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Prepd
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This document is developed from Phase 2 Document No. 503406-0000-43EC-0001 Modification to Section 5.4

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TABLE OF CONTENTS
1.0

INTRODUCTION .................................................................................................................. 5

2.0

CODES, STANDARDS AND GOVERNMENT REGULATIONS ........................................... 5

2.1
2.2
2.3
2.4
2.5

Definitions ............................................................................................................................. 5
International Codes and Standards ....................................................................................... 5
Project Standard Specifications ............................................................................................ 7
Government Regulations ...................................................................................................... 8
Codes and Standards Conflicts ............................................................................................. 8

3.0

MATERIALS ......................................................................................................................... 8

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10

Material Certification ............................................................................................................. 8

Structural Steel ..................................................................................................................... 8
Bolts and Fasteners .............................................................................................................. 8
Anchor Bolts.......................................................................................................................... 9
Stanchion Packs ................................................................................................................... 9
Handrailing ............................................................................................................................ 9
Ladders ................................................................................................................................. 9
Floor and Platforms ............................................................................................................. 10
Stair Treads ........................................................................................................................ 10
Concrete ............................................................................................................................. 10

4.0

DESIGN AND FABRICATION DRAWINGS ....................................................................... 10

4.1
4.2
4.3
4.4
4.5

Structures Design ............................................................................................................... 10

Structural Design Calculations and Design Brief Content ................................................... 11
Deflection Limits.................................................................................................................. 12
Structural Steel Work Design .............................................................................................. 13
Concrete Work Design ........................................................................................................ 14

5.0

GENERAL DESIGN LOADS .............................................................................................. 16

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11

Dead loads (D.L.) ................................................................................................................ 16

Wind loads (W.L.) ............................................................................................................... 16
Imposed Loads (I.L.) ........................................................................................................... 17
Seismic Loads (S.L.) ........................................................................................................... 18
Thermal Load (T.L.) ............................................................................................................ 18
Crane Girders ..................................................................................................................... 19
Environmental Conditions ................................................................................................... 20
Combined Loads ................................................................................................................. 21
Loading Combinations ........................................................................................................ 21
Construction Loads ............................................................................................................. 21
Lifting Loads ....................................................................................................................... 21

6.0

FACTOR OF SAFETY ........................................................................................................ 21

6.1
6.2
6.3

Overturning ......................................................................................................................... 21
Sliding ................................................................................................................................. 21
Structural Stability ............................................................................................................... 23
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6.4

Flotation .............................................................................................................................. 23

7.0

SURFACE TREATMENT AND PAINTING ......................................................................... 23

8.0

STORAGE TANKS AND SILOS......................................................................................... 23

9.0

PIPE RACKS ...................................................................................................................... 24

9.1
9.2
9.3
9.4
9.5
9.6

Vertical Loads ..................................................................................................................... 24

Transverse Loads ............................................................................................................... 24
Longitudinal Loads .............................................................................................................. 25
Longitudinal Beams ............................................................................................................ 25
Intermediate Beams at tier levels ........................................................................................ 25
Transverse restraint guides ................................................................................................. 25

10.0

CLADDING ......................................................................................................................... 25

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INTRODUCTION
This criteria sets out the requirements for materials and procedures for the design of all
structural steel and reinforced concrete structures, including all foundations and
concrete slabs for Emirates Global Aluminium (EGA) projects, located at Al Taweelah,
Abu Dhabi, United Arab Emirates.

2.0

CODES, STANDARDS AND GOVERNMENT REGULATIONS

2.1

Definitions
The terms used in the Design Criteria are defined and shall be interpreted as follows:

2.2

API

American Petroleum Institute

ASTM

American Society for Testing and Materials

BS

British Standards

Client/ Owner

EMAL Aluminium Company Limited

Contractor

Contractor to EMAL that EPCM Contractor is managing on behalf

of the Client.

EEMUA

Engineering Equipment and Materials Users Association

EPCM Engineer

Engineer Representative of the EPCM Contractor managing on

behalf of the Client

EPCM Contractor

Contractor managing on behalf of the Client

ISO

International Standard Organization

SLII

SNC Lavalin International Incorporated

Vendor

Supplier of equipment and or material

BCSA.

The British Constructional Steelwork Association

International Codes and Standards

All materials, workmanship and practices for Phase 2 specific facilities shall be in
accordance with the latest issue of the international codes and standards where
applicable. Exceptions are noted below.

API Std 650

Welded Tanks for Oil Storage, Includes Addendum 1 and 2

API Std 653

Tank Inspection, Repair, Alteration and Reconstruction

ASTM A36 / A36M

Standard Specification for Carbon Structural Steel

BS 4-1

Structural Steel Sections. Specification for Hot Rolled Sections

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BS 2573

Rules for the Design of Cranes

BS 2853

Specification for the Testing of Steel Overhead Runway Beams

BS 3692

ISO Metric Precision Hexagon Bolts, Screws

and Nuts. Specification.

BS 4190

ISO Metric Black Hexagon Bolts, Screws and

Nuts. Specification.

BS 4320

Specification for Metal Washers for General Engineering

Purposes. Metric Series.

BS 4449

Steel for the Reinforcement of Concrete. Weldable Reinforcing

Steel. Bar, Coil and Decoiled Product.

BS 4592, parts 0-6

Flooring, Stair Treads and Handrails for Industrial Use.

