2mm 7.24 4.25 30.77 0.00304 8.208 49.91 4 2.049
76.3x3.2mm 1.2 5.77 6.924
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3 Static wind load

Basic wind speed is taken as 37m/s.
[1]
Referring to Indian Code IS: 875 (Part 3) – 1987 , we take
K1 = 1.06, K3 = 1.0.
Wind loads are then calculated as follows.

EL OD K2 Vz pz pstatic
(m) (m) (m/s) (kPa) (kN/m)
80 1.080 1.14 44.79 1.20 0.91
75 1.463 1.14 44.53 1.19 1.22
70 1.845 1.13 44.26 1.18 1.52
65 2.228 1.12 43.97 1.16 1.81
60 2.610 1.11 43.65 1.14 2.09
55 2.494 1.10 43.31 1.13 1.96
50 2.813 1.09 42.93 1.11 2.18
45 3.131 1.08 42.51 1.08 2.38
40 3.450 1.07 42.05 1.06 2.56
35 3.769 1.06 41.52 1.03 2.73
30 4.088 1.04 40.91 1.00 2.87
25 4.406 1.02 40.19 0.97 2.99
20 4.725 1.00 39.30 0.93 3.07
15 5.044 0.97 38.16 0.87 3.09
10 5.363 0.93 36.56 0.80 3.01
5 5.681 0.93 36.56 0.80 3.19
0 6.000 0.93 36.56 0.80 3.37

This load is applied as piece-wise linear load on the beam elements as shown below.
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4 Dynamic wind
[2]
From our earlier analysis , we note the first mode natural period of vibration is:
Ti = 0.964 sec

ξi = Ti x Vb / 1200
= 0.03

For dynamic
influence,
ξi = 2.61
ν= 0.63

Considering the first mode shape,

Dist.
j/k EL Mode Mass Y2ik . Mk mk Yik .Pst,k . mk ηij Pdyn,ij Load
2
(m) ordinate (kg) (m/s ) (kN) (kN/m)
1 80 1 1257.0 1257.0 0.570 3032.6 2.56 5.32 1.064
2 75 0.87751 2757.6 2123.4 0.578 3466.5 2.24 10.24 2.049
3 70 0.75876 3800.2 2187.8 0.585 3691.4 1.94 12.21 2.441
4 65 0.64654 4165.8 1741.4 0.593 3732.2 1.65 11.40 2.280
5 60 0.54271 5254.1 1547.5 0.600 3299.3 1.39 12.07 2.414
6 55 0.44823 5517.4 1108.5 0.613 2842.3 1.15 10.47 2.094
7 50 0.3635 6839.7 903.7 0.625 2586.3 0.93 10.52 2.105
8 45 0.28856 7152.8 595.6 0.638 2271.1 0.74 8.74 1.747
9 40 0.22325 8477.9 422.5 0.650 1919.1 0.57 8.01 1.602
10 35 0.16726 8568.4 239.7 0.675 1580.9 0.43 6.07 1.213
11 30 0.12019 9992.8 144.4 0.700 1232.8 0.31 5.08 1.017
12 25 0.08161 10258.6 68.3 0.725 895.5 0.21 3.54 0.709
13 20 0.05106 12142.9 31.7 0.750 588.9 0.13 2.62 0.525
14 15 0.02807 12022.3 9.5 0.790 337.9 0.07 1.43 0.286
15 10 0.0122 15732.4 2.3 0.830 156.9 0.03 0.81 0.162
16 5 0.00298 13613.9 0.1 0.830 40.5 0.01 0.17 0.034
17 0

The dynamic loads are applied on the chimney model as shown below.
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5 Analysis results
The analysis results are obtained in the form of axial force and bending moment values at each level.

Maximum deflection at the top for combined static and dynamic wind = 172.02mm

6 Design checks
6.1 Deflection check

Max. deflection at the top = 172.017 mm

Permissible deflection = H/200
= 400 mm. OK
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6.2 Deflection check

Corrosion allowance is taken as 5 mm as per IS: 6533 Table 1.

Effective shell thickness = 10mm

6.3 Stress check

EL OD Area Z From STAAD analysis fa = P/A fb = M/Z Combined he/D Permissible
(m) (mm) (mm2) (mm3) P M (MPa) (MPa) stress stress
(kN) (kN.m) (MPa) (MPa)
80 900.0 14058.6 3.13E+06 2.0 0.0 0.1 0.0 0.1 0.0 99
75 1218.8 19065.5 5.76E+06 25.3 26.0 1.3 4.5 5.8 4.1 99
70 1537.5 24072.5 9.19E+06 56.2 121.3 2.3 13.2 15.5 6.5 99
65 1856.3 29079.4 1.34E+07 96.7 310.7 3.3 23.2 26.5 8.1 99
60 2175.0 34086.3 1.84E+07 140.9 604.4 4.1 32.8 36.9 9.2 99
55 2493.8 39093.2 2.43E+07 195.7 1007.2 5.0 41.5 46.5 10.1 99
50 2812.5 44100.1 3.09E+07 253.2 1516.9 5.7 49.1 54.8 10.7 99
45 3131.3 49107.0 3.83E+07 324.9 2133.5 6.6 55.7 62.3 11.2 99
40 3450.0 54113.9 4.65E+07 398.5 2857.6 7.4 61.4 68.8 11.6 99
35 3768.8 59120.8 5.56E+07 485.1 3687.6 8.2 66.4 74.6 12.0 99
30 4087.5 64127.8 6.54E+07 572.6 4620.8 8.9 70.7 79.6 12.3 99
25 4406.3 69134.7 7.60E+07 674.0 5653.6 9.7 74.4 84.2 12.5 99
20 4725.0 74141.6 8.74E+07 780.9 6782.6 10.5 77.6 88.1 12.7 99
15 5043.8 79148.5 9.96E+07 903.7 8003.5 11.4 80.4 91.8 12.9 99
10 5362.5 84155.4 1.13E+08 1025.2 9311.4 12.2 82.7 94.9 13.1 99
5 5681.3 89162.3 1.26E+08 1166.7 10701.2 13.1 84.7 97.7 13.2 99
0 6000.0 94169.2 1.41E+08 1302.9 12173.2 13.8 86.3 100.2 13.4 99

Hence, the shell is found to be safe.

6.4 Check for base plate/ foundation bolts

The concrete below the base plate is modelled along with foundation bolts as an RCC section, and
analysed for combined vertical load and bending moment as follows:
2
Grade of concrete = 173 kg/cm = 17.6 MPa.
This is cylinder strength, so the corresponding cube strength is approximately 22.04 MPa.
[4]
The modulus of elasticity is then :
E = 5000 × fck = 23475 MPa.

From STAAD analysis, at the base,

P = 1302.9 kN
M = 12173.2 kN.m

The section is analysed using a working stress analysis program. The stresses in concrete and steel
(foundation bolts) are obtained as follows:
Maximum concrete stress = 2.73 MPa – OK for concrete grade 22 MPa.
Maximum steel stress = 73.52 MPa – OK for bolt.
Force in bolt = 73.52 × π / 4 × 20 2 = 23.1 kN.
3
Bond stress for 800mm long bolt = 23.1× 10 = 0.46 MPa.
π × 20 × 800
From IS: 456, permissible bond stress for M20 concrete is 0.8 MPa > 0.46, OK.
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Check for base plate bending/ shear

190.4 mm

23.1 kN

PL 23.1× 0.1904
M≈ =
8 8
= 1.1 kN.m
The resisting section is 75mm wide x 30mm thick.
M 1.1× 10 6 × 6 97.7 MPa < 165 MPa [5], OK
σb = = =
Z 75 × 30 2

23.1× 10 3 1
τ= × = 5.13 MPa <100, OK.
2 75 × 30
Hence, the base plate is found to be safe.

6.5 Check for piles

From STAAD, load at the top of the ring wall is as follows:
P = 1302.9 kN
H = 302.8 kN
M = 12173.2 kN.m

Self weight of ring wall = π x 6 x 0.3 x 0.6 x 25 = 84.8 kN

2
Self weight of pile cap = 11 x 1.2 x 25 = 3630.0 kN
2
Soil on pile cap = 11 x 0.3 x 18 = 653.4 kN

Total load at base of pile cap = 5671.1 kN

Moment at base of pile cap = 12173.2 + 302.8 x (0.6 + 1.2) = 12718.2 kN.m

No. of
x piles Σx2
5 5 125
2.5 5 31.25
0 5 0
-2.5 5 31.25
-5 5 125

312.5

Maximum/minimum force on pile is

P M⋅ x
F= ±
N ∑ x2
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5671.1 12718.2 × 5
= ±
25 312.5
Pmax = 430.3 kN > 30 t pile capacity, FAIL
Pmin = 23.4 kN > 0, no uplift

The pile is found to fail for the above load.

6.6 Check for pile cap

Maximum force in pile from above = 430.3 kN.
Bending moment at the face of the ring wall = 430.3 x 5 x (5-3.15)
= 3980.3 kN.m
Shear = 430.3 x 5 = 2151.5 kN

For M20 concrete and fy = 300 MPa,

Q = 1.101, j = 0.881, σst = 168 MPa.

Given overall depth of 1200mm, clear cover of 40mm,

Effective depth d = 1200 – 40 – 20 – 10 = 1130mm.

Moment of resistance
2 2
MR = Qbd = 1.101 x 11000 x 1130
= 15465 kN.m > 3980.3, OK.

M
Reinforcement required =
σ st ⋅ j ⋅ d
3980.3 × 10 6 2 2
Bottom = = 23799 mm = 2163.5 mm /m
168 × 0.881× 1130
2
Provided reinforcement = T20 @ 150 c/c = 2094 mm /m, FAIL.

Check for shear:

pt = 0.185
τc = 0.19 MPa – IS 456 Table 23.
2151 .5 × 10 3
τv = = 0.17 MPa < 0.19, OK.
11000 × 1130

7 Conclusion
Stack structure and foundation have been checked for added loads due to strakes. The stack structure,
foundation bolts and base plate are found to be safe and serviceable. However, the foundation is found
to be overloaded. The capacity of pile is inadequate. Also, the reinforcement in the pile cap is inadequate
in bending.

Remedial measures will have to be undertaken immediately.

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8 References

Sr. No. Title

1 IS: 875 (Part 3) – 1987
2 ICS design report No. 230/E/DN-01
3 IS: 6533 (Part 2) – 1989
4 IS: 456 – 2000
5 IS: 800 – 1984
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Annex. A – STAAD input file

STAAD PLANE CHIMNEY
START JOB INFORMATION
ENGINEER DATE 21-Apr-18
END JOB INFORMATION
UNIT METER KN
JOINT COORDINATES
1 0 0 0; 2 0 5 0; 3 0 10 0; 4 0 15 0; 5 0 20 0; 6 0 25 0; 7 0 30 0;
8 0 35 0; 9 0 40 0; 10 0 45 0; 11 0 50 0; 12 0 55 0; 13 0 60 0;
14 0 65 0; 15 0 70 0; 16 0 75 0; 17 0 80 0;
MEMBER INCIDENCES
1 1 2; 2 2 3; 3 3 4; 4 4 5; 5 5 6; 6 6 7; 7 7 8; 8 8 9; 9 9 10;
10 10 11; 11 11 12; 12 12 13; 13 13 14; 14 14 15; 15 15 16; 16 16 17;
DEFINE MATERIAL START
ISOTROPIC STEEL
E 2e+008
*Equivalent density to account for rock wool and Al cladding as well.
DENSITY 83.21
END DEFINE MATERIAL
MEMBER PROPERTY INDIAN
1 PRIS ROUND STA 6 END 5.681 THI 0.015
2 PRIS ROUND STA 5.681 END 5.363 THI 0.015
3 PRIS ROUND STA 5.363 END 5.044 THI 0.015
4 PRIS ROUND STA 5.044 END 4.725 THI 0.015
5 PRIS ROUND STA 4.725 END 4.406 THI 0.015
6 PRIS ROUND STA 4.406 END 4.088 THI 0.015
7 PRIS ROUND STA 4.088 END 3.769 THI 0.015
8 PRIS ROUND STA 3.769 END 3.45 THI 0.015
9 PRIS ROUND STA 3.45 END 3.131 THI 0.015
10 PRIS ROUND STA 3.131 END 2.813 THI 0.015
11 PRIS ROUND STA 2.813 END 2.494 THI 0.015
12 PRIS ROUND STA 2.494 END 2.175 THI 0.015
13 PRIS ROUND STA 2.175 END 1.856 THI 0.015
14 PRIS ROUND STA 1.856 END 1.538 THI 0.015
15 PRIS ROUND STA 1.538 END 1.219 THI 0.015
16 PRIS ROUND STA 1.219 END 0.9 THI 0.015
CONSTANTS
MATERIAL STEEL ALL
SUPPORTS
1 FIXED
LOAD 1 GRAVITY LOADS
SELFWEIGHT Y -1
MEMBER LOAD
*Mass of ladder
1 TO 16 UNI GY -0.55
*Masses of stiffeners
1 UNI GY -3.86
2 UNI GY -3.64
3 UNI GY -3.42
4 UNI GY -3.2
5 UNI GY -2.98
6 UNI GY -1.74
7 UNI GY -1.6
8 UNI GY -1.47
9 UNI GY -1.33
10 UNI GY -1.19
11 UNI GY -0.59
12 UNI GY -0.51
13 UNI GY -0.44
14 UNI GY -0.36
15 UNI GY -0.28
*Masses of platforms
JOINT LOAD
3 FY -12.51
5 FY -8.537
7 FY -7.04
9 FY -6.042
11 FY -5.043
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13 FY -4.045
15 FY -3.047
17 FY -2.049
LOAD 2 LOADTYPE Wind TITLE STATIC WIND
MEMBER LOAD
16 LIN Y -1.22 -0.91
15 LIN Y -1.52 -1.22
14 LIN Y -1.81 -1.52
13 LIN Y -2.09 -1.81
12 LIN Y -1.96 -2.09
11 LIN Y -2.18 -1.96
10 LIN Y -2.38 -2.18
9 LIN Y -2.56 -2.38
8 LIN Y -2.73 -2.56
7 LIN Y -2.87 -2.73
6 LIN Y -2.99 -2.87
5 LIN Y -3.07 -2.99
4 LIN Y -3.09 -3.07
3 LIN Y -3.01 -3.09
2 LIN Y -3.19 -3.01
1 LIN Y -3.37 -3.19
LOAD 3 LOADTYPE Wind TITLE DYNAMIC WIND
MEMBER LOAD
16 UNI GX 1.064
15 UNI GX 2.049
14 UNI GX 2.441
13 UNI GX 2.280
12 UNI GX 2.414
11 UNI GX 2.094
10 UNI GX 2.105
9 UNI GX 1.747
8 UNI GX 1.602
7 UNI GX 1.213
6 UNI GX 1.017
5 UNI GX 0.709
4 UNI GX 0.525
3 UNI GX 0.286
2 UNI GX 0.162
1 UNI GX 0.034
LOAD COMB 4 COMBINATION LOAD CASE 4
1 1.0 2 1.0 3 1.0
PERFORM ANALYSIS
FINISH