PROPOSED NEW CEMENT FACTORY, HARIPUR, KPK

DESIGN CRITERIA
JULY-2018
Draft V1.0
Main Scope of Work

The consultancy services to be provided by NESPAK include the civil and structural design of
the complex. The design will cover the following works.
i. Structural & Architectural Works
- Buildings
- Foundations
- Silos
- Storage Facilities
- Retaining Walls
- Sheds (Concrete / Steel)
- Steel-works
- Water tanks (UGWT, OHWT)
- R.C Flooring For Raw Material Storage
- Pre-Engineered Works
ii. Distribution Works
- Pipe Racks
- Compressor Belts
- Cable Trenches
- Cable Wells
iii. Public Health Engineering
- Water supply
- Sewage Works.
iv. Electrical Works
- Sub-station
- Electrical Power Distribution
v. Road Works
- Slab Bridges
- Culverts
- R.C Pavements
- Stone Pitching Works
- Yard Formation etc.
vi. Storm Water Management Works
- Storm Water Drainage
- Storm Water Drainage Structures

The Cement Factory Layout comprises of “One production-line”, “Plant Structure”, “Allied
facilities” and “Residential colony”. The layout, general arrangement and load drawings of the
plants will be provided by the Client, which will be incorporate in-conjunction process works.
A. PRODUCTION LINE-1

1. Raw Material Proportioning Silos/08

2. Raw Meal Grinding/09
3. Waste Gas Treatment Systems for Kiln & Mill/10
4. Raw Meal Blending Silo/11
5. Kiln Inlet/12
6. Kiln/13
7. Kiln Outlet/14
8. Waste Gas Treatment Systems for Clinker Cooler/15
9. Off-Spec Clinker Silo/16
10. Clinker Silo/17
11. Raw Material Proportioning Silos for Cement Mill/18
12. Cement Grinding System/19
13. Cement Storage and Bulk Loading Silo/20
14. Cement Packing/21
15. Baggerd Cement Loading/22
16. Large Bag Cement Packing/23
17. Main Sub-Station/24

B. PLANT STRUCTURES

1. Limestone & Clay Conveying/01

2. Correctives Crushing & Conveying/02
3. Coal Dum-Hopper & Conveying/03
4. Limestone Pre-Blending Stockpile/04
5. Correctives and Additives Pre-Blending/05
6. Coal Pre-Blending/06
7. Coal Grinding System/07
8. Electrical Room for Raw Material Proportioning/25
9. Electrical Room for Raw Meal Grinding/26
10. Electrical Room for Kiln Inlet/27
11. Electrical Room for Kiln Outlet/28
12. Electrical Room for Clinker Silo/29
13. Electrical Room for Cement Grinding Building 1/32
14. Electrical Room for Cement Grinding Building 2/31
15. Electrical Room for Cement Packing/32
16. Electrical Room for Steam Turbine Generator/33
17. Warehouse for Refractory Materials/34
18. Laboratory & Central Control Room/35
19. Compressed Air Station (1) / 37
 20. Compressed Air Station (2) / 38
21. Mechanical & Electrical Workshop/36
22. Main Store/40
23. SP Boiler/47
24. AQC Boiler/48
25. Steam Turbine Generator/49
26. Cooling Tower and Pump Station/50
27. Chemical Water Treatment/51
28. Pipe Racks and Pipe Sleepers
29. Weigh bridge
a) Weigh Bridge 1 for Raw Material/41
b) Weigh Bridge 2 for Finished Production/42
c) Weigh Bridge 3 for Cement Bulk Loading/43
d) Weigh Bridge 3 for Cement Bulk Loading/44

C. ALLIED FACILITIES

1. Gate and Guard’s Room 1 /45

2. Gate and Guard’s Room 2 /46
3. Rest Room (Total 2 Nos.)/52
4. Car Parking Area/60
5. Office Building/61
6. Infrastructure Works for Plant

D. BRIDGES/CULVERTS/NALLUH CROSSINGS

1. Bridges
2. Culverts/Nalluh Crossings (approx. 8~10 Nos.)

E. TOWNSHIP AREA

1. Employee Dorm and Bath Room/62

2. Canteen/63
3. Infrastructure-works for Township

F. WATER SUPPLY AND DRAINAGE SYSTEM

1. Water Pumping Stations etc.

2. Water Supply System for Production/36
3. Water Distribution Systems
4. Sewerage System and Network
5. Storm Water Drainage (Independent System)
 G. POWER DISTRIBUTION SYSTEM

1. Electric Poles
2. Transformers
3. Cable Ducts

Based on relevant specialty, the design criteria for the said project has been divided into
following four sections.
SECTION - 1 STRUCTURAL DESIGN

SECTION - 2 PUBLIC HEALTH WORKS

DESIGN

SECTION - 3 ELECTRICAL WORKS DESIGN

SECTION - 4 ROAD WORKS DESIGN

 Section - 1

STRUCTURAL DESIGN
1.1 GENERAL

The Structural Design Criteria describes general design requirements applicable to the
structural design of all building elements, structures and foundation, to ensure adequate
strength for the whole structure and all parts thereof for safe support of all
superimposed live and special loads in addition to the dead loads.

