Master of Engineering in Civil (Structures)

Design of Economical Bunker
A
SEMINAR REPORT ON
DESIGN OF ECONOMICAL BUNKER
SUBMITTED TO SHIVAJI UNIVERSITY KOLHAPUR
IN PARTIAL FULFILLMENT OF THE DEGREE
MASTER OF ENGINEERING IN CIVIL (STRUCTURES)
BY
Mr. AJINKYA SHRIKANT DIXIT
UNDER THE GUIDANCE OF

Prof. Dr.V.G. KHURD
DEPARTMENT OF CIVIL ENGINEERING

Sou. Sushila Danchand Ghodawat Charitable Trusts
SANJAY GHODAWAT GROUP OF INSTITUTIONS

Gate No. 583 to 585, A/P. Atigre, Taluka. Hatkanangale, Dist. Kolhapur- 416118, Maharashtra
2015-16
Dept Of Civil Engg.,SSDGCTS SANJAY GHODAVAT ROUP OF INSTITUTIONS
Page 1
CERTIFICATE
This is to certify that the seminar report entitled

Submitted by
Mr Ajinkya Shrikant Dixit
under the supervision of Prof./Dr/ V.G. KHURD and it is submitted towards the partial
fulfillment of the requirement of Shivaji University Kolhapur for the award of Master of
Engineering in Civil ( Structures)
Seminar Guide
(Prof/Dr/ V.G. Khurd)
(Dr
Raikar)
HOD
Director
(Dr S.M. Shiyekar)
Page 2
ACKNOWLEDGEMENT
It is a great pleasure for me to acknowledge the assistance & contribution of

number of individuals who helped me in successful completion of this seminar report on
First & foremost I wish to express my deep sense of gratitude towards my
guide Prof. Mr.V.G. Khurd & H.O.D. Dr. Mr.S.M. Shiyekar for their valuable &
enthusiastic guidance.
I also express my thanks to all teaching & non teaching staff of civil
engineering department who helped me directly or indirectly in completion of this
seminar report.
Ajinkya S. Dixit
Page 3
INDEX
chapter name
list of figures
list of tables
Abstract
Chapter :1
1.1
1.2
1.3
1.4
1.5
1.6
Chapter : 2.0
Chapter :3.0
Chapter :4.0
Chapter :5.0
Title
Page no
II
III
07
Introduction
What is bunker?
08
General characteristics
Objective of investigation
Scope of investigation
Methodology
Design consideration
a)design of vertical wall
b) design of hopper bottom
Design example
Cost comparison
Conclusion
Reference
09
09
09
0
10
11
13
15
25
28
29
List Of Tables
Page 4
Sr No
1
2
3
4
5
Title
Table No 1 (L/B=1)
Table No 2 (L/B=1.2)
Table No (L/B=1.4)
Table No 4 (L/B=1.6)
Table No 5 (L/B=2)
Page No
23
23
24
24
24
List of figures
Figur
Title
e no.
Page
no.
Page 5
1.
2
3
4
5
6.1
6.2
6.3
6.4
6.5
Difference between bunkers and silos

Pressure on wall
Design example figure

Wall section subjected to B.M. (M)and pull (T)
Reinforcement detail of bunker
Cost comparison fig. (a/b=1)
Cost comparison fig. (a/b=1.2)
Cost comparison fig. (a/b=2)
08
12
15
17
22
25
26
26
27
27
ABSTRACT
Bins are used by a wide range of industries to store bulk solids in quantities ranging from
a few tones to over one hundred thousand tones. A bin is an upright container for the storage of
bulk granular materials. Shallow bins are usually called as bunkers and deep bins are usually
called as silos. If the depth and breadth of a bin are such that the plane of rupture meets the
surface of the material, before it strikes the opposite side of the bin, it is called a shallow bin or a
bunker. Hopper of bins is four sloping slabs. Bunkers are made from many different structural
materials. They can be constructed of steel or reinforced concrete and may discharge by gravity
Page 6
flow or by mechanical means. Steel bins range from heavily stiffened flat plate structures to
efficient unstiffened shell structures. They can be supported on columns, load bearing skirts, or
they may be hung from floors. Bins with flat bottom are usually supported directly on
foundations.
Reinforced concrete is an ideal structural material for the building of permanent bulkstorage facilities for dry granular like fillings. Initially concrete storage units are economical in
design and reasonable in cost. Concrete can offer the protection to the stored materials, requires
little maintenance, is aesthetically pleasing, and is relatively free of certain structural hazards
(such as buckling or denting).
Page 7
Page 8
Page 9
Page 10
Page 11
Page 12
Page 13
Page 14
1.1 INTRODUCTION
Bunkers and silos are structures meant for storing materials like cement, coal,
wheat, broken stone clinkers etc. A bunker is shallow structure in which the plane of rupture of
the material stored meets the surface of the stored material before meeting the opposite side of
structure. See the below figure .The angle of rupture may be taken at
90 +
2
with the
horizontal ( is the angle of response)
Page 15
Figure no 1.Difference between bunkers and silos
Silos are generally circular in cross section .for self cleansing and for emptying it is supported on
a number of column, through a ring beam .its bottom height is fixed in a such way that truck can
pass its underneath. It is covered with shallow spherical or conical dome or with a beam and slab
type flat roof with suitable man hole
The stored material exerts pressur on side of bin. this pressure varies during the filling and
emptying processes and also with the location of discharging hole.
1.2 GENERAL CHARACTERISTICS

