INDEX PAGE NO. 1.0 2.0 3.0 4.

0 GENERAL DATA LOADS & LOAD COMBINATION DESIGN CRITERIA MATERIAL SPECIFICATION 3 3 7 12

DESIGN BASIS FOR STRUCTURAL WORK

DESIGN BASIS REPORT FOR STRUCTURAL WORKS

The Design basis report has been prepared taking into consideration the technical requirements specified in NIT & subsequent clarifications and is intended to be used as a basis for the detail design engineering. The different parameters as will be adopted in detail design are as follows : GENERAL DATA 1.0 Finished Grade Level (FGL) a) FGL(s) in various areas within the battery limit of this package are shown on Plant Layout drawing. Elevation 0.0 refers to the Finished Ground Floor level of the Station Building, which is equivalent to RL 600 b) c) c.1 Finished ground floor level (plinth level) of all buildings shall be 500 mm above the formation level/ finished grade level in the adjoining area. Underside of base plate level of structural steel column Underside of base plate of Steel Columns for building structures: Underside of base plate of structural column normally shall be kept atleast 250mm above finished floor level (FFL) unless specified otherwise. c.2 Underside of base plate for Stair and ladder supporting column/post shall be kept 200 mm above the finished floor level. d) MINIMUM HEIGHTS FOR ENCASEMENT OF STEEL COLUMNS In case the top of pedestal is kept at a lower level so that the column base plate together with gussets and stiffeners remain below finished floor level (FFL) the column bases as well as the column sections shall be encased in concrete above FFL as per following: i) ii) Open area Covered area : Minimum300 mm above FFL. : Minimum 300 mm above FFL.

2.0

LOADS and LOAD COMBINATIONS

The various loads to be considered in design shall be as under :

2.1

Dead Load The dead load to be considered in design of members/ structures shall consist of the following: a) Weight of all permanent construction and materials. b) Weight of all equipment, which are permanently fastened to or supported on building structure.

DESIGN BASIS FOR STRUCTURAL WORK

c) Unit weight of materials shall be as per IS-875. Following unit weight of material shall be considered for computation of dead loads. Loads given in IS: 875 (part-I) shall be made use of for material not listed below. Materials Plain cement concrete & Floor Finish Reinforced cement concrete Structural steel Brick work & Cement- Sand Plaster 2.2 : : : : : Unit weight 2,400 kg/cum 2,500 kg/cum 7,850 kg/cum 2,000 kg/cum

Imposed loads Imposed loads in different areas shall include live loads, dust loads, minor equipment loads, cable trays, small pipe racks / hangers, erection loads, operation/ maintenance loads, etc. The following minimum Imposed loads shall be considered in the design are indicated below: Live Loads a) Flat roof : Accessible roof 200 kg/m2 (150 kg/m2 for LL and 50 kg/m2 for dust load) Non-accessible roof 200 kg/m2 (75 kg/m2 for LL and 125 kg/m2 for dust load) b) Inclined roof (including : roof for TPs and conveyor galleries) All industrial Floor Building : As per IS:875 for live load plus 25 kg/m2 dust load

2.2.1

c)

500 kg/m2

e) f) g) h) i) k) l)

Walkways of conveyor : galleries Equipment loads Material on belt : :

400 kg/m2 (300 kg/m2 live load plus 100 kg/m2 spillage load) As applicable 1.1 times design weight of material on belt with weight of belt 500 kg/m2 Load due to cables per cable tray 150 kg/m on platform supporting beam 200 kg/m2 As per IRC standard for Class AA loading

Access platforms, stairs : of junction towers Cable rack Toilet rooms : :

Culverts and their allied : structures including RC pipe.

DESIGN BASIS FOR STRUCTURAL WORK

How, if erection loads are higher than the specified live load on any floor or part thereof, then the erection load will be considered for design.

2.3

Wind Loads

Wind Load shall be calculated as per IS: 875 (Part-3). The basic wind parameters are as follows: a) Vb = Basic wind speed = 39 M/S
b) c) d) Terrain Category 2 K1 = Probability factor (Risk Co-efficient) = 1.06 K2 - As per Table-2 (IS: 875,Part-3) depending upon Terrain category, height and class of structure. e) K3 = Topography factor = 1.0

2.4

Seismic Loads Design for seismic loads shall be in accordance with latest version of IS:1893. Bellery falls under seismic zone III. The importance factor for all buildings and structures shall be considered as per latest version of IS: 1893.

