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Sarcheshmeh Flash Smelting Project

Client’s Document No.:

Contractor’s Document No.: Rev

Contract No. : 4047 418/200-B00-C1-001 01 Client Area No. : 200

Document Title: CIVIL DESIGN CRITERIA Date: 9 Nov 2011 of 52

CIVIL DESIGN CRITERIA

A.AH.MB.GHIFCIssued For Construction28 Nov 201101

A.AH.MB.GHIFRIssued for Review22 OCT 201100

APPROVEDCHECKEDPREPAREDPURPOSE OF ISSUEDESCRIPTIONDATEREV.

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Revision Index

Rev. Sheet Rev. Sheet Rev.

No. 00 No. 00 No. 00

1 x 24 x 47 x

2 x 25 x 48 x

3 x 26 x 49 x

4 x 27 x 50 x

5 x 28 x 51 x

6 x 29 x 52 x

7 x 30 x

8 x 31 x

9 x 32 x

10 x 33 x

11 x 34 x

12 x 35 x

13 x 36 x

14 x 37 x

15 x 38 x

16 x 39 x

17 x 40 x

18 x 41 x

19 x 42 x

20 x 43 x

21 x 44 x

22 x 45 x

23 x 46 x

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Table of Contents

CIVIL DESIGN CRITERIA .................................................................................................................. 1

1 GENERAL ............................................................................................................................................. 6

1.1 PROJECT OVERVIEW 6

1.2 DOCUMENT SCOPE 6

1.3 DEFINITIONS 6

1.4 CODES AND STANDARDS 6

1.4.1 REINFORCED CONCRETE STRUCTURES: ................................................................................................... 7

1.4.2 VIBRATING MACHINERY:...................................................................................................................... 8

1.4.3 STEEL STRUCTURES: ........................................................................................................................... 8

1.4.4 DESIGN LOADS:................................................................................................................................. 9

1.4.5 AMERICAN SOCIETY FOR TESTING MATERIALS (ASTM).............................................................................. 9

1.5 SITE GENERAL DATA 13

1.5.1 LOCATION ...................................................................................................................................... 13

1.5.2 TEMPERATURE ................................................................................................................................ 13

1.5.3 WINDS .......................................................................................................................................... 13

1.5.4 RAINS ........................................................................................................................................... 13

1.5.5 SOIL INVESTIGATIONS ....................................................................................................................... 14

1.5.6 ALLOWABLE BEARING CAPACITY ......................................................................................................... 14

1.5.7 EXPECTED SETTLEMENTS ................................................................................................................... 14

1.5.8 SOIL CHEMICAL PARAMETERS AND CEMENT TYPE ................................................................................... 14

1.6 IMPORTED FILL 14

2 LOADS AND LOAD COMBINATIONS .................................................................................................. 15

2.1 LOADS 15

2.1.1 DEAD LOAD (DL)............................................................................................................................. 16

2.1.2 ERECTION LOAD (ER)........................................................................................................................ 16

2.1.3 SNOW LOAD (S).............................................................................................................................. 16

2.1.4 LIVE LOAD (L) ................................................................................................................................. 16

2.1.5 TEST LOAD (TEST)............................................................................................................................ 18

2.1.6 OPERATING LOAD (OPER) ................................................................................................................. 18

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2.1.7 THERMAL LOAD ............................................................................................................................... 18

2.1.7.1 Equipment or piping thermal load ............................................................................................ 18

2.1.7.2 Ambient Thermal Load (Temp) ................................................................................................. 19

2.1.8 TRUCK LOADS.............................................................................................................................. 19

2.1.9 IMPACT LOAD (IL)............................................................................................................................ 20

2.1.10 MAINTENANCE LOAD (ML).............................................................................................................. 212.1.11 EXCHANGERS BUNDLE PULLING ........................................................................................................ 21

2.1.12 SURGE LOAD ................................................................................................................................ 21

2.1.13 WIND LOAD (W)........................................................................................................................... 22

2.1.14 SEISMIC LOAD. (Q) ........................................................................................................................ 22

2.1.15 PIPE RACK AND PIPE SUPPORT DESIGN LOAD ....................................................................................... 23

2.1.15.1 Vertical Loads......................................................................................................................... 23

2.1.16 VIBRATION LOAD (VL) .................................................................................................................... 24

