P-2772-DD-CR-001-R0

PIPE RACK FOUNDATION CALC

TABLE OF CONTENTS page

1.GENERAL ....11.1Scope of Works .........................11.2Reference ........11.3Language ........11.4Units of Measurement ..................11.5Codes and Standards ...............11.6Other Design Conditions .................22.DESIGN CONDITIONS .......22.1Local Conditions ..... 22.1.1 Site conditions .... ..22.1.2 Geological characteristics .......2 2.2 Design Ground Elevation 2 2.3 Ground Water Level .23.MATERIAL PROPERTIES AND ALLOWABLE STRENGTH OF MATERIALS 33.1Concrete . ...33.2Stuctural Steel ...34.BORED PILE CAPACITY ............................................................45.STRUCTURAL DESIGN CONCEPT ....55.1Structure Design Principle . ........ 55.2Stability....65.3Outline of Office Room .65.4Structural Model ..76.LOADS AND LOAD COMBINATIONS ....... 76.1Live Loads (L/La) .. ..............76.2Dead Loads (D) .....86.3Seismic Loads (E) .......116.4Wind Loads (W) .....146.5Load Combinations .......157.STRUCTURE DESIGN VERIFICATION .. ......................................................168. DESIGN OF MEMBERS ...168.1Slabs 168.2 Joint Connections 178.3Tie beams . 198.4Pile cap .. 20

9.SUMMARY ...................................................................12

Appendix 1 : Architectural Drawings ...............................13

TeamworX

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1.GeneralPT. Integrated Healthcare Indonesia requested PT. TeamworX to assist and perform engineering work for this project. This Design calculation is to outline the design criteria, design concepts and scope of works for the developing of the existing plant at Cimanggis, East Jakarta, Indonensia.1.1scope of workSThis document covers the analysis and design calculation of the extension of the office building. The new building will be a steel structure using bored pile foundations with the dimension about 10m x 15m. The new building will be 4 stories, located exactly beside the existing office. In the initial stages, 2 stories (1st and 2nd floor) will be constructed first. Another 2 stories (3rd and 4th floor) will be constructed in the future. Work not included in design scope is geotechnical investigation.1.2referenceFollowing documents will be referenced in the design:a) General arrangement drawingsb) Report on Soils Investigation for PT. Bayer Indonesia by SOFOCO dated March 1992.1.3LANGUAGEAll drawings, calculations and documents are in the English language.

1.4Units of measurementThe units used in the calculation are consistent as below: Length:mm, mArea:mm2, m2Volume:m3Force:kg, N, kN, tonMoment:kg.m, kNm, ton.mStress:N/mm2, kN/m2, Pa, MPa1 Pa = 1 N/m21 MPa = 106 Pa = 106 N/m2 = 1N/mm21.5CODES AND STANDARDSThe following Standards and Codes of Practice are used in the design:1) IBC- 2006: International Building Code2) ASCE / SEI 7 05 : Minimum design Loads for Buildings and other Structures 3) AISC LRFD 99: Steel Frame Design Manual4) ASTM A36: Standard Specification for Structural Steel5) ACI-318-05 : Building Code Requirements for Reinforced Concrete6) SNI 03-1726-2012: Seismic Resistance Design for Houses and Building Guide7) SNI 03-2846-2002: Building Code Requirements for Structural Concrete 8) SNI 03-1729-2002: Building Code Requirements for Steel Structure9) SKBI -1.3.53.1987: Minimum design Loads for Houses and Buildings

1.6other design conditionsAny other internationally authorized standard proved to be as deemed equivalent may be substituted for the above. In addition to this, the manufacturers standard or common practice may be applied subject to the Engineers approval.

2.DESIGN CONDITIONS2.1LoCAL CONDITIONS2.1.1Site ConditionsThe extension office building measured about 10x15m is located within the existing factory area of the former PT Bayer plant at Cibubur, East Jakarta, Indonesia. 2.1.2Geological CharacteristicsSoil data is according to the soil investigation done by SOFOCO on March 1992 which is still applicable to this project. In general, the soil type is cohesive soil and the cone resistance has a similar pattern. From the surface to 14m depth, the cone resistance is ranging from 4 35 kg/cm2. Below this depth, the cone resistance is increasing until the hard layer with cone resistance exceeding 250 kg/cm2 was encountered at a depth between 15 16.8m.2.2DESIGN GROUND ELEVATIONThe ground elevation shall be -0.240 m2.3GROUND WATER LEVELAccording to the Soil Investigation report, no water level was encountered to 6m depth around the site project.

