DOCUMENT NO
DOCUMENT NO.2006-PANIPAT-DM-001
JAYPEE CEMENT GRINDING UNIT PANIPAT PACKING PLANT & TRUCK
LOADING PLATFORM
DESIGN MEMO
1.0 INTRODUCTION
1.1The Packing Plant and Truck loading plant comprises three
packers and seven unloading bays. The total system is supported on
72 RC columns having outer dimensions of 62.0 m x 54.0 m in plan
and floors at different EL.+3.00m + 5.50 m, +, + 7.90 m, + 11.50 m,
15.20 m, 18.40 m, 21.40 m and 30.0 m
1.2 This volume presents design of piles, pile caps and design
of columns and beams of different floors.
2.0 LAYOUT
All three packers are supported at EL. +7.90 m level and its
feeding bin supported at El. +15.20 m level. Bag filter supported
at EL. +18.40 m level and its handing arrangement supported from
EL. +34.0m level.
From + 5.50 m level cement bags are feeding into a truck which
are resting at ground level.
Empty bags are stored in at EL. + 11.50 m level and handling
from EL. +18.40 m level through crane
3.0 CODES, STANDARDS & SOFTWARE
The following codes, standards & software have been used in
the design:
IS 456-2000Code of Practice for Plain and Reinforced
Concrete
SP 16-1978Design Aids to IS: 456
SP 34-1987Handbook on Concrete Reinforcement and Detailing.
IS 875 (part-3)-1987Code of Practice for Design Loads (Other
than
Earthquake) for Buildings and Structures part-3
Wind Load
IS 1893(part-1)-2002Criteria for Earthquake resistant design
of
structures, part 1 - General provisions and buildings,
IS 13920-1993Ductile detailing of reinforced concrete
structures
subjected to seismic forces
IS 800 1984
Code of practice for general construction in steel
STAAD/Pro 2004
Text book of REINFORCED CONCRECETE, Limit State Design by
Dr. Ashok K. Jain
Text book of REINFORCED CONCRETE DESIGN by S.N. Sinha
4.0 MATERIAL SPECIFICATION
4.1Material
Concrete
:M25 / A20 Grade
Reinforcement:Fe 415 Grade
5.0 INPUT DATA
5.1a)EEL INDIA LIMITED PANIPAT: 04148, JHCP--- Annexure - 1:
Packer
= 120 KN
Storage Bin
= 600 KN
Electrical Hoist loadin empty-
Bags godown
= 30 KN
b)Seismic zone=IV (as per IS 1893-2002)
c)Wind velocity=47 m/sec (as per IS 875-1987)
6.0 GEOMETRY
The geometry of the structure is as follows
6.1 Beams
Different sizes of beams have been used; the various sizes are
as follows:
1500 X 800
1200 X 600
1200 X 500
1000 X 500
1000 X 400
900 X 500
900 X 400
800 X 500
800 X 400
700 X 400
500 X 300
400 X 300
6.2 Columns
Column sizes are as follows
a. Column - 1000 X 1000
b. Column - 800 X 800
c. Column - 600 X 600
d. Column - 500 X 500
7.0 DESIGN LOADS
7.1 Dead load
a. Self weight of structure
b. Material load + Equipment load = 11269.0 KN
7.2 Live load
a. Live load of 500 kg/sqm considered at all floors.
7.3Wind Load
Wind load in two horizontal directions i.e., X and Z directions
considered separately.
Vb=Basic wind speed = 47 m/sec (as per IS 875 (part 3)-1987)
K1=Probability factor (risk coefficient) = 1.07 (Table-1)
K2=Terrain, lt & structure size factor = 1.03 at +34.0 m LVL
(Table-2)
K3=Topography factor = 1.00
Design wind Pressure=Pz=0.6 Vz2 (cl 5.4 of IS 875 (part 3))
Design wind speed=Vz=Vb. K1. K2. K3Since the building is having
cladding on all faces, so wind load is taken on the nodal points
considering effective areas for the calculation of wind force.