BS 4933

Specification for ISO Metric Black Cup and Countersunk Head

Bolts and Screws with Hexagonal Nuts

BS 5395

Stairs. Code of Practice for the Design of Stairs with Straight

Flights and Winders.

BS 6180

Barriers in and about Buildings, Code of Practice

BS 7419

Specification for Holding Down Bolts

BS 7608

Guide to Fatigue Design and Assessment of Steel Products

BS EN 197-1

Cement. Composition, Specifications and Conformity Criteria

for Common Cements

BS EN 10025-1

Hot Rolled Products of Structural Steels. General Technical

Delivery Conditions.

BS EN 10025-2

Hot Rolled Products of Structural Steels. Technical Delivery

Conditions for non-alloy Structural Steels.

BS EN 10029

Hot-rolled Steel Plates 3 mm Thick or Above. Tolerances on

Dimensions and Shape

BS EN 10056-1

Specification for Structural Steel Equal and Unequal Angles.

Dimensions.

BS EN 10056-2

Specification for Structural Steel Equal and Unequal Leg

Angles. Tolerances on Shape and Dimensions

BS EN 10067

Hot Rolled Bulb Flats. Dimensions and Tolerances on Shape,

Dimensions and Mass.

BS EN 10210-1 & 2 Hot Finished Structural Hollow Sections of non-alloy and Fine
Grain steels.
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BS EN 10296-1 & 2 Welded circular steel tubes for mechanical and general
engineering purposes. Technical Delivery Conditions.

BS EN 10297-1 & 2 Seamless circular steel tubes for mechanical and general
engineering purposes. Technical Delivery Conditions.

BS EN 13001-1 & 2 Cranes. General Design.

BS EN 14015

BS EN 14399-1 to 9 High-strength Structural Bolting Assemblies for Preloading.

BS EN 1990

Eurocode: Basis of Structural Design.

BS EN 1991-1 to 4

Eurocode 1. Actions on Structures.

BS EN 1992-1 to 3

Eutorcode 2. Design of Concrete Structures.

BS EN 1993-1 to 4

Eurocode 3. Design of Steel Structures.

BS EN 1993-6

Eurocode 3. Design of Steel Structures. Crane Supporting

Structures.

BS EN ISO 1461

Hot Dip Galvanized Coatings on Fabricated Iron and Steel

Articles. Specifications and Test Methods.

BS EN ISO 14713-1 to 3 Zinc Coatings. Guidelines and Recommendations for the

Protection against Corrosion of Iron and Steel in Structures.

IBC 2009

International Building Code

ASCE/SEI 7-10

Minimum Design Loads for Buildings and Other structures

EEMUA

Publication No. 105 Factory stairways, ladders and handrails

Specification for the Design and Manufacture of Site Built,

Vertical, Cylindrical, Flat-bottomed, Above Ground, Welded,
Steel Tanks for the Storage of Liquids at Ambient Temperature
and Above.

Project Standard Specifications

All materials, workmanship and practises shall be in accordance with the current issue
of the listed project standards specification.

610555-0000-40EC-0003

Site Conditions

610555-0000-41EG-0001

Excavation and Backfill

610555-0000-42EG-0001

Concrete Works

610555-0000-42EG-0002

Reinforcement for Concrete

503406-0000-42D0-0001

Structural Standards General Notes & General Concrete

Notes

610555-0000-43EG-0001

Structural Steel Works

610555-0000-43EG-0002

Anchor Bolts

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610555-0000-44EG-0005

Tanking Damp-Proofing and Roofing System

610555-0000-45EG-0004

Painting and Galvanizing

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Government Regulations
All materials, workmanship and practises shall be in accordance with the local agencies
that have jurisdiction over the project and Abu Dhabi municipality.

2.5

Codes and Standards Conflicts

Any conflicting requirement between the various referenced documents shall be brought
to the attention of the EPCM Engineer for resolution.
The Contractor shall at all stages inform in writing the EPCM Engineer immediately if
there appears to be doubts as to the specified requirements. The Contractor shall not
proceed with any such aspects of the work until he has received the necessary
confirmation in writing from the EPCM Engineer. The EPCM Engineer
confirmation/ assessment is based on the appropriate requirement on sections 2.2, 2.3
and 2.4 above

3.0

MATERIALS
Materials, sections, connections and manufacture shall comply with the requirements of
relevant British Standards.

3.1

Material Certification
Mill test certificates shall be supplied and give the chemical analysis and physical
properties for all steel used.

3.2

Structural Steel
Structural Steel shall be in accordance with Standard Project Specifications 6105550000-43EG-0001.

3.3

Bolts and Fasteners

All bolts and nuts are to be to ISO metric standard dimensions. Washers shall be in
accordance with BS 4320.
Bolts shall have a round washer under the nut and, where necessary, tapered washers
to give the head and nut a true bearing. Not more than two washers shall be used. At
least one thread shall project beyond the face of the nut after tightening, and no part of
the threaded bolt shall be within the thickness of the bolted parts.
High strength friction grip (H.S.F.G.) bolts and associated nuts and washers may be
used where approved by the EPCM Engineer. They shall be from an approved supplier
and comply with BS EN 14399. All high strength bolts shall be preloaded.

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Anchor Bolts
Anchor Bolts shall be in accordance with Standard Project Specifications 610555-000043EG-0002.

