A4-P 13.0 en

Structural design and erection
General requirements
Approved date: 11 July 2013

Created by: OMa
Approved by: KimN
Doc. No.
749500-13.0

749500-13.0
List of contents:
Page:
0.
Revision historic ........................................................................................... 3
General ....................................................................................................... 4
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
Loads
Purpose ........................................................................................................
Standards .....................................................................................................
General Arrangement drawings .......................................................................
Sequential progression ...................................................................................
Estimated information ....................................................................................
On hold ........................................................................................................
Buyer supplied equipment ..............................................................................
Release status ...............................................................................................
Update of drawings ........................................................................................
Overlapping plant departments .......................................................................
for calculation of civil structures .............................................................
4
4
4
4
4
4
4
5
5
5
6
2.1
2.2
2.3
2.4
2.5
General information ....................................................................................... 6

Units of measure ........................................................................................... 6
Natural loads ................................................................................................ 6
Dynamic loads exerted by the equipment ......................................................... 7
Load categories ............................................................................................. 7
2.5.1
Dead load (permanent loads) .............................................................. 7
2.5.2
Live loads, normal (variable loads) ....................................................... 7
2.5.3
Live loads, extraordinary .................................................................... 8
2.5.4
Natural loads ..................................................................................... 8
2.5.5
Special loads ..................................................................................... 8
2.6
Deck and roof ............................................................................................... 9
2.7
Special load requirements for roofs without access ........................................... 10
2.8
Stairs and landings .......................................................................................10
Execution of support structure ....................................................................... 10
3.1
Settlements ................................................................................................. 10
3.2
Concrete strength ......................................................................................... 10
3.3
Surface reinforcement ................................................................................... 10
3.4
Alignment and grouting ................................................................................. 11
3.5
Bolt holes .................................................................................................... 13
3.6
Final grouting ............................................................................................... 13
Various specifications ................................................................................... 13
4.1
Water seepage ............................................................................................. 13
4.2
Covering and flashing.................................................................................... 13
4.3
Drain ..........................................................................................................14
4.4
Floors and walls............................................................................................ 14
4.5
Stairways and walkways ................................................................................ 14
4.6
Exit doors ....................................................................................................15
4.7
Steel or concrete structures ........................................................................... 15
4.8
Constructional elements (beams, columns, braces, etc.) .................................... 15
4.9
Tolerances ................................................................................................... 15
Erection corrections...................................................................................... 16
2/16
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

749500-13.0
0 Revision historic
Version 12.0
5-Mar-08
Section 0 Revision historic added
Section 1.2 Standards added
Section 1.7 Buyer supplied equipment added
Section 1.8 Release status. Editorial changes
Section 1.9 Update of drawings. Editorial changes
Section 2.8 Stairs and landing added
General: the equipment supplier and the supplier have been substituted by Seller
Version 13.0
11-Jul-13
General: Seller changed to Supplier

General: Loads changed with equipment loads
Section 2.3 Natural loads. Editorial changes
Section 4.4 Floors and walls. Misfit phrases included
3/16

749500-13.0
General
1.1
Purpose
This instruction manual is to provide the civil designer, the civil contractor and the
erection contractor with general requirements regarding civil design and erection of
the equipment. Specific requirements are stated in plant layout documentation and
instruction manuals.
1.2
Standards
Reference by Supplier to any international or national Standard does not incur
an obligation on Supplier to provide any recipient, reader or user of the
documentation with samples or copies of the said Standard(s).
Hence, any recipient, reader or user of the documentation is expected at his
own cost to obtain necessary knowledge of the contents of any of the
Standards referred to.
1.3
General Arrangement drawings
General Arrangement drawings (GA drawings) serve to show the project
arrangements with an indication of installation dimensions, conditions of space,
access and loadings, etc. Loads and detailed dimensions are specified on GA
drawings or Outline and Load drawings (OL drawings).
1.4
Sequential progression
The GA drawings are developed through sequential progression and are issued in
different stages of completion.
1.5
Estimated information
On GA drawings some equipment measurements and loads may be estimated. This is
indicated by a cloud marked with E. The cloud may cover the equipment or
localised areas, where the detailed information is not available. Such drawings may
still be used for the ongoing civil design work.
1.6
On hold
Some information in the drawings may be on hold, which is indicated by a cloud
marked with H. The cloud may cover some items of equipment or localised areas,
where the detailed information is not available or needs verification by the Buyer or
other parties. Such drawings may still be used for the ongoing civil design work with
exception of the on hold areas.
1.7
Buyer supplied equipment
Buyer supplied equipment (BSS), e.g. screw conveyors, secondary filters etc,
is estimated in size, if the equipment is a natural part of the arrangement.
Detailed information regarding hole sizes, platform sizes, loads, reference to
Outline and Load Drawing etc., are not given by Supplier.
If water pipes, compressed air pipes, cables, etc. are Buyer supply, trenches
and holes in floors are not shown by Supplier.
Buyer supplied equipment is usually shown as being Supplier supply i.e.
Supplier equipment.
In case the documentation shows equipment, lining, etc. supplied by Buyer
the measurements and loads have to be informed by the Buyer.
4/16

749500-13.0
In case equipment or the operational conditions at a later stage is changed

by Buyer the impact on the structure has to be considered by a civil
designer.
1.8
Release status
The release status of the GA drawings (e.g. Basic, Main, Detail) is not written on the
drawing. The release status is only described in the release note.
1.9
Update of drawings
Every time a GA drawing is updated, the revisions are shown encircled with clouds,
and the drawing is given a new version number for example 2.0. Minor version
numbers, for example 2.1, may be used for communication internally in Suppliers
organisation. These minor versions numbers are not forwarded to the Buyer
1.10 Overlapping plant departments
The department numbering follows the equipment rather than the physical
boundaries of the buildings. Therefore some GA drawings may show parts of other
departments where the equipment overlaps. In such cases, the GA drawing will show
the outline of the overlapping department(s) together with a reference to the
relevant department(s). In such cases the civil designer must cross-reference
between departments to find the required information and the civil designer must
take due consideration of these loads and other influences and restrictions.
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749500-13.0
Loads for calculation of civil structures

2.1
General information
The drawings state loads originating from the equipment as well as live loads on
decks, platforms, walkways, etc. For load categories, see sub-section 2.5.
In some cases the actual load data may not be available in due time. A higher
general floor replacement load might then be given for the area concerned (for
example for electrical panels or minor equipment).
Design the individual decks to withstand all the loads specified, i.e. loads from the
equipment as well as the uniformly distributed loads.
Apply load factors, safety system and partial coefficient according to applicable
codes and design norms.
The civil designer assumes full responsibility for compliance with all local regulations
and codes of practice.
2.2
Units of measure
The units applied are SI-units.
Elevations are in m, whereas other dimensions are in mm.
Loads are in N (Newton) or kN (kilo Newton).
2.3
Natural loads
Loads originating from external forces, e.g. wind load, snow load and seismic loads,
are not indicated on the drawings, but must be determined by the civil designer in
accordance with local regulations codes of practice and conditions.
When calculating natural loads assume, that expansion joints on machines and
ducts cannot transfer loads.
When calculating seismic loads, the assumption is to safeguard against major
structural failure and loss of life, but not to prevent damage nor to maintain function
of the equipment.
The civil designer is also required to evaluate and determine loads caused by
settlement, temperature stresses, etc.
Consult Supplier, if deflections or settlements of the civil structure are greater than
specified.
Fixtures (Foundation bolts, anchor plates) for the equipment fixed to the ground or
floors are designed for loads caused by wind, snow and seismic loads.
Supports and foundations must be designed in accordance with local regulations
codes of practice and conditions.
6/16

749500-13.0
2.4
Dynamic loads exerted by the equipment
a) For equipment subject to comparatively small dynamic loads, the dynamic loads
are specified as an equivalent additional static load (See sub-section 2.5).
b) For equipment subject to considerable dynamic loads (e.g. heavy-duty fans) the
individual load rates of the equipment are specified (dead load, live load and
dynamic loads).
c) The load rate applying to certain equipment will be specified as the total load (P)
of the equipment multiplied by factor (k). The specified factor (k) incorporates
dynamic loads and load variations.
Unless otherwise specified on the drawing, the load can be divided into a dead
load (permanent load) of 1 x P and a normal live load (variable load) of (k - 1) x
P.
Attention is drawn to the fact that in each individual case the civil designer assumes
full responsibility in respect of ensuring that the individual constructions are so
designed that vibrations and noise nuisances from the building structures are
eliminated in accordance with the local codes and regulations.
A minimum 20 % deviation from the dynamic frequency of the equipment and the
natural frequency of the load-carrying structures (incl. the mass of the equipment
and its foundation) is required.
2.5
Load categories
2.5.1 Dead load (permanent loads)
Dead load of equipment, lining and other well-defined installations (in terms of
both load and location).
The dead load is sub-divided as follows:
DL1 Dead load from equipment, etc.
DL2 Dead load from lining or insulation.
2.5.2 Live loads, normal (variable loads)
Normally occurring loads from e.g. plant operators, furniture and equipment,
traffic, material (stored, transported, occasional accumulations, dust, fillings,
etc.).
When a dynamic load is approximated to an additional static load, this additional
load, which stems from normally occurring conditions of impacts and vibrations, is
included in this load category. (See sub-section 2.4.a).
Normal live loads are sub-divided as follows:
LL1
Live load (per m, per m2 or as a point load) from plant operators,
furniture and equipment, stored or transported goods and materials.
(Normal operating conditions).
LL2
Material accumulations and similar conditions.
LL3
Traffic load. (As e.g. loads originating from trucks operating in stores,
loads from rolling materials handling devices, etc.).
LL4
Static additional load equivalent to a dynamic vibration or impact
load.
LL5
Dynamic vibration or impact load.
LL6
Explosion load and similar conditions.
LL7
Friction load originating from thermal expansions and contractions.
7/16

749500-13.0
2.5.3 Live loads, extraordinary
The loads only affect the construction transiently and only occur where extreme
operating conditions for the equipment or plant department are encountered.
Cases in point include explosions, falling objects or collisions.
Extraordinary live loads are sub-divided as follows:
EL1
Falling objects, shock impacts, etc.
EL2
Collision impacts, etc.
EL3
Extraordinary material accumulations, etc.
EL4
Explosion recoil loads, etc.
Additional information regarding explosion recoil load might be stated in the
drawings:
The duration of the pulse of explosion recoil loads in seconds [s].
tR
The impulse transmitted by the explosion recoil load [kNs].
IR
The assumption is that extraordinary live loads act simultaneously with the load
types DL1, DL2, LL1, LL2 and LL3, but not simultaneously with neither LL4, LL5,
LL6 nor LL7.
2.5.4 Natural loads
Reference is made to sub-section 2.3.
2.5.5 Special loads
In case of quite extraordinary load types, these will in each individual case be
specified and described on drawings.
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749500-13.0
2.6
Deck and roof
Levels are given to top of concrete or top of steel structure. However, for secondary
platform without equipment the level is to top of grating or embossed plate
(chequered plate).
The drawings specify the uniformly distributed live load as well as any live loads
acting as line or point loads.
If specific deck areas require designing for a higher live load than the remaining part
of the deck (uniformly distributed loads or point loads), this area will be marked on
the drawing, specifying the live load applying to that area.
All concrete decks and roofs must be designed to withstand the below-mentioned
single loads (P1 and P2) which are applied to the deck at random points. The single
loads, which may be considered as normal live loads, are not assumed to act
simultaneously nor coinciding with the live loads specified on the drawings for deck
and roof constructions.
Specified uniformly
distributed live load
Single
load
Single
load
Single
load
P1
P2
P3
kN/m2
kN
kN
kN
25.0
18.0
7.0
20.0
15.0
6.0
10.0
12.0
5.0
7.5
11.0
4.5
5.0
10.0
4.0
2.5
5.0
1.5
3.0
2.0
4.0
1.5
2.5
1.5
2.0
1.0
1.0
P1 is assumed to act over an area of 0.75 m x 0.75 m

9/16

749500-13.0
2.7
Special load requirements for roofs without access
Unless otherwise specified, it must be assumed that light roofs without access are
subjected to a uniformly distributed live load LL1 (dust) of 0.75 kN/m2 (horizontal
projection), whereas concrete roofs without access are assumed to be subjected to a
uniformly distributed live load LL1 (dust) of 1.0 kN/m2 (horizontal projection).
In connection with pre-fabricated concrete roofs and light steel roofs, the purlins
must as a minimum requirement be able to absorb a single load of 1 kN, applied at
random points and act simultaneously with LL1. Rafter constructions in workshops,
etc. must likewise be capable of absorbing a single load of 10 kN, applied at random
points to the underside of rafter and simultaneously with LL1.
2.8
Stairs and landings
If not otherwise stated the connecting stairs and landings have to be

designed for the same load as the evenly distributed load for the deck or
platform, where the stairway leads to. However max 5 kN/m2.
Execution of support structure

3.1
Settlements
If the equipment is supported by several supports, the supports must be executed so
that detrimental differential settlements are avoided.
In general the GA- or OL-drawings are specifying the maximum acceptable
settlement. If settlements, deflections or bendings of the structure due to poor soil
conditions, wind, earthquake etc. exceed the given figures, the Supplier must be
contacted for his approval.
Separate supports for gear units and motors must be executed to prevent differential
settlements from occurring between the support of the machine and the support of
the drive station.
If a number of silos are erected next to one another or in connection with other
buildings, the silo foundations must be executed so that following a maximum load
condition (full silo) no settlements occur having detrimental effects on the connecting
conveyors.
3.2
Concrete strength
Concrete used for the execution of support structures must have a 28-day cube
strength T 30 MN/m2, corresponding to a 28-day cylinder strength of C 25
MN/m2.
3.3
Surface reinforcement
Concrete support structure for kilns, mills, main gear units, crushers and other heavy
machinery must be executed with an appropriate surface reinforcement, however, as
a minimum 7 kg/m2.
When determining the reinforcement, account must be taken of the influences from
the equipment, including temperature loads.
Concrete supports for small-size equipment must be executed with appropriate
surface reinforcement, however, as a minimum 3.5 kg/m2.
The lateral face reinforcement of the concrete support must be carried to level where
it covers the construction joint between the first pour and grouting which is executed
after the equipment has been mounted. See Figs. 3.4a and 3.4b and sub-sections
3.4, 3.5 and 3.6.
10/16

749500-13.0
3.4
Alignment and grouting
The support heights are stated on the drawings with a level corresponding to the
underside of the equipment supporting surface.
Normal mounting means that the equipment must be aligned. Unless otherwise
specified, the equipment must be supported on the entire supporting face.
When equipment has small supporting faces, alignment plates must be used, if
required directly on to steel or concrete bases.
Gear unit and motor must always be supported by minimum 10 mm alignment irons,
taking account possible future replacement of gear unit and motor, which may have
minor dimensional deviations when supplied. Place the alignment irons between the
foundation blocks or the rails, if any, according to the instruction manuals.
When aligning equipment having large supporting faces, subsequently involving
grouting with concrete or mortar, the support must not be carried to the full height
during the initial pouring operation.
To ensure proper grouting under the entire supporting face, usually 100 mm are
required for large supporting faces, whereas small supporting faces require 50 mm.
In special cases is required non-shrinking mortar. The use of non-shrinking mortar is
specified in the applicable instruction manuals.
The grout thickness must be determined by the consulting civil engineering
company.
The contractor must consider to use templates in order to keep the tolerances
between multiple bolt for fixing the bolts during grouting.
The construction joint between first pour and the grout must be executed so that an
effective connection is established.
11/16

749500-13.0
Figs. 3.4a and 3.4b.

1.
Grout the holding down bolts here after coarse alignment of the equipment.
2.
Do not forget wedges or shims on either side of the bolt.
3.
Bend down the side face reinforcement.
4.
Spot welding, if required.
5.
Support height specified on drawings.
6.
Grout (50-100 mm) after fine alignment of the equipment.
7.
Support height without grout.
8.
In some cases it is required to embed the support frames. See specifications on

drawings.
When the equipment is attached to embedded plates, the plates must be inserted in
the formwork and support must be carried up to full height.
Supports for equipment requiring fastening with expansion bolts, stud anchors or
similar must be carried to the full height.
Some heavy equipment, e.g. preheater cyclones, is supported directly on the first
concrete pour. Grouting below the supporting surface can not be used due to friction
loads from heat expansions and extractions from the equipment. Tolerances of the
first pour are stated on the GA- or OL-drawings.
12/16

749500-13.0
3.5
Bolt holes
After the equipment has been mounted and aligned, grout the holding down bolts
freely suspended from the equipment. Use mortar or concrete having a minimum
strength as specified in sub-section 3.2.
Holding down bolt holes indicated on drawings by e.g. 100/M24 may be made round
having a diameter of 100 mm, or square with a side of 100 mm. M24 indicates that a
24 mm bolt must be grouted.
The hole must be made using corrugated steel or plastic moulds ensuring an
effective connection with the grout.
When the holding down bolts are to be grouted, the bolts must be degreased and be
absolutely free from oil. Remove water and impurities at the bottom of the holding
down bolt holes before grouting.
3.6
Final grouting
Having finally aligned the equipment and tightened up the holding down bolts, grout
or embed the equipment.
Use mortar or concrete having strength as specified in sub-section 3.2.
When proportioning mortar and concrete, use correctly graduated additives having
an adequate maximum stone size to ensure good placement properties. It may be
required to use special grouting mortars for particular applications.
For heavy equipment the sequence and number of groutings as well as the use of
non-shrinking mortar are described in the mechanical instruction manuals. These
manuals must be handed over to the contractor before the work commence.
Prior to grouting or embedment of the equipment, the parts to be grouted and
embedded must be degreased and cleaned.
Remove (chip off) any oil spillage, grease stains and impurities on the concrete in
the construction joint.
Embed the support flange only if it is shown on the drawings or required in the
instruction manuals.
Various specifications
4.1
Water seepage
Roofs must be constructed so as to avoid water accumulations and water seepage.
Holes in roofs for lead-in of machines and pipes to be made with a raised edge of
minimum 100 mm in order to prevent rainwater seepage. On completion of
mounting, the equipment must be provided with a cap, which is extended beyond the
raised edge.
Storey partitions, which also are roofs in a closed room, must be constructed so that
no water seeps into the room.
4.2
Covering and flashing
Coverings and flashings must be made to the extent shown on the GA drawings.
Coverings and flashings must be constructed to avoid water ingress and water
seepage. Openings in building fronts for ventilation or pressure relief from explosion
flaps must likewise be made as shown on the GA drawings.
Any deviations will be accepted only subject to prior arrangement with Supplier.
13/16

749500-13.0
4.3
Drain
Pits, basements, inspection trenches, etc. placed below ground level must be made
watertight and must be provided with pump sumps or water drainpipes discharging
into a permanent drainage system.
When carrying out the design and execution of drainpipes and drainage systems,
spillage of raw meal, clinker, cement, oil, petrol, etc. entering the drainage system
must be avoided.
Drains are required at water drain-off points.
Where equipment is placed at ground level, it must be inclined to ensure that
surface water is diverted.
Rain water must be drained away from the foundations and supports.
4.4
Floors and walls
Due consideration must be taken to the finish of surfaces of floors and walls in rooms
for oil, water, electrical equipment, etc. Tiles and painting to be considered due to
house keeping and resistance for water and oil.
Holes in floors for equipment passing through must be provided with a 100 mm high
surrounding edge and closed with a max remaining opening of 50 mm. For larger
openings hand railing may be provided.
Examples of "misfit":
Examples of holes that must be closed or otherwise ensured against personal
injures:
Mentioned "misfit" examples can be corrected by closure, surrounding edges and/or

hand railing:
4.5
Stairways and walkways
Safety guards to stairways, walkway, platforms, etc. to be made in compliance with
local safety and health regulations.
Openings in floors to be provided with toe plates or raised edges with a minimum up
stand of 100 mm and placed maximum 10 mm from the finished floor level.
The locations given for main stairways and stair flights are for guidance only.
However, the location of stairways and ladders for access platforms and equipment
is final and binding.
14/16

749500-13.0
If not otherwise stated in the contract permanent stairs and guardrails have to
conform to EN ISO 14122-3.
Example: The minimum headroom (vertical distance) for working platforms and
walkway, etc. is 2100 mm. The minimum headroom for stairs is 2300 mm. The
minimum clearance (perpendicular distance) is 1900 mm.
Guardrails must be provided if the vertical distance between two levels exceeds 500
mm.
4.6
Exit doors
Exit doors must be equipped with anti-panic bar opening system.
4.7
Steel or concrete structures
Indications of building construction for steel or concrete are for guidance only.
4.8
Constructional elements (beams, columns, braces, etc.)
The dimensions of constructional elements (beams, columns, etc.) are approximate.
It is the obligation of the civil designer to assess the indicated location of columns
and beams, choice of materials and enclosures, and in consultation with Supplier to
establish the most suitable structural system from a material optimisation point of
view but still ensuring a robust and flexible structural system which is easy to
manufacture and construct and which can be adjusted to the possible changes which
may be introduced by the Buyer and/or the authorities during the approval process.
Consult Supplier, if the final dimensions result in reduced space around the
equipment.
GA drawings do not specify stiffening braces in steel constructions. These must be
determined taking account of equipment, pipes, access conditions, maintenance and
service, etc.
Special requirements apply for buildings where inflammable dust can occur.
4.9
Tolerances
If GA or OL drawings does not specify any special tolerance requirements, the civil
contractor must ensure that the geometry of the finished buildings meets the
following requirements concerning maximum permissible tolerances:
General:
Plotting of main axes relative to
established superior plotting system
25 mm
Concrete constructions:
Position of construction elements relative
to plotted line system
15 mm
Cross sectional dimensions of

construction elements
+ 15 mm
Dimensions and position of holes and

recesses
10 mm
Position of grouted components
10 mm
Straightness of decks measured with 3metre straight edge
- 5 mm
+ 5 mm
15/16

749500-13.0
Steel constructions:
Distance between columns
3 mm
Deck elevations
5 mm
Dimensions and location of holes, etc.
5 mm
5 Erection corrections
Normal erection operations include the correction of minor misfits by moderate
amounts of straightening, shimming, reaming, chipping, cutting or grinding and the
drawing of elements into line using drift pins. Misfits which cannot be corrected by
the foregoing means or which require major changes in equipment configuration are
to be reported immediately to Supplier by the erection contractor, to enable Supplier
either to correct the misfit or to approve the most efficient and economic method of
correction to be implemented.
---o0o---
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Structural design and erection

Approved date: 11 July 2013

Structural design and erection

Revision historic ........................................................................................... 3

General information ....................................................................................... 6

Structural design and erection

General: Seller changed to Supplier

Structural design and erection

Buyer supplied equipment

Structural design and erection

In case equipment or the operational conditions at a later stage is changed

Structural design and erection

Loads for calculation of civil structures

Structural design and erection

Structural design and erection

Structural design and erection

P1 is assumed to act over an area of 0.75 m x 0.75 m

Structural design and erection

Stairs and landings

If not otherwise stated the connecting stairs and landings have to be

Execution of support structure

Structural design and erection

Structural design and erection

Figs. 3.4a and 3.4b.

Do not forget wedges or shims on either side of the bolt.

Bend down the side face reinforcement.

Spot welding, if required.

Support height specified on drawings.

Grout (50-100 mm) after fine alignment of the equipment.

Support height without grout.

In some cases it is required to embed the support frames. See specifications on

Structural design and erection

Structural design and erection

Mentioned "misfit" examples can be corrected by closure, surrounding edges and/or

Structural design and erection

Cross sectional dimensions of

Dimensions and position of holes and

Position of grouted components

Straightness of decks measured with 3metre straight edge

Structural design and erection

Dimensions and location of holes, etc.

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