3.material properties and ALLOWABLE strength of materials3.1CoNCRETECement : SNI 15-2049-2004 type IIModulus of elasticity Ec = 4700 fc = 25742 MPaUnit weight c = 2400 kg/m3

Minimum compressive strength of concrete as below:GradeMinimum Compressive Strength at 28 days by Cylinder moulds, fcKUse

Grade 1717 N/mm2200 kg/cm2Lean Concrete

Grade 2828 N/mm2330 kg/cm2General Structures

Concrete cover for pile cap & tie beam = 50mmConcrete cover for slab= 20mmReinforcingDeformed bars BJTD 40 with minimum yield strength, fy = 400 N/mm2 (ASTM A615 Gr60) Plain bars BJTD 24 with minimum yield strength, fy = 240 N/mm2 (ASTM A615 Gr40) Wire mesh BJTD 50 with minimum yield strength, fy = 500 N/mm2 (ASTM A884 Gr75) 3.2STRUCTURAL STEELStructural steel must be conformed to ASTM A36 or Bj-37 with minimum yield strength, Fy = 240 MPaYoung,s modulus, Es = 2.1x105 MPaUnit weight, s = 7850 kg/m3FastenerBolts must be high strength bolts conformed to ASTM A325Anchor bolts must be conformed to ASTM A307 grade CNuts must be conformed to ASTM A563 grade DHWasher must be conformed to ASTM F436Welding electrodeElectrode must be conformed to AWS D1.1 full penetration and have a minimum grade E7016Steel deckMinimum thickness shall be 0.70mm (BMT) with a minimum yield strength, fy = 550 N/mm2. It must be conformed to ASTM 653 & 792.

5.bored pile CAPACITYBored piled (dia. 300mm) foundations are adopted, the piles will be driven to set which is expected to average around 16.0m below existing grade. Piles will be designed to support all imposed loads from the building columns and earthquake loads. Reinforced concrete pile caps will be cast on top of the piles and will be connected each other with the tie beams. Bored pile capacity shall be based on the soil data according to Mayerhoff method and based on the allowable concrete strength according to ACI 543R-16 table 2.2. The smallest value from both will be used as allowable bored pile capacity.According to the soil investigation data, there is no N-SPT value presented. Therefore a value of N-SPT can be derived from cohesion (c) value from laboratory test. Cohesion, c = 0,1.N but maximum N-SPT at pile base is 40. Safety factor for end bearing is taken 3.The calculation is presented as below.

5.structural design concept5.1STRUCTURE DESIGN PRINCIPLEThe steel structure will be analysed and designed based on AISC LRFD-1999 design code. The structural model is performed by the computer aid program (SAP2000). Design capacity values for axial, bending and shear actions are calculated by the program. The design is based on user-specified loading combinations.The new building will be built for 4 stories but initially it will be built for 2 stories then the rest will be built in the future. Therefore the current structure particularly for foundation, it must be able to support for 4 stories. Floor slab use reinforced concrete with 150mm thick.The frame type is taken as Special Moment-Resisting Frame (SMRF) as the project location is in Jakarta area which is high risk seismic zone. Seismic loadings input are based on IBC 2009 code which is similar to the current Indonesian seismic code and input into the program as Auto Lateral Load Pattern. The structure is made from steel structure with pinned supports. Columns use H beams in order to get stronger capacity in X and Y direction while steel beams use WF beam. Bolt (HTB) is used for connection between columns and beams. All loads from the upper structure are supported by bored pile through pile caps. Bored pile shall be driven to the hard soil (end bearing point). Pile caps and tie beams will be manually and separately designed by accommodate reaction loads from the upper structure. 5.2stabilityDeflection of structures and individual members shall be limited to the following values for serviceability limit state load combinations.Steel stress Ratio 1The ratio of resisting force due to stress shall not more than 1Allowable deflection of individual members shall be limited to the following values for serviceability loads and shall follow SNI 03-1729-2002 in 6.4.3 Chapter 6:Maximum beam deflection .......... L/360 (LL)Maximum slab deflection ............... L/240 (DL+LL)

5.3outline of office room

Plan - Ground floorPlan - 1st floor

Top floor as membrane, t=100mm5.4STRUCTURal model

Floor as membrane 1st, 2nd & 3rd, t=150mmSteel beamsSteel columnsPinned support6.LOADS AND LOAD COMBINATIONS6.1Live LoadS (l/La)Live loads are all loads imposed by the use and occupancy of the structure and do not include materials of construction, environmental loads or otherwise dead loads. Live load (L) of all working floors according to the Client request is 500 kg/m2 but on the roof floor (La) which can be reached by the people will be 100 kg/m2. Live load of rain water on the roof floor (20 kg/m2) will be neglected as less governing. Slabs is modelled as shell membrane type, therefore the load working on slab in the software model is acted as uniform to frame (shell). In this case, concrete slab does not have strength contribution in the structure except its load.

