Engineering Report

SAER-5974 31 October 2004

Use of High Strength Steel W & WT Shapes
Per ASTM A-992 to Replace ASTM A 36 Steel
Document Responsibility: Consulting Services Dept.

Study By: Hisham Abu-Adas

Civil Engineering Unit
M&CED/CSD

Peer Review: Mohammed Al-Mehthel

Saudi Aramco DeskTop Standards

Table of Contents

1 Executive Summary....................................... 1
2 Introduction..................................................... 2
3 Purpose of Study........................................... 2
4 Scope of Study.............................................. 2
5 Design Benefits.............................................. 2
6 Case Study.................................................... 3
7 Cost Savings.................................................. 5
8 Conclusion...................................................... 5

Attachments (1, 2, & 3)......................................... 6

Previous Issue: New Next Planned Update: 1 November 2009

Page 1 of 31
Primary contact: Hisham A. Abuadas on 874-6908

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

1 Executive Summary

In the past few years, ASTM A-992 Grade 50 ksi steel has become the dominant
specification for wide-flange shapes in the industry, solidly displacing the very common
ASTM A 36 wide flanges. In fact, ASTM A-992 is so commonly rolled that it now
costs less than ASTM A 36 wide-flange shapes - and it would be easier these days to
find high strength steel than A36 wide flange shapes. The study in this report conclude
that using high strength shapes conforming to A-992 instead of the currently specified
A-36 steel shapes will result in cost savings of $20.5 MM per year or $102.5 MM per
business plan. This is based on consumption of 50,000 m-tons per year at a total
approximate cost of $2,000 per ton. The use of high strength steel A-992 has become
mandatory requirement in the newly revised and released Saudi Aramco Materials
System Specification 12-SAMSS-007 "Fabrication of Structural and Miscellaneous
Steel".

2 Introduction

Past projects such as Hawiyah, Haradh and Qatif Gas Projects consumed a large
quantity of structural steel for the main and secondary pipe racks. For example, Haradh
project used 22,000 tons of structural steel and Qatif project will consume about 28,000
tons. The study will concentrate on the feasibility of utilizing structural shapes of grade
steel ASTM A-992 instead of ASTM A 36 steel in future projects for the next business
plan.

3 Purpose of Study

Conduct engineering study for the feasibility to utilize high strength structural steel
W-shapes ASTM A-992 (Grade 50) in the design and construction of new capital
projects instead of the current specified ASTM A 36 (Yield Strength 36 ksi). The study
will calculate the potential savings in material, fabrication and erection costs associated
with the use of higher grade steel.

4 Scope of Study

Perform comparison design study of the higher grade steel material compared to current
practice with lower grade steel. Such study would concentrate on the various aspects of
the new material such as:
• Properties
• Advantages
• Availability

Page 2 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

• Weldability
• Cost Comparison
• Potential Savings in Business Plan

5 Design Benefits

Newly produced ASTM A 992 structural steel shapes includes a yield strength range of
50 ksi to 65 ksi, a minimum tensile strength of 65 ksi and a maximum yield-to-tensile
strength ratio of 0.85. This tighter material definition provided in ASTM A 992 is
important for several reasons. From a welding standpoint, the specified upper limit on
yield strength in ASTM A 992 significantly reduces the possibility of weld metal
becoming under-matched. This is in turn reduces the potential for brittle fracture. Also,
ASTM A 992 is a prequalified base metal per AWS D1.1 Table 3.1.

The major advantage of A992 is its better material definition. It has an upper limit on
yield strength of 65 ksi, a minimum tensile strength of 65 ksi, a specified maximum
yield –to-tensile ratio of 0.85. In addition, it requires maximum carbon equivalent of
0.45. The inclusion of a maximum strength and a maximum yield-to-tensile strength
ratio assures material ductility, particularly important in high-seismic applications.

There is also an advantage of using longer spans for beams and girders to increase
column spacing. The result of these changes is a much more efficient steel design with
fewer and lighter members. The approximately 40% increase in steel strength accounts
for the decrease in member sizes.

The new material has already been incorporated into the latest set of revisions to the
AISC specification. ASTM A 992 is referenced as an acceptable Material in 1999
AISC LRFD Specification in Section A3. Also, AISC has issued Supplement No. 1 for
the 1989 ASD Specification to ASTM A 992 material. ASTM A 992 steel is here to
stay – it's the material standard for strength, weldability and availability for wide
flange shapes.

6 Case Study

A case study is conducted for interconnecting pipe rack 42D of Riyadh Refinery DHT
Project. The pipe rack is 395 meters long and 6 meters wide and is 3 levels high and
consists of 64 frames (see attachment for details).

A STAAD PRO computer analysis was performed for typical frame using two different
cases, case one using A-36 steel and case two utilizing A-992 steel. The design results
indicate lighter members may be used when using the higher grade steel A-992. A
summary of the total weight for a typical frame is listed below. The resultant in weight
saving is 12.6%.