2.5

Impact Factor For design of monorails, an impact factor of 1.25 for electrically operated and 1.1 for hand operated shall be considered. Due consideration of weight of pulley blocks, lifting rope and other accessories will be given while estimating the load which to be lifted and for design of floor beams directly supporting drive machinery like head end/ tail end/drive pulley, motors, gear boxes, etc., an impact factor of 1.50 shall be considered. For Pedestals supporting gravity take ups for conveyors shall be designed assuming 100% impact factor.

2.6

Live load reduction shall be in accordance with the provisions of IS:875 and IS:1893 in case of seismic analysis

2.7 Equipment Loads Static and dynamic loads of major equipment shall be based on the manufacturers data of the specified equipment and shall be considered in design in addition to the live load. . 2.8 Basic Load Cases The following basic load cases shall be considered for the analysis: i) Dead load DL

DESIGN BASIS FOR STRUCTURAL WORK ii) iii) iv) v) vi) vii) viii) Live load Equipment Load Hoist/Crane load Wind load Seismic load Temperature Load Other Load as Applicable LL EL CL WL SL TL OL

2.9

Load Combinations The individual members of the frame shall be designed for worst combination of forces such as bending moment, axial force, shear force and torsion. Permissible stresses for different load combinations shall be taken as per IS: 875 (Part-V) and other relevant IS codes. Wind and seismic forces shall not be considered to act simultaneously.

3.0 3.1

DESIGN CRITERIA Design Methodology (a) The Design of steel structures shall be done by working stress method, in accordance with the provisions of IS: 800-1984 and other relevant IS codes as applicable to specific structures. (b) All buildings/structures shall be framed structure. (c) An increase of 33.33% in permissible stresses for different members shall be allowed only when wind load is combined with dead and any other loads such as live loads. However, for all structural members, footings and pedestals, no increase in permissible stresses shall be allowed when wind/seismic is combined with dead load alone. (d) For design which requires the use of the minimum column load (such as, uplift on anchor bolts, column axial tension, etc.) the following criteria shall be used in determining minimum load. Use 90% of the column dead load, No live load is to be used, Uplift forces from vertical bracing are included where applicable and Wind uplift on the roof is included, where applicable. (e) Design of base plates shall be based on design pressure on foundation which shall not exceed the following: Pedestal in concrete grade M25 Pedestal in concrete grade M30 6.25 N / sq.mm 7.5 N / sq.mm

(f) The total horizontal shear force at the base of column is transferred to the column pedestals through friction between the base plate and the grout. A coefficient of friction of 0.30 shall be used in conjunction with the minimum column load as defined above. If the horizontal shear force exceeds the frictional resistance force or if the column is subjected to a net uplift load, the total force shall then be transmitted through shear bars / shear keys welded to the base plate. Anchor bolts are not assumed to resist any horizontal shear force. Necessary recesses shall be kept in the foundation concrete for shear lugs.

(g) The design of steel structures for the following system components shall take into consideration of the design guidelines indicated hereinafter:

DESIGN BASIS FOR STRUCTURAL WORK 1.0 Conveyor gallery girders and supporting trestles

1.1 Overhead conveyors shall be housed in a suitably enclosed gallery of structural steel. Maximum span of gallery shall be limited to 24 m unless higher span is necessitated due to site constraints, which shall be subject to approval of BHEL/KPCL. No camber shall be provided for conveyor gallery girder. If gallery span is more than 24m, then frequency check shall be performed. If time period is greater than 1second then dynamics wind shall be considered. 1.2 For double conveyor gallery one central and two side walkway shall be provided. For single conveyor, walkway shall be provided on either side. Width of walkway and clear height of the gallery shall be as specified in mechanical section of the document. Both sides of central and side walkways shall be provided with pipe handrails with kerb plates using pipe of medium class as per IS:1161 having 32mm nominal size. Handrails shall not be connected to conveyor supporting stringer. Walkway shall be of chequered plate construction with anti skid arrangement. Floors of the conveyor gallery shall be provided with seal plates as specified in mechanical section. 1.3 Conveyor gallery shall have permanently colour coated metal sheet on roof and on both side. Roof framing shall be given a slope of 1 vertical: 3 horizontal. A continuous slot opening of 500mm height shall be provided on both side of walls just below the roof sheeting. Adequate provision of windows shall be provided on both sides. Windows shall have grills of wire mesh. Cross-over shall be provided at approximately 100m interval along the conveyor preferably at 4 legged trestle locations. 1.4 In between transfer points four legged trestles shall be given at a specing of 100m. In between four legged trestles, two legged trestles shall be provided wherever applicable. 1.5 Sliding PTFE bearing support shall be provided at one end of the gallery for relieving forces due to temperature variation. Accordingly, for the purpose of analysis, one end shall be treated as hinged and other end on rollers. 1.6 End of conveyor gallery, which shall be supported over transfer tower, shall be so detailed that, only vertical reaction is transferred from conveyor gallery. This side of the gallery shall therefore be supported on sliding PTFE support. 1.7 Transverse horizontal load of conveyor gallery due to wind shall be transferred to the foundation by two legged trestles. However longitudinal horizontal force of conveyor gallery shall also be transferred through hinged supports on two legged trestle. The same will be also transferred through four legged trestle/tower placed at least 100m interval.

2.0

Junction towers .

2.1 Design shall be carried out for the case of one belt at starting condition and the other belt in running condition along with wind / seismic load in combination with others. 2.2 Chute loads on floors shall be considered as plugged with material for its entire height. 2.3 RCC slabs shall be suitably connected with shear lugs to all floor beams in case horizontal forces are transferred through these RC slabs. However, no composite action of RC slab with steel beam shall be considered for the design of floor / roof

DESIGN BASIS FOR STRUCTURAL WORK beams. Alternatively, plan bracings shall be provided at a minimum of 75 mm below top of steel to transfer horizontal loads to braced columns. Horizontal load transfer through RC slabs on the braced frames shall also take into account stiffness of slab / frame and bracing system. 2.4. The crusher and Transferred house structures shall be so designed that transverse deflection at places where conveyor galleries meet, should be equal to the respective transverse deflection of conveyor supporting trestles. 2.5 Diagonal wind shall be considered for four legged towers. However, for high junction tower where wind dynamics effect shall be considered, diagonal wind effect shall be ignored as that will be too conservatives. Because junction towers are laterally supported by conveyors, yet where height/min base dimension is more than 5 or natural frequency less than about 1 HZ, dynamics wind effect shall be considered as per code provision for which wind load shall be increased approximately 2 times. Further if 1.4 is multiplied for diagonal wind , design will be too conservatives. Further for this towers base dimensions are larger, so these are not four legged towers.

(h) Permissible Deflections (i) The permissible deflections of various steel members under normal loading conditions shall be as specified below. For calculation of deflections in structures and individual members dynamic effects shall not be considered, unless specified otherwise. Also, no increase in deflection limits shall be allowed when wind or seismic loads are acting concurrent with normal loading conditions. (ii) Vertical Deflection: - For roofing and cladding components : Span / 250 - For gratings and chequered plates : Span / 200 (subject to a max. of 6 mm) - For manually operated cranes and monorails : Span / 500 - For electric overhead cranes up to 50T capacity - For electric overhead cranes over 50T capacity - Drive machinery supporting beam - Floors/masonry supporting beams -Coal Conveyor gallery / bridge : : Span / 750 : Span / 1000

: Span / 500 : Span / 325 Span / 420 Span / 325 Span / 325 Span / 400

Gallery cross beams directly supporting : conveyor short posts Gallery walkway supports, floor beams For Beams supporting pipes (pipe racks) : :

(iii) Horizontal deflections The permissible horizontal deflections shall be as per following unless specified Otherwise

DESIGN BASIS FOR STRUCTURAL WORK Trestle supporting coal conveyor gallery in transverse direction End portal of conveyor gallery girder Single storey building (without crane load) : : : Height / 1000 Height / 325 Height / 325

Multi-storied building (without crane load) Pipe Rack columns Open structures Crane gantry girder due to surge

: : : :

Height / 500 Height / 200 Height / 200 Span / 2000

(Limited to maximum of 15 mm)

Building main columns at crane rail level due to action of crane surge only Open gantry columns at crane rail level : Span / 2500 (Limited to maximum of 10 mm) Span / 400 (Limited to maximum of 10 mm)

Provisions of IS: 800 and relevant IS code shall be followed for limiting deflections of structural elements not listed above

(i) Minimum Thickness and Sizes of Steel Elements - Minimum Thickness The minimum thickness of various components of a structure and hot rolled sections shall be as follows. The minimum thickness of rolled shapes shall mean flange thickness regardless of web thickness. i) Trusses, purlins, girts and bracing : 6 mm ii) Columns and beams : 8 mm iii) Gussets : 8 mm iv) Stiffeners : 8 mm v) Base plates : 10 mm & above vi) Chequered plates : 6 mm o/p & above vii) Grating flats : 5 mm viii) Min. thickness of structural members other than gratings & chequered plate directly exposed to weather, and inaccessible for painting and maintenance: 8mm. The above donot apply for non load bearing members like toe-guard, seal plate, flat etc.

- Minimum Sizes
The flange width of purlins supporting light weight concrete slab shall not be less than 65 mm and for those supporting roof sheeting and wall cladding, it shall not be less than 50

DESIGN BASIS FOR STRUCTURAL WORK mm. Width of steel rolled section connected to other member shall be at least 50 mm. The depth of beams for platform shall not be less than 125 mm. (j) Slenderness Ratio and Depth to Span Ratio - The slenderness ratio of main members in tension, compression or bending shall be in accordance with IS:800; - The following limiting ratios of depth to span shall be considered as a general guide. a) Truss 1 / 10 b) Rolled beams and girders for 1 / 24 Ordinary floors and rafters c) Supporting floor beams for vibrating 1 / 15 Machines / equipments d) Roof purlins and girts 1 / 45 e) Gable columns 1 / 30

k)

Vertical Headroom All accessible areas shall be provided with a minimum clear headroom as follows, unless otherwise specified: Doors, Walkways, Platforms, Stairs etc. Safety cage for ladders Main road/railway crossings & crane access Other plant roads and truck access Cable & Pipe rack (Except Road crossings) : : : : : 2100 mm 2500 mm 7000 mm 6000 mm 3000 mm

3.2

Connections: Welding shall be used for shop fabrication and joint. For site connections, welding or high strength friction grip (HSFG) type bolts shall be used, except in few cases for shear connections of lighter members or removable beam connections where bolted joints may be adopted e.g purlins, side girts etc. A minimum of two bolts per connection shall be used. IS: 816 and IS: 9595 shall be followed for welding of structures. For high strength friction grip bolt connections IS: 4000 shall be followed. High strength friction grip bolts shall be property class 6.6 or 8.8 and shall conform to IS: 3757 and shall not be less than 20 mm dia unless designated otherwise. High strength bolts shall be installed as bearing type joint except where loads are reversible. All bolted connections shall have bolts of minimum 16 mm dia. The connections of stairs and handrail shall be made with 20 mm diameter threaded fasteners conforming to IS: 1363. Erection bolts shall be black bolts of minimum 1.2 mm dia. All bolts and nut shall have property class compatible to each other. For bolts carrying dynamic or fluctuating loads and those in direct tension shall be provided with an additional double coil helical spring washer conforming to IS: 6755. The threaded portion of the bolt shall project through the nut at least one thread.

DESIGN BASIS FOR STRUCTURAL WORK Where a steel beam or member is to be connected on RCC structure, it shall be connected using an insert plate and preferably through shear connection. For crane girders, welding between web and flange plates shall normally be carried out by submerged arc welding process. Full penetration of weld between web plate & top flange shall be ensured. Intermediate stiffeners shall be connected with top flange plate by full penetration butt weld. Welding across tension flange shall not be permitted. Bearing edges of crane girder shall be machined. The working point of the bracing connection shall be the center of the column and girder to which it connects where practical. The connections of gusset plates to column and girders shall be made to include provisions for eccentricity in connection. Horizontal bracings shall be angle/tee section located at the bottom of framing beams. Field welding of bracing at the underside of beam as required to meet slenderness requirement of bracing shall be arranged to avoid framing into the Horizontal beams at column locations. Minimum size of fillet weld shall be 5 mm. Main structural elements shall be welded continuously. Intermittent weld shall be used only on secondary members, which are not exposed to weather or other corrosive influence. Efficiency of site welds to be considered as follows: A) Butt weld above 25m from Ground : 50% B) Others : 80%

The connections shall be designed for 70% of shear capacity of the member or the actual shear force, which is higher.

4.0

MATERIAL SPECIFICATION: The various materials for structures shall conform to the following Indian Standard. i) ii) iii) iv) v) Rolled section: Grade A of IS 2062 Plates of thicknesses upto 20mm: Grade A of IS 2062 Plates of thicknesses above 20mm: Grade B (Killed) of IS 2062 Chequered Plates: IS 3502 Grating : pressure Locked type manufactured in accordance with Indian standard Pipes for hand rail : Medium grade of I.S.1161. Seal Plates shall conform to IS:1079. Crane rails: IS: 3443

vi) vii) viii)