Concrete storage units can be designed and built in any shape and size to fit the site or the
process for which they are required. They can be poured monolithically by the use of sliding
forms when the walls are high, in single lifts when they are low, and in rapidly following lifts of
fixed forms when they are of moderate height.
Page 16
1.3 OBJECTIVE OF THIS INVESTIGATION

The main objective of the investigation reported herein is to identify the most economical
size of bunkers to store for a given volume of material.
1.4 SCOPE OF THE INVESTIGATION

The volume of bunkers is varied from 100 m3 to 200 m3. The material to be stored is
taken as bituminous coal, having an angle of internal friction of 35o and unit weight of 8kN/m3.
For storing a given volume of material, the effect of the ratio of height to lateral dimension on
the total cost has been studied in depth. The provision of IS: 4995(Part1)-1974 (Criteria for
design of Reinforced Concrete Bins for Storage of Granular and Powdery Materials), IS:
4995(Part II)-1974 (Criteria for design of Reinforced Concrete Bins for Storage of Granular and
Powdery Materials), and IS: 456-2000(Code of Practice for Plain and Reinforced Concrete) are
made use of whenever required. Concrete grade of M20 and steel of Fe 415 grade are used
throughout the investigation for design of bunkers.
1.5 METHODOLOGY:
All the designs have been based on the recommendations of I.S 4995 -1974 and I.S 456
2000 codes. Estimation of cost of bunkers and its supporting structures are done by using
Microsoft excel.
1.6 DESIGN CONSIDERATION:

The design process for bunkers is of two types functional and structural, functional
design must provide for adequate volume, proper protection of the stored materials, and
satisfactory methods for filling and discharge. Structural considerations are stability, strength and
Page 17
control (minimizing) of crack width and deflection. Loads to be considered include the
following:
1. Dead load of the structure itself and items supported by the structure.
2. Live Load forces are taken based on the type of material stored.
Bin design procedures consist of four parts as follows:
i. Determine the strength and flow properties of the bulk solid.
ii. Determine the bin geometry to give the desired capacity, to provide a flow pattern with
Acceptable flow characteristics and to ensure that discharge is reliable and predictable.
Specialized mechanical feeder design may be required.
iii. Estimate the bin wall loads from the stored material and other loads such as wind,
ancillary equipment, thermal, etc.
iv. Design and detail the bin structure.
Before the structural design can be carried out, the loads on the bin must be evaluated.
Loads from the stored material are dependent, amongst other things, on the flow pattern, the
properties of the stored material and the bin geometry while theme thuds of structural analysis
and design depend upon the bin geometry and the flow pattern. The importance of Stages I and ii
of the design should not be underestimated. Simplified rules for the functional design of bins and
for estimating wall loads are given in IS 4995-1974.
1.6 a) Design of vertical wall

The lateral pressure p exerted by filled material on wall is given by Rankine formula
p=
cos cos 2cos 2

h cos
cos + cos 2cos 2
Page 18
Where
= unit weight of material stored
h= depth measured from top of stored material
= angle of surcharge
= angle of repose
The above pressure acts parallel to the top surface of the retained material. Hence the horizontal
pressure is given by
ph
p cos
h cos
cos cos 2cos 2

cos + cos 2cos 2
Maximum angle of surcharge is naturally equal to angle of repose, which is equal

to . In such case,
ph
h cos 2 = h cos 2
If the top surface is horizontal,

ph
=0
1sin
1+sin
Thus the wall is subjected to triangular load increasing with the depth. The boundary
conditions are free edge at top and continuous at the other three edges. One can use table 3 of IS
code 3370-part
IV
for the analysis. Since height of wall is less. Usually, it is treated as a
horizontal continuous beam and hence moments are calculated using the following formulae:
Page 19
Figure no. 2 Pressure on wall
Corner moment
MA= MB= MC= MD=
ph
2
2
12 [ L + B LB
Hence +ve moment at center of long walls AB and CD