2.1.17 CONSTRUCTION LOAD (CL) .............................................................................................................. 24

2.1.18 EARTH LOAD (HL).......................................................................................................................... 25

2.2 LOADING COMBINATIONS 25

2.2.1 FIXED EQUIPMENT ........................................................................................................................... 252.2.2 PIPE-RACKS, SHELTERS, STRUCTURES AND PIPE SUPPORTS ....................................................................... 27

2.2.3 LOAD COMBINATION FOR STEEL STRUCTURE DESIGN AND SOIL PRESSURE CHECK. .......................................... 28

2.2.4 LOAD COMBINATION FOR EQUIPMENT FOUNDATION DESIGN .................................................................... 29

3 GENERAL DESIGN CRITERIA .............................................................................................................. 30

3.1 ALLOWABLE VERTICAL DEFLECTION 30

3.2 ALLOWABLE HORIZONTAL DISPLACEMENT 31

3.3 REINFORCED CONCRETE WORKS 32

3.3.1 GENERAL ....................................................................................................................................... 323.3.2 CONCRETE GRADES .......................................................................................................................... 32

3.3.3 REINFORCING STEEL ......................................................................................................................... 33

3.3.4 ANCHOR BOLTS, PLATES AND STEEL INSERTS ......................................................................................... 33

3.3.4.1 Material ................................................................................................................................... 33

3.3.4.2 Design Requirement................................................................................................................. 33

3.3.5 CONCRETE COVER ............................................................................................................................ 34

3.4 STEEL STRUCTURE 35

3.4.1 MATERIAL ...................................................................................................................................... 35

3.4.1.1 Structural Steel......................................................................................................................... 35

3.4.1.2 Bolts, Nuts and Washers........................................................................................................... 35

3.4.2 CHEQUERED PLATES ......................................................................................................................... 36

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3.4.3 STEEL GRATINGS ............................................................................................................................. 36

3.5 FOUNDATION DESIGN 36

3.5.1 GENERAL DESIGN CRITERIA AND DETAILS .............................................................................................. 36

3.5.2 TANK FOUNDATIONS ........................................................................................................................ 37

3.5.3 ELEVATIONS OF FOUNDATION PLINTHS ................................................................................................. 38

3.5.4 SOIL CHECK .................................................................................................................................... 383.5.5 ALLOWABLE SETTLEMENTS ................................................................................................................ 39

3.5.6 STABILITY RATIOS ............................................................................................................................ 40

3.5.7 SLIDING STABILITY ........................................................................................................................... 40

3.6 FOUNDATION AND STRUCTURES FOR HEAVY VIBRATING MACHINERY 41

3.6.1 DESIGN CRITERIA FOR RECIPROCATING MACHINERY ................................................................................ 44

3.6.2 DYNAMIC ANALYSIS SHALL BE CARRIED OUT AS FOLLOWS: ......................................................................... 44

3.6.3 DESIGN CRITERIA FOR ROTARY MACHINERY ........................................................................................... 45

3.6.3.1 Dynamic Analysis...................................................................................................................... 45

3.6.3.2 Natural Frequencies ................................................................................................................. 45

3.6.4 ANALYSIS OF VIBRATIONS DUE TO UNBALANCED FORCES ......................................................................... 46

3.6.4.1 Exciting Forces.......................................................................................................................... 463.6.4.2 Allowable Displacements.......................................................................................................... 47

4 CIVIL WORKS .................................................................................................................................... 48

4.1 PAVING 48

4.1.1 TYPES OF PAVING ............................................................................................................................. 48

4.1.1.1 Light duty paving ...................................................................................................................... 48

4.1.1.2 Medium Duty Paving ................................................................................................................ 48

4.1.1.3 Heavy duty paving.................................................................................................................... 48

4.1.2 PAVING ELEVATION .......................................................................................................................... 494.1.3 PAVING DESIGN .............................................................................................................................. 49

4.2 SIDEWALKS 50

4.2.1 WALKWAYS .................................................................................................................................... 50

4.2.2 LOCATION OF SIDEWALKS .................................................................................................................. 50

4.2.3 CROSS SLOPE .................................................................................................................................. 50

4.2.4 WIDTHS ........................................................................................................................................ 51

4.2.5 GRADES ......................................................................................................................................... 51

4.2.6 DITCH CROSSINGS ............................................................................................................................ 51

4.3 PIPE CROSSINGS 51

4.4 CABLE TRENCHES 51

4.5 SURFACE DRAINAGE SYSTEM 52

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1 GENERAL

1.1 PROJECT OVERVIEW

Sarcheshmeh Copper Complex is located at 50 km west of Sarcheshmeh and 30 km east from

Shahr-e-Babak city at Kerman Province, Iran. The copper production facilities at the complex

comprise the mine, the concentrator, the smelter and the refinery, together with the required utilities.