3.5

Stanchion Packs
All levelling packs for column bases shall be supplied by the Contractor. These are to
be manufactured from galvanized steel plate Grade S275, or stainless steel plate.

3.6

Handrailing
Handrails, ladders and balustrades are to conform to the requirements of BS 6180, BS
5395-3 and EEMUA, Publication No. 105 "Factory Stairways, Ladders and Handrails".
Height of rails should be defined according to Table 1.
Table 1 Height to top handrail and mid-rail

Height to top handrail for stairs

900 mm

Height to top handrail for platforms

1,100 mm

Height to mid-rail for stairs

450 mm

Height to mid-rail for platforms

550 mm

Handrail standards are to be Lionweld Type 0 38 mm solid standard with two 70 mm

diameter balls drilled for 33.7 mm outside diameter tube; or similar approved in which
case drilled balls may become redundant.
Handrail and mid-rail are to comply with BS EN 10296 and BS EN 10297-1 tube,
33.7 mm outside diameter and 3.2 mm wall thickness.
Tubes are to be butt jointed using screwed tubular steel ferrules or welded as per
manufacturer recommendation.
Centres of handrail standards are to be adjusted to suit the duty in accordance with the
EEMUA Publication No. 105.
3.7

Ladders
Ladders over 2 m high shall be provided with a safety cage and self closing gate.
Ladders shall be provided with landings as necessary, to ensure that the height of a
single length of ladder does not exceed 6 m unless specified otherwise. Landings shall
not be less than 840 mm square and shall be guarded by handrails and kick plates.
Ladder rungs shall be 20 mm diameter solid round bar spaced equally for any one climb
of ladder at between 230 mm and 260 mm centres.
The ladder rungs shall be welded to stringers of 12 mm thickness and correct section
for the height involved. The minimum section for stringers shall be 60 mm x 12 mm.

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The stringer spacing shall be 450 mm. The whole ladder shall be constructed in mild
steel to be painted after fabrication. Sections for the ladders may be joined with
galvanized bolting. The ladders shall be secured to steelwork or reinforced concrete
work in the main structure as approved by the EPCM Engineer, and the foot of each
ladder shall normally be required to bed properly on a prepared foundation unless the
wall fixing brackets are designed to cater for all possible loading.
3.8

Floor and Platforms

Open grid flooring is to consist of 32 mm x 5 mm main bearing bars at 30 mm centres
with twisted transverse bars at 50 mm centres. Edging bars are to be furnished all
round each panel. The spacing between bearing bars shall be reduced to 12 mm in
areas where falling articles cause a hazard to humans.
A 150 mm high by 6 mm thick kick flat is required around all platforms, floor edges and
penetrations.

3.9

Stair Treads
Stair treads shall be the open grid type to match the open grid flooring. They shall be
furnished with non-slip nosings. The width of the tread shall be at least equal to the
"going" dimension of the stair plus 16 mm.

3.10

Concrete
Concrete shall be in accordance with Standard Project Specifications 610555-000042EG-0001.

3.10.1

Grouting
Grout shall be non-shrinking, non-metallic type. The grouts thickness under column and
machinery base plates shall be determined according to plate size and grout
characteristics, but unless noted otherwise shall be 50 mm.
For secondary columns and stairs use 25 mm unless noted otherwise on drawings.

4.0

DESIGN AND FABRICATION DRAWINGS

4.1

Structures Design
Structures design shall be performed by considering the limit states at which they would
become unfit for the use for which they are considered and applying appropriate safety
factors to provide an adequate degree of safety and serviceability.
The overall design concept shall give due regard to the fact that the structure as a
whole will be required to behave as one three dimensional entity. The layout of its
constituent parts, including the steel or concrete members, the other structural
elements, the foundations and the connections between each component, shall be such
as to produce a strong stable structure.

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The structure shall be checked for the effects of all possible vertical and horizontal
loads, acting both in conjunction and separately as appropriate, using factored loads
when checking strength and stability to a limit state analysis and unfactored loads when
checking deflections.
The structures shall be designed to be capable of accepting without overstress a
reasonable amount of extra loading due to any cause including extra services, heavier
cladding, or other appurtenances that may reasonably be added during the life of the
structure.
The structure shall be designed to support and withstand all dead loads, superimposed
loads, wind loads, erection loads, live loads, seismic loads and any other loads, which
be applied to it, all as specified in Section 5.0 of this specification.
Loading generally shall conform to BS EN 1991-1 unless otherwise indicated in
drawings.
Where the scope of the Contractor's work includes design; calculation sheets for the
whole of the work shall be submitted.
4.2

Structural Design Calculations and Design Brief Content

Structural design calculations shall satisfy the following minimum requirements which
shall be duly included in the Structural Design brief for each facility/structure.

Project calculation cover sheet, fully filled-in and duly signed.

Index to show major sections and page numbers.
A detailed introduction explaining the circumstances and basis for design and the
path chosen.
A summary of the design output.
Sketches that tie in calculations and member locations.
Copies of all inputs such as general arrangements, vendor data, and geo-tech info.
All relevant correspondence pertaining the design, data sheets, faxes, emails, etc.
Whenever possible, these should be scanned or copied as part of the calculations
and not just referenced.
Ensure all electronic calculations and any other engineering package output is selfexplanatory and easily followed without having to make use of the software for
interpretation.
All structural analysis software calculations to include the following:
a)
b)
c)
d)

Graphics hard copy frames, sections and each load case.