Wind pressure for different heights
HEIGHTWIND PRESSURE (KN/m2)
5.5 M1.46
7.90 M1.46
11.50 M1.48
15.20 M1.56
18.40 M1.64
21.90 M1.70
30.0 M1.87
7.4
Seismic loads
Seismic zone- V (as per IS 1893 (Part-I))
Horizontal seismic coefficient=Ah=
Z =Zone factor
=0.24 (Table-2)
I=Importance factor=1.5 (Table-6)
R=Response reduction factor = 5.0 (Table-7)
Sa/g=1.00
Ah=(0.24/2) x (1.5/5) x 1.00=0.036
Response spectrum analysis is performed by STAAD. This analysis
is performed for three directions X, Y & Z. Spectral
combinations are done by CQC (complete quadratic combination)
method.
Values corresponding to 5% damping for spectrum corresponds to
medium soil sites are provided in STAAD input.
Average response acceleration coefficient calculated for the
time periods corresponding to STAAD analysis and also for empirical
formula as per cl: 7.6.1 of IS 1893-2002. Base shear factor was
enhanced as per cl: 7.8.2 of IS 1893-2002. Details of calculations
are given below
Time period from empirical formula, Ta = 0.075 x h0.75
= 0.075 x 300.75
= 0.96
Sa/g = 1.41 (as per cl: 6.4.5 of IS 1893-2002)
Time period from STAAD= 1.69
Sa/g = 0.80 (as per cl: 6.4.5 of IS 1893-2002)
Enhanced Base shear factor = 0.036 x 2.10 = 0.0756
8.0 SUPPORT CONDITIONS
The piles are modeled along with the structure, the end bearing
of pile is taken care by providing pin support at the ends and for
the friction of the pile different spring constant have been taken
along the height
Soil Springs:
Column
Pile Cap
12 m
Liquefaction Zone
18 m
1 m
1 m
The horizontal modulus of sub grade reaction is (Refer J. Bowles
Eq. 9-10 Page 504)
Ks = As + Bs Zn
Z = Depth of Interest below ground
As = constant for either horizontal or vertical members
Bs = coefficient for depth variation
n = exponent to give Ks the best fit
Substituting
As = Area x (80xFOSxBC)
= (0.5x0.8)(80x2.5x10) = 800 Ton/m
And n =1
Ks = As + Bs ZnWhere Bs = C Nq Sq
C = 80 (corresponding to = 12 mm settlement)
submergedm3As per MeyerhofNq = etantan 2(45 + /2)
Sq = 1
For = 30o
Nq = 18.38
Bs = C Nq Sq
Bs = 80x0.8x18.38x1 = 1176.32
For 800 mm dia pile:
K 0.0 = 800 + 1176.32x0.0X0.8 = 800
(Ton/m)K 0.5 = 800 + 1176.32x0.5X0.8 = 1270.5
K 1.0 = 800 + 1176.32x1.0X0.8 = 1741.0
K 1.5 = 800 + 1176.32x1.5X0.8 = 2211.5
K 2.0 = 800 + 1176.32x2.0X0.8= 2682.1
K 2.5 = 800 + 1176.32x2.5X0.8 = 3152.6
K 3.0 = 800 + 1176.32x3.0X0.8 = 3623.2
K 3.5 = 800 + 1176.32x3.5X0.8 = 4093.6
K 4.0 = 800 + 1176.32x4.0X0.8 = 4564.2
K 4.5 = 800 + 1176.32x4.5X0.8 = 5034.7
K 5.0 = 800 + 1176.32x5.0X0.8 = 5505.2
K6 = 1600 + 1176.32x6.0X0.8 = 7246.3
K7 = 1600 + 1176.32x7.0X0.8 = 8187.4
K8 = 1600 + 1176.32x8.0X0.8 = 9128.5
K9 = 1600 + 1176.32x9.0X0.8 = 10069.5
K10 = 1600 + 1176.32x10X0.8= 11010.5
K11 = 1600 + 1176.32x11X0.8 = 11951.6
K12 = 1600 + 1176.32x12X0.8 = 12892.6
K13 = 1600 + 1176.32x13X0.8 = 13833.7
K14 = 1600 + 1176.32x14X0.8 = 14774.7
K15 = 1600 + 6176.32x15X0.8 = 15715.8
K16 = 1600 + 1176.32x16X0.8 = 16656.8
K17 = 1600 + 1176.32x17X0.8 = 17597.9
K18 = 1600 + 1176.32x18X0.8 = 18539.0
K19 = 1600 + 1176.32x19X0.8 = 19480.0
K20 = 1600 + 1176.32x20X0.8 = 20421.1
K21 = 1600 + 1176.32x21X0.8 = 21362.0
Group Efficiency:
The Converse Labarre equation is (refer J. Bowles Eq. 18-1 page
1009)
Where m n and are no. of rows, columns D and dia of pile and tan
1(D/s)
E g = 1 [m (n-1) + n(m-1) ]
90 mn
(1)For 6 group of piles:
E g = 1 18.4[3(2-1) + 2(3-1)]
90x2x3E g = 73.2 %
(2)For 4 group of piles:
E g = 1 18.4[2(2-1) + 2(2-1)]
90x2x2E g = 80%
(3)For 3 group of piles:
E g = 1 18.4[3(2-1) + 2(3-1)]
90x2x3E g = 73.2 %
(4)For 2 group of piles:
E g = 1 18.4[1(2-1) + 2(1-1)]
90x2x1E g = 95.0 %
(5)For single pile:
E g = 1 18.4[1(1-1) + 1(1-1)]
90x1x1E g = 100 %
As per test results Capacity of 800 dia pile (Normal Case) = 195
Tons
Capacity of 800 dia pile (Liquefaction Case) = 175x1.25 = 218.75
TonsFor determining number of piles requirement, unfactored support
reaction is taken for different supports. The STAAD output for
support reaction is as follows:
SUPPORT NO.SUPPORT REACTION (KN)
143863.6
156030.76
165794.21
174126.38
182492.7
192465.64
202464.18
222474.62
232297.16
275049.68
288441.73
298546.06
306160.36
314075.9
324080.69
334054.05
354310.24
363915.28
405204.97
418338.83
428037.63
435489.3
443204.3
453150.12
463378.51
483282.3
493054.5
524746.94
536824.71
546184.71
554399.33
561756.99
571697.58
581902.25
601392.57
611307.83
642602.57
654040.11
663476.16
672138.36
682078.79
692098.03
701081.31
72811.79
73535.16
761823.63
771476.32
781419.77
791198.29
80868.8
82667.07
83479.66
84789.26
85751.28
86580.57
139032462.73
139064133.76
139093399.8
139122061.49
13915990.84
139162143.41
139173199.07
139182174.61
142461018.02
15123415.45
15124289.03
15127396.98
15128286.06
15131240.56
15132318.65
15133314.27
15134237.2
Based upon this we can find out the number of piles required at
each support by using capacity of 800 mm dia pile as 1950 KN (for
normal case).
Therefore, for different supports, numbers of piles required are
as follows:
SUPPORT NO.NO. OF PILES REQUIREDNO. OF PILES PROVIDED
141.981333333SILO RAFT
153.092697436SILO RAFT
162.9713897444
172.1160923083
181.2783076922
191.2644307692
201.2636820512
221.2690358972
231.1780307692
272.589579487SILO RAFT
284.329092308SILO RAFT
294.3825948726
303.1591589744
312.0902051283
322.0926615383
332.0793
352.2103794873
362.0078358973
402.669215385SILO RAFT
414.276323077SILO RAFT
424.1218615386
432.8150256414
441.6432307693
451.6154461543
461.7325692313
481.6832307693
491.5664102563
522.434328205SILO RAFT
533.499851282SILO RAFT
543.1716461544
552.2560666673
560.9010205132
570.8705538462
580.9755128212
600.7141384622
610.6706820512
641.3346512822
652.0718512822
661.7826461543
671.0965948722
681.0660461542
691.0759128212
700.5545179492
720.4163025641
730.2744410261
760.9351948722
770.7570871792
780.7280871792
790.6145076921
800.4455384621
820.3420871791
830.2459794871
840.4047487181
850.3852717951
860.2977282051
139031.2629384622
139062.1198769233
139091.7434871793
139121.0571743592
139150.5081230771
139161.0991846152
139171.6405487182
139181.1151846152
142460.5220615382
151230.2130512821
151240.1482205131
151270.2035794871
151280.1466974361
151310.1233641031
151320.1634102561
151330.1611641031
151340.1216410261
9.0
LOAD COMBINATIONS AND LOAD FACTORS
The load combinations considered s per IS 875 and IS 1893. The
following load factors considered for corresponding load
combinations in design:
Load CombinationsLoad Factor
Dead load + Live load1.5
Dead load + 50% live load + EQ load1.2
Dead load + EQ load1.5
Dead load + Live load + Wind load1.2
Dead load + Wind load1.5
Dead load + Material load + EQ load1.5
10.0
ANALYSIS
The followings procedure is adopted for analysis
a. STAAD/Pro 2004 software used in analysis.
b. Dimensions along centre line considered.
c. Analysis carried out as per load combinations, as stated in
para 8.0. above, and columns & beams will be designed for worst
combinations of bending moments & axial loads using provision
of IS 456-2000.
12.0
DESIGN OF PILES AND PILE CAPS
DESIGN OF PILESSIX PILE GROUP
Considering Critical piles, the maximum percentage of
reinforcement as per STAAD output is 2.24 %
FOUR PILE GROUP
Considering Critical piles, the maximum percentage of
reinforcement as per STAAD output is 2.24 %
THREE PILE GROUP
Considering Critical piles, the maximum percentage of
reinforcement as per STAAD output is 1.80 %
TWO PILE GROUP
Considering Critical piles, the maximum percentage of
reinforcement as per STAAD output is 2.04 %
SINGLE PILE CASE
Considering Critical piles, the maximum percentage of
reinforcement as per STAAD output is 2.31 %
Reinforcement provided: 2.88 % in 800 mm dia pile
5600
PILE CAP DESIGN
12.2 FIVE PILES GROUP
Critical Column No. 1612
Maximum design axial force,
Pu=4414.40 kN
Mz=22.64 kN-m
Mx=2686.52 kN-m
Size of Pile cab = 5.6 x 3.6
Using,
P=
=
=882.88 ( 559.69 ( 2.69
P1=882.88 559.69 +2.69
=325.88 kN
P2=882.88 + 559.69 2.69
=1439.88 kN
P3=882.88 + 559.69 + 2.69
=1445.26 kN
P4=882.88 559.69 2.69 =320.5 kN
Maximum moments at the face of the column
=(1439.88 + 1445.26) x 1.1
=3173.65 kN-m
Equating,M = 0.138 fck bd23173.65 x 106=0.138 x 25 x 5600 x
d2
d=405.299 mm
Provided depth=1500 mm (total)( O.K.
For Area of Steel
=
= 0.44
Percentage of reinforcement required as Pc
SP 16=0.127% > 0.12% (Minimum reinforcement)
Check for One Way Shear
For one-way shear check, shear will be taken at d distance from
the face of the column
(2800 1000 600 1415=-205 mm
Since section d (effective depth) is coming outside the c.g. of
load points, so no one way shear check is required.
Check for Punching Shear
deff=1415 mm
Total periphery at distance of d/2
=2 X ((1415 + 1000) + (1415+2000))
=11660 mm
Punching stress=
= 0.214 N/mm2
< 0.25
< 0.25
< 1.25 N/mm2
(OK
Area of Steel
Since percentage of reinforcement as per moment is grater than
minimum reinforcement. Therefore, provide required area of
steel
=0.127%
=
x 1415 x 1000
=1797.05 mm2/m
Spacing of 25 dia. bars = x 1000 = 174.7 mm c/c
Provide 25 ( @150 mm c/c at bottom
Also provide 16 ( @150 mm c/c at top
5600
PILE CAP DESIGN
12.2 FOUR PILE GROUP
Critical Column No. 385
Maximum design axial force,
Pu=2195.34 kN
Mz=691.21 kN-m
Mx=2370.83 kN-m
Size of Pile cab = 5.6 x 3.6
Using,
P=
=
=728.84 ( 493.92 ( 82.29
P1=728.84 493.92 + 82.29
=317.21 kN
P2=728.84 + 493.92 - 82.29
=1140.47 kN
P3=728.84 + 493.92 + 82.29
=1305.05 kN
P4=728.84 493.92 - 82.29 =152.63 kN
Maximum moments
=(1140.47 + 1305.05) x 1.1
=2690.1 kN-m
Equating,M = 0.138 fck bd22690.1 x 106=0.138 x 25 x 5600 x
d2
d=373.16 mm
Provided depth=1500 mm (total)( O.K.
For Area of Steel
=
= 0.373
Percentage of reinforcement required as Pc
SP 16=0.113% < 0.12% (Minimum reinforcement)
Check for One Way Shear
For one-way shear check, shear will be taken at d distance from
the face of the column
(2800 1000 600 1415=-205 mm
Since section d (effective depth) is coming outside the c.g. of
load points, so no one way shear check is required.
Check for Punching Shear
deff=1415 mm
Total periphery at distance of d/2
=2 X ((1415 + 1000) + (1415+2000))
=11660 mm
Punching stress=
= 0.133 N/mm2
< 0.25
< 0.25
< 1.25 N/mm2
(OK
Area of Steel
Since percentage of reinforcement as per moment is less than
minimum reinforcement. Therefore, provide minimum area of steel
=0.12%
=
x 1415 x 1000
=1698 mm2/m
Spacing of 25 dia. bars = x 1000 = 184.9 mm c/c
Provide 25 ( @150 mm c/c at bottom
Also provide 16 ( @150 mm c/c at top
PILE CAP DESIGN
12.4 TWO PILE GROUP
Critical Column No. 187
Maximum design forces for column,
Pu=2593.44 kN
Mz=1358.83 kN-m
Mx=191.24 kN-m
Using,
P=
=
P1=1296.72 566.18
=730.54 kN
P2=1296.72 + 566.18
=1862.9 kN
Maximum moments
=1862.9 X 0.7
=1304.03 kN-m
Equating,M = 0.138 fck bd21304.03 x 106=0.138 x 25 x1200 x
d2
d=561.23 mm
Provided depth=1200 mm (total)( O.K.
For Area of Steel
=
= 0.88
Percentage of reinforcement required as Pc
SP 16=0.261% > 0.12% (Minimum reinforcement)
Check for One Way Shear
For one way shear check, shear will be taken at d distance from
the face of the column
(2100 1000 1110=-10 mm
Since section d (effective depth) is coming outside the c.g. of
load points, so no one way shear check is required.
Check for Punching Shear
deff=1110 mm
Total periphery at distance of d/2
=2 x ((1200) + (1110+2000))
=8620 mm
Punching stress=
=0.27 N/mm2
< 0.25
< 0.25
< 1.25 N/mm2
(OK
Area of Steel
Since percentage of reinforcement as per moment is less than
minimum reinforcement. Therefore, provide minimum area of steel
=0.261%
=0.261 x 1200 x 1200 / 100 = 3758.4 mm2/m
Spacing of 32 dia bars = (804 / 3758.4 x 1200) = 256.7 mm
Provide 32 ( @ 200 mm c/c at bottom
Also provide 16 ( @ 125 mm c/c at top
13.0 EFFECTIVE LENGTH FACTORS FOR PILES AND COLUMNS
FOR PILES:
PILE CAP
9.8 M
ELZ/ELY=14.8/9.8 = 1.51
5.0 M
ELZ/ELY=14.8/0.5 = 29.6
15.20 M
FOR COLUMNS:
Effective length factors have been taken for the columns between
floor 5.50 m and 11.50 m floor
ELZ = 11.50/6.0 =1.9166
6.0 M
ELZ = 11.50/5.5 = 2.09
5.50 M
Elz factor of 1.9166 for column no. 749 750 738 751 755 767 768
769 756 757 758 745 746 747 759 760 748 735 736
Elz factor of 2.090 for column no. 359 360 350 361 363 373 374
375 364 365 366 355 356 357 367 368 358 347 348
3600
3600
PAGE 19
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