The complex was constructed during the 1970's. The current smelting technology is conventional,

based on Reverbratory furnace smelting of concentrates, followed by Peirce-Smith converting of

matte, copper fire refining and anode casting.

The target of this project is to replace the conventional smelting technology with new FSF

technology. The scope of the project is construction on EPC basis of Flash Smelter Furnace with the

steady production capacity of 875 ton per day Cathodic copper including of basic engineering review,

detail engineering, site engineering, Material supply (Foreign/local), manufacturing / inspection, packing,

insurance covering, site fabrication, all construction activities including of Civil works, Equipment erections &

test, pre-commissioning, test performance, EMPLOYER personnel training, 2 years spare parts supply for

operation, consumable material supply for 12 month operation, supervision on operation for 6 month.

1.2 DOCUMENT SCOPE

This specification covers general design criteria for foundations, concrete& steel structures and civil

works for the Project Flash Smelter Furnace Sarcheshme Copper Complex.

1.3 DEFINITIONS

Employer : National Iranian Copper Industries Co.(NICICO)

Consultant: NIPEC Company / HAK consortium

Contractor : Sadid J ahan Sanat, Bam Rah, Fakoor Sanat Teharn, Sanayea-E-Madani Mobina Tekjoo

1.4 CODES AND STANDARDS

All work shall be completed in accordance with engineering codes and standards listed in this

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document unless otherwise stipulated, the International Standards referenced as applicable or their

version of these documents, including relevant appendices and supplements. Where there are national

regulations, their particular requirements, and those of the standards and codes to which they refer,

must be applied, supplementing or amending the provisions of this document.

1.4.1 Reinforced Concrete Structures:

• ACI 318-2005 Building Code Requirements for Reinforced Concrete

• ACI 201-2R Guide to Durable Concrete

• ACI 211-1 Standard Practice for Selecting Proportions for Normal, Heavyweight, and Mass

Concrete.

• ACI 212-3R Chemical Admixture For Concrete

• ACI 214-3R Simplified Version of the Recommended Practice for Evaluation of Strength

Test Results of Concrete

• ACI 221-R Guide for Use of Normal Weight and Heavyweight Aggregates in Concrete

• ACI 222-R Protection of Metals in Concrete against Corrosion

• ACI 224-R Control of Cracking in Concrete Structures

• ACI 224-1R Causes, Evaluation and Repair of Cracks in Concrete Structures

• ACI 224-2R Cracking Of Concrete Members in Direct Tension

• ACI-225-R Guide to the Selection And Use Of Hydraulic Cements

• ACI 301 Specifications for Structural Concrete

• ACI 302-1R Guide for Concrete Floor and Slab Construction

• ACI 304-R Guide for Measuring, Mixing, Transporting and Placing Concrete

• ACI 305-R Hot Weather Concreting

• ACI 308 Standard Practice For Curing Concrete

• ACI 309-R Guide for the Consolidation of Concrete

• ACI 309-2R Identification and Control of Visible Effects of Consolidation on Formed Concrete

Surface.

• ACI 311-4R Guide for Concrete Inspection

• ACI 313 Standard Practice For Design And Construction Of Concrete Silos And Stacking

Tubes For Storage Of Granular Materials.

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• ACI 315 Details & Detailing of Concrete Reinforcement

• ACI 318-2005 Building code requirements for structural concrete and commentary.

• ACI 347 Guide to Formwork for Concrete

• ACI 350M Code Concrete Sanitary Structures.

• ACI 352 Recommendations for Design of Beam-Column Connections in MonolithicReinforced Concrete Structures.

• ACI 408 -R Suggested Development, Splice and Standard Hook Provisions for Deformed

Bars in Tension.

• ACI 442-R Response of Concrete Buildings to Lateral Forces

• ACI 504-R Guide to Sealing J oints in Concrete Structures

• ACI 530 Building Code Requirements for Masonry Structures and Commentary

• INBC-Part9-1388 Iranian Building code requirements for Concrete Structures.