Graphics hard copy of governing frame deflection.
Graphics hard copy of critical M, V, N diagrams whenever applicable.
Graphics hard copy of primary load cases including, but not limited to;
Dead, Live and Wind, as well as Seismic Loads.
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f)
g)
h)

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Copy of all load case and combination titles.

Copy of all load combinations.
Copy of all footing reactions for all load cases.
List all structural analysis software files and description.

Add an appendix for hard copy attachments; make the calculation a stand-alone
document whenever possible, by attaching the final IFC drawings to the
calculations.
Ensure there is a HOLDS list. All HOLDS should be cleared prior to final check and
approval.
Ensure each page is numbered and contains the calculation number.

4.3

Date
2015-02-12

The ADM DPPS Procedure Manual 2013 design checklist items should all be
addressed.

Deflection Limits
When checking the deflections of a structure, the most adverse realistic combination
and arrangement of unfactored loads shall be assumed.
The deflection of a building or part of a building shall be limited so as not to impair the
strength or efficiency of the building or of its contents, nor be unsightly or cause
damage to the finish or inconvenience to the occupants.
Deflections of members listed in Table 2 shall not exceed the tabulated limits, unless it
can be demonstrated that greater values would not be detrimental to the performance of
the structure.
Table 2 Deflection limit

Beams

Deflection due to imposed

loads

Cantilevers

Length/250

Beams carrying plaster finish

Length/360

Roof beams not carrying plaster finish

Length/250

Purlins and sheeting rails

Length/250

Beams supporting cross piping

Length/250

Beams for piping expansion loop

Length/250

Beams supporting piping for pumps and

compressors

Length/600

Beams supporting high temp. or pressure

piping

Length/600

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Columns

Horizontal; deflection due to

wind and imposed loads

Each storey,

Height/200

Building with metal panels, wall cladding and

bare frames

Height/150

Building with partition walls and/or sensitive

architectural elements attached to or in
contact with the building frame.
Building with cranes
C

Date
2015-02-12

Crane girder

Height/375

Height/240 or 50 mm at the
crane rail, whichever is less
Deflection at point of
maximum span moment:
See BS 2573

Vertical deflection static wheel loads

4.4

Jib Crane

Span/700

Horizontal deflection (calculated on

properties of top or bottom flange alone as
applicable)

Span/225
Span/400

Structural Steel Work Design

Steel work design, including connections shall conform to BS EN 1993, and 6105550000-43EG-0001.
Runway beams shall be designed in accordance with BS 2853, BS EN 13001-1:2004
as well as BS EN 1993-6:2007.
Where the scope of the Contractor's work does not include general design, he shall be
responsible for the design of all connections not shown on the drawings. These shall be
designed to satisfy all reactions, moments and forces in the structure.
The details of connections on shop drawings shall be such as to minimize formation of
pockets to hold condensation, water or dirt and a 6 mm minimum gap between abutting
ends of bolted members and adjacent flanges, angles and the like shall be provided
wherever possible to eliminate any traps and facilitate maintenance painting.
Load carrying connections shall be designed for a minimum load of 75 kN, if welded, or
if bolted shall have not less than two M16 bolts along the force line of action (for angles
or tees) or two M20 bolts along the force line of action (for UB, channel or RSJ <
200 mm deep and UC < 160 mm deep) unless noted otherwise on the drawings.
Use four M20 bolts minimum for any section greater than noted above.

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The Contractor shall prepare all necessary erection and workshop drawings giving
complete information for the fabrication and location of each component and joint and
the location, type, size and number of bolts and the type and extent of all welds. A clear
distinction must be shown between shop and site bolts and welds.
Fabrication details, dimension lengths, notches, and clearances on fabrication detail
drawings shall be specified in accordance with guide lines stipulated in the B.C.S.A.
Metric Practice for Structural Steelwork.
The detailed design of galvanized members shall be in accordance with BS EN ISO
14713 and adequate provision for filling, venting and draining shall be made for
assemblies fabricated from hollow sections - vent holes to be plugged after galvanizing.
Drawings shall be submitted for approval before work begins and the EPCM Engineer
shall return any drawings on which comment is made for revision and re-submission.
Approval of drawings by the EPCM Engineer does not absolve the Contractor from
responsibility for errors which may subsequently be found.
4.5

Concrete Work Design

Concrete design shall conform to BS EN 1992: Eurocode 2, and 610555-0000-42EG0001.
Structural concrete such as piling, foundations, beams, columns, structural slabs and
walls shall be designed with a minimum Grade of 40MPa unless otherwise required.
Refer to Appendix 1 for preferred concrete mixes.

4.5.1

Fire Resistance
The provisions of fire resistance shall be applied to all superstructures and
substructures which may be occupied by personnel in the course of normal use. This
includes building superstructures, electrical buildings, treatment buildings, etc. It does
not apply to water retaining structures, including storage reservoirs, water culverts, etc.
Fire resistance to all superstructures and substructures shall be in accordance with BS
Codes and Standards latest issue as of the 1 July, 2010.

4.5.2

Concrete Cover to Reinforcement

The minimum concrete cover to all reinforcement shall be in accordance with BS codes
unless noted otherwise on the drawings.
Provisions shall be made in the design of concrete structures for the use of different
types of joints as described below, and appropriate for the structure concerned.
The spacing of movement joints and the type selected is dependent upon the plan
shape of the structural units being considered, and upon whether it is more appropriate
to cater for shrinkage and thermal effect by the provision of reinforcement or to allow
movement to occur at defined points of the structure.

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Provision for movement joints shall be made at locations where there is a possibility of a
future extension.
4.5.3

Construction Joints
Construction joints are joints for convenience in construction. All reinforcement shall be
carried through such joints and measures shall be taken to ensure continuity of
concrete. Joint positions shall be selected as far as possible to avoid zones of
maximum stress and to coincide with surface features. The first horizontal joint in a
column or wall shall normally be 100 mm above a slab or footing. Polyvinyl chloride
type water stops shall be provided.

4.5.4

Contraction Joint or Control Joint

Both partial contraction and complete contraction joints are for the control of shrinkage.
At partial contraction joints, approximately 50 percent of the reinforcement shall be
discontinuous at the joint, while at complete contraction joints, there shall be complete
discontinuity in the reinforcement and a 3 mm wide by of the slab depth deep saw cut
filled with flexible industrial sealant shall be installed. The exposed edge(s) of the joint
shall be protected with sealant.

4.5.5

Expansion Joints
15 mm thick joint with impregnated compressible filler and flexible industrial joint
sealant. Required spacing of joint could be calculated theoretically. Maximum spacing
of expansion joints for buildings shall be 40 meters.
Expansion joints are joints to accommodate relative movement between adjoining
structures or between parts of structures. There shall be complete discontinuity of
concrete and reinforcement at expansion joints with compressible filler separating the
joint faces. The exposed edge(s) of the filler shall be protected with a sealant.

4.5.6

Isolation Joint
15 mm thick joint between equipment pad and slab on grade or pavement with
impregnated compressible filler and flexible industrial joint sealant.

4.5.7

Control of Shrinkage and Temperature Cracks

Permissible Crack Widths:
The acceptable width of flexural cracks in service depends mostly on the conditions of
exposure and should be established in view of the possibility of corrosion of the
reinforcement. The recommendations are summarized in Table 3. However, good
engineering judgment shall be used in setting limiting values in particular cases.
Table 3 - Tolerable crack widths for reinforced concrete
Tolerable crack width
Exposure condition

in.

mm

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Dry air or protective membrane

0.016

0.41

Humidity, moist air, soil

0.012

0.30

Seawater and seawater spray; wetting and drying

0.006

0.15

Water-retaining structures, excluding no pressure

pipes

0.004

0.10

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Crack Control
Control of maximum crack width in reinforced concrete structures shall be in
accordance with referenced specifications and the provisions of BS code.

4.5.9

Concrete Surface Protection

Concrete surface protection shall be in accordance with Standard Project Specifications
610555-0000-42EG-0001.

4.5.10

Geotechnical Design Criteria

Foundations for the structures shall be based on the data and recommendation of the
Geotechnical Investigation Report.

5.0

GENERAL DESIGN LOADS

Specific facilities, buildings, and other structures, including floor slabs and foundations
shall be designed to resist the minimum loads defined in BS EN 1990 and BS EN 19911.

5.1

Dead loads (D.L.)

Dead loads shall be the actual self-weights of the structural elements forming the
building, structure, foundation and all other permanently attached appurtenances. Dead
loads shall be based on a self-weight of 24 kN/m for concrete, on manufacturers data
for equipment and on weights of materials given in BS EN 1991-1-1 for general building
materials.

5.2

Wind loads (W.L.)

Wind loads shall be computed and applied in accordance with BS EN 1991-1-4. Site
specific design parameters are:

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Basic wind speed

V = 45 m/s
o Basic wind speed V is the 3-second gust speed, at 10m above ground in an open
situation that is likely to be exceeded on the average only once in 50 years.
Hence Vb,0 = (1.06*V)/1.78 to obtain the 10 minutes mean value

Fundamental basic wind velocity (10 minutes mean value)

Altitude factor

calt = 1.0

Direction factor

cdir = 1.0

Seasonal factor

cseason = 1.0

Probability factor

cprob = 1.0

Basic wind speed

vb = Vb calt cdir cseason cprob

Vb,0 = 27 m/s

vb = 27 m/s

Mean wind speed

vm = cr(z) c0(z) vb

o Where cr(z) is the roughness factor and is a function of the height above level and
the ground roughness as defined BS EN 1991-1-4 section 4.3.2 and c0(z) is the
orography facten, taken as 1.0.
Dynamic wind effects: Where appropriate, consideration shall be given to wind-excited
oscillations.
5.3

Imposed Loads (I.L.)

Imposed loads (Live loads) shall be the loads produced by the use and occupancy of
the building or structure. These shall include the weight of all movable loads, such as
personnel, tools, miscellaneous equipment, movable partitions, wheel loads, parts of
dismantled equipment, stored materials, etc.
Imposed loads shall signify all loads imposed on the structure, other than dead loads,
wind loads and seismic forces and shall include equipment weights and dynamic
blanket loadings covering equipment, piping and services, as stipulated by the EPCM
Engineer. Horizontal forces other than wind and seismic forces shall be included in the
imposed loads.
Roofs shall be designed for an imposed load of 0.6 kN/m measured on plan or a load
of 0.9 kN concentrated on a roof area 300 mm square, if no access is provided (in
addition to that required for cleaning and repair). If additional access is provided roofs
shall be designed for an imposed load of 1.5 kN/m or a load of 2.0 kN concentrated on
a roof area 300 mm square. The loads shall be selected to give the worst stress at any
location.
Roof supporting structures shall be designed to carry an additional roof loading of
0.2 kN/m measured on plan in addition to the imposed roof loading. This loading shall
be deemed to cover miscellaneous services and fittings. If these miscellaneous loads
are particularly specified the additional roof loading of 0.2 kN/m shall not be
considered.

