DOCUMENT NO: E23C01-STD-DOC-001 REV.

Design Criteria for Civil and Structural Engineering

COMPANY : M/s PURE CEMENT FZE, FUJAIRAH UAE

PLANT : 7000TPD GREEN FIELD CLINKERIZATION
UNIT AT AL TUWIYAIN FUJAIRAH, UAE

PROJECT : E23C01

1 Released for Approval LRM LRM 23.11.2023

REVISION DESCRIPTION MADE CHECKED/APPROVED DATE

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TABLE OF CONTENTS

1. GENERAL 6

2. LOCAL LAWS, CODES AND STANDARDS (LCS) 6

3. MATERIAL 8

3.1. CONCRETE 8

3.1.1. Cement 8

3.1.2. Concrete grade 9

3.1.3. Plain Cement Concrete (PCC) 9

3.2. REINFORCEMENT BARS FOR CONCRETE 9

3.3. STRUCTURAL STEEL 9

3.4. BOLTS 10

3.5. ANCHOR BOLTS 10

4. DESIGN LOADS 10

4.1. DEAD LOAD 11

4.1.1. Soil and hydrostatic pressure 11

4.1.2. Material Densities for dead load 11

4.2. LIVE LOADS 12

4.2.1. Occupancy 12

4.2.2. Bulk materials 12

4.2.3. Crane loads 13

4.2.4. Dynamic loads 13

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4.2.5. Impact and vibratory loads 14

4.2.6. Vehicles loads 14

4.3. WIND LOADS 14

4.4. SEISMIC LOADS 14

4.5. THERMAL LOADS 15

4.5.1. Environmental 15

4.5.2. Process 15

4.5.3. Friction 15

4.6. ACCIDENTAL LOADS 16

4.6.1. Abnormal operating loads for buildings 16

4.6.2. Accidental loads for ducts 16

4.7. COSTRUCTION PROGRESS LOADING CASES 16

5. LOAD COMBINATIONS 17

5.1. LOAD COMBINATION FOR SERVICAEABILTY 17

5.2. LOAD COMBINATION FOR STRENGTH 18

6. DESIGN PROCEDURE 18

6.1. LIMITING DEFLECTION 18

6.1.1. Concrete Buildings 18

6.1.2. Steel Structure 19

6.2. SOFTWARE 20

6.3. SOIL PROPERTIES 20

6.4. FOUNDATIONS 21

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6.4.1. Equipment foundation 21

6.4.2. Settlement 21

6.4.3. Foundation stability 22

6.5. CONCRETE STRUCTURES 22

6.6. STEEL STRUCTURES 22

6.6.1. Joints and bracing system 22

6.6.2. Floors and roofs 23

6.6.3. Stairs, ladders and walkways 23

6.6.4. Conveyor belt and utility bridges 23

6.6.5. Overhead cranes 24

6.6.6. Hoists, monorails 24

6.7. SILOS 24

6.8. STACK 24

6.9. COATING AND PAINTING 25

7. DESIGN SPECIFICATION 25

7.1. REINFORCED CONCRETE STRUCTURES 25

7.1.1. General 25

7.1.2. Structure 26

7.1.3. Joints 26

7.1.4. Floors and roofs 26

7.1.5. Edges and openings 26

7.1.6. Roof construction 26

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7.1.7. Minimum cover to main reinforcement 27

7.1.8. Minimum thickness of structural concrete elements 27

7.1.9. Minimum cover to foundation bolts 27

7.1.10. Minimum height of pedestals 28

7.1.11. Movement joints 28

7.1.12. Machine foundations 28

7.1.13. Minimum & Maximum Reinforcement 30

7.2. STEEL STRUCTURES 30

7.2.1. General 30

7.2.2. Permissible stresses 31

7.2.3. Minimum thickness 32

7.3. SILOS 32

7.3.1. Silo foundation 33

7.3.2. Concrete silos 33

7.4. MASONRY WORKS 33

7.4.1. General 33

7.4.2. Cement mortar 33

7.4.3. Fire walls 33

7.5. SHED TYPE STRUCTURES 34

7.5.1. Day lighting 34

ANNEXURE-1: SAMPLE CALCULATIONS OF WING LOAD

ANNEXURE-2: SAMPLE CALCULATIONS OF SEISMIC LOAD (FROM STAAD).

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1. GENERAL

This specification establishes the minimum design criteria and technical requirements that shall be followed
for the structural design of steel structures, ducts, reinforced concrete structures and foundations, other steel
and metallic components (e.g. roofing, cladding, etc.)

The guidelines and Standards set within this design criteria are to be used as a rational approach to the design
of all buildings and structures that are part of the project. The life of structures should be taken as 50 years in
design.

However, literal adherence to elements of this specification shall not relieve the Contractor/Consultant of
ultimate responsibility for accomplishing the intent of the specification.

2. LOCAL LAWS, CODES AND STANDARDS (LCS)

Structural design shall comply with in force American Codes and this Specification.

Contractor/Consultant shall take into account all applicable LCS in their latest revision, not limited to those
mentioned in this specification.

The design & drawings shall be developed on the basis of the standard codes and documents listed below:

a. ACI 224R-01 Control of Cracking in Concrete Structure.

b. ACI 301-05 Specification for Structural Concrete for Buildings.

c. ACI 302-1R-4 Guide for Concrete Floor & Slab Construction.

i. ACI 318R-14 Building Code Requirement for Structural Concrete, Commentary on Building Code
Requirement for Structural Concrete.

d. ACI 336.2R-88 Suggested Analysis & Design Procedure for Combined footings & Mat.

e. ACI 350-06 Environmental Engineering Concrete Structures.

f. ACI 350.3-06 Seismic Design of Liquid Containing Concrete Structure and commentary.

g. ACI 351.3R-04 Foundation for Dynamic Equipment’s.

h. ACI 530-05 Building code Requirement for Masonry Structure.

i. ACI 543-00 Design, Manufacture, and Installation of Concrete Piles.

j. ANSI/AISC-360-05 AISC Steel Construction Manual 14th Edition & AISC Specification for
Structural Steel Building.

k. AISC Manual for Steel Construction – Load and Resistance Factor Design (LRFD) .

l. ANSI/AISC-341-02 Seismic Provisions for Structural Steel Buildings.