• INBC-Part 123-1374 Iranian Building code for Under Ground reservoirs.

• BS CP 110& CP 114 The Structural use of Reinforced Concrete in Buildings.

• BS CP 2012-1 Code of Practice for Foundations for Machinery. Foundations for Reciprocating

Machines.

• DIN 1045 Concrete, Reinforced and Pre-stressed Concrete Structures.

• DIN 4024-1 Machine Foundations, Flexible Structures that Support Machines with Rotating

Elements.

• DIN 4024-2 Machine Foundations, Rigid Foundations for Machinery with Periodic Excitation

1.4.2 Vibrating machinery:

• DIN 4024 Machines Foundations

• VDI 2056 Evaluating the Mechanical Vibrations of Machines.

• VDI 2060 Evaluating the Balanced Condition of Vibrating Rigid bodies.

1.4.3 Steel Structures:

• Specification for Structural Steel Building – ANSI/AISC 360-2005.

• Seismic Provision for Structural Steel Buildings – ANSI/AISC 341-2005.

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• Prequalified Connections for Special and Intermediate Steel Moment Frames for Seismic

Applications – ANSI/AISC 358

• Steel Construction Manual 13th Edition.

• Code of Standard Practice for Steel Buildings and Bridges – AISC 303.

• Iranian national building code for Structural Steel Building -Part 10-1387• Iranian national building code for Industrial Structural Steel Building -Part 325.

• AWS: American Welding Society

• ANSI/ASCE, American Society of Civil Engineers,

1.4.4 Design Loads:

• Uniform Building code, UBC 1997.

• ASCE, American Society of Civil Engineers for Minimum Design Loads for Buildings and Other

Structures, Rev7.• Iranian Code for seismic resistant design of buildings, standard No.2800-03R-05.

• Iranian national building code for Building Design Loads -Part 6-1385.

1.4.5 American Society for Testing Materials (ASTM)

• ASTM A6/6M Standard Specification for General Requirements for Rolled Structured

Steel Bars, Plates, Shapes and Sheet Piling.

• ASTM A36/36M Standard Specification for Carbon Structural Steel

• ASTM A53/A53 M Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-

Coated, Welded and Seamless.

• ASTM A108 Standard Specification for Steel Bars, Carbon and Alloy Cold Finished.

• ASTM A123 Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and

Steel Products

• ASTM A135 Standard Specification for Electric-Resistance-Welded Steel Pipe.

• ASTM A139/139M Standard Specification for Electric Fusion (Arc)-Welded Steel Pipe (NPS4

and over).

• ASTM A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel

Hardware

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Document Title: CIVIL DESIGN CRITERIA Date: 9 Nov 2011 of

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• ASTM A185 Standard Specification for Steel Welded Wire Reinforcement, Plain, for

Concrete.

• ASTM A193/193M Standard Specification for Alloy Steel and Stainless Steel Bolting

Materials for High Temperature Service

• ASTM A194/194M Standard Specification for Carbon and Alloy-Steel Nuts for Bolts for HighPressure or High Temperature Service, or Both.

• ASTM A307 Standard Specification for Carbon Steel Bolts and Studs, 60 000 psi,

Tensile Strength

• ASTM A320 Standard Specification for Alloy Steel Bolting Materials for Low

Temperature Service.

• ASTM A325 Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105

Ksi Minimum Tensile Strength.

• ASTM A-392 Standard Specification for Zinc-Coated Steel Chain-Link Fence Fabric

• ASTM A 490 Standard Specification for Structural bolts, alloy steel, heat treated, 150

Ksi tensile strength

• ASTM A497 Standard Specification for Steel Welded Wire Fabric, Deformed, for

Concrete Reinforcement

• ASTM A500 Standard Specification for Cold-Formed, Welded and Seamless Carbon

Steel Structural Tubing in Round and Shapes.

• ASTM A501 Standard Specification for Hot-Formed Welded and Seamless Carbon

Steel Structural Tubing

• ASTM A563 Specification for Carbon and Alloy Steel Nuts.• ASTM A572 Standard Specification for High-Strength Low-Alloy Columbium-Vanadium

Structural Steel.

• ASTM A615 Standard Specification for Deformed and Plain Carbon Steel Bars for

Concrete Reinforcement.