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Platforms and walkways not accessible to service vehicles or heavy equipment shall be
designed for an imposed load of 2.0 kN/m or a load of 1.8 kN acting on an area
300 mm square, whichever gives the worst stress at any location.
Operating floor shall be designed for a minimum imposed load of 5.0 kN/mm2 . All floor
members shall be adequately designed to support a minimum concentrated load of 9
kN. This load shall not be combined with any other floor load.
Handrails should be of adequate strength and stiffness to sustain the applied loads
given in BS EN 1991-1-1 without permanent deflection or distortion.
Floor loads where not specified, shall be based on BS EN 1990-1-1.
5.4

Seismic Loads (S.L.)

Seismic Loads - Structures and foundations shall be designed to withstand a seismic
load in accordance with the seismic provisions of the IBC 2009 standard and relevant
clauses of the ASCE 7 standard, based on the following parameters as obtained from
ADM user guide to IBC 2009, Figures 1613.5(1), (2) and (3):
0.2 sec. Spectral Response Acceleration Ss= 0.7
1.0 sec. Spectral Response Acceleration S1= 0.21
Long Period Transition Period TL = 8sec.
Soil Class D (unless proven otherwise)

5.5

Thermal Load (T.L.)

Thermal effect shall be considered where significant. Thermal effects on structural
design caused by the climate shall be based on Table 4 in the absence of other data:
Table 4 Temperature variation for materials

Mean Temperature and Temperature

Variation
(C)
Material
Reinforced Concrete

29 17

Steel

29 22

In addition, where a structural element is exposed to a different extent on opposite

faces (e.g. a column with one face outside and the opposite face inside a building)
consideration shall be given to the thermal effects caused by the resulting temperature
gradient across the structural section. In the absence of other data a temperature
difference of 15C shall be considered in such cases.
The table of mean temperatures above, may not necessarily give the maximum surface
temperature conditions and reference should be made to the ambient temperatures
noted in 5.7. Consideration shall also be given to the degree of exposure during
construction.
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In general, temperature conditions exceeding those given above shall be "particularly

specified".
Thermal loads shall be included with operating loads in the appropriate load
combinations. Thermal load shall have the same load factor as dead load.
Thermal loads and displacements shall be calculated on the basis of the difference
between ambient or equipment design temperature and installed temperature. To
account for the significant increase in temperatures of steel exposed to sunlight, 20oC
shall be added to the maximum ambient temperature.
Friction loads caused by thermal expansion shall be determined using the appropriate
static coefficient of friction. Coefficients of friction shall be in accordance with Table 5.

Table 5 Friction coefficient

Friction Material

5.6

Friction coefficient

Steel to steel

0.4

Steel to Concrete

0.6

Crane Girders
Crane girder shall be designed according to BS EN 1993-6.
Design for a horizontal force as specified by the Manufacturer of the crane, but not less
than the maximum of the following two cases:
A horizontal force applied normal to the top of the rails equal to not less than 20% of the
sum of the weight of the lifted load and the crane trolley. This force shall be equally
distributed on each side of the runway and shall be assumed to act in either direction.
A horizontal force applied normal to the top of the rails equal to not less than 10% of the
combined total weight of the lifted load and the crane weight. This force shall be equally
distributed on each side of the runway and shall be assumed to act in either direction.
Dynamic effects for gantry cranes and for all other machinery and moving equipment
shall be allowed for in accordance with information supplied in writing by the
manufacturers and approved by the EPCM Engineer. Where such information is not
available at the start of structural design work, the following minimum vertical impact
factors shall be used:

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Table 6 Minimum vertical impact for dynamic effects

Elevators

2 x maximum tension on cables

Belt conveyor

1.25 x weight of belt and conveyed

material

Motor driven cranes

1.30 x maximum wheel load

Hand operated cranes

1.10 x maximum wheel load

Hangers supporting floors or balconies

1.33 x imposed load

Light machinery

1.25 x weight of unit

Reciprocating machinery

1.50 x weight of unit

Highway vehicles, railway vehicles and forklifts 1.25 x wheel load

Cyclic dynamic effects, where significant, shall be allowed for in accordance with
information supplied in writing by the manufacturers. Appropriate consideration shall be
given to natural frequency values of support structures and to vibration amplitudes, as
applicable.
The ratio of the natural frequency of the supporting element (FN) to the impressed
frequency (FI) shall be:
FN
FI

Less than 0.75 or greater than 2.0

Fatigue effects shall be considered in structural elements, (e.g. crane girders subject to
significant and frequent stress fluctuations) and checked in accordance with BS 2573:
Part 1: and BS 7608.
Supports for pipes, cables and other services shall be designed for loads suitably
increased to allow for future developments.
5.7

Environmental Conditions
Ambient temperature

7 to 50C

Site location

Coastal position subject to sandstorms, windborne salts,

fog/heavy dew and condensation

Rainfall

Less than 250mm per annum occurring mainly in the

winter months with a design rate of 75 mm/hour

For further site conditions, refer to 610555-0000-40EC-0003

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Combined Loads

5.9

Loading Combinations

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Loading combinations and factors shall be generally as defined in BS EN 1990 and BS

EN 1991, BS EN 1992, or BS EN 1993 whichever applicable. In addition, loading
combination including seismic loads shall be generally as defined in IBC.
Live load shall include loading by cranes.
The imposed load shall include for dynamic effects where appropriate. The imposed
and wind loads shall be combined with the dead load and with each other in such a way
as to give the worst possible stresses at any location. In addition thermal effects shall
be considered where significant, acting in conjunction with the combined load cases.
Load cases need not be combined arbitrarily without regard for practical possibilities
e.g. an outdoor crane need not be capable of carrying its maximum operating load and
maximum wind load simultaneously, since it would not be operating whilst subject to the
maximum wind loading.
5.10

Construction Loads
Consideration shall be given to the construction sequence in order to ensure that a
structure is able to carry the design loads which act before completion of the structure
and, also, that exceptional loads resulting from the construction sequence are catered
for. This consideration shall include dead, wind and thermal loads together with suitable
imposed loads, as appropriate. 2.5 kPa DL construction load for platforms shall be
used, and operating wind load shall be used because of the temporary nature of the
loads.

5.11

Lifting Loads
Consideration shall be given to the loads induced during lifting and placement.

6.0

FACTOR OF SAFETY

6.1

Overturning
Structures subject to a tendency to overturn due to unequal loads on either side, such
as retaining walls, shall have a minimum factor of safety against overturning of 1.5
times overturning moment for the completed structure. This shall be calculated on the
basis of the dead weight of the structure plus any additional dead weight upon the
structure such as backfilled earth, and lateral forces applied including earth pressures
and any possible surcharges. Due allowance shall be made for the effects of buoyancy,
if any part of the sub-structure is below ground water level.

6.2

Sliding
Structures subject to a tendency to slide, due to unequal loads on either side shall have
a factor of safety against sliding as shown in the table below.

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The total resistance to sliding shall be calculated as follows:

Base friction F (f) + Passive resistance F (p) > Thrust + Active force (Pa)
The forces calculated shall be the dead weight of the structure plus any additional dead
weight upon the structure such as backfilled earth, and lateral forces applied including
earth pressures and any possible surcharges.
Due allowance shall be made for the effects of buoyancy, if any part of the sub-structure
is below ground water level.
Particular requirements for factors of safety as applied to thrust blocks and other
structures resisting pipe thrusts.
These structures shall be designed for stability at the working condition where the
pressure is equal to the greater of the following:
Either :
Or
:

maximum static pressure

maximum operating pressure

Also, these structures shall be checked for stability at the testing and surge conditions
where the pressure is equal to the greatest of the following:
Either :
Or

Or

1.5 times maximum working pressure, where maximum working

pressure is less than 15 bars.
1.25 times maximum working pressure, where maximum working
pressure is equal to or greater than 15 bars.
the maximum estimated surge pressure

The method of calculation of total resistance to sliding shall be as given above, but the
factors of safety shall be as given in Table 7.
Table 7 Sliding Safety Factor

Working
Soil type

Test or Surge

Frictional
F(f)

Passive
F(p)

Frictional
F(f)

Passive
F(p)

Clay

2.0

3.0

1.5

2.5

Sand & gravel

2.0

2.5

1.5

2.0

The forces calculated for the working and surge conditions, shall be as stated above,
i.e., including any dead weight upon the structure.
The forces calculated for the test condition, shall allow for excavations remaining open
during testing, allowing inspection of pipes and joints. Therefore, no backfilled earth
upon the thrust block or structure shall be included in the calculations.
Ideally, thrust blocks will be sized such that the applied thrust coincides with the
resultant of passive and frictional resistances. Where this is not practical, the factor of
safety against overturning shall also be checked.
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Backfilled trenches shall not be considered as providing any passive resistance. The
passive resistance and base shear friction shall only be calculated on undisturbed soil.
Notwithstanding the inclusion of the foregoing factors of safety, the consequence of
movement of any structure shall also be considered and any appropriate measures
taken to ensure that possible movement is within acceptable limits to ensure the
integrity of the pipeline and thrust resisting structures.
6.3

Structural Stability
Stability analyses shall be considered to demonstrate the ability of structures to resist
overturning, sliding and uplift, and that allowable foundation bearing values have not
been exceeded. As a minimum, the following factors of safety (FS) shall be considered:
FS (Against Overturning)
FS (Against Sliding)

:
:

1.5
1.5

Allowable soil bearing capacity and other soil properties shall be based on the actual
soil condition and the Geotechnical Studies.
6.4

Flotation
Structures subject to uplift, due to groundwater, shall have a minimum factor of safety
against flotation of 1.1 for the completed structure. This shall be calculated on the basis
of the dead weight of the structure only, without super-imposed load and with ground
water at the level determined by the geotechnical report.
Foundations of pipe support structures shall have a minimum factor of safety against
flotation of 1.5

7.0

SURFACE TREATMENT AND PAINTING

All steelwork and fittings shall be treated in accordance with the Specification
No 610555-0000-45EG-0004 Painting and Galvanizing.