Page 3 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Pipe Rack Quantity Estimate and Comparison for Grades 36 & 50 Ksi Steel
Ref. BI-10-0008- RR - DHT Complex Project - Pipe length 395 meters (64 frames)

Typical Frame - Weight - Grade A-36 Steel

Size Unit Weight Length Weight

kg/m m kg
Beam @ El. 10500 HE200A 42 6 252
Beam @ El. 8500 HE300A 88 6 528
Beam @ El. 6500 HE320A 98 6 588

Column @ Grid 01 HE280A 76 10.3 782.8

Column @ Grid 02 HE280A 76 10.3 782.8

Longitudinal Struts HE160A 30 24 720

4 Beams * 6 m = 24 m

3654
kg/frame

Typical Frame - Weight - Grade A-992 Grade 50 Steel

Size Unit Weight Length Weight

kg/m m kg
Beam @ El. 10500 HE200A 42 6 252
Beam @ El. 8500 HE280A 76 6 456
Beam @ El. 6500 HE300A 88 6 528

Column @ Grid 01 HE240A 60 10.3 618

Column @ Grid 02 HE240A 60 10.3 618

Longitudinal Struts HE160A 30 24 720

4 Beams * 6 m = 24 m

3192
kg/frame

Ratio = 0.874
Savings 12.6%

Page 4 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

7 Cost Savings

ASTM A-992 steel W-shapes presents some attractive cost benefits over A36. There is
cost savings resulting from weight savings, this is true even when member sizes need to
be increased to meet serviceability concerns. Based on our analysis of typical pipe rack
design for an on-going project, a weight savings of about 12.5% has resulted from using
A992 steel instead of A36. It is estimated that Saudi Aramco consumes approximately
50,000 m-tons of structural steel annually. With an average cost savings of 12.5%
resulting from weight savings and a total approximate cost of $2,000 per m-ton
(Material Supply, Fabrication and Erection Cost); the resulting potential savings will be
around 12.50 MM per year. Additionally, cost savings will result form using longer
spans for beams and girders to increase column spacing. A study conducted by Jacobs
Engineering on the main pipe rack for Hawiyah NGL (HNRP) regarding increasing the
bent spacing from 6.0 meters to 9.0 meters resulted in an additional savings of $4.0
MM. This additional savings would not have been possible if high strength steel ASTM
A-992 grade 50 is not used. Therefore, it is expected that the total saving per year that
will result from increasing bent spacing will be $8.00 MM. This will bring the total
savings to $20.5 MM per year.

8 Conclusion

Due to the design benefits and cost savings the ASTM A-992 W-shapes offer over
conventional ASTM A 36 steel, the use of high strength steel ASTM A-992 has become
mandatory requirement in the newly revised and issued Saudi Aramco Materials System
Specification 12-SAMSS-007 "Fabrication of Structural and Miscellaneous Steel".

Revision Summary
31 October 2004 New Saudi Aramco Engineering Report.

Page 5 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Attachments

Attachment 1:

Chemical Composition & Tensile Requirements Comparison

Chemical Composition:
A36 A992
Element Composition % Element Composition %
Carbon, max 0.26 Carbon, max 0.23
Columbium, max 0.05
Copper, max 0.60
Manganese 0.85 to 1.35 Manganese 0.5 to 1.50

Molybdenum, max 0.15

Nickel, max 0.45
Phosphorus, max 0.04 Phosphorus, max 0.035
Silicon, max 0.40 Silicon, max 0.40
Sulfur, max 0.05 Sulfur, max 0.045
Vanadium, max 0.11
Vanadium + Columbium, max 0.15
Carbon Equivalent, max 0.45

Tensile Requirements:
A36 A992
Tensile Strength 58-80 ksi Tensile Strength, min 65 ksi
Yield Point 36 ksi Yield Point 50 to 65 ksi
Yield to tensile ratio, max 0.85
Elongation in 8 in, 20% Elongation in 8 in, min 18%
min
Elongation in 2 in, 23% Elongation in 2 in, min 21%
min

Page 6 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Attachment 2:

Case Study of Pipe Rack (Structural Analysis & Design)

2.0 Structural Steel Design for 42D – Interconnecting Pipe Rack

2.1 General Geometry

TYPICAL FRAME ELEVATION (UNO)

(Scale 1:100)

Page 7 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Layout of Pipe Rack (42D) (Part)

Page 8 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Layout of Pipe Rack (42D) (Part)

Page 9 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Layout of Pipe Rack (42D) (Part)

Page 10 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Layout of Pipe Rack (42D) (Part)

Page 11 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Structural Steel Design for 42D – Interconnecting Pipe Rack

General Geometry

TYPICAL FRAME ELEVATION (UNO)

(Scale 1:100)

Page 12 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

ASTM A 36

Structural Steel Design for 42D – Interconnecting Pipe Rack

General Geometry

TYPICAL FRAME ELEVATION (UNO)

(Scale 1:100)

ASTM A-992

Page 13 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 14 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 15 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 16 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

A-36

Page 17 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 18 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 19 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 20 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 21 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 22 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

A-992

Page 23 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 24 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 25 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Attachment 3:

JACOBS STUDY

Page 26 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 27 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 28 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 29 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 30 of 31

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Consulting Services Dept. SAER-5974
Issue Date: 31 October 2004 Use of High Strength Steel W & WT Shapes
Next Planned Update: 1 November 2009 Per ASTM A 992 to Replace ASTM A 36 Steel

Page 31 of 31

Copyright©Saudi Aramco 2009. All rights reserved.