All structures and their components for the Cement Factory shall be analyzed for all
phases of construction for a high degree of structural competence, reliability and ease
of construction, as per the various standards and codes described hereunder:

1.2 DESIGN CODES

The following codes and standards will be used:

ACI 318-14 - Building Code Requirements for Structural

Concrete.
ACI 350-01 - Code Requirements for Environmental
Engineering
Concrete Structures
ACI 313-97 - Standard Practice for Design and Construction
of Concrete Silos and Stacking Tubes for
storing granular materials.
AISC - American Institute of Steel Construction
Specifications for Structural Steel Buildings,
9th edition (1989).
UBC – 97 - Uniform Building Code
PBC – 86 - Pakistan Building Code

AWS D 1.1 - American Welding Society Code

ANSI A 58.1 - American National Standards Institute

ASCE 7-16 “Minimum design loads for Buildings and

Structures”.
ANSI/AISC 360-16 Specification for Structural Steel Buildings
AWS D1.5 Bridge Welding Code, American Welding Society
API Recommended Practice Recommended Practices for Machinery
Installation and Installation Design
 PIP STC01015 Structural Design Criteria

1.3 CONSTRUCTION MATERIALS

1.3.1 Concrete

Minimum compressive cylinder strength at 28 days of reinforced concrete to be used in

different components of the project works will be as below:

Piles 28 MPa (4000 psi)

Pile Caps & Rafts 28 MPa (4000 psi)
Superstructure (beams, slabs, 28 MPa (4000 psi)
Columns
Silos and Hoppers 28 MPa (4000 psi)
Cable, trenches, manholes and other 21 MPa (3000 psi)
unimportant structures
Fill Concrete 14 MPa (2000 psi)
Blinding Concrete 10 MPa (1400 psi)
Pre-stressed Concrete 35 MPa (5000 psi)

The Sulphate Resisting Cement instead of Ordinary Portland Cement will be used in
concrete where sulphates in the soil or ground water exceeds the permissible limits.

1.3.2 Reinforcing Steel

The reinforcing steel will conform to ASTM A-615 Grade 60 having minimum yield
strength of 415 MPa (60,000 psi).

1.3.3 Brick Work

Design of brick masonry structures shall be in accordance with the Building Code of
Pakistan, using first class brick with cement sand mortar (1:4) in general, no mortar joint
shall exceed 6.25 mm (0.25 inch) in thickness.

1.3.4 Structural Steel

Structural steel design, fabrications and erection shall confirm to following standards.
  Structural Steel ASTM A36 248MPa (36,000Psi)

 Nuts and Bolts ASTM A307

 High strength steel bolts,

nuts and washers ASTM A325

 Unfinished Bolts ASTM A307, Grade A

Unfinished Nuts ASTM A563, Grade A

 Structural steel Piping ASTM A53 Type E or S, Grade B

 Pipe Handrail ASTM A120

 Welding AWS D1.1, E70XX electrode

 Grating Galvanized welded steel, plain surface.

 Cold Formed Products ASTM A446, Grade B

1.4 LOADS

The following loads will be considered in the analysis and design of the structures and
different components of the project works.

1.4.1 Dead Load

These are the vertical loads due to the weight of permanent structural and
nonstructural components of a building or structure, including empty vessels,
equipment, built-in partitions, fireproofing, insulation, piping and ducting, electrical
conduits, and permanent fixtures.

The self-weight of the structure and the superimposed dead load will be calculated
using the following unit weights of materials.

Concrete 24 kN/m3 (150 lbs/ft3)

Steel 77 kN/m3 (490 lbs/ft3)
Earth (compacted) 19 kN/m3 (120 lbs/ft3)
Brickwork 19 kN/m3 (120 lbs/ft3)
1.4.2 Live Load
 These are the loads produced by the use and occupancy of the building or structure.
They include the weight of all movable loads, including personnel, tools, miscellaneous
equipment, movable partitions, cranes, hoists, parts of dismantled equipment and
stored material.

Design will be carried out for live loads as recommended in ANSI A58.1. Unless
otherwise noted, generally a live load of 5 kN/m 2 (100 lbs/sq.ft) will be assumed on
floors, stairs and steel grating of plant buildings.

1.4.3 Equipment Load

The loads specified by the Plant/Machinery Supplier shall be strictly followed. A

dynamic load factor of two (2) on the equipment load shall be used to cater for the
dynamic effect unless otherwise provided by the Machinery Supplier.

1.4.4 Wind Load

The wind pressure and load will be computed using the recommendations of the
Uniform Building Code (UBC – 97). The following design formula/parameters will be
adopted.

P= CeCqqsIw
Where

Ce = Combined height, exposure and gust factor coefficient as given in

Table 16-G of UBC

Cq = Pressure coefficient for the structure or portion of structure under

consideration as given in Table 16-H of UBC

Iw = Importance factor as set forth in Table 16-K of UBC P =

Design wind pressure

qs = Wind stagnation pressure at the standard height of 10 m (33 feet) as set

forth in Table 16-F of UBC
 The basic parameters to be used for evaluating the design wind pressure P, are as
follows:

Design wind speed =160 kph (100 mph)

Exposure category = C (open area)

1.4.6 Seismic Load

The seismic forces will be computed and distributed using the seismic load generator
of the program SAP 2000.The seismic design of the structures will be based on Zone
2B of Pakistan Building Code (1986), site located, Haripur.

1.4.7 Temperature/Thermal Load

The temperature effects on buildings will be investigated against the maximum

differential temperature of + 25 degree centigrade. For special plants, the operational
conditions specified by the equipment supplier will be used for temperature analysis.

1.5 LOADING CONDITIONS AND COMBINATION

The load combination producing the largest resultant forces and moments shall be
used in design.