0000001743-Calculation Report Conveyor Structure T-1022

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Rev. : A Page 1 of 29

Conveyor T-1022

CALCULATION REPORT FOR CONVEYOR STRUCTURE T-1022

A

OWNER

: PT ANTAM (PERSERO) Tbk

CONTRACTOR

: PT WIJAYA KARYA (PERSERO) Tbk

PROJECT NAME

: CONVEYOR MOPP FeNi-1

LOCATION

: POMALAA, SULAWESI TENGGARA

CONTRACT DATE

: 17 January 2012

09-05

31

Approval

DRP

SMS

AP

BR

AA

2012

Originator REV

DATE

Page Number

STATUS

Reviewed

Approved By

Reviewed By

Approved By

By PT. WIJAYA KARYA (PERSERO) Tbk

PT ANTAM (PERSERO) Tbk

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Rev. : A Page 2 of 29

CALCULATION REPORT FOR CONVEYOR STRUCTURE T-1022

REV

DATE

REVISION DETAIL

ORIGINATOR DRP

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Rev. : A Page 3 of 29

TABLE OF CONTENT

1.

GENERAL

1.1.

SCOPE

4

1.2.

CODE AND STANDARD

4

1.3.

REFERENCES

4

1.4.

BASIC DESIGN

4

2.

STRUCTURAL MODEL

2.1

3D STRUCTURAL MODEL

6

2.2

LONGITUDINAL AND TRANSVERSAL SECTION

7

2.3

LOADS APPLIED IN STRUCTURE MODEL

7

3.

EXTERNAL LOADING CALCULATION

3.1

DEAD LOAD (D)

9

3.2

LIVE LOAD (L)

11

3.3

EARTHQUAKE LOAD (E)

12

3.4

WIND LOAD (W)

16

4.

MEMBER DESIGN

4.1

CHECK CODE

22

4.2

DEFLECTION CHECK

29

5.

MEMBER TAKE OFF

31

ATTACHMENT ATTACHMENT 1 STAAD INPUT MODEL ATTACHMENT 2 STAAD OUTPUT ANALYSIS

CALCULATION Document Number

PBA-CAL-CVL-001-A4 1.

GENERAL

1.1.

SCOPE

Conveyor T-1022

Rev. : A Page 4 of 29

This calculation sheet is purposed to describe design of structure as a part of bulk material handling system in MOPP FeNi-1 Project PT. Aneka Tambang, Pomalaa, Sulawesi Tenggara.

1.2.

CODE AND STANDARD

1.2.1. Uniform Building Code, UBC 1997 1.2.2. Minimum Design Loads for Building and Other Structures - ASCE 7-02 1.2.3. Pedoman Perencanaan Bangunan Baja untuk Gedung, SNI 03-1729 – 2002 1.2.4. Structural Welding Code – AWS D.1.1 - 1998 Edition 1.2.5. American Institute of Steel Construction, AISC 360-05 1.2.6. American Society for Testing and Materials, ASTM 1.2.7. American Railway Engineering Association, AREA 1.2.8. Steel Structure Painting Council, SSPC

1.3.

REFERENCES

1.3.1. PBA–SP–50–001–A4 Structure Design Specification 1.3.2. PBA–SP–50–005–A4 Fabrication and Construction of Steel Structure Specification

1.4.

BASIC DESIGN

1.4.1

Material

a.

Steel Structure : JIS SS400 minimum fy = 245 MPa minimum fu = 400 Mpa

b.

Structural bolt : High strength bolt ASTM A-325 & BS 1367 Gr.8.8 shear strength Fvb = 1470 kg/cm2 tension capacity Ftb = 3090 kg/cm2

c.

Anchor Bolt : ASTM A-307

CALCULATION Document Number

PBA-CAL-CVL-001-A4 1.4.2

Conveyor T-1022

Rev. : A Page 5 of 29

LOADING DATA Loading data shall refer to PBA–SP–50–001–A4 Structure Design Specification document.

1.4.3

LOADING COMBINATION Load combination for steel structure with ultimate design Primary Load Load 1 Seismic Load in X-axis direction (SX) Load 2 Seismic Load in Z-axis direction (SZ) Load 3 Self Weight (included as dead load) Load 4 Dead Load (D) Load 5 Live Load (L) Load 6 Wind Load in Z-axis direction (WZ) Load Combination based on ASCE 7-02 Comb 1 D Comb 2 D+L Comb 3 D+0.75L Comb 4 D+W Comb 5 D+0.75L+0.75WZ Comb 6 0.6D+W Comb 7 D+0.7S Comb 8 D+0.75L+0.525S Comb 9 0.6D+0.7S

CALCULATION Document Number

PBA-CAL-CVL-001-A4 2.

STRUCTURAL MODEL

2.1

3D STRUCTURAL MODEL

Conveyor T-1022

Rev. : A Page 6 of 29

Structure is modelled as 3D steel frame structure with fixed support at longitudinal direction and pinned support at transversal direction on trestle base while connection between gallery and trestle is fixed connection at transversal direction and simply supported (pinned) longitudinally.

(a)

(b) Fig 2.1 3D Model Design in STAAD PRO Program Analysis (a) 3D (b) longitudinal section

2.2

LONGITUDINAL AND TRANSVERSAL SECTION In longitudinal direction, structural members are designed to fully utilize its material strength by using fixed connection to join bottom chord, shear web, and top chord. In transversal section, structural member are joined with high strength bolt connection as shear and truss member.

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Rev. : A Page 7 of 29

Fig 2.2 Longitudinal and transversal section in STAAD PRO Program Analysis

2.3

LOADING APPLIED IN STRUCTURE MODEL Steel truss gallery will be subjected to equipments and bulk material weight. Nodal loads at top chord steel are considered as uniform load subjected along the span. Based on preliminary design, gravitational load governs steel truss gallery design.

Fig. 2.3 Uniform Load is applied at top chord of steel truss conveyor gallery

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Rev. : A Page 8 of 29

Conveyor T-1022

EZ WZ

(a)

(b)

Fig. 2.4 (a) Wind pressure as uniform load is applied at trestle & gallery cross section (b) Earth quake load is subjected as nodal load at highest point of trestle.

Fig. 2.5 Single segment 6 meters-long of steel truss gallery structure

CALCULATION Document Number

Rev. : A Page 9 of 29

Conveyor T-1022

PBA-CAL-CVL-001-A4 3.

EXTERNAL LOADING CALCULATION

3.1

DEAD LOAD (D) Dead loads are the self weight of structures or foundations and all permanent facilities, such as floor, roof, joist, stairways, etc.

3.1.1. Structure Self-weight The Dead Load is the load of the structure itself (calculated by STAAD-PRO). with command "Selfweight Y-1.0", and other dead load as describes below. 3.1.2. Equipment Load

conveyor belt

=

0,29

kN/m

30

kg/m

Frame

=

0,27

kN/m

28

kg/m

Idler (carry)

=

0,33

kN/m

34

kg/m

Idler (return)

=

0,25

kN/m

26

kg/m

corrugated sheet belt cover 4 kg/m x 1 m

=

0,04

kN/m

4

kg/m

pipe

=

0,16

kN/m

16

kg/m

1,20

kN/m

2

total equipment load (exc. Pipe)

=

subjected to idler supports

=

0,60

kN/m

Platform Area Load span 0.8 m

=

0,08

19,5

Handrail at 1.5 m interval

=

0,10

kN/m kN/m

10

kg/m

0,30

kN/m

30

kg/m

3.1.3. Walkway Platform

cable tray 1

=

kg/m2

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Rev. : A Page 10 of 29

Fig. 3.1 Dead Load (a) uniformly distributed force along top chord member (b) nodal load at walkway

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4 3.2

Rev. : A Page 11 of 29

LIVE LOAD (L)

3.2.1. Ore/Bulk Material Load

bulk material on conveyor belt width

1

m x 2.35 kN/m

2

subjected to idler supports

=

2,35

kN/m2

=

2,35

kN/m

=

1,18

kN/m

240

kg/m2

3.2.2. Walkway Live Load Inspection Platform subjected at 100 kg/m2 x 0.8 m span

=

0,98

kN/m2

100

kg/m2

=

0,80

kN/m

80

kg/m

Fig. 3.2 Liveload uniformly distributed along top chord member along with nodal load for walkway

CALCULATION Document Number

PBA-CAL-CVL-001-A4 3.3

Conveyor T-1022

Rev. : A Page 12 of 29

EARTHQUAKE LOAD (E) Seismic load will be calculated by staadpro automatically with dynamic analysis. Seismic load design is depend on natural period and ductility factor of the structure.

Design spectral = Spectral acceleration / R R (structural system factor) = 4.5 (ordinary moment resisting ftrame) Importance factor = 1 Design response spectra for return period 500 years. Dead Load (Self-weight + permanen equipment load) is used for seimic load calculation Seismic Load is calculated based on V 

3.3.1

Cv I W RT

Rx =

4.5

(Ordinary moment resisting frame)

Rz =

4.5

(Ordinary moment resisting frame)

Soil Properties Based on soil investigation on site, Soil profile types on which conveyor structure is sat on is considered as stiff soil - SD (Soil Profile Types – UBC 1997-Table 16-J). Based on this category, Seismic coefficient Ca and Cv can be determined as follows : Zone 3, SD soil profile type Ca = 0.36 Cv = 0.84

3.3.2

Self-Weight Structure self-weight for conveyor structure is calculated on STAAD Pro “self-weight” command.

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4

Rev. : A Page 13 of 29

Table 3.1 Maximum Dead Load Support Reaction

Table 3.2 Maximum Dead Load Support Reaction for convetor side without walkway 3.3.3

Structure Natural Periode Based on UBC 1997, steel moment resisting frame can be determined with T=Ct(hn)3/4 Where, Ct

= 0.0853

Hn

= structure height (meter)

T = Tx = Tz = 0.0853 x (12)3/4 = 0,549 s T = 0,549 s

CALCULATION Document Number

PBA-CAL-CVL-001-A4 3.3.4

Conveyor T-1022

Rev. : A Page 14 of 29

Base Shear Force Transversal Seismic Load (connection between gallery and trestle) Total base shear for seismic load calculation, for W = 27.840 kN

V

Cv I W = RT

Maximum total base shear

V

2 .5 C a I W = R

Maximum base shear value will be used for seismic load at transversal direction at node 450 SZ = 5.568 kN

Transversal Seismic Load (connection between gallery and trestle) Total base shear for seismic load calculation at node 965, W = 19.261 kN

V

Cv I W = RT

Maximum total base shear

V

2 .5 C a I W = R

Maximum base shear value will be used for seismic load at transversal direction at node 973 SZ = 3.852 kN

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4 3.4

Rev. : A Page 15 of 29

WIND LOAD (W)

Wind loads shall be generally as ASCE 7-05 Building category = III Exposure C V =

68,351 mph

I =

1

Kz =

1.005

Kd =

0,85

10.21 m lattice framework

qz = 0.00256*Kz*Kd*(V*I)2

Gust factor

=

10.14 lb/ft2

=

0,489 kN/m2

G =

0,85

Structure Properties Longitudinal dimension = 24

m

Transversal dimension = 2,6 m Height

110 km/h

= 10.21 m

Basic wind speed Importance factor (see table 3.1) (see table 3.2)

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Transversal direction

Longitudinal direction

Table 3.3 Kz coefficient based in structure height and exposure

Rev. : A Page 16 of 29

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4

with z=

Kz =

33.497

zg =

900

α=

9,5

ft ft

1.00532

Table 3.4 Kd Coefficient based on structure type

Table 3.5 product of internal pressure coefficient and gust effect factor

Rev. : A Page 17 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Table 3.6 Wall pressure coefficient

Table 3.7 Roof pressure coefficient

Rev. : A Page 18 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Transversal direction L/B

=

0,144

h/L

=

12.884

Fig 3.5 Wind Load applied to structural

contact surface

Cp

direction

code

windward

1

0,8

2=3

-1,3

leeward

4

-0,5

side wall

5

-0,7

roof

Table 3.8 Wind direction coefficient

Rev. : A Page 19 of 29

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4 F = Af*(qz*G*Cp) wind

trib. area

direct

Af (m)

GCp

qz

Fz kN/m

1 trestle 1

1.5

0.68

0.489

0.50

0.5

0.68

0.489

0.17

4 trestle 4

1.5

-0.425

0.489

-0.31

0.5

-0.425

0.489

-0.10

2=3

1.5

-1.105

0.489

-0.81

5

0.65

-0.595

0.489

-0.19

Table 3.9 Wind Force on Gallery Structure

Rev. : A Page 20 of 29

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4 4.

Rev. : A Page 21 of 29

MEMBER DESIGN

Steel profile selection is done by limitting unity ratio to 1. However, there are practical considerations involved in steel profile selection. Main members are mainly consist of angle and UNP steel profile which are used as bottom chord and top chord respectively. Equal angle is also chosen for shear web and lateral bracing.

4.1

CHECK CODE BASED ON AISC ASD FOR UNITY RATIO

4.1.1. BOTTOM CHORD UNITY RATIO

Table 4.1 Bottom Chord Unity Ratio Maximum unity ratio for top chord is 0.871 < 1 OK!

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

4.1.2. TOP CHORD UNITY RATIO

Table 4.2 Bottom Chord Unity Ratio Maximum unity ratio for top chord is 0.613 < 1 OK!

Rev. : A Page 22 of 29

CALCULATION Document Number

Conveyor T-1022

PBA-CAL-CVL-001-A4 4.1.3. VERTICAL SHEAR WEB UNITY RATIO

Table 4.3 Shear Web Unity Ratio Maximum unity ratio for shear web is 0.962 < 1 OK!

Rev. : A Page 23 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

4.1.4. DIAGONAL SHEAR WEB

Table 4.4 Diagonal Shear Web Unity Ratio Maximum unity ratio for shear web is 0.426 < 1 OK!

Rev. : A Page 24 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

4.1.5. TRESTLE COLUMN

Table 4.5 Trestle Column Unity Ratio Maximum unity ratio for shear web is 0.600 < 1 OK!

Rev. : A Page 25 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

4.1.6. TRESTLE BRACING

Table 4.6 Trestle Bracing Unity Ratio Maximum unity ratio for shear web is 0.587 < 1 OK!

Rev. : A Page 26 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4 4.2

Conveyor T-1022

DEFLECTION CHECK

4.2.1. Vertical Deflection Allowable vertical deflection shall be less than L/240

Fig 4.1 Vertical deflection at top chord member

Fig 4.2 Vertical deflection at bottom chord member

Rev. : A Page 27 of 29

CALCULATION Document Number

PBA-CAL-CVL-001-A4

Conveyor T-1022

Rev. : A Page 28 of 29

Allowable deflection at mid span of conveyor gallery is L/240 = 12000 mm /240 = 50 mm Maximum deflection on main member (bottom chor and top chord) is 8.780 mm which is below allowable vertical deflection. Based on this value, it can be concluded that conveyor steel structure has adequate stiffness and strength capacity to withstand gravitational load.

4.2.2

Lateral Drift Maximum lateral drift shall be less than H/200 where H is height of structure or in particular case such as conveyor trestle, H is defined as distance between base plate top surface and joint between gallery and trestle. Conveyor structure T-1022drift is calculated at +10.21 elevation. Thus, allowable lateral drift of the structure is H/200 = 10528 mm/200 = 52.64 mm

According to Table 4.7 maximum lateral drift in Z axis is 19.312 mm < 52.64 mm

OK!

In X axis direction or longitudinal section, maximum longitudinal deflection is 13.278 mm < 52.64 mm OK! This longitudinal deflection doesn’t represent proportional structure behaviour because at start and end point of conveyor, the structures are tied in transfer tower with pinned and rolled support respectively. However, lateral deflection in longitudinal direction shall be less than 2 span 12 meters model.

CALCULATION Document Number

PBA-CAL-CVL-001-A4 5.

Conveyor T-1022

Rev. : A Page 29 of 29

MEMBER TAKE OFF Based on steel membes take off for 12 m span including gallery and trestle, rate of steel material requirement for main member is 162.989 kg/m.

Table 4.8 Conveyor structure Member Take Off