• ASTM A706 Standard Specification for Low-Alloy Steel Deformed and Plain Bars for

Concrete Reinforcement.

• ASTM A759 Standard Specification for Carbon Steel Crane Rails

• ASTM A775 Standard Specification for Epoxy-Coated Steel Reinforcing Bars

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• ASTM A820 Standard Specification for Steel Fibers for Fiber-Reinforced Concrete

• ASTM A884 Standard Specification for Epoxy-Coated Steel Wire and Welded Wire

Reinforcement.

• ASTM B695 Standard Specification for Coatings of Zinc Mechanically Deposited on

Iron and Steel.• ASTM C31 Standard Practice for Making and Curing Concrete Test Specimens in the

Field

• ASTM C 33 Standard Specification for Concrete Aggregates

• ASTM C 39 Standard Test Method for Compressive Strength of Cylindrical Concrete

Specimen

• ASTM C 40 Standard Test Method for Organic Impurities in Fine Aggregates for

Concrete.

• ASTM C 88 Standard Test Method for Soundness of Aggregates by Use of Sodium

Sulphate or Magnesium Sulphate

• ASTM C90 Standard Specification for Load bearing Concrete Masonry Units

• ASTM C94 Standard Specification for Ready-Mix Concrete

• ASTM C 109 Standard Test Method for Compressive Strength of Hydraulic Cement

Mortars (Using 2-in. or (50-mm) Cube Specimens).

• ASTM C 114 Standard Test Methods for Chemical Analysis of Hydraulic Cement

• ASTM C 117 Standard Test Method for Material Finer than 75-µm Micrometers

(No.200) Sieve in Mineral Aggregates by Washing

• ASTM C 127 Standard Test Method for Density, Relative Density (Specific Gravity) andAbsorption of Course Aggregate

• ASTM C 128 Standard Test Method for Density, Relative Density (Specific Gravity) and

Absorption of Fine Aggregate

• ASTM C 131 Standard Test Method for Resistance to Degradation of Small-Size

Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine

• ASTM C 136 Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates

• ASTM C 138 Standard Test Method for Density, Yield and Air Content (Gravimetric) of

Concrete

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• ASTM C 142 Standard Test Method for Clay Lumps and Friable Particles in Aggregates

• ASTM C Standard Test Method for Slump of Hydraulic Cement Concrete

• ASTM C 150 Standard Specification for Portland Cement

• ASTM C172 Standard Practice for Sampling Freshly Mixed Concrete

• ASTM C 227 Standard Test Method for Potential Alkali Reactivity of Cement-AggregateCombinations (Mortar-Bar Method).

• ASTM C 260 Standard Specification for Air-Entraining Admixtures in Concrete

• ASTM C270 Standard Specification for Mortar for Unit Masonry

• ASTM C289 Standard Test Method for Potential Alkali-Silica Reactivity of Aggregates

(Chemical Method)

• ASTM C309 Standard Specification for Liquid Membrane-Forming Compounds for

Curing Concrete

• ASTM C494 Standard Specification for Chemical Admixtures in Concrete

• ASTM C535 Standard Test Method for Resistance to Degradation of Large-Size

Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine.

• ASTM C566 Standard Test Method for Total Evaporable Moisture Content of

Aggregate by Drying

• ASTM C579 Standard Test Methods for Compressive Strength of Chemical-Resistant

Mortars, Grouts, Monolithic Surfacing and Polymer Concretes

• ASTM C618 Standard Specification for Coal Fly Ash and Raw or Calcined Natural

Pozzolan for Use in Concrete.

• ASTM C1017 Standard Specification for Chemical Admixtures for Use in Producing

Flowing Concrete.

• ASTM C1064 Standard Test Method for Temperature of Freshly Mixed Hydraulic-

Cement Concrete.

• ASTM D512 Standard Test Methods for Chloride Ion in Water..

• ASTM D516 Standard Test Method for Sulfate Ion in Water.

• ASTM F436 Standard Specification for Hardened Steel Washers.

• ASTM F606 Standard Test Methods for Determining the Mechanical Properties of

Externally and Internally Threaded Fasteners, Washers and Rivets.

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• ASTM F959 Standard Specification for Compressible-Washer-Type Direct Tension

Indicators for Use with Structural Fasteners.

1.5 SITE GENERAL DATA

1.5.1 Location

The plant is located in Latitude & Longitude N 29.95° E 55.85° and Elevation about 2450 m above sea

level, according to seismology studies the earthquake zone is as per UBC Zone 3 or high risk zone

according to Iranian national standard no 2800 (acceleration 0.3 g).

1.5.2 Temperature

The minimum & maximum temperature is between -25 °C / 35 °C and design Min / Max temperature is

between: -17.7 °C / 32.5 °C

1.5.3 Winds

Prevailing wind directions in winter is between South and South-West and in summer is between North

and North-East.

Annual mean wind velocity is 3.5 m/s, mean minimum velocity is 2.3 m/s. Maximum wind velocity

recorded: 28 m/s (100 km/h)

Stormy days per annum are 10 days.

1.5.4 Rains

Annual average rainfall: 400 mm / a

Design rainfall: 400 mm / a

Rainfall intensity: 76 mm / h

Annual average snowfall: 80 mm / a (as water)

Design snowfall intensity: 150 mm / a (as water)

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Frost line: 1200 mm below grade

1.5.5 Soil Investigations

Design of foundations, structures, earthworks and other concrete works shall be carried out in

accordance with the prescriptions included in the Soil Investigation Reports by PEY KAV Consulting

Engineers for Sarcheshmeh Flash Smelting plant.

1.5.6 Allowable Bearing Capacity

Allowable bearing capacity of soil relate to allowable settlements, dimensions and depth of foundations.

For allowable bearing capacity of soil, refer to Soil Consulting Engineers Reports with doc No 418/200-

000-C5-001.

1.5.7 Expected Settlements

The settlements shall be limited to 25 mm up to 40 mm (according to type of structure and

manufacturer instructions), based on curves given in the Soil Consulting Engineers Reports.

1.5.8 Soil Chemical Parameters and Cement Type

According to soil report issued by PEYKAV Consulting Engineers, type of used cement is cement type I

but according to environmental consideration cement type IV shall be used.

1.6 Imported Fill

In case of substantial fill needs to be imported then until such time as the imported fill is tested it may

be assumed that it may have the following properties:

• Cohesion c = 0

• Internal angle of friction φ = 320-34

• Unit weight = 18-21 kN/m

0

3

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2 LOADS AND LOAD COMBINATIONS

2.1 Loads

All civil works including buildings, equipment structures, pipe racks, shelters, process equipment and

foundations shall be designed for the following loads:

• Dead load (DL)

• Erection Load (Er)

• Live (imposed) load (LL)

• Test load (Test)

• Operating Load (Oper)

• Thermal loads (Fric,TH, Temp)

• Truck Load

• Impact load

• Maintenance Load(ML)

• Surge Load (Surge)

• Wind load (W)

• Seismic load(Q)

• Vibration Load(VL)

• Construction Load (CL)

• Earth Load (HL)

• Fluid Load (FL)

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2.1.1 Dead Load (DL)

Dead load for buildings includes the weight of walls, foundations, floors and roofs, partitions, ceiling

finishes, partitions, stairways and fixed service installations.

Dead load for equipment structures, pipe-racks and process equipment includes the weight of structure, vessels including internals, pipes, valves and accessories, electrical and lighting conduits,

switch-gear, instrumentation, fireproofing, insulation, ladders, platforms, davits etc.

Equipment and piping shall be considered empty of product load when calculating dead load.

The weight of soil overburden shall be considered as dead load in the design of foundations.

2.1.2 Erection Load (Er)

The erection load is the weight of empty equipment and structure at the time of erection plus the weight

of foundation.

2.1.3 Snow Load (S)

Design snow load shall be: 150 Kg/ m2 uniformly distributed over the horizontal projection of the loaded

area. Snow on grating shall not be taken into account.

2.1.4 Live load (L)

Live load is defined as the weight superimposed by the use and occupancy of the building or other

structure, but not permanently attached to it. For industrial plant, live load is defined as additional load

produced by personnel, moveable equipment, tools, etc. placed on the structure but not permanently

attached to it.

The Live Loads shall be considered as uniformly distributed over the horizontal projection of the loaded

areas, except for the loads with a concentrated nature

Minimum recommended live loads for buildings shall be in accordance with IRANIAN NATIONAL

BUILDING CODE-part6, except otherwise stated in this Design Criteria.

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Table 2-1: Minimum Live Load

For operating platforms, floor grating and slabs subject to concentrated load during the installation or

removal of equipment known to be greater than the above values, the greater load shall be used in

design.

For design against seismic conditions, 25% of live load shall be considered.

In case of multi story buildings/structures above figure may be reduced for columns and foundationsdesign.

TYPE OF STRUCTURE MINIMUM LIVE LOAD

Stairs to equipment structures

(excluding buildings)

250 Kg/m2

or 500 Kg point load

Walkways / access platforms 250 Kg/m2


Operating platforms, Laboratory,operating and maintenance areas:

500 Kg/m2


Hand railing 360 kg/m applied horizontally to the top rail

740 Kg applied horizontally to the top of handrail post

Cover plates and Slabs &Concrete paving

with no vehicular access (positioned toproduce maximum stress)

1000 Kg point load or 500 Kg/m2

Concrete trench covers in off-site andunpaved areas with no vehicular access

500 Kg/m2

Control Rooms, Switch Gear Rooms,Battery Rooms and CompressorBuildings, Pump Houses

Uniformly distributed load of 1000 Kg/m²(These live loads shall be checked against Manufacturer’sdocuments.)

Platform in Storage Areas Uniformly distributed load of 600 kg/m2 for light and 1200kg/m

2

for heavy storage areas or a concentrated load of 900kg at any point over the platform, whichever is critical.

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2.1.5 Test Load (Test)

Test load is defined as the gravity load imposed during hydrostatic test of vessels, tanks, equipment or

piping. In test conditions 20% increase in allowable stress is permitted. In case a hydrotest is required,

in static calculation the weight of water shall be considered as a live load.

2.1.6 Operating Load (Oper)

Product load is defined as the gravity load imposed by liquid, solid or viscous materials in vessels,

tanks, equipment or piping during operation. In static calculation this load shall be considered as a

dead load.

2.1.7 Thermal Load

Thermal loads are those forces caused by temperature variations. Two different types of thermal

loads shall be considered in design of structures and foundations:

2 .1 .7 .1 Equ ipmen t o r p i p ing t he rma l l oad

The primary source of thermal load in an industrial plant is the expansion and contraction of vessels

and piping. This force is exerted to structure in two ways:

2.1.7.1.1 F r i c t i o n fo rce (Fr i c )

The Forces caused by equipment or piping expansion or contraction shall be defined as those required

to overcome the static friction between two surfaces in contact and one liable to sliding over the other,

and shall be termed as friction forces. These can take place only during operation and must be

considered as live loads. These loads shall not be combined with earthquake load. Friction forces are

used only for local design of main supports. Columns and foundation shall not be designed for this

load.To calculate friction loads caused by equipment and single pipes, the following friction coefficient f

shall be used:

• Teflon to teflon f = 0.10

• Teflon to stainless steel f = 0.10

• Steel to steel f = 0.30

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• Steel to concrete f =0.50

On pipe racks and pipe supports with 4 or more lines the friction force shall be taken as10% of the total

pipe weight tributary to the pipe rack or pipe support, under operating conditions. On pipe racks and

pipe supports with 3 or less lines the friction force shall be taken as 20% of the total pipe weight

tributary to the pipe rack or pipe support, under operating conditions. The transversal (perpendicular to

the pipe ) friction force shall be taken as 5% of the total tributary pipes weight. The thermal load caused

by the expansion – contraction of the structure shall be computed based on the coefficients of

expansion specified in AISC manual of steel construction.

2.1.7 .1.2 Opera t ing therma l loads (TH)

Operating thermal loads are the forces caused by equipment or piping expansion or contraction shall

be defined as those resisted by anchors or guide supports and are calculated with appropriate software

by other departments, These loads can take place only during operation and must be considered as

live loads. These loads shall be combined with other instantaneous loads such as wind and

earthquake.

2.1.7 .2 Amb ien t Therma l Lo ad (Temp)

Thermal loads are also generated due to the expansion or contraction of the entire structure or

individual structural components. Regarding the design criteria for thermal load due to change in

ambient temperature, the recommendation is Δθ=25°c should be considered, in order to minimize

temperature effect on structure expansion joints shall be provided in steel structures which are 45 m

long or greater considering the centre of structural elements. This load is considered as dead load but

shall not be assumed to act with earthquake simultaneously.

2.1.8 TRUCK LOADS

All pavements, slabs, bridges, trenches, trench covers and underground installations accessible to

truck loading shall be designed to withstand the worst of the following loading cases. HS 15-44 wheel

loading or its equivalent lane loading as defined by the American Association of State Highway and

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Transportation Officials (AASHTO) under Standard Specifications for highway bridges. For the design

of paving the following axle load should be considered.

• Light duty paving: Maximum axle load is equal to 10 kN.

• Medium duty paving: Maximum load of 60 kN per axle.

• Heavy duty paving : Maximum load per axle of120 kN (4 tyres)

2.1.9 Impact Load (IL)

Any live load that can produce a dynamic effect (such as a moving load) shall be increase by an impact

factor, impact factors are applied to crane vertical wheel loads and should be applied to crane runway

beams and their connections and connection elements including brackets but excluding columns and

foundation. Loads applied by cranes, runway beams, jib cranes, davits, hoists and other lifting

appliances shall be calculated in accordance with AISC and UBC codes but shall not be less than the

following:

Table2-2: Dynamic Impact Load

STRUCTURE LOAD DIRECTION DYNAMIC INCREASE

Bridge-crane runways

a) Vertical

b) Horizontal (longitudinal)

c) Transversal

Take into account manufacturer loading data if

any or the following requirements :

25% of lifted load

20% of maximum wheel load applied at top of

runway

20% of the sum of the lifted load and the weight

of the crane trolley applied at top of runway, one

half on each side.

This force shall be considered acting in either

directions normal to runway rail.

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Monorails runway

a) Vertical

b) Horizontal (longitudinal)

c) Transversal

25% of lifted load

20% of wheel load

20% of lifted load

Davits (1)a) Vertical

b) Horizontal

50% of lifted load

20% of equipment weight

Elevator Supports

Vertical

100% of elevator weight

Hangers supporting

floors and Balconies

Vertical

33% off vertical load

Machinery Supports

50% off vertical load

Transverse and longitudinal impact forces shall not be assumed to act simultaneously.

2.1.10 Maintenance Load (ML)

Maintenance loads are temporary forces due to dismantling, repair or painting of equipment. In static

calculations they shall be considered as live loads.

2.1.11 Exchangers Bundle Pulling

Structures and foundations supporting heat exchangers shall be designed to withstand a longitudinal

force applied at the centre of the tube bundle. The fixed saddle only shall support such force. It shall be

equal to 0.5 of the weight of the bundle or to 10 kN, whichever is bigger. In case of stacked equipment

it shall be assumed that the bundle pulling of equipment shall not be contemporary.

Above figures may be reduced if only special extraction devices are provided. This maintenance load

shall be considered as a live load

2.1.12 Surge Load

Supporting structures and foundations shall be designed for surge loads occurring in vessels or

equipment. The magnitude and direction of the load shall be given in the Equipment Specification.

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2.1.13 Wind Load (W)

Wind pressure shall be calculated according to INBC Part: 6, based on the following:

Basic Wind Speed: V should be considered as 100 km/h

• Ce: Accordance to Section 6.6.6-INBC Part: 6

• Cq: Accordance to Section 6.6.7 to 6.6.9-INBC Part: 6

Wind loads on structures and foundations will be evaluated according to INBC Part: 6.

Wind loads and Earthquake loads shall not be considered simultaneously.

Wind loads shall be assumed from any direction.

For towers, stacks and slender equipment the phenomena of wind induced vortex shedding and natural

frequency induced instability shall be assessed and appropriate measures taken to avoid such

instabilities.

2.1.14 Seismic Load. (Q)

Earthquake load on structures and foundations shall be calculated according to INBC Part: 6, or

UBC97 based on the following:

• Seismic Zone: Zone 3

• Peak ground horizontal acceleration: PGA = 0.30g.

• Peak ground vertical acceleration 2/3 x 0.30g

• Seismic Importance Factor I: 1

• Soil profile type: Type II, According to Soil Investigation Report

Total weight contributed in seismic load is combination of dead load or operating load in addition 25%

of live load, for other buildings following loads should be considered concurrent with dead loads.

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• Buildings: as per INBC Part: 6

• Vibration equipment: 150 % of total static weight

• Pipe racks: operating loads

• Industrial buildings with crