Professional Documents
Culture Documents
5BA
ATUR
RAJA
A CEM
MENT
T PR
ROJEC
CT
(PL
LANT
T II)
S
STRUC
CTUR
RE CA
ALCUIIATIO
ON RE
EPORT
T
FOR
71-C
CEMENT SIILO (F
FOUN
NDATIION)
C
STR
RUCTURE CALCUIATI
C
ION REPOR
RT FOR
F175-CE
EMENT SIL
LO(FOUNDA
ATION)
B
A
0
Rev
199/08/2015
Date
W
WuLingyu
Prep. by
Songguiqianng
Chkd. By
Page
75 71 SC 001
F17
Rev
0
Table of Contents
1. Introduction ................................................................................................................................................... 1
1.1 General......................................................................................................................................................... 1
1.2Building description...................................................................................................................................... 1
2. Design criteria................................................................................................................................................ 3
2.1Design priciples and basis ............................................................................................................................ 3
2.2Design local conditions................................................................................................................................. 3
2.2.1Geological conditions ................................................................................................................................ 3
2.2.2Earthquake response acceleration .............................................................................................................. 5
2.2.3Wind pressure ............................................................................................................................................ 5
2.2.4 Weather condition ..................................................................................................................................... 5
2.3Design load ................................................................................................................................................... 5
2.3.1 Dead load .................................................................................................................................................. 5
2.3.2Live load .................................................................................................................................................... 5
2.3.3Chart of vertical load ................................................................................................................................. 6
2.3.4Wind load................................................................................................................................................... 8
2.3.5Seismic load ............................................................................................................................................. 12
2.3.6Stored material load ................................................................................................................................. 15
2.3.7Load combination .................................................................................................................................... 27
2.4Building material ........................................................................................................................................ 28
2.4.1Reinforcement ......................................................................................................................................... 28
2.4.2Concrete ................................................................................................................................................... 29
2.5Structure scheme ......................................................................................................................................... 29
2.5.1Foundation ............................................................................................................................................... 29
2.5.2Superstructure .......................................................................................................................................... 29
2.6 Structure calculation .................................................................................................................................. 29
3. 3Danalysis model(FEM) .............................................................................................................................. 30
4. Load sketch of the silo ................................................................................................................................. 32
5. Structure analysis ......................................................................................................................................... 33
5.1Effective modal masses ratio ...................................................................................................................... 33
5.2Base reaction............................................................................................................................................... 35
6.Foundation Design ........................................................................................................................................ 40
6.1Foundation dimension ................................................................................................................................ 40
6.2 Design of punching shear and shear reinforcement ................................................................................... 44
6.2 Design of flexural reinforcement ............................................................................................................... 48
6.2.1 Full silo ........................................................................................................................................... 48
6.2.2 Empty silo ....................................................................................................................................... 70
7. Inner Column Design ................................................................................................................................... 71
7.1Design internal force from FEM analysis result ......................................................................................... 71
7.2Design of inner column .............................................................................................................................. 74
8. Lower Silo Wall(t=350mm) Design............................................................................................................. 78
8.1Design vertical reinforcement..................................................................................................................... 79
8.2Design hoop reinforcement......................................................................................................................... 80
8.3Openings added reinforcement ................................................................................................................... 81
1. Introduction
1.1 General
This document is used for the foundation design of the cement silo workshop of Baturaja project.
The document is to show how the structures are calculated and designed,and it includes the below
parts:
1. Introduction
2. Design criteria
3. 3D analysis model(FEM)
4. Load sketch of the silo
5. Structural analysis
6. foundation design
7. Inner Column Design
8. Lower Silo Wall(t=350mm) Design
1.2Building description
The Cement silo have a storage capacity of 10400 ton and 9200 ton respectively.The silo is designed
to be circular in shape and consists of post tensionedpre-stressed walls above the silo bottom level
andnon pre-stressed wall below the silo bottom level which is rested on a ring shallow foundation.The
raft foundation thickness is 2000mm. The height and inner diameter of the cement silo are 51.00m and
18.00m respectively.Wall thickness of the cement silois considered as 350 mm over the bottom slab and
inner column down to the foundation,The silo roof is a flat RC floor with metal deck resting on the steel
beams. The calculations of the sheet roof will be submitted in a separate document .The bottom level of
the bottom slab is 16.00m and 19.5m respectively and the thickness of the bottom slab is 1500 mm. The
static and dynamic analysis of the cement silois performed by SAP2000.The analysis and design are
made according to the AMERICAN CODE.
The document is to show how the structures` foundation are calculated and designed.
The sketch of the silo structure as follows:
LayOut Plan
Plan0.000
2. Design criteria
2.1Design priciples and basis
1.Codes of practice and standards
(1)ASCE/SEI-7-10: Minimum Design Loads for Buliding and Other Structures.
(2)ACI313-97: Standard Practice for Design and Construction of Concrete Silos andStacking Tubes
for Stroring Materials (ACI313-97)and Commentary-ACI313R-97.
(3)ACI318-14: Buliding Code Requirements for Structural Concrete (ACI318-08)and Commentary.
2.Contract and minutes of meeting
(1) The provisions to civil and steel works in the contract.
(2) KICK OFF MEETING BTA II. Date:25-30 April,2015.
3. Geotechnical report
Binder-Soil Investigation Report for Baturaja II Project_April 2015(2015-04-30)
4. Reference drawings
Process drawings :
Structure drawings :
F175- 71SC-001~005
PT. Semen Baturaja proposed to construct the new Cement Baturaja Plant Project5000
TPDproduction line-II at Baturaja, the south Sumatra Province, Indonesia. Theproject closed to the
3
existing Cement Baturaja plant the 1st Line at north side. The overallEngineering Procurement and
Construction (EPC) to be contracted by SINOMA TianjinCement Industry Design and Research Institute
co., LTDTCDRI). An advanced for therequirements of geotechnical investigation works of the project,
SINOMA TCDRIinstructed PT. Soilens to perform soil investigation works of the proposed plant siteunder
the Contract No: F175(S)002.2.
3. Groundwater conditions
No groundwater was observed within 35m depth of the surface in any of the 78explorations drilling
conducted at the site. However, it should be noted that perchedgroundwater could develop in the future
due to changes in the site drainage or antecedentrainfall.
4. Corrosivity of the soil
4
Based on the water levels monitored and recorded during the field works, no water levelswere
observed within 35.42m in the boreholes. Therefore, there is no need to consider thecorrosiveness of
ground water to reinforcement and concrete.
2.2.2Earthquake response acceleration
The 0.2 sec. spectral response acceleration (Ss) is 0.52, and the 1 sec. spectral response acceleration
(S1) is 0.33.
2.2.3Wind pressure
As per the contract and the local regulation, all structures shall be designed to withstand wind
pressure resulting from the basic wind velocity v(at a height of 10m, with return period of 50 years). The
value of W0 should be:
Wo=0.4KPa;
2.2.4 Weather condition
Site conditions are tropical and humid for the whole of the year.
Normal max ambient temperature C 33
Normal min ambient temperature C 23
Average annual ambient temperature C 30
HumidityAverage 83%
Rainfall mm/month228 typical
Rainfall main season - November to April
2.3Design load
2.3.1 Dead load
1. Density of materials
lean concrete22 kN/ m3
reinforced concrete25 kN/ m3
brick masonryto be determined
steel78.5 kN/ m3
backfill18 kN/ m3
cement mortar20 kN/ m3
Bulk material(Cementl)16 KN/m
2. Utilitiesaccording to requirement
2.3.2Live load
1. Industrial concrete or steel floor in process buildings,
5
5 kN/m2
1.0 KN/ m
2.3.4Wind load
1.Wind load calculation will be according to ASCE7-10.
2.As per the ASCE7-10.,section6, The fundamental value of the basic wind velocity, v, is the
characteristic 3 second mean windvelocity, irrespective of wind direction and time of year, at 10 m above
ground level in open countryterrain with low vegetation such as grass and isolatedobstacles with
separations of at least 20obstacle heights.
Based on the definition of term ,v, in the ASCE code, and as per the contract ,the basic wind
velocity should be converted.
3. The calculation of wind load acting on silos follow the below steps:
10
11
2.3.5Seismic load
1. The calculation of the earthquake effects is in accordance with the ASCE7-10.
2. Design response spectrum
The 0.2 sec. spectral response acceleration (Ss) is 0.52, and the 1 sec. spectral response
acceleration (S1) is 0.33.
3.. Site class.
As per the Chapter 11&20 and Soil investigation, the site should classified as Site class C.
4. Site coefficient Faand
Fa
=1.31; Fv = 1.81
Where:
Ra: for concrete silo and kiln, Ra=3,Ie=1;
SDS=0.454/(Ra/Ie)=0.151; SD1=0.398/(Ra/Ie)=0.133
7: Design Response Spectrum. See Section 11.4.5
Gk , j :Dead load
Qk ,i : Live load
account.
2If the requirements specified in (1) cannot be satisfied(e.g. in buildings with a significant
contribution from torsional modes),the minimum number k of modes to be taken into account in a
spatial analysis should satisfy both the following conditions:
where:
SRSS method (Square Root of Sum of Square): Adopted when all relevant modal responses
may be regarded as independent of each other, and their period satisfy T j 0.9Ti .
CQC method (Complete Quadratic Combination): Adopted when the relevant modal responses
can not be regarded as independent..
For the anti-sesmic design of the project,the CQC method is recommended,take into account
the relation between the relevant modal reponses
10. The calculation of seismic load acting on silos follow the below steps:
14
15
16
17
18
19
20
21
22
23
24
25
26
2.3.7Load combination
1. The load combination will be as per theMinimum Design Loads for Bulidings and Other
StructuresASCE7-10;
2. Load combinations of the silo design
The load combination of the projectfor silo calculation are as followed: D dead
load ,Eearthquake effect ,Llive load, ,Lrroof live load,Wwind loadP- prestressing load,
PPm-material loadTtemperature load
1) Basic Combination(LRFD)
1U=1.4D
2U=1.2D+1.2P+1.6 Pm+0.5Lr
2aU=1.4D+1.2 P+1.4T+1.7 Pm+0.5LrACI313-97
3U=1.2D+1.2P+1.6Lr+Pm
4U=1.2D+1.2P+1.6Lr+0.8Wempty silo
5U=1.2D+1.0W +Pm +0.5Lr
6U=1.2D+1.0E+Pm
7U=0.9D+1.0Wempty silo
8U=0.9D+1.0Eempty silo
2) Serviceability limit states
The characteristic combinations
1U=D+P+ Pm+Lr+T
2U= D+P+0.5Pm+0.7W
The quasi-permanent combination
U=D+P+0.5Pm
3) Load combinations for determination of the size of the foundations or pile numbers. (ASCE
7-10,section2.4.1, as the soil report is done according to the ASTM)
1U= D+L+Pm
2U=D+0.6W
3D+0.75W+0.75Pm
27
40.6D+0.6W
5D+0.7E
6D+0.525 E+0.75Pm
70.6D+0.7E
2.4Building material
2.4.1Reinforcement
1. Reinforcement OriginIndonesian, comply with SNI07-2052 1997.
2.The reinforcement characteristic value of the yield strength
f yk =235Mpa(BJTP24),
f yk
=390Mpa(BJTS40), material partial coefficient s =1.15, the design value of reinforcement strength f yd =
BJTP24
D13D16D19D22D25D29D32BJTS40
5.Normal value of strength of prestressing tendon (Chinese type) shall be as follows(to be
determined):
Type
Normal Value of
Design Value of
Diameter
Strength of
Tensile Strength
(mm)
Prestressing
of Prestressing
Tendon(N/mm2)
Tendon(N/mm2)
8.6
1X3
Steel
strand
1X7
1860
1320
12.9
1960
1390
9.5
1860
1320
1960
1390
Design Value of
Crushing
Strength of
Prestressing
YoungsModulus
(x105N/mm2)
Tendon(N/mm2)
10.8
390
12.7
15.2
17.8
The 1X7 ,diameter 15.2 prestressing tendon shall be used tin the silo wall design.
28
1.95
2.4.2Concrete
1. The strength of the concrete should comply with chinese code.
2. The concrere quality used in the silo design is as follows:
Silo wall C40
Silo bottom slab and raft foundation C40
Silo roof slab C30
4. The Poisson ratio of concrete is 0.2
2.5Structure scheme
2.5.1Foundation
1. Shallow raft foundation shall be adopted in the silo foundation design.
2.5.2Superstructure
The silo is designed to be circular in shape and consists of post tensioned walls above the silo
bottom level non pre-stressed wall resting on a raft foundation .
29
3. 3Danalysis model(FEM)
30
31
Load sketch
Selfweight of the silo concrete has been taken into account by the sap2000 software.
Bulk material load used to calculate the pile foundation is Pvmax,the value is 300.041KN/mfor bottom slab
level 16.000. the value is 291.152KN/mfor bottom slab level 19.500.
Wind pressure acted on the silo wall is as follows
see 2.3.3
z
qp(z)
(m
(KN/m)
16/19.5-51
1.617
0-16/19.5
1.267
5. Structure analysis
5.1Effective modal masses ratio
1. Bottom slab level 19.500
The Full silo:
The sum of the effective modal masses for the modes taken into account >90% of the total mass of the
structure.
The Emptysilo:
33
The sum of the effective modal masses for the modes taken into account >90% of the total mass of the
structure.
2. Bottom slab level 16.000
The Full silo:
The sum of the effective modal masses for the modes taken into account >90% of the total mass of the
structure.
34
The Emptysilo:
The sum of the effective modal masses for the modes taken into account >90% of the total mass of the
structure.
5.2Base reaction
1. Bottom slab level 19.500
The Full silo:
35
The Emptysilo:
36
37
38
The Emptysilo:
39
6.Foundation Design
6.1Foundation dimension
1. Bottom slab level 19.500
40
41
42
43
44
45
46
V23kN/m
V23kN/m
47
ULS1.2D+1.6Pm-pfmax
48
49
50
ULS1.2D+1.6Pm-pvmax
ULS1.2D+1.0Pm-pfmax +1.0Ex
ULS1.2D+1.0Pm-pfmax+1.0Ey
5.Conclusion:
5-1:The bottom reinforcement:
Under the Silowall:
The most unfavourable load combination is 1.2 D+1.0Pm-pfmax+1.0Ey
Hoop bending
Radial bending
moment: M22=5463kNm/m
57
moment: M22=1850kNm/m
moment: M11=1997kNm/m
moment: M22=3383kNm/m
59
60
Between
moment: M11=3026kNm/m
moment: M22=2286kNm/m
61
R=3m:
The most unfavourable load combination is1.2 D+1.6Pmvmax+0.5Lr
Hoop bending
Radial bending
moment: M11=3125kNm/m
moment: M22=3118kNm/m
62
moment: M11=3805kNm/m
moment: M22=3877kNm/m
63
64
The 1#silo(the bottom slab level is 19.500)foundation flexual calculation process as follows.
The reinforcement see the drawings.
65
66
67
68
69
70
71
Axial force(KN)
The most axial compressive force of column is 14777.55KN.
72
74
75
As=19978mm
Choose 28D32(22517.6mm);
Reinforcement rario:
2.35%
Links: D13@200
C4(800x1000)
Required reinforcement :
As=18022mm
Choose 24D32(19300.8mm);
Reinforcement rario:
2.41%
Links: D13@200
76
As=17061mm
Choose 28D29(18494.6mm);
Reinforcement rario:
1.93%
Links: D13@200
C2(800x1000)
Required reinforcement :
As=14538mm
Choose 24D29(15852.5mm);
Reinforcement rario:
1.98%
Links: D13@200
77
Lower silo wall FEM Model for bottom slab level 16.00
78
Lower silo wall FEM Model for bottom slab level 19.50
8.1Design vertical reinforcement
For bottom slab level 16.00
The most unfavorable load combination:1.2D+1.6Pmpfmax,the internal force is as follows:
79
Ned=-5270KN/m
Choose 2D16@200(2011mm);
Reinforcement rario:
ok!
80
81
The maximum horizontal tensile force :2378KN/m at the bottom of the opening.
As=F11/fyd=2378KN/m /339.13MPa=7012.1mm
Need reinforcement: 16D29 (10568.32mm)
The hoop reinforcement of the lower silo wall(t=350mm) adopts 2D16@200. The opening height is
5050mm,Cutting-off reinforcement area is 5050mm/200mmx2x201.1mm=10055mm,so the top/bottom of the
opening need 0.6x10055mm(6033mm) at least. The choosed reinforcement area is satisfied.
82
The vertical reinforcement of the lower silo wall(t=350mm) adopts 2D16@200 The opening width is
4100mm,Cutting-off reinforcement area is 4100mm/200mmx2x201.1mm=4122.5mm,so the side of the opening
need 0.5x4122.5mm(2061.3mm) at least. The choosed reinforcement area is satisfied.
83
2.opening 2 (3500mmx4050mm)
The maximum horizontal tensile force :2413KN/m at the bottom of the opening.
As=F11/fyd=2413KN/m /339.13MPa=7118mm
Need reinforcement: 13D29 (8586.8mm)
The hoop reinforcement of the lower silo wall(t=350mm) adopts 2D16@200. The opening height is
4050mm,Cutting-off reinforcement area is 4050mm/200mmx2x201.1mm=8044mm,so the top/bottom of the
opening need 0.6x8044mm(4826.4mm) at least. The choosed reinforcement area is satisfied.
84
The vertical reinforcement of the lower silo wall(t=350mm) adopts 2D16@200 The opening width is
3500mm,Cutting-off reinforcement area is 3500mm/200mmx2x201.1mm=3019.25mm,so the side of the
opening need 0.5x3019.25mm(1508.25mm) at least. The choosed reinforcement area is satisfied
85