8.0

STORAGE TANKS AND SILOS

The basic specification for the design, fabrication and erection of storage tanks (other
than oil) and silos shall be BS EN 1993-4 and BS EN 14015.
Welding of the tanks and silos, as well at the weld inspections and verifications shall
follow the recommendations of BS EN 14015.
Structural members for the roof of the tanks (other than oil) and silos shall be designed
in accordance to BS EN 1993-4.
Silo shell plates shall have a corrosion allowance of 2 mm added to the minimum
thickness required by calculations or code.
The tanks and silos as well as their supports shall be designed to withstand a horizontal
or vertical acceleration as required in section 5.4.
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For silos containing granular material, the horizontal and vertical forces exerted on the
silo walls shall be based on the Janssen formulas.
Silos containing granular material shall be constructed of steel conforming to
BS EN 10025, with a minimum grade quality of S275. For liquid storage tanks (other
than oil) , follow the recommendations of BS EN 14015.
The basic specification for the design, fabrication, erection and inspection of oil storage
tanks shall be API Std 650 and API Std 653.
Structural members of the oil storage tank shall be in accordance with ASTM A36 /
A36M.
Cathodic protection of steel tanks shall be provided when required on the drawings.
9.0

PIPE RACKS
A pipe stress analysis shall be completed and all forces shall be confirmed prior to
finalizing the structural design. Seismic loads shall be in accordance with the
requirements of IBC for non-building structures. Close coordination between the piping
and structural engineers is deemed essential.
Pipe rack lateral deflections shall be limited as required by the piping engineer.

9.1

Vertical Loads
The nature of process fluid and the likelihood of scale formation shall be ascertained
and accounted for in the structural design.
The vertical loads shall include the weight of pipes, fittings, valves, insulation and the
fluid contents of piping, as well as loads due to scaling and sanding. In determining the
weight of insulation, a density of 200 kg/m3 shall be adopted. A minimum vertical load
(including self weight of pipes) of 2.5 KPa shall be used for each level of pipe rack.
The procedure for hydro-testing and the resultant loads shall be evaluated to determine
the worst load case acting on supports.

9.2

Transverse Loads
Transverse loads include those from thermal expansion and the transverse component
of wind load.
Wind loads shall be in accordance with BS EN 1991-1-4. For congested pipe racks,
loads shall be explicitly calculated for all pipes (with due allowance for future
expansions) but shall not be less than calculated using the above simplified method
unless approved by the lead engineer.

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Longitudinal Loads
Longitudinal loads include those from thermal expansion and the longitudinal
component of wind load.
Thermal forces are those forces caused by temperature changes during operations and
maintenance conditions over the life of the plant. Thermal forces shall be considered
for the following conditions:

Loads occurring at the anchor points of piping and equipment.

Sliding friction forces due to the thermal expansion and contraction of the piping
and equipment.

Horizontal loads due to thermal expansion shall be a minimum of 15% of the vertical
pipe loads and shall be applied to each transverse frame and the longitudinal steel
immediately adjacent to the frame on each side. Where anchor loads are higher they
shall be adopted for design. A minimum longitudinal load of 10% of vertical pipe loads
shall be accumulated at braced bays and carried down to the foundations.
Longitudinal thermal forces shall be considered as uniformly distributed loads over the
entire span of the beam applied to the top flange of the pipe support beam.
9.4

Longitudinal Beams
All longitudinal beams connecting pipe racks shall be designed for a minimum 10% of the
vertical load on the transverse beams with a minimum of 10 KN.
Horizontal load shall be a minimum of 15% of the vertical load from pipe off-takes but shall
not be less than 3 KN. Loads from monorails and platforms etc. shall be considered to act
simultaneously with these loads.

9.5

Intermediate Beams at tier levels

When determining distribution of load between main pipe rack beams and intermediate
transverse beams at tier levels, consideration of the relative stiffnesss of the beams and
supported pipes shall be taken into account.

9.6

Transverse restraint guides

Loadings on restraint guides shall be determined in consultation with the piping engineer.

10.0

CLADDING
The design, fabrication, supply, erection and completion of roof and wall cladding shall
conform to the technical specification No. 610555-0000-44EG-0001.

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APPENDIX 1
TABLE 1 : REFERENCE CONCRETE MIXES
Typ.
Cementious
Typ.
material
Aggregate
Content
(mm)
(kg/m)

Comp.
Strength
28 day
(N/mm)

Type of
Cement

40

OPC

20

50

OPC + 8%
SF

60

Max.
Free
w/c.

Slump
(mm)

420

0.39

160

Structures with
interior
exposure

20

420

0.35

180

Foundations
and structure
below ground

OPC +
GGBS +
4% SF

20

212+230+80

0.33

200

Piling

40

SRC

20

420

0.37

160

Duct banks and

secondary
concrete

20

SRC

20

250

0.55

160

Blinding

Screed

OPC

10

0.95

Flowable

Roof screed

50

OPC+
GGBS+4%
SF

20

193+210+17

0.35

160

30

OPC

10

370

0.43

160

Floor screed

45

OPC +
GGBS

20

210 + 210

0.37

160

Slab on grade

Notes

Targeted
temperature
24C

Possible
Application

Mass concrete
and Power
Plant
foundations

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