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m. AWS D 1.1 Structural Welding Code.

n. ASCE/SEI 37-02 American Society of Civil Engineers – Design Loads on structures during construction.

o. ASCE/SEI 7-10 Minimum Design Loads For Building & Other Structures.

p. ASCE/SEI 7-05 Wind and Load Combination

q. UBC 1997 Uniform Building Code

r. BS 4.1-1993 Structural Steel Sections Part-1 Specification for Hot Rolled Sections

s. BS 4190-2014 Black Hexagonal Bolts

t. API 650 Welded Steel Tanks for Oil Storage (Seismic Design)- Twelfth Edition.

u. ASTM C39M-05 Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens.

v. ASTM C 150 Standard Specification for Portland Cement.

w. ACI 360 Guide to design of slab on grade.

x. ASTM A36/A36M-2 Standard Specification for Carbon Structural Steel.

y. ASTM325 Standard Specification for Structural Bolts, steel, heat treated,120/1-5 ksi min. tensile
strength.

z. ASTM A572/A572M Standard Specification for High Strength Low – Alloy Columbium-Vanadium
Structural Steel.

aa. ASTM A500 Specification for Hollow Structural Sections (HSS).

bb. ASTM C55 Specification for Concrete Brick

cc. ASTM F1554 Specification for Foundation Bolt.

dd. BS EN-10025-2 Hot Rolled Products for Structural Steel (S235JR/S275JR/S355JR)

ee. ASME B30.11-2010 Monorails & Underhung Cranes

ff. CMAA Crane Manufaturer’s Association of America

gg. NFPA Code for Safety to Life from Fire in Buildings & Structures.

hh. MBMA Material Building Manual 2006, Metal Building Manufacturer’s Acssociation (MBMA)

ii. ARS13120 Pre-engineered Metal Building Specification.

jj. ASTM A615 Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete.

kk. ASTM A706 Standard Specification for Deformed & Plain Low-Alloy Steel Bars for Concrete
Reinforcement.

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ll. RCSC Research Council on Structural Connections – Guide to Design Criteria for bolted & Riveted
Joints.

mm. SSPC Steel Structure Painting Manual.

nn. EN1991-4(2006) Design loads for buildings (Loads in Silo bins) for silo analysis

For general notes and specifications drawing no. E23C01-1-GEN-G-01 shall be referred.

In case of conflicts between LCS and this Specification, the specification shall prevail.

For those cases do not covered by LCS, the application of equivalent international Laws, Codes and Standards
of attested reliability (e.g. EN, DIN, BS, ASTM, ACI, AISC, API....) may be proposed by the Contractor/Consultant
to Owner for its approval, after confirmation of applicability.

UNITS: Calculations and drawings shall be made with SI units.

Language: Calculations and drawings shall be made with English text

3. MATERIAL

Material shall be clearly indicated in the design drawings and it shall be used for the construction.

3.1. CONCRETE

Contractor/Consultant shall take into account, in addition to the resistance requirements, also the durability
requirements and the environmental conditions for the definition of the concrete class to be used and of the
related concrete mix design.

Unless noted otherwise reinforced concrete conforming to ACI 301-05 code shall be used using 20mm and
down size graded crushed stone aggregate.

3.1.1. Cement

Unless otherwise specifically required, cement for RCC, Lean and PCC concrete works shall be as per ASTM C
150 Standard Specification for Portland Cement.

Below Ground SRC cement shall be used and above ground OPC cement shall be used. For Silos, GGBS cement
may be used.

The type of cement selected shall be appropriate for the intended use.

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3.1.2. Concrete grade

Minimum requirements for concrete classes to be used in the design are reported below:

For Flooring and pavement work C25 Grade min.

General reinforced concrete (For all buildings) C35 Grade min.

Heavily Loaded Columns (Such as Preheater Columns ) C40

Post tensioning concrete/silo slipform work(All silos) C45 Grade min.

If needed for particular applications, and for durability, a higher class of concrete shall be used.

3.1.3. Plain Cement Concrete (PCC)

Plain cement concrete of grade C20 of minimum 100mm thickness (using 20mm and down size graded crushed
stone aggregate) shall be provided under all masonry wall foundations.

Plain cement concrete of grade C20 (by weight) of minimum 40mm thickness (using 10mm and down size
graded aggregates) shall be provided as damp proof course at plinth level of all masonry walls.

3.2. REINFORCEMENT BARS FOR CONCRETE

High strength deformed (HSD) TMT steel bars of minimum grade Fe 500, conforming to ASTM A706M shall be
used.

Code Grade Min. Yield strength Tensile strength MPa Elongation

MPa
A706M GR80 500 690 12%

Permissible stress in steel reinforcement (Ref: ACI 301-05)

3.3. STRUCTURAL STEEL

Structural steel shall be of yield stress of 250 MPa confirming to ASTM A36/A50.

Mechanical properties of structural steel: Yst 250 Yst 240

Tensile strength 410 MPa 410 MPa

Yield stress 250 MPa 240 Mpa

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Percentage elongation 23 % 17 %

Modulus of elasticity ”E” 2.0 x 105 MPa 2.0 x 105 MPa

Grade Designation Tensile strength Yield stress

A36 ASTM A36 400 250
A50 ASTM A572 450 345
A50 ASTM A992 450 345

3.4. BOLTS

Bolts shall be of grade 8.8/10.9.

Bolts grade 10.9 can be used if requested in particular connections. In principle only one grade of bolt will be
used in each structure.

In case different grades of bolt (8.8 and 10.9) are required to be used in a structure, Contractor/Consultant
shall submit, for Owner's review, a control procedure to ensure the correct use of each grade of bolt during
the construction, in order to avoid mistakes (e.g. typical mistake is using the lower grade of bolts in the
connections).

In any case, only one grade of bolt shall be used in each connection. And shall be as per ASTM A325

3.5. ANCHOR BOLTS

Material for Anchor Bolts such as MS bars, washers, nuts, pipe sleeves and plates etc. shall be as per ASTM
F1554 grade 36 and 55(8.8 Grade).

4. DESIGN LOADS

Buildings and other structures shall be designed to resist, as a minimum requirement, to the loads as specified
in the ASCE/SEI 37-02, SEI 7-10 and in this specification. In case of different indications, the most conservative
and stringent value shall be applied.

In addition to the loads specified in this section, other loads according to the good engineering practice shall
be considered where necessary. These shall include, but are not limited to, dynamic conditions, earth pressure,
vehicles, buoyancy, particular environmental conditions and erection loads.

Loads for future provisions shall be considered when specified by the Owner.

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4.1. DEAD LOAD

Dead loads include self-weight of structure, foundation, and all permanently attached appurtenances (e.g.
piping, valves, fireproofing, insulation, finishing, etc).

Weight of fixed process equipment and machinery are to be treated as dead loads; the weight shall include all
relevant permanent fixture related to the equipment, such built-in partitions, fireproofing, refractory lining,
insulation, piping, electrical conduits, etc.

Equipment loads shall be provided by Suppliers/Manufacturers.

An additional minimum uniform dead load of 1.0 kN/m² shall be included in the design of roofs and floors of
buildings and structures to take into account the dust load and the load due to lighting, HVAC, cable tray and
fire protection sprinklers (0.1 kN/m²).

Contractor/Consultant shall take into account connections, stiffeners, bolts, etc. in the self-weight of the steel
structure. An accepted and simplified method consists in considering the steel specific weight of sections
increased minimum by 8%.

Contractor/Consultant shall design all buildings for both configurations: cladded and not cladded. Weight of
cladding shall be considered into dead loads.

4.1.1. Soil and hydrostatic pressure

The weight and pressures due to soil shall be considered as per the recommendations of the geotechnical
investigation report.

Pressure on basement walls

In the design of basement walls or similar (approximately vertical) structures below grade, provision shall be
made for resisting lateral pressure of the adjacent soil. If a portion or whole of the adjacent soil is below free
water surface, pressure computations shall be based on the diminished weight of the soil (due to buoyancy)
plus full hydrostatic pressure. Due allowance shall also be made for possible surcharges from fixed or moving
loads. K0=0.5 at rest shall be considered in design.

4.1.2. Material densities for Dead load

❖ Ranforced Concrete: 25 KN/m 3

❖ Concrete(Without reinforcement): 24 KN/m3
❖ Brick (Masonry wall): 20 KN/m3
❖ Soil : 18 KN/m3
❖ Structural steel : 78.5 KN/m3
❖ Thermal block wall : 23.75 KN/m3
❖ Solid Block wall : 17.85 KN/m3

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4.2. LIVE LOADS

Live loads include the action produced by occupancy, stored materials, process pressures, cranes, vehicles,
etc.

4.2.1. Occupancy

Live loads are produced by the use and occupancy of the building or structure.

Minimum live load values shall be the more conservative between LCS and the following:

❖ Stairs and Exit ways: 2.5 KN/m2

❖ Operating floors: 5.0 KN/m2
❖ Walkways, access platforms & local maintenance floors: 2.5 KN/m2
❖ False Ceilings 0.6 KN/m2
❖ Belt conveyor bridges:
I. Working areas: 2.5 KN/m2
❖ Control rooms & electrical floors: 10.0 KN/m2
❖ Preheater Tower:
I. Main floors: 5.0 KN/m2
II. Kiln inlet floor(Specific area marked for brick storage): 15.0 KN/m2
❖ Burner stand floor: 20.0 KN/m2
❖ Storage areas:
I. Brick pallets storage: 10.0 KN/m2
II. General storage areas: 10.0 KN/m2
❖ Roofs:
I. Non accessible/sloping roofs(with reduction for the slope of the roof): 0.75 KN/m 2
II. Accessible/flat roofs (Concrete): 2.0 KN/m2

4.2.2. Bulk materials

For the design of storages, values for material bulk densities and angles of repose shall be taken as below.

ANGLE OF ANGLE OF
DENSITY FOR DENSITY FOR
REPOSE DURING REPOSE DURING
MATERIAL SIZING CIVIL DESIGN
FILLING EMPTYING
(MT/M3) (MT/M3)
(IN DEGREE) (IN DEGREE)
Raw Meal 1.1 1.4 10
Clinker 1.4 1.8 34
Cement 1.3 1.6 10
Fly Ash 0.8 1.5 38
Gypsum 1.4 1.65 38
Coal 0.8 1.0 38

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a. In particular, silo-loading Design shall be as per EN1991-4(2006) Design loads for buildings (Loads in
Silo bins) for silo analysis

All conditions have to be taken into account for filling and discharging of materials as well as the respective
dynamic effect due to uneven extraction of material and its impact effects. Effects of pneumatic extraction
should be taken into account as per LCS and process description.

4.2.3. Crane loads

Requirements for overhead cranes and monorails shall be as per relevant American Code.

i.e as per ASCE/SE17-16-AISC STEEL DESIGN GUIDE 7-PART 2

All support components of moving bridge crane and monorail cranes, including runway beams, brackets,
bracings, and connections shall be designed according to the most conservative between Manufacturer’s
instructions and American Code and in any case to support:

❖ the maximum wheel loads of the crane;

❖ the lateral and longitudinal forces induced by the moving crane with the trolley positioned on its
runway at the location where the resulting load effect is maximum.

The loads shall be amplified according to applicable industrial codes, in order to take into account the foreseen
normal working number of cycles/year.

Crane stops shall be designed according to American Code or Manufacturer’s requirement (the most
conservative).

Impact load of cranes

Type Vertical impact Lateral impact Longitudinal impact

Crane Power operated 25% 20% 10%
Monorail Power operated 25% 20% 10%
Monorail manual 25% 20% 10%

4.2.4. Dynamic loads

The dynamic effect of rotating or oscillating equipment on the supporting structure shall be considered during
the design.

Particular attention shall be paid for Dynamic Separators, Roll Presses, Crusher house, Mill foundations, Main
fan foundations, etc.

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For the above mentioned items dynamic analysis shall be performed in accordance to ACI 351.3R-04 and in
accordance to the manufacturer’s specification.

Use of Vibration Isolation system must be explored wherever possible particularly for the dynamic equipment
supported on structural floors.

4.2.5. Impact and vibratory loads

Structures subjected to impact or vibratory loads shall be designed as per the provisions of ANSI/AISC-360-05
or ACI 351.3R-04 whichever is applicable.

4.2.6. Vehicles loads

Buildings, trenches and underground installation accessible to vehicles shall be designed to withstand truck
wheel loads.

Floors accessible to vehicles shall be designed at least for a 3 Ton forklift:

❖ Floor load 20.0 KN/m2

❖ Wheel load 140.0 KN per axle. 2-wheels per axle. wheel pressure per 0,2m x 0,2m

Maintenance or construction crane loads shall also be considered where applicable.

Structures subjected to train loads shall be designed according to relevant American Code.

Vehicle impact loads shall be evaluated according to relevant American Code.

4.3. WIND LOADS

The basic wind speed on the site is 45 m/s (3 seconds gust effect),exposer category C, as per ASCE-7-05 and
UAE authorities requirement.

4.4. SEISMIC LOADS

The site is located in Zone-2A of seismic zoning as per Zone 2A of UBC-97. The design horizontal seismic co-
efficient shall be taken as per ACI-350.3-06. The importance factor to be considered as I = 1.0 and Z=0.15 for
design of structure against seismic forces for category -II.

As per the provisions of ductile detailing of reinforced concrete structures subjected to seismic forces (ACI-
350.3-06), shall be done. However, seismic analysis is needed to establish the design load combination.

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The Earthquake resistant design for various structures to be carried out in accordance to the provision made
in ACI-350.3-06, depending on type of structure. The definition of the participating masses is included in the
same code for each specific structure type.

Loading on silo bottom, in earthquake combinations, shall be taken with full magnitude (material-wall friction
neglected).

4.5. THERMAL LOADS

With sub-tropic climatic condition, site temperature varies from +55 deg. C to +5 deg. C.

Thermal loads and relative displacements shall be evaluated taking into account environmental and, process
temperature.

Thermal loads shall be included in the appropriate load combinations.

Suitable expansion joints should be planned as per relevant American Code.

4.5.1. Environmental

When any portion of a structure is not free to expand or contract under variation of temperature, allowance
shall be made for the stresses resulting from temperature changes by ±25°C for metal structures as well as for
plain and reinforced concrete structures.

Except as otherwise specified, thermal loads shall be computed and applied in accordance with LCS.

4.5.2. Process

All support structures, ducts, pipes and equipment shall be designed taking into account the loads or effects
produced by thermal expansion or contraction, according to process conditions including provision of
expansion joints.

Equipment design temperature shall be provided by the equipment manufacturer or the engineer in charge
of the process. Such temperatures shall be subject to Owner’s approval as specified by the process supplier.

4.5.3. Friction

Friction loads caused by thermal expansion shall be determined using the following coefficients:

❖ Friction steel to steel: 0.40

❖ Friction steel to concrete: 0.60
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❖ Friction steel to PTFE: 0.12

For other sliding surfaces or coatings, Manufacturer’s instructions shall be followed, duly taking into account
the presence of dust in the definition of the friction coefficient.

Friction loads shall be considered temporary and shall not be combined with earthquake loads.

