Design Memo of Storage Yard-panipat

DOCUMENT NO

DOCUMENT NO.2006-PANIPAT-DM-001

JAYPEE CEMENT GRINDING UNIT PANIPAT PACKING PLANT & TRUCK LOADING PLATFORM

DESIGN MEMO

1.0 INTRODUCTION

1.1The Packing Plant and Truck loading plant comprises three packers and seven unloading bays. The total system is supported on 72 RC columns having outer dimensions of 62.0 m x 54.0 m in plan and floors at different EL.+3.00m + 5.50 m, +, + 7.90 m, + 11.50 m, 15.20 m, 18.40 m, 21.40 m and 30.0 m

1.2 This volume presents design of piles, pile caps and design of columns and beams of different floors.

2.0 LAYOUT

All three packers are supported at EL. +7.90 m level and its feeding bin supported at El. +15.20 m level. Bag filter supported at EL. +18.40 m level and its handing arrangement supported from EL. +34.0m level.

From + 5.50 m level cement bags are feeding into a truck which are resting at ground level.

Empty bags are stored in at EL. + 11.50 m level and handling from EL. +18.40 m level through crane

3.0 CODES, STANDARDS & SOFTWARE

The following codes, standards & software have been used in the design:

IS 456-2000Code of Practice for Plain and Reinforced Concrete

SP 16-1978Design Aids to IS: 456

SP 34-1987Handbook on Concrete Reinforcement and Detailing.

IS 875 (part-3)-1987Code of Practice for Design Loads (Other than

Earthquake) for Buildings and Structures part-3

Wind Load

IS 1893(part-1)-2002Criteria for Earthquake resistant design of

structures, part 1 - General provisions and buildings,

IS 13920-1993Ductile detailing of reinforced concrete structures

subjected to seismic forces

IS 800 1984

Code of practice for general construction in steel

STAAD/Pro 2004

Text book of REINFORCED CONCRECETE, Limit State Design by

Dr. Ashok K. Jain

Text book of REINFORCED CONCRETE DESIGN by S.N. Sinha

4.0 MATERIAL SPECIFICATION

4.1Material

Concrete

:M25 / A20 Grade

Reinforcement:Fe 415 Grade

5.0 INPUT DATA

5.1a)EEL INDIA LIMITED PANIPAT: 04148, JHCP--- Annexure - 1:

Packer

= 120 KN

Storage Bin

= 600 KN

Electrical Hoist loadin empty-

Bags godown

= 30 KN

b)Seismic zone=IV (as per IS 1893-2002)

c)Wind velocity=47 m/sec (as per IS 875-1987)

6.0 GEOMETRY

The geometry of the structure is as follows

6.1 Beams

Different sizes of beams have been used; the various sizes are as follows:

1500 X 800

1200 X 600

1200 X 500

1000 X 500

1000 X 400

900 X 500

900 X 400

800 X 500

800 X 400

700 X 400

500 X 300

400 X 300

6.2 Columns

Column sizes are as follows

a. Column - 1000 X 1000

b. Column - 800 X 800

c. Column - 600 X 600

d. Column - 500 X 500

7.0 DESIGN LOADS

7.1 Dead load

a. Self weight of structure

b. Material load + Equipment load = 11269.0 KN

7.2 Live load

a. Live load of 500 kg/sqm considered at all floors.

7.3Wind Load

Wind load in two horizontal directions i.e., X and Z directions considered separately.

Vb=Basic wind speed = 47 m/sec (as per IS 875 (part 3)-1987)

K1=Probability factor (risk coefficient) = 1.07 (Table-1)

K2=Terrain, lt & structure size factor = 1.03 at +34.0 m LVL (Table-2)

K3=Topography factor = 1.00

Design wind Pressure=Pz=0.6 Vz2 (cl 5.4 of IS 875 (part 3))

Design wind speed=Vz=Vb. K1. K2. K3Since the building is having cladding on all faces, so wind load is taken on the nodal points considering effective areas for the calculation of wind force.

Wind pressure for different heights

HEIGHTWIND PRESSURE (KN/m2)

5.5 M1.46

7.90 M1.46

11.50 M1.48

15.20 M1.56

18.40 M1.64

21.90 M1.70

30.0 M1.87

7.4

Seismic loads

Seismic zone- V (as per IS 1893 (Part-I))

Horizontal seismic coefficient=Ah=

Z =Zone factor

=0.24 (Table-2)

I=Importance factor=1.5 (Table-6)

R=Response reduction factor = 5.0 (Table-7)

Sa/g=1.00

Ah=(0.24/2) x (1.5/5) x 1.00=0.036

Response spectrum analysis is performed by STAAD. This analysis is performed for three directions X, Y & Z. Spectral combinations are done by CQC (complete quadratic combination) method.

Values corresponding to 5% damping for spectrum corresponds to medium soil sites are provided in STAAD input.

Average response acceleration coefficient calculated for the time periods corresponding to STAAD analysis and also for empirical formula as per cl: 7.6.1 of IS 1893-2002. Base shear factor was enhanced as per cl: 7.8.2 of IS 1893-2002. Details of calculations are given below

Time period from empirical formula, Ta = 0.075 x h0.75

= 0.075 x 300.75

= 0.96

Sa/g = 1.41 (as per cl: 6.4.5 of IS 1893-2002)

Time period from STAAD= 1.69

Sa/g = 0.80 (as per cl: 6.4.5 of IS 1893-2002)

Enhanced Base shear factor = 0.036 x 2.10 = 0.0756

8.0 SUPPORT CONDITIONS

The piles are modeled along with the structure, the end bearing of pile is taken care by providing pin support at the ends and for the friction of the pile different spring constant have been taken along the height

Soil Springs:

Column

Pile Cap

12 m

Liquefaction Zone

18 m

1 m

1 m

The horizontal modulus of sub grade reaction is (Refer J. Bowles Eq. 9-10 Page 504)

Ks = As + Bs Zn

Z = Depth of Interest below ground

As = constant for either horizontal or vertical members

Bs = coefficient for depth variation

n = exponent to give Ks the best fit

Substituting

As = Area x (80xFOSxBC)

= (0.5x0.8)(80x2.5x10) = 800 Ton/m

And n =1

Ks = As + Bs ZnWhere Bs = C Nq Sq

C = 80 (corresponding to = 12 mm settlement)

submergedm3As per MeyerhofNq = etantan 2(45 + /2)

Sq = 1

For = 30o

Nq = 18.38

Bs = C Nq Sq

Bs = 80x0.8x18.38x1 = 1176.32

For 800 mm dia pile:

K 0.0 = 800 + 1176.32x0.0X0.8 = 800

(Ton/m)K 0.5 = 800 + 1176.32x0.5X0.8 = 1270.5

K 1.0 = 800 + 1176.32x1.0X0.8 = 1741.0

K 1.5 = 800 + 1176.32x1.5X0.8 = 2211.5

K 2.0 = 800 + 1176.32x2.0X0.8= 2682.1

K 2.5 = 800 + 1176.32x2.5X0.8 = 3152.6

K 3.0 = 800 + 1176.32x3.0X0.8 = 3623.2

K 3.5 = 800 + 1176.32x3.5X0.8 = 4093.6

K 4.0 = 800 + 1176.32x4.0X0.8 = 4564.2

K 4.5 = 800 + 1176.32x4.5X0.8 = 5034.7

K 5.0 = 800 + 1176.32x5.0X0.8 = 5505.2

K6 = 1600 + 1176.32x6.0X0.8 = 7246.3

K7 = 1600 + 1176.32x7.0X0.8 = 8187.4

K8 = 1600 + 1176.32x8.0X0.8 = 9128.5

K9 = 1600 + 1176.32x9.0X0.8 = 10069.5

K10 = 1600 + 1176.32x10X0.8= 11010.5

K11 = 1600 + 1176.32x11X0.8 = 11951.6

K12 = 1600 + 1176.32x12X0.8 = 12892.6

K13 = 1600 + 1176.32x13X0.8 = 13833.7

K14 = 1600 + 1176.32x14X0.8 = 14774.7

K15 = 1600 + 6176.32x15X0.8 = 15715.8

K16 = 1600 + 1176.32x16X0.8 = 16656.8

K17 = 1600 + 1176.32x17X0.8 = 17597.9

K18 = 1600 + 1176.32x18X0.8 = 18539.0

K19 = 1600 + 1176.32x19X0.8 = 19480.0

K20 = 1600 + 1176.32x20X0.8 = 20421.1

K21 = 1600 + 1176.32x21X0.8 = 21362.0

Group Efficiency:

The Converse Labarre equation is (refer J. Bowles Eq. 18-1 page 1009)

Where m n and are no. of rows, columns D and dia of pile and tan 1(D/s)

E g = 1 [m (n-1) + n(m-1) ]

90 mn

(1)For 6 group of piles:

E g = 1 18.4[3(2-1) + 2(3-1)]

90x2x3E g = 73.2 %


E g = 1 18.4[2(2-1) + 2(2-1)]

90x2x2E g = 80%


E g = 1 18.4[3(2-1) + 2(3-1)]

90x2x3E g = 73.2 %


E g = 1 18.4[1(2-1) + 2(1-1)]

90x2x1E g = 95.0 %

(5)For single pile:

E g = 1 18.4[1(1-1) + 1(1-1)]

90x1x1E g = 100 %

As per test results Capacity of 800 dia pile (Normal Case) = 195 Tons

Capacity of 800 dia pile (Liquefaction Case) = 175x1.25 = 218.75 TonsFor determining number of piles requirement, unfactored support reaction is taken for different supports. The STAAD output for support reaction is as follows:

SUPPORT NO.SUPPORT REACTION (KN)

143863.6

156030.76

165794.21

174126.38

182492.7

192465.64

202464.18

222474.62

232297.16

275049.68

288441.73

298546.06

306160.36

314075.9

324080.69

334054.05

354310.24

363915.28

405204.97

418338.83

428037.63

435489.3

443204.3

453150.12

463378.51

483282.3

493054.5

524746.94

536824.71

546184.71

554399.33

561756.99

571697.58

581902.25

601392.57

611307.83

642602.57

654040.11

663476.16

672138.36

682078.79

692098.03

701081.31

72811.79

73535.16

761823.63

771476.32

781419.77

791198.29

80868.8

82667.07

83479.66

84789.26

85751.28

86580.57

139032462.73

139064133.76

139093399.8

139122061.49

13915990.84

139162143.41

139173199.07

139182174.61

142461018.02

15123415.45

15124289.03

15127396.98

15128286.06

15131240.56

15132318.65

15133314.27

15134237.2

Based upon this we can find out the number of piles required at each support by using capacity of 800 mm dia pile as 1950 KN (for normal case).

Therefore, for different supports, numbers of piles required are as follows:

SUPPORT NO.NO. OF PILES REQUIREDNO. OF PILES PROVIDED

141.981333333SILO RAFT

153.092697436SILO RAFT

162.9713897444

172.1160923083

181.2783076922

191.2644307692

201.2636820512

221.2690358972

231.1780307692

272.589579487SILO RAFT

284.329092308SILO RAFT

294.3825948726

303.1591589744

312.0902051283

322.0926615383

332.0793

352.2103794873

362.0078358973

402.669215385SILO RAFT

414.276323077SILO RAFT

424.1218615386

432.8150256414

441.6432307693

451.6154461543

461.7325692313

481.6832307693

491.5664102563

522.434328205SILO RAFT

533.499851282SILO RAFT

543.1716461544

552.2560666673

560.9010205132

570.8705538462

580.9755128212

600.7141384622

610.6706820512

641.3346512822

652.0718512822

661.7826461543

671.0965948722

681.0660461542

691.0759128212

700.5545179492

720.4163025641

730.2744410261

760.9351948722

770.7570871792

780.7280871792

790.6145076921

800.4455384621

820.3420871791

830.2459794871

840.4047487181

850.3852717951

860.2977282051

139031.2629384622

139062.1198769233

139091.7434871793

139121.0571743592

139150.5081230771

139161.0991846152

139171.6405487182

139181.1151846152

142460.5220615382

151230.2130512821

151240.1482205131

151270.2035794871

151280.1466974361

151310.1233641031

151320.1634102561

151330.1611641031

151340.1216410261

9.0

LOAD COMBINATIONS AND LOAD FACTORS

The load combinations considered s per IS 875 and IS 1893. The following load factors considered for corresponding load combinations in design:

Load CombinationsLoad Factor

Dead load + Live load1.5

Dead load + 50% live load + EQ load1.2

Dead load + EQ load1.5

Dead load + Live load + Wind load1.2

Dead load + Wind load1.5

Dead load + Material load + EQ load1.5

10.0

ANALYSIS

The followings procedure is adopted for analysis

a. STAAD/Pro 2004 software used in analysis.

b. Dimensions along centre line considered.

c. Analysis carried out as per load combinations, as stated in para 8.0. above, and columns & beams will be designed for worst combinations of bending moments & axial loads using provision of IS 456-2000.

12.0

DESIGN OF PILES AND PILE CAPS

DESIGN OF PILESSIX PILE GROUP

Considering Critical piles, the maximum percentage of reinforcement as per STAAD output is 2.24 %

FOUR PILE GROUP


THREE PILE GROUP


TWO PILE GROUP


SINGLE PILE CASE


Reinforcement provided: 2.88 % in 800 mm dia pile

5600

PILE CAP DESIGN

12.2 FIVE PILES GROUP

Critical Column No. 1612

Maximum design axial force,

Pu=4414.40 kN

Mz=22.64 kN-m

Mx=2686.52 kN-m

Size of Pile cab = 5.6 x 3.6

Using,

P=

=

=882.88 ( 559.69 ( 2.69

P1=882.88 559.69 +2.69

=325.88 kN

P2=882.88 + 559.69 2.69

=1439.88 kN

P3=882.88 + 559.69 + 2.69

=1445.26 kN

P4=882.88 559.69 2.69 =320.5 kN

Maximum moments at the face of the column

=(1439.88 + 1445.26) x 1.1

=3173.65 kN-m

Equating,M = 0.138 fck bd23173.65 x 106=0.138 x 25 x 5600 x d2

d=405.299 mm

Provided depth=1500 mm (total)( O.K.

For Area of Steel

=

= 0.44

Percentage of reinforcement required as Pc

SP 16=0.127% > 0.12% (Minimum reinforcement)

Check for One Way Shear

For one-way shear check, shear will be taken at d distance from the face of the column

(2800 1000 600 1415=-205 mm

Since section d (effective depth) is coming outside the c.g. of load points, so no one way shear check is required.

Check for Punching Shear

deff=1415 mm

Total periphery at distance of d/2

=2 X ((1415 + 1000) + (1415+2000))

=11660 mm

Punching stress=

= 0.214 N/mm2

< 0.25

< 0.25

< 1.25 N/mm2

(OK

Area of Steel

Since percentage of reinforcement as per moment is grater than minimum reinforcement. Therefore, provide required area of steel

=0.127%

=

x 1415 x 1000

=1797.05 mm2/m

Spacing of 25 dia. bars = x 1000 = 174.7 mm c/c

Provide 25 ( @150 mm c/c at bottom

Also provide 16 ( @150 mm c/c at top

5600

PILE CAP DESIGN

12.2 FOUR PILE GROUP


Maximum design axial force,

Pu=2195.34 kN

Mz=691.21 kN-m

Mx=2370.83 kN-m

Size of Pile cab = 5.6 x 3.6

Using,

P=

=

=728.84 ( 493.92 ( 82.29

P1=728.84 493.92 + 82.29

=317.21 kN

P2=728.84 + 493.92 - 82.29

=1140.47 kN

P3=728.84 + 493.92 + 82.29

=1305.05 kN

P4=728.84 493.92 - 82.29 =152.63 kN

Maximum moments

=(1140.47 + 1305.05) x 1.1

=2690.1 kN-m

Equating,M = 0.138 fck bd22690.1 x 106=0.138 x 25 x 5600 x d2

d=373.16 mm


For Area of Steel

=

= 0.373


SP 16=0.113% < 0.12% (Minimum reinforcement)


For one-way shear check, shear will be taken at d distance from the face of the column

(2800 1000 600 1415=-205 mm



deff=1415 mm


=2 X ((1415 + 1000) + (1415+2000))

=11660 mm

Punching stress=

= 0.133 N/mm2

< 0.25

< 0.25

< 1.25 N/mm2

(OK

Area of Steel

Since percentage of reinforcement as per moment is less than minimum reinforcement. Therefore, provide minimum area of steel

=0.12%

=

x 1415 x 1000

=1698 mm2/m

Spacing of 25 dia. bars = x 1000 = 184.9 mm c/c

Provide 25 ( @150 mm c/c at bottom

Also provide 16 ( @150 mm c/c at top

PILE CAP DESIGN

12.4 TWO PILE GROUP


Maximum design forces for column,

Pu=2593.44 kN

Mz=1358.83 kN-m

Mx=191.24 kN-m

Using,

P=

=

P1=1296.72 566.18

=730.54 kN

P2=1296.72 + 566.18

=1862.9 kN

Maximum moments

=1862.9 X 0.7

=1304.03 kN-m

Equating,M = 0.138 fck bd21304.03 x 106=0.138 x 25 x1200 x d2

d=561.23 mm


For Area of Steel

=

= 0.88


SP 16=0.261% > 0.12% (Minimum reinforcement)


For one way shear check, shear will be taken at d distance from the face of the column

(2100 1000 1110=-10 mm



deff=1110 mm


=2 x ((1200) + (1110+2000))

=8620 mm

Punching stress=

=0.27 N/mm2

< 0.25

< 0.25

< 1.25 N/mm2

(OK

Area of Steel

Since percentage of reinforcement as per moment is less than minimum reinforcement. Therefore, provide minimum area of steel

=0.261%

=0.261 x 1200 x 1200 / 100 = 3758.4 mm2/m

Spacing of 32 dia bars = (804 / 3758.4 x 1200) = 256.7 mm

Provide 32 ( @ 200 mm c/c at bottom

Also provide 16 ( @ 125 mm c/c at top

13.0 EFFECTIVE LENGTH FACTORS FOR PILES AND COLUMNS

FOR PILES:

PILE CAP

9.8 M

ELZ/ELY=14.8/9.8 = 1.51

5.0 M

ELZ/ELY=14.8/0.5 = 29.6

15.20 M

FOR COLUMNS:

Effective length factors have been taken for the columns between floor 5.50 m and 11.50 m floor

ELZ = 11.50/6.0 =1.9166

6.0 M

ELZ = 11.50/5.5 = 2.09

5.50 M

Elz factor of 1.9166 for column no. 749 750 738 751 755 767 768 769 756 757 758 745 746 747 759 760 748 735 736

Elz factor of 2.090 for column no. 359 360 350 361 363 373 374 375 364 365 366 355 356 357 367 368 358 347 348

3600

3600

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Design Memo of Storage Yard-panipat

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