Roof floorOffice floor

6.2Dead Loads (D)Dead loads consist of the weight of all materials of construction. Unit weights of major construction materials shall be as follows:a. Reinforced concrete slab= 2400 kg/m3 (selfweight calc. by the program) Slabs thickness 150mm and 100mm for roof slab.b. Structural steel= 7850 kg/m3 (selfweight calc. by the program)c. Lightweight wall (Hebel)= 200 kg/m1d. Ceramic + mortar, t = 50 mm= 2200 kg/m3e. Ceiling + hollow frame= 10 kg/m2

Lightweight wall:Office floors (h = 3.3m, h = 3.8m and h = 4.0m):Dead load at exterior beams= 3.3 x 200= 720 kg/m= 3.8 x 200= 760 kg/m= 4.0 x 200= 800 kg/mRoof floor (h = 1.5m):Dead load at exterior beams= 1.5 x 200= 300 kg/m

Wall loadsCeramic + mortar:

Ceramic load

Ceiling + hollow frame:

Ceiling load

6.3seismic load (e)Seismic load will be calculated based on the latest Indonesian code, SNI 03-1726-2012 which is similar to the IBC 2009. The seismic loads act in X and Y direction accordingly. By inputting appropriate seismic factors based to the site conditions, input data for seismic load calculation is presented in the table below.

Ss = 0.749Location

S1 = 0.317Location

This figure are derived from: http://puskim.pu.go.id/Aplikasi/desain spektra indonesia 2011/

SNI 03-1726-2012, table 15

Data (according to SNI 03-1726-2012):Risk category = I (table 1)Occupancy important, I= 1.0 (table 2)Site class= SE (table 3)Site coefficient, Fa= 1.202 (table 4)Site coefficient, Fv= 2.732 (table 5)Response modification, R= 8 (table 9)System over strength, = 3 (table 9)Deflection amplification, Cd= 5.5 (table 9)

6.4wind load (W)Wind pressure shall be based on Indonesian code, SKBI -1.3.53.1987. Wind pressure is computed based on wind speed data by using the formula ( V = wind speed, m/sec.) with the minimum wind pressure is 25 kg/m2 and the maximum win pressure is 40 kg/m2 (close to the beach area). As the wind speed data is unavailable, therefore wind pressure is taken as 30 kg/m2.X direction (applied from 2nd floor to 4th floor): Windward 0.9 x 30 x 3.25= 87 kg/m(0.9 and 0.4 is wind factor)0.9 x 30 x 4.5= 121 kg/m0.9 x 30 x 2.25= 61 kg/m Leeward -0.4 x 30 x 3.25= 39 kg/m -0.4 x 30 x 4.5= 54 kg/m -0.4 x 30 x 2.25= 27 kg/mY direction (applied from 3rd floor to 4th floor): Windward 0.9 x 30 x 2.5= 68 kg/m0.9 x 30 x 5.0= 135 kg/m Leeward -0.4 x 30 x 2.5= 30 kg/m -0.4 x 30 x 5.0= 60 kg/m

Y directionX direction

6.5LOAD combinationSStructural components including its connections will be designed based on the ultimate strength method. The basic load combinations are according to SNI 03-1729-2002 in 6.2.2 Chapter 6 as follows:

1. 1,4D 2. 1,2D + 1,6L + 0,5La3. 1,2D + 1,6La + L L 4. 1,2D + 1,6La + 0,8W5. 1,2D + 1,3 W + L L + 0,5La6. 1,2D 1,0E + L L 7. 0,9D 1,3W 8. 0,9D 1,0Ex 0.3Ey9. 0,9D 1,0Ey 0.3ExNote : L = 0.5 if L < 500 kg/m2 (live load on roof) and L = 1.0 if L > 500 kg/m2 (all office floors). La = live load on roof Seismic load direction is 100% in X or Y direction + 30% in its perpendicular.

10. Structure DESIGN VERIFICATIONThe structure will be analyzed using the SAP 2000 structural analysis program to verify the capacities of the structural member elements. The beams have stress ratios less than or equal to 1 are considered acceptable.

Result: all steel members stress ratios are less than 1 but one beam has a ratio 1.088. However this ratio is located at the end of beam which is actually has an additional strength since using a HAUNCH plate in connection with column. So, it can be acceptable.

8.DESIGN OF MEMBERS 8.1slabData: Slab thickness =150 mm, live load = 500 kg/m2, ceramic + mortar = 50mm and ceiling = 10 kg/m2. Calculation using PROCON software as below: Q = 0.14 x 2400= 336 kg/m2 (excluded, calculated by the program) 0.05 x 2200= 110 kg/m2 = 10 kg/m2= 120 kg/m2Slab no. 1 ( at corner ).

Slab no. 2 ( at middle ).

Base on the two situations of slab position above, it can be simplified to use rebar 10-200 double reinforcement in X and Y direction. Check Amin, 0.002x1000x150 = 300 mm2/m < 10-250 (392 mm2/m).

Check Deflection

Load case 3: 1DL + 1LLMaximum short time deflection = 0.10 mm < L/240 = 2250/240 = 9.37 mmMaximum long time deflection = 0.32 mm < 9.37 mm

8.2joint connections

Bolt connections use High Strength Bolt, HTB A-325, with the specification of allowable tensile stress and allowable shear stress .Bolt connection calculations are based on the Allowable Stress Design.

Section detail 2 (moment connection):

Joint no.1Joint no.2 Joint no. 1Tensile stress:Load comb. 8M= 25370 kgm, Number of bolt= 2x6M20Shear stress:Load comb. 8V= 16939 kg,

Joint no. 2Tensile stress:Load comb. 8M= 24641 kgm, Number of bolt= 2x6M20Shear stress:Load comb. 8V= 12964 kg,Section detail 3 (moment connection):

Joint no.3Joint no.4Joint no. 3Same with joint no. 1

Joint no. 4Tensile stress:Load comb. 8M= 18704 kgm, Number of bolt= 2x6M20Shear stress:Load comb. 8V= 11131 kg,

Section detail 4 (shear connection):

Joint no.5Joint no. 5Shear stress:Load comb. 2V= 4207 kg ; bolt = 16mm ; connection plate thickness, d = 16mm

Section detail 5 (moment connection):

Joint no.6Joint no.7Joint no. 6 Tensile stress:Load comb. 2M= 8542 kgm, Number of bolt= 8M16Shear stress:Load comb. 2V= 8779 kg,

Joint no. 7Tensile stress:Load comb. 2M= 3310 kgm, Number of bolt= 4M20Shear stress:Load comb. 8V= 3969 kg,Section detail 6 (shear connection):

Joint no. 8Shear stress:Load comb. 2V= 4207 kg ; bolt = 16mm ; connection plate thickness, d = 16mm

8.3tie beamsTie beams shall be designed to support the differential settlement between the isolated footings in addition to the vertical loads of the block works.It is assumed that there is a differential settlement of 5mm as the bored pile shall be driven to the hard soil layer. The designed moments and shear force will be as follow:Data : TB1 (250x300mm) and L = 4.5m d = 300 60 = 240 mm Ec = 4700 = 24870 N/mm2 = 248700 kg/cm2 I = 1/12 x 0.25 x 0.33 = 0.00056 m4 = 5 mm = 0.005 m Distributed load, q = 0.25 x 0.35 x. 2400= 210 kg/m qu= 1.2D = 1.2 x 180= 252 kg/mPoint load,P= 500 kg, assumed working in the middle (forklift) Pu= 1.6 x 500= 900 kgEnd span reinforcement:

Mid span reinforcement:

=

8.4pile capVertical loads for 3-pile caps analysis:

Load comb. 14: 1D Load comb. 15: 1L+1La

Vertical loads for 2-pile cap analysis:

Load comb. 14: 1D Load comb. 15: 1L+1La

Pile cap analysis are calculated by RCM ACI-Builder as presented below: 8.5anchor bolt

Data : Load comb. 17:Pz= 82.0 tonPx= 6.29 tonPy= 1.53 tonCompute:Max shear stress= 6290 kgAnchor 4M25 ASTM A-307, allowable shear stress s = 812 kg/cm2s = Px/As= 6290/(0.25x4xx2.52) = 320 kg/cm2 > 812 kg/cm2

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