4.6. ACCIDENTAL LOADS

Accidental loads represent actions, usually of short duration but of significant magnitude, such as explosion,
fire, abnormal operating loads or local failure. These actions shall be used for global and local checks.

Accidental loads and wind or earthquake loads shall not be combined together.

4.6.1. Abnormal operating loads for buildings

Accidental conditions occur when equipment, hoppers, vessels, conveyors, etc are full of material or dust up
to their capacities and they cannot operate anymore.

On the Preheater Tower, only one cyclone per string shall be considered plugged at one time. In case of
clogged cyclone, live load of 5,0 kN/m2 acting simultaneously on the clogged cyclone’s floor shall be
considered for the floor check, with a live load of 2,5 kN/m2 on all the remaining floors for the overall check
of the structure.

4.6.2. Accidental loads for ducts

Accidental loads are due to abnormal conditions in the process. The designer shall propose accidental
temperatures and pressures for Owner’s approval.

4.7. CONSTRUCTION PROGRESS LOADING CASES

Separate load cases corresponding to the stages of construction of the structure shall also be considered
where applicable, in consultation with the contractor.

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5. LOAD COMBINATIONS

According to American Code ASCE/SEI 7- 10, SEI 37-02, the described loads shall be combined

DL = Dead load defined in chapter 4.1

H = load due to lateral earth pressure, ground water pressure,

or pressure of bulk materials as applicable

LL = Live load defined in chapter 4.2

LL1 = Live Load for material in storage areas

LLr = Roof Live Load

WL = Wind load defined in chapter 4.3

EL = Seismic load defined in chapter 4.4

TL = Thermal load defined in chapter 4.5

AL = Accidental loading defined in chapter 4.6

Wind and earthquake loads shall not be considered to act simultaneously.

Also accidental loads (AL) shall not be combined with WL or EL.

5.1. LOAD COMBINATION FOR SERVICEABILITY (AS PER ASCE 7-05 CALUSE NO.2.4.1, PAGE NO.5)

1. 1.0DL
2. 1.0DL+1.0H+1.0LL+1.0LL1+1.0TL
3. 1.0DL+1.0H+1.0LLr
4. 1.0D+1.0H+0.75(LL+TL) +0.75LLr+0.75LL1
5. 1.0D+1.0H+1.0WL
6. 1.0D+1.0H+0.7EL
7. 1.0D+1.0H+0.75WL+0.75LL+0.75LLr+0.75LL1
8. 1.0D+1.0H+0.75EL+0.75LL+0.75LLr+0.75LL1
9. 0.6D+1.0WL+1.0H
10. 0.6D+0.7EL+1.0H

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5.2. LOAD COMBINATION FOR STRENGTH (AS PER ASCE 7-05 CLAUSE NO.2.3.2,PAGE NO.5)

1. 1.4DL
2. 1.2DL+1.6H+1.6LL+1.6LL1+1.2TL+0.5LLr
3. 1.2DL+1.0H+1.6LLr+1.0LL+1.0LL1
4. 1.2DL+1.0H+1.6LLr+0.8WL
5. 1.2DL+1.6WL+1.0LL+1.0LL1+0.5LLr
6. 1.2DL+1.0EL+1.0LL+1.0LL1
7. 0.9DL+1.6WL+1.6H
8. 0.9DL+1.0EL+1.6H
9. 1.2DL + AL +0.5LL+0.5 LLr
10. 0.9DL + AL +0.5LL+0.5 LLr

6. DESIGN PROCEDURE

All designs shall be as per the relevant American Codes following Limit State Design method.

All structures shall be checked and designed to satisfy the worst load combinations associated to the maximum
stress ratio and/or the maximum deflection.

6.1. LIMITING DEFLECTION

The more stringent value between the next tables and the American Code/MBMA shall be taken into account.

6.1.1. CONCRETE BUILDINGS

Control of Deflection

The maximum permissible computed deflections, depending on the type of member and deflection to be
considered, are presented in Table 13 (Refer Table 24.2.2 – ACI 318 -14)

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Drift check

Maximum allowable inter-story drift shall satisfy the requirements of UBC97-Volume 2 and ASCE-7/SEI 05.

6.1.2. STEEL STRUCTURE

Limiting vertical and horizontal deflection for structural members will not exceed the recommendations of
relevant code and standards. Some indicative allowable values are given below but Codal (IBC-2009 / ASCE/SEI
7-05 / ACI-318 chapter 24 / MBMA Metal Building System

Maximum Vertical Deflection to Span Ratio

Members Vertical Deflection Load Case Code Reference

Span/150 or as otherwise Table 3.1 – MBMA2006
Roof Purlins and Side Girt recommended by the --
cladding system vendor
Roof Members Span/240 Live/Wind Table 1604.3 – IBC2009
Supporting nonplaster
ceiling Span/180 Dead + Live
Roof Members Not Span/180 Live /Wind Table 1604.3 – IBC2009
supporting ceiling
Span/120 Dead + Live
Floor Members & Beams Table 1604.3 – IBC2009
Span/360 Live
supporting pipes
Span/ 240 Dead + Live
Monorail Design Guide 3, 2nd
Span/450 Dead +
Edition / Serviceability
Operational
load Design Considerations For
Steel Buildings
Crane runway beams Table 3.5-MBMA2006
Span/600 Crane
CMAAA, B & C
Lateral
Static Load
Crane runway beams Span/800 Crane Lateral Table 3.5-MBMA2006
CMAA D Static Load
Crane runway beams Span/1000 Crane Lateral Table 3.5-MBMA2006
CMAA E& F Static Load
Cantilevered beams Span/180 Dead + Live BS EN 1993-1-
(excludingequipment 1:2005,7.2.1(1)B
support)

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Maximum Horizontal Deflection to Height Ratio

Members Horizontal Deflection Code Reference

Building and structures Height/300 BS EN 1993-1-
1:2005,7.2.1(1)B
Metal Wall Panels Design Guide 7,
Industrial Building-
1. Frame Deflection Eave Height/ 60 to
100 roofs to Anchor Rods,
(Perpendicular to 2nd Edition
the wallsurface of
frame)
2. Girts and Wind Length / 120
columnsDeflection
Crane runway beams Span/400 Table3.5-MBMA2006

Bare frame – Drift at Runway

Elevation
Table 3.5-MBMA2006
1. Top Running Cab Operated
H/240 ≤ 1-IN. Maximum
2. Top Running Pendant
Operated H/100 ≤ 1-IN. Maximum

Differential Horizontal Deflection between parallel crane girders shall be limited to maximum of 20 mm or as
per crane supplier specification.

Contractor/Consultant shall guarantee that the vertical and horizontal deflection will meet the requirements
given by the equipment suppliers and plant serviceability, if more stringent, than the indications given above.

6.2. SOFTWARE

Internationally accepted commercial licensed software viz. STAADPRO, STAAD FOUNDATION, RCDC shall be
permitted for analysis and design.

6.3. SOIL PROPERTIES

For soil information reference shall be made to the Geotechnical report to be developed by Client/Contractor
and approved by consultant. Table for SBC consideration for different building will be added later.

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6.4. FOUNDATIONS

Type of cement, grade of concrete, minimum cement content and maximum water cement ratio (for
concrete), minimum cover to reinforcing steel to be used in foundations and substructures and any other
remedial actions required for foundations due to aggressiveness of sub soil/water shall be as per the
Geotechnical data.

NGL (Natural ground level) and FGL (Finished ground level) shall be marked on all drawings showing
foundation/sub-structure details and related design documents.

Minimum depth of foundation for all structures shall be as per Geo-technical data. Depth of ground water
level shall be as per the Geo-technical data and hydrostatic pressure shall be adequately accounted for in the
design.

6.4.1. Equipment foundation

Machine/static equipment foundations shall be separated from adjoining parts of buildings, other foundations
and floor/pavement slabs.

Joints at floor/pavement slabs shall be suitably sealed.

Isolation devices shall be approved by Owner.

Resonant conditions shall be avoided: foundations and structures for machines subject to vibrations shall be
so proportioned that the amplitude and frequency of the foundation/structure are within the permissible
limits as per relevant American codes (or as required by the machine vendor).

Machine foundations shall be designed and detailed as per ACI 351.3R-04

Structural vibrations are limited by the equipment and machinery supplier requirements.

6.4.2. Settlement

Safe bearing pressure (allowable net safe bearing capacity) shall be based on the following minimum criteria
under Dead Load + Live Load (or with Operating) condition:

❖ Foundations in unit areas, utility areas and foundations for Plant buildings 25mm settlement
❖ Raft Foundations 50mm settlement
❖ Silo Raft Foundation 75mm settlement

Contractor/Consultant shall guarantee that the settlements will meet the requirements given by the
equipment suppliers and plant serviceability, if more stringent than the indications given above.

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As per IBC 2009, Section 1806, mentioned in soil report , the values of vertical foundation pressure shall be
permitted to be increased by one-third, when used with alternative basic load combinations, that include wind
load and earthquake loads.

6.4.3. Foundation Stability

As per IBC 2009,

Factor of safety against overturning – 1.5 for overturning due to characteristic dead load and 1.5 for
overturning due to characteristic live load.

Factor of safety against sliding – 1.5

For all stability calculations, only 0.9 times the characteristic Dead load should be taken into account.

6.5. CONCRETE STRUCTURES

Unless otherwise specified elsewhere in this document only ACI 318 shall be followed in the design.

Limit state of serviceability i.e. deflection and cracking shall be checked for all RCC structures in accordance to
the relevant American Code.

6.6. STEEL STRUCTURES

The steel structures are shop welded/bolted construction. Shop splices for all main members shall generally
be developed by full strength butt welds of controlled quality. Cover plates may also be used for additional
precaution.

As a general rule, welding on site is avoided as far as possible. Site connections and splices will be deigned
bolted with high strength bolts for all main structural elements.

If, for any major reason, site splices or connections are to be developed by welding necessary erection bolts
will be provided. This alternative is only permitted for secondary members and after OWNER’s approval.

6.6.1. Joints and bracing system

Expansion joints shall be provided to accommodate thermal effects.

The buildings and structures shall be designed for adequate rigidity and stability in both lateral and longitudinal
directions.

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Special consideration will be given in the design of floors or structures supporting mechanical equipment to
minimize vibration and maintain alignments and levels.

6.6.2. Floors and roofs

Floors in all sections of production departments, where no particular operation or loading requirements could
restrict the adoption of such a construction principle, shall be designed as steel frame covered with chequered
plates.

The use of steel open grating shall, in general, be avoided for main floors. As indicated above, floors of sections
in which heavy equipment is installed and operated or that should sustain severe loading conditions, shall be
made of RCC.

6.6.3. Stairs, ladders and walkways

Staircases are generally to be provided instead of vertical ladders, except where ladders are absolutely
necessary. Staircase inclination shall be 35 to 40 degree & maximum riser should not exceed 180 mm.
Minimum Headroom shall be 2.30 M. Standard staircase width shall be 1.2 M & in some exceptional cases can
be reduced to 0.80 M

In production buildings, all stairs are to be made of steel with chequered plate of minimum thickness not less
than 5/7 mm or open gratings (in places of possibility of dust accumulation).

Cross-over above conveyors and other equipment and structures will be made heavily caged to guard against
any accident of personnel from any moving or rotating equipment.

Walkways, platforms, staircase and ladders will be properly designed and heavily caged to guard against any
accident of personnel from any moving or rotating equipment.

6.6.4. Conveyor belt and utility bridges

Conveyor belt gallery shall be designed to support the pull of the belt and not to transfer the pull of belt to
external supporting structures (e.g. only vertical actions shall be transferred to supporting structures/silo by
the driver/motor).

Conveyors placed above ground shall be carried on closed or open type bridges of structural steel with
reinforced concrete foundations.

The conveyor bridges shall be provided with accessible walkways, giving a minimum clear width of 800 mm.
Walkways shall be provided also between multiple conveyors leaving a minimum clear width of 800 mm.
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Platforms that are not enclosed shall be fully guarded with hand railing. If not otherwise specified, the
conveyor walkways shall be of grating. Steps of clinker conveyor walkways shall be with gratings.

Steel plate (e.g. 3mm thickness minimum, to be provided under conveyors and grating walkways running
above road, machinery etc., in order to avoid dust falling below conveyor galleries).

Columns or trestles supporting conveyor bridges shall be spaced so as to provide a minimum of 10 m clear
access between columns. Where bridges cross access roads or hard standings, a minimum height of 6 m shall
be provided from surfaced ground level to the underside of the conveyor bridge.

6.6.5. Overhead cranes

Rails, stoppers, etc. to be provided. Rails shall be laid true to line (maximum tolerances of +/-2.5 mm in gauge
and level) in accordance with the requirements of the crane manufacturer.

Access to motor, drive and accessories shall be provided.

6.6.6. Hoists, monorails

Where hoists or monorails are specified, all necessary supporting beams, anchors, fixing bolts, etc. shall be
installed. Wherever required, maintenance facility with handrails and other safety precautions shall be
provided.

6.7. SILOS

Cracks control verifications for the silos have to be submitted together with the structural analyses. The
following maximum surface crack widths (Wm, permanent loads) will be allowed:

❖ Wm = 0.2 mm for blending and clinker silos

The shuttering for the cylindrical walls shall be executed with sliding forms.

The silos roof shall be watertight with roof waterproofing treatment.

6.8. STACK

Steel stacks shall be designed as per the requirements of relevant American code. The minimum plate
thickness for steel stacks shall be 8mm and an additional corrosion allowance of 2mm shall be considered.

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6.9. COATING AND PAINTING

Contractor/Consultant shall take into account the process condition and shall propose for Owner’s approval
alternative coating and/or painting procedures if supported by references.

7. DESIGN SPECIFICATION

7.1. REINFORCED CONCRETE STRUCTURES

7.1.1. General

I. All buildings, structures, foundations, machine/equipment foundations, liquid retaining/storage

structures, pipe/cable trenches, pits, etc. shall be designed based on referenced American Codes in
general and other relevant American Codes as applicable. It shall be ensured that the skin temperature
of concrete at no time exceeds 80°C.

II. All structures shall be of frame-type construction.

III. All machine/equipment foundations, cable/pipe trenches shall be of RCC construction only.
Cable/pipe trenches shall be suitably sloped and adequate provision shall be made for draining out of
accumulated water.

IV. Cable and pipe trenches shall be provided with precast covers, adequately designed for the anticipated
traffic movement (Cranes/Hydra etc.). Trenches of different category of loading shall be clearly
identified for design. The covers shall, however, be designed for a minimum uniformly distributed load
of 20 kN/m2. The walls of cable trenches shall be designed to resist a minimum surcharge load of 10
kN/m2.

V. Foundations placed at varied depths shall be designed considering bearing capacity at that particular
level as per the soil report.

VI. If the specified design depth of ground water table so warrants all underground pits, tunnels,
basements, cable trenches etc. shall be provided with leak-proof treatment.

VII. Inter mixing of different grades of concrete in the same structure/structural element (excepting
columns, walls, etc. with element extending in sub and super structure both) shall not be accepted.

VIII. Inter mixing of different grades of steel (main reinforcement) in the same structure shall not be
accepted.

IX. RCC pits, tanks etc. for storage of corrosive liquids shall be provided with suitable anticorrosive
treatment.

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7.1.2. Structure

RCC structures are in general be designed as monolithic frames, that is, all bearing elements-columns and load
bearing walls, slabs and their supporting beams and girders made of RCC and closely linked to each other by
the reinforcing bars.

7.1.3. Joints

Expansion, Construction and shrinkage joints of suitable features will be also provided at the required location
and according execution stages.

7.1.4. Floors and roofs

All RCC floors of production departments will be provided with a surface finish well adapted to the particular
use for which it is intended.

All RCC roof slabs are to be provided with a waterproof.

Pits and underground constructions for installations or equipment will as far as possible, be avoided.

The ground floor level of the buildings above the finished site level around the respective sections shall be as
follows:

❖ for plant buildings: 400mm (including 200mm of walk side)

❖ for all auxiliary buildings: specified in the Architectural G.A. drawings for each single building

7.1.5. Edges and openings

Edges of concrete slabs and other constructions at places where a risk of damage exists, or when required for
fixing guard – rails, supports for walkways and others, will be protected by embedded steel angles or channels.

The same applies to all edges of openings in slabs for staircases and passages for equipment.

7.1.6. Roof construction

Roofed buildings shall have waterproof roofs.

Production/auxiliary buildings shall have drainage outlets and discharge pipes connected to the plant drainage
system with proper arrangement without affecting the construction foundations.

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7.1.7. Minimum cover to main reinforcement

The minimum cover to the reinforcing bars considering corrosive environment shall be as listed below or equal
to the diameter of the bar, whichever is greater:

MINIMUM COVER
POSITION
(mm)
Internal Beams, Columns, and internal faces of
40
externalbeams and columns (above ground)
Cast-in-situ slabs and walls (above ground) 40
Externally exposed faces of Beams and Columns 50
Cast-in-situ walls (below ground) 75
Shallow Foundations, Ground Beams, Tie
75
Beams, Slabsand Columns in contact with soil
Piles, Pile-caps and diaphragm wall foundation 100

7.1.8. Minimum thickness of structural concrete elements

The following minimum thickness shall be followed:

❖ Footings (All types - With/without beams) 300mm

❖ Slab thickness in Raft foundations with beam and slab construction 150mm
❖ Basement wall 200mm
❖ Floor/Roof Slab, Walkway and Canopy Slab 125mm
❖ Cable/Pipe Trench/Launder Walls and Base Slab 125mm
❖ Parapet 100mm
❖ Pre-cast Trench Cover/Floor Slab 100mm
❖ Liquid Retaining / Leak Proof Structure:
I. Walls 150mm
II. Base slab with beams 200mm
III. Base slab without beams 300mm
❖ Underground Pit:
I. Walls 150mm
II. Base Slab with beams 200mm
III. Base slab without beams 300mm

7.1.9. Minimum cover to foundation bolts

Minimum distance from the center line of foundation/anchor bolt to edge of pedestal shall be the maximum
of the following:

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❖ Clear distance from the edge of the base plate/base frame to the outer edge of the pedestal shall be
minimum 50mm.
❖ Clear distance from the face of pocket to the outer edge of the pedestal shall be 75mm.
❖ Clear distance from the edge of the sleeve or anchor plate to the edge of pedestal shall be 75mm.

7.1.10. Minimum height of pedestals

The minimum projection of outdoor/indoor pedestals supporting equipment/structures shall be 300mm and
150mm respectively above the high point of pavement/finished grade level/finished floor level, whichever is
higher. And for conveyor trestles/transfer towers pedestal height 1000mm above finished ground level to be
adopted.

7.1.11. Movement joints

Expansion and/or separation joints in non-suspended ground floor slab shall be filled with sand for the full
depth of slab except the top 12mm which shall be filled up with approved two part liquid polysulphide sealing
compound. Joints in basement slabs shall be made leak proof by providing PVC water stops.

Joints in the super-structure shall be provided by means of gap between two consecutive structural members.
The gap shall be based on the design requirements and shall be treated to a minimum as under:

❖ When the vibrating equipment is separately supported on a structure, a clear air gap shall be provided
between the vibrating equipment supporting structure and the surrounding floor with provision of
suitable moulding/kerb to stop any leakage/overflow of any floor wash to the next lower floor.

❖ In normal floors, expansion and/or separation joints shall be covered both on top and bottom with
3mm thick Aluminium sheet fixed on both sides of the joint with brass screws. Provision of movement
on one side shall be kept with proper slotted holes. Similar cover plates shall be provided for all
exterior columns on both interior and exterior faces. The edges of these plates shall be properly
chamfered. Bitumen impregnated fiber board shall be used between the gap of the two members on
either side of the joint for the full depth in such movement joints. The top 12mm depth shall be filled
up with two-part liquid polysulphide sealing compound as per relevant code.

7.1.12. Machine foundations

Machine foundations shall satisfy the following requirements:

The minimum grade of concrete to be used shall be C35.

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Minimum reinforcement as per requirements of ACI 351.3R-04 shall be provided unless required otherwise by
design.

The soil stress below foundations under dead loads shall not exceed 50% of the allowable soil bearing capacity,
or safe load on pile, for static loading.

The combined center of gravity of the machine and foundation system shall, as far as possible, pass through
the center of area of the foundation raft or centroid of the pile group. Where unavoidable, eccentricity shall
be less than 5% for block foundations and 3% for frame foundations.

Foundations shall be so designed that natural frequency of the foundation system shall not resonate with the
following:

❖ Operating speed of the motor.

❖ Operating speed of the machine.
❖ Critical speed of the machine (for centrifugal machines).

Natural frequency of the foundation shall preferably be +20% away from the above-mentioned frequencies.
However, amplitudes of vibration of the foundation block shall always be checked to be within permissible
limits.

Amplitudes of vibration shall be less than values specified by the machine manufacturer. If not specified,
provision of ACI 351.3R-04 shall be followed.

The foundation and its superstructure shall be separated from adjacent foundations and platforms. Clear air
gaps shall be provided in the superstructure to avoid transmission of vibration to adjacent structures. Special
note shall be given on the drawing in this respect, and suitable details shown as required.

Foundations resting partly on rock and partly on soil shall preferably be avoided. However, if unavoidable, the
soil area shall be replaced by Plain Cement Concrete. However, Owner/owner’s representative concurrence
shall be obtained for such cases.

Foundations shall not rest on previously backfilled or sensitive soils.

A properly designed construction joint shall be provided between the base slab and columns.

The entire superstructure of columns and upper deck shall be cast in a continuous concreting operation.

If height of the frame columns above raft level exceeds 8.0m, an additional construction joint at the junction
of columns/top-deck may be provided.

Block foundations shall be cast in a single concreting operation.

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7.1.13. Minimum & Maximum Reinforcement

Minimum reinforcement in the concrete block shall not be less than 25 kg/m3. For machines requiring special
design consideration of foundations, like machines pumping explosive gases, the reinforcement shall not be
less than 40 kg/m3.

Minimum & Maximum percentage of reinforcement in various structural elements shall be as follows.

Element Minimum % Maximum %

Column vertical reinforcement 1% 4%

(of required cross section area)
Slab Tension reinforcement 0.12 % -
Beam Tension reinforcement 1.4
OR
0.25√𝑓𝑐
(Whichever is 2%
𝑓𝑦 4𝑓𝑦
maximum)
0.28% for Fe500
Vertical reinforcement (Normal 0.12 % -
concrete wall)
Horizontal reinforcement 0.10 % -
(Normal concrete wall)
Silo wall vertical reinforcement 0.2 % (including both faces) -
Silo wall horizontal 0.25 % (including both faces) -
reinforcement
Concrete pedestal 1.0% -

7.2. STEEL STRUCTURES

7.2.1. General

Design, fabrication and erection of the above works shall be carried out in accordance with the referenced
ASTM Codes in general and other codes as applicable to the specific structure.

Basic consideration of structural frame work shall primarily be stability, ease of fabrication/erection and
overall economy satisfying relevant Indian Standard Codes of Practice. Simple and fully rigid design as per
ASTM standards shall be used. Where fully rigid joints are adopted they shall generally be confined to the
major axis of the column member.

Structural elements continuously exposed to temperatures above 200°C shall be designed for reduced stress
as per relevant American Code. The expected temperature of steel components shall not be allowed to exceed
400°C.

Crane gantry girders shall generally be of welded construction and of single span length. Chequered plate shall
be used for gantry girder walkway flooring.

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Electro-forged hot dipped galvanized welded MS Gratings shall be minimum 25mm deep. The maximum size
of voids in the grating shall be limited to Galvanized gratings: Mesh Size 35mm X 100mm and flat 25mm X 5
mm thk at 35mm c/c and distribution square bar 5mm, 100mm c/c, permitted uniformly distributed load
capacity of 5 KN/m2. Gratings shall be electro-forged with hot dip galvanizing of average zinc coating of
610gm/sqm.

To the maximum extent possible all fabrication work shall be done in the Contractor/Consultant’s shop. Field
fabrication shall be authorized in written by the Owner connections for structural steel shall be shop welded
and field bolted, unless otherwise indicated for particular cases. Structural connections shall have minimum
two bolts of 12 mm dia. unless otherwise limited by the size of members.

Minimum two nuts shall be used for all anchor bolts.

All steel bars, sections, plates, and other miscellaneous steel materials, etc. shall be free from loose mill scales,
rust as well as oil, mud, paint or other coatings. The materials, construction specifications such as dimensions,
shape, weight, tolerances, testing etc, for all materials covered under this section, shall conform to respective
BIS codes.

7.2.2. Permissible stresses

Permissible stresses in structural members, Bolts, welds shall be as specified in relevant American Code:

Basic consideration of structural frame work shall primarily be stability satisfying relevant American Codes
and specifications given herein.

Crane gantry girders shall be of welded construction and of single span length. Splicing in the girder shall not
be permitted. Chequered plate shall be used for gantry girder walkway flooring.

Unless otherwise permitted in writing by Owner/owner’s representative only welded connections shall be
adopted. All permanent connections shall have at least two 12 mm diameter bolts.

All connections shall be designed for full moment carrying capacity of the connecting members together with
60% full shear carrying capacity for sections with depth 200mm and above and 50% full shear carrying capacity
for sections with depth less than 200mm or for the actual design forces, whichever is more.

All fabricated structures (except electrical switchyard structures and transmission towers) shall be given one
shop coat of primer compatible with the final paint system. The paint system shall conform to the painting
specification.

Gusset plates of different thicknesses shall not be used in the same truss or girders. Gusset plates for all bracing
shall be of same thickness as that used for truss/girders unless a higher thickness is required by design.

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If so required by piping support detail, minimum 20mm diameter plain round MS rod shall be welded on the
top flange for full length on all transverse beams and at locations where pipes are supported on longitudinal
beams of pipe racks, pipe supporting structural members.

7.2.3. Minimum thickness

The minimum thickness of various structural components (Hot rolled sections) shall be as given:

❖ Trusses, purlins, side girts and bracings 6mm

❖ Columns, beams 7mm
❖ Gussets in trusses and girders:

i. Up to and including 12m span 10mm

ii. Above 12m span 12mm

❖ Stiffeners 10mm
❖ Base plates 12mm
❖ Chequered plate 6mm (on plain)
❖ Grating flats 5mm
❖ Insert plates 12mm

The minimum thickness for rolled beams and channels shall be the mean flange thickness regardless of the
web thickness.

The minimum thickness of structural components (except gratings and chequered plates), which are directly
exposed to weather and inaccessible for repainting, shall be 8mm.

The minimum thickness of tubes shall be 4 mm as specified in ASTM A500.

Structural members exposed to marked corrosive action shall be increased in thickness or otherwise suitably
protected against corrosion.

7.3. SILOS

For silos of large storage capacity, concrete solutions (either in-situ cast RCC or pre-stressed concrete) should
be considered as per design.

Feed bins and silos of less capacity may be designed in steel construction as well as their supporting structures,
unless otherwise prescribed in the description of the works or agreed.

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7.3.1. Silo foundation

The concrete silos shall be constructed in watertight reinforced concrete with or without cable post-
tensioning. If post-tensioning shall be used, the respective essential characteristics shall be submitted for the
Owner's approval.

7.3.2. Concrete silos

The method of construction to be considered while designing the silos shell will be of the slip forming
technique. All construction provisions and details will be consequently designed, as, for example, steel
reinforcement and/or pre-stressing material disposition, connecting joints between shell and slabs, inserted
and embedded parts to be placed during the construction, etc.

All silo foundation supporting walls and columns and bottom slabs are to be designed as in-situ cast RCC.

Intermediate floors for equipment may be designed as in-situ or precast concrete slabs supported by steel or
prefabricated concrete girders.

Roofs for silos will be supported by steel girders.

The roof slab shall be designed as in situ on deck sheet.

7.4. MASONRY WORKS

7.4.1. General

All masonry works shall be designed in accordance with the latest revision of referenced relevant American
Codes in general as applicable to the specific structure.

7.4.2. Cement mortar

All masonry work shall be constructed in cement sand mortar 1:5 for load bearing walls and 1:6 cement sand
mortar for non-load bearing walls except half brick partition walls which shall be constructed in 1:4 cement
sand mortar with two numbers of 6mm diameter MS bars provided at every fourth course properly anchored
with cross walls or pillars.