2
ph L ph
L2+B2 LB
[
8
12
And at Centre of short walls AD and BC
ph B 2 ph
2
2
L +B LB
[
8
12
Pressure in short wall transfer direct tension to long wall. Hence direct tension in long wall
=
ph B
2
Similarly, direct tensile force on short wall

=
ph L
2
Page 20
The walls may be designed for axial tension and moments
1.6 b) Design of hopper bottom:

This is sloping bottom subjected to 1) Direct tension and 2) bending moment
1. Direct tension in hopper bottom
Referring to the figure
W= total weight of material and self-weight of hopper bottom
If is the slope of hopper bottom, the tension caused by w is given by
T = sin W
T=W cosec
2. bending moment
sloping slab acts as a continuous closed form slab supported at sloping edges .The design
is made for the strip at Centre of slope and same and the same is provided throughout let h be
the height of material stored from this central strip and l be its span consider the forces on a unit
length of strip
Vertical downward pressure on the strip = h cos
Horizontal pressure on the strip = p h sin
2
2
Normal pressure on the strip p
h cos + h sin
n=
If self-weight of sloping slab is Ws , then
Page 21
Its normal component
= Ws cos
Total normal pressure
Then, maximum ve moment =
2
2
q = h cos + h sin + Ws cos
q l2
12
q l2
And maximum + ve moment= 24
Edge beam
Top edge beam is provided to accommodate attachment of conveyor supports. It also
accommodates the reinforcement in the wall behaving as deep beam. The nominal beam size is
300 600 mm with nominal reinforcement of 4 bars of 25mm provided.
Column and footings
The vertical load from bins and horizontal wind pressure on bins are to be considered in
the design of column and bins.
Page 22
2.0 DESIGN EXAMPLE
Figure no. 3 Design example
Volume of bunker =100m3

Dimension of bunker:
Adopt a bunker size 5.35x5.35x2.5m with the depth of 1.2m hopper bottom.
Page 23
Height of surcharge
a
= 2 x tan
a
= 2 x tan35
=1.87m.
Check for volume:
1
a b h
Volume of surcharge (V1) = 3
V1=17.5m.
Volume of cylindrical portion (V2) = a b h.
V2= 5.3 55.352.5
=71.42m.
1
Volume of hopper bottom portion (V3) = 3 (ab+c +
ab +c)
1
= 3 (5.35x5.35+
5.355.35 +0.5
V3=11.35m.
Total Volume (V)=100.27m 100m.
As per IS 4995(part 1)-1974, table 1, the density of bituminous coal is 8kN/m. And angle of
repose is 35.
Design of Side walls:

Horizontal working pressure
p = whcos
= 8 5.35 cos(35)
p=28.71kN/m
Assume the thickness of side wall(t) =230mm.

Effective span =5.35+0.23=5.58m.
L=B
Maximum bending moment at corners is
Page 24
M=p (L+B-LB)/12
= p (L)/12
= (28.71x5.35)/12
=68.47kNm.
Ultimate design moment, Mu=1.5x68.47
=102.72kNm.
Direct tension in wall,
T=pB/2 (for longer wall)
T=pL/2 (for shorter wall)
T=28.71x (5.35/2)
=76.79kN.
Ultimate direct tension in wall, Tu
Tu=1.5x76.79=115.18kN.
Providing a cover of 30mm,
Assume the thickness of side wall (t) =230mm.
Providing effecting depth (d) = t
cover
=230-30=200mm.
Figure no. 4 wall section subjected to bending moment M and pull T
Distance between reinforcement of slap, x=85mm.

Net design moment = Mu-Tu X
Page 25
=102.72-(115.18x0.085)
=92.93kNm.
Based on limiting moment resistance, effective depth required is given by
D=
MuTu x
0.138 fck b
102.72( 115.180.085 ) x 106

0.138201000
=183.5 mm
183.5mm <200mm.
Since the depth provided is more. The section is under reinforced. Hence the area of steel
required is,
Mu=0.87fyAstd {1-Ast.fy/b.d.fck}
92.93 10
=0.87415Ast183.5{1-Ast415/1000183.520}
Ast=1748.18mm.
Provide 12mm bars,

Ast=
Spacing S =
X 12=113
mm.
4
ast
X 1000
AST
113
X 1000
1748.18
=64.6mm
Hence provide 12mm bars at 50mm c/c.
Positive bending moment at Centre of span
M=p (L+B-LB)/24
= p (L)/24
=(28.71x5.35)/24
=34.23kNm.
Page 26
Design ultimate moment(Mu)=1.5x34.23=51.35kNm.

Net resultant moment = Mu-Tux
=51.35-(115.180.085)
=41.597kNm
Hence the area of steel required to resist the moment is
Mu=0.87fyAstd {1-Astfy/b.d.fck}
41.597106=0.87415Ast183.5{1-Ast415/1000183.520}
Ast=680.15mm2.
Provide 12mm bars,
X 12=113
ast= 4
mm.
Spacing S =
ast
X 1000
AST
113
X 1000
= 680
Provide 12mm bars at 150mm c/c
Distribution reinforcement = 0.12%bD
=0.00121000210
=252mm.
Use 8mm bars,
Ast =
x 8
4
=50.26mm.
ast
X 100
Spacing S= AST
=
50.26
252 X1000mm.
=199.46mm
Hence provide 8mm bars at 175mmc/c
Design of hopper bottom:

Page 27
Weight of bituminous coal (W) = V

=8100=800kN.
Weight of sloping hopper bottom (210mm) thick is computed as
40.2125
Wh=(5.35+0.5/2) (2.425+1.5)()
=287.16kN.
Total load on 4 walls
=800+287.16=1087.16kN
Total load on one wall
=1087.16/4=271.79kN.
Then tan =1.5/2.425
= tan 1 (1.5/2.425)=31.74 and cosec =1.9
Direct tension in sloping wall = WT.cosec
= 340.711.9
= 565.58 58 KN
Working tension per meter run = 647.349 /5.35
=120.9 KN/m run
Design of ultimate tension (Tu)= 1.5 120.9
= 181.499 KN
Area of reinforcement for resisting direct tension is,
Ast = (181.499103 ) / (0.87 415)
= 502.69mm
Spacing S = ast / Ast 100
= (120.9/502.69) 1000
= 240.45 mm
Provide 12mm bars @ 225 mm c/c in the direction of sloping faces
Ast = ast / s 1000
Ast = (120.9 / 225) 1000
= 537.3.2mm
Page 28
Normal component of coal pressure @ Centre of slab is,

Pn = w.hp [cos + cos2 . Sin ]
Where,
W = 8 KN/m
hp = [5.35 + (0.5 1.5 ) + (0.5 1.87) ]
hp = 6.95 m
= 37.07
& = 35
Pn = 8 6.95 [cos (37.07) + cos ( 35). Sin 37.07]
= 48.78 KN/ m
Working pressure = Pn = 848.78 KN/ m
Normal component due to weight of sloping slab,
= wd. cos
= 0.21 25 cos 37.07
= 4.19 KN / m
Total normal pressure P = Pn + wd. Cos
P = 48.78 + 4.19
P = 52.97 KN / m
Effective Design moment, L1 = ((5+0.5) / 2) + 0.21 = 2.96m
Maximum negative bending moment, M
= P. (L1+ B1-L1B1)/12
=p.L1/12
=52.972.962/12=38.67kNm
Ultimate design moment=1.538.67
=58kNm.
Limiting moment of resistance, Mu limit =0.138201000176.652.
=86.13kNm
=86.13kNm>58kNm.
Mu<Mulimit
The section is under reinforced section.
Page 29
58106=0.87415Ast183.5{1-Ast415/1000183.520}
Ast=985.15 mm .
Provide 12mm bars,
X 12=113
Ast= 4
mm.
Spacing S=
ast
X 1000
AST
985.15
x 1000=114.7 100
113

Maximum positive bending moment at centre is = P. (L1+B1 +L1B1)/12
= (52.972.7252)/12
=32.77kNm
Ultimate bending moment = 1.532.77
=49.17kNm.
Area of reinforcement steel required is
49.17106=0.87415Ast183.5{1-Ast415/1000183.520}
Ast=810.6mm.
Provide 12mm bars,
12=113
Ast= 4
mm.
Spacing (S) =
ast
X 1000
AST
810.6
1000=114.7 100
= 113
Page 30
Edge beams:
Provide edge beams of 300x635mm connecting the corner columns as the top and the junction of
vertical walls and sloping slab with 4 numbers of 25mm bars.
Page 31
3
Various sizes adopted for 100 m
VOLUME
100m
100m
100m
100m
VOLUME
100m
100m
100m
100m
VOLUME
100m
100m
100m
100m
storage by changing h/b and a/b ratio
H
2.5
4.3
5.8
7.1
TABLE NO 1
a/b ratio
h/b ratio
1
0.5
1
1.0
1
1.5
1
2.0
a
5.35
4.40
3.86
3.54
b
5.35
4.40
3.86
3.54
H
2.3
4.0
5.4
6.6
TABLE NO 2
a/b ratio
h/b ratio
1.2
0.5
1.2
1.0
1.2
1.5
1.2
2.0
a
6.00
4.90
4.30
4.00
b
4.90
4.10
3.70
3.30
H
2.4
4.0
5.1
6.30
TABLE NO 3
a/b ratio
h/b ratio
1.4
0.5
1.4
1.0
1.4
1.5
1.4
2.0
a
6.20
5.20
4.80
4.35
b
4.50
3.80
3.40
3.12
Page 32
VOLUME
100m
100m
100m
100m
VOLUME
100m
100m
100m
100m
H
2.2
3.5
4.9
5.90
TABLE NO 4
a/b ratio
h/b ratio
1.6
0.5
1.6
1.0
1.6
1.5
1.6
2.0
a
6.80
5.80
5.20
4.75
b
4.20
3.70
3.20
3.00
H
2.05
3.3
4.4
5.5
TABLE NO 5
a/b ratio
h/b ratio
2
0.5
2
1.0
2
1.5
2
2.0
a
7.60
6.60
5.90
5.50
b
3.80
3.30
3.00
2.70
3.0 COST COMPARISON OF R.C.C BUNKERS WITH VARIOUS H/B

RATIO
Rate of concrete: Rs4300 per m
Page 33
Rate of Steel: RS.58 per kgf.

Rate of Formwork+ wastage of concrete and steel +including other charges =17%
Graph which shows the cost comparison
230000
225388.45
225000
220000
213836.28
215000
210589.2
210000
208539.13
205000
200000
0.5
1.5
Figure no 5.1 cost comparison (a/b= 1)
Page 34
224000
222232.33
222000
219720.15
220000
220325.04
218000
216000
214000
212000
211032.75
210000
208000
206000
204000
0.5
1.5
Figure no 5.2 cost comparison (a/b= 1.2)

218000
215704.49
216000
214162.64
214000
212000
209566.62
210000
208000
206000
205605.19
204000
202000
200000
0.5
1.5

Page 35
224000
221651.86
222000
220946.95
220000
218018.76
218000
216000
215246.65
214000
212000
0.5
1.5
Page 36
248000
245605
246000
244000
242724.92
242000
239844.8
240000
238000
236000
234868.23
234000
232000
230000
228000
0.5
1.5
4.0 CONCLUSION
From the above Figures it is concluded that for storing Bituminous coal for volume of
100m3. The most economical h/b ratio of 0.5 and l/b ratio of 1 is found to be economical. As the
ratio of h/b ratio increases the total cost of construction of the storage structure also increases.
Page 37
5.0 REFERENCES
Bhavikatti.V (2008), Advanced Reinforced Concrete design, second edition, new age
international publishers, new delhi.

IS: 4995(Part1)-1974 (Criteria for design of Reinforced Concrete Bins for Storage of
Granular and Powdery Materials),

IS: 4995(Part II)-1974 (Criteria for design of Reinforced Concrete Bins for Storage of
Granular and Powdery Materials).

IS: 456-2000 (Code of Practice for Plain and Reinforced Concrete)
N. Karthiga Shenbagam, Mahesh., Loganayagan. S, N. V. Manjunath, A. S (September2014) Studies on Economical Design of Bunkers.International Journal of Advanced
Research in Computer Science and Software Engineering, referred page no. 417-429
N.Krishna Raju(2009), Advanced Reinforced Concrete Structuresthird edition,
O.P Jain and Jai Krishna, Plain and reinforced Concrete fourth edition, Volume-II.
Page 38
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Design of Economical Bunker