7.4.3. Fire walls

All masonry fire walls shall be of minimum 345mm thickness.

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7.5. SHED TYPE STRUCTURES

Roofs of all shed type structures shall have 1:4.7 slopes(12⁰ Approx.). MS wind ties (40mm x 6mm) painted as
per painting specifications shall be provided over roof sheeting on the last purlin towards eaves and the first
purlin at ridge, on each slope of the roof. From ground level up to 3.0 m block wall to be provided followed by
cladding on all sides and continuing up to roof level, alternatively full cladding to be adopted up to roof level.
Provision for equipment entry and drop out area shall also be made as per approved equipment layout.

Rain water gutters and PVC pipes shall be provided for proper roof drainage.

7.5.1. Day lighting

Unless otherwise specified, all buildings, which are enclosed with cladding, shall be day lighted by continuous
rows of translucent sheets on the appropriate facades and/or roofs of the building, giving a clear opening of
not less than 1 m. The number of rows in any particular building shall be such that all floors are adequately
day lighted.

The appropriate day lighting Mechanical/Electrical shall be in accordance with the relevant industrial
standards. (Ventilation & Natural lighting should not less than 5% of the total built up area of the
warehouse/workshop or any factory).

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ANNEXURE-1:WIND LOAD CALCULATION(SAMPLE)

ASCE-7

Height of structure = H 128.75 m

Length of structure = L 23.3 m
Width of structure = w 19.3 m

qz = 0.613 x v^2 x I x Kz x kzt x Kd

v = Basic wind speed, (m/s)

qz = Velocity wind pressure at ht z above ground level.
I = Important factor as per table …. Table 6-1
Kz = Velocity exposure coefficient as per Height …….Table 6-3
Kd = wind directionality factor as per type of structure. ….Table 6-4
Kzt = Topographic factor

V = 45 m/s P = qzxGXCp
I 1 G = Gust factor
Kz = - varies Cp = External pressure coefficient
Kd = 0.85
Kzt = 1 G = 0.85 ….for rigid structure

Gust factor
1 + 1.7 X Iz gq^2 X Q^2 + gr^2 R
Gf = 0.925
1 + 1.7 x gv x Iz

1 /6
Iz* = C 10
z*
gq = 3.4
1 /6 gv = 3.4
Iz* = 0.2 10
77.25 Z* = 77.25 …6-2
C = 0.2 …6-2

Iz* = 0.1424

1
Q = 1 + 0.63 B+h 0.63
Lz* B = 23.3 …6.3 X DIRECTION
B = 19.3 …6.3 Z DIRECTION
h = 128.75 …6.3
Q = 0.898
E*
Lz = γ z*
10
γ = 152.4 …6-2
E* = 0.2 …6-2
Lz = 229.3848

gr = 2 x In (3600 x n1) + 0.577

2 x In (3600 x n1)

gr = 6.073869

R = 1 Rn x Rh x Rb ( 0.53 + 0.47 RL) = 0.292587

B

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 DOCUMENT NO: E23C01-STD-DOC-001 REV.1

ANNEXURE-1:WIND LOAD CALCULATION(SAMPLE)

n1 = 0.163
Rn = 7.47 x N1 n = 4.6 X n1 x h/Vz 2.413895
(1 + 10.3N1)^5/3 n = 4.6 X n1 x EB/Vz 0.07237
n = 15.4X n1 x L/Vz 1.46248

Rn = 0.138061

N1 = n1 x Lz* = 0.935
Vz*

Rү = 1 - 1 x (1-e^-2n) = 2.45826 = Rh
n 2n^2 = 3.717922 = Rb
= 1.658281 = RL

α* α* = 1/6.5 ..6-2
Vz* = b* z* xV b* = 0.65 ..6-2
10 z* = 77.25 ..6-2

Vz = 39.992

1 + 1.7 X Iz* gq^2 X Q^2 + gr^2 R^2

Gf = 0.925
1 + 1.7 x gv x Iz*

Gf = 0.94

HEIGHT V I Kz Kd Kzt qz qz(KN/m2) G P

10.35 45 1 1.004 0.85 1 1059.35 1.06 0.941 0.997
21.50 45 1 1.172 0.85 1 1236.61 1.24 0.941 1.164
37.40 45 1 1.317 0.85 1 1389.60 1.39 0.941 1.308
57.20 45 1 1.412 0.85 1 1489.84 1.49 0.941 1.402
76.70 45 1 1.531 0.85 1 1615.40 1.62 0.941 1.521
95.15 45 1 1.544 0.85 1 1629.11 1.63 0.941 1.534
113.75 45 1 1.667 0.85 1 1758.90 1.76 0.941 1.656
128.75 45 1 1.707 0.85 1 1801.10 1.80 0.941 1.695

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 DOCUMENT NO: E23C01-STD-DOC-001 REV.1

ANNEXURE-1:WIND LOAD CALCULATION(SAMPLE)

Wind load on X- DIRECTION:-

WIND LOAD CAL. IBN WL+X/ WL-X

Sr P influence width load (KN/m)

Force coefficient (Cp)
Windward Direction
1 0.997 0.8 11.65 9.294
2 1.164 0.8 11.65 10.849
3 1.308 0.8 11.65 12.191 0.7
4 1.402 0.8 11.65 13.071
5 1.521 0.8 11.65 14.172
6 1.534 0.8 11.65 14.293
7 1.656 0.8 11.65 15.431 0.8 0.3
8 1.695 0.8 11.65 15.802
Leeward Direction
1 0.997 0.3 11.65 3.485
2 1.164 0.3 11.65 4.068 0.7
3 1.308 0.3 11.65 4.572
4 1.402 0.3 11.65 4.902
5 1.521 0.3 11.65 5.315
6 1.534 0.3 11.65 5.360
7 1.656 0.3 11.65 5.787
8 1.695 0.3 11.65 5.926

Wind load on Z- DIRECTION:-

WIND LOAD CAL. IBN WL+Z/ WL-Z

Sr P influence width load (KN/m)

Force coefficient (Cp)
Windward Direction
1 0.997 0.8 9.65 7.698
2 1.164 0.8 9.65 8.987
3 1.308 0.8 9.65 10.098 0.8
4 1.402 0.8 9.65 10.827
5 1.521 0.8 9.65 11.739
6 1.534 0.8 9.65 11.839
7 1.656 0.8 9.65 12.782 0.7 0.7
8 1.695 0.8 9.65 13.089
Leeward Direction
1 0.997 0.3 9.65 2.887
2 1.164 0.3 9.65 3.370 0.3
3 1.308 0.3 9.65 3.787
4 1.402 0.3 9.65 4.060
5 1.521 0.3 9.65 4.402
6 1.534 0.3 9.65 4.440
7 1.656 0.3 9.65 4.793
8 1.695 0.3 9.65 4.908

Page 3 of 3
 DOCUMENT NO: E23C01-STD-DOC-001 REV.1

ANNEXURE-2:SEISMIC LOAD APPLICATION IN STAAD(SAMPLE)

DEFINE UBC LOAD

ZONE 0.15 I 1 RWX 3.5 RWZ 3.5 STYP 2 PX 2.96 PZ 2.96 NA 1 NV 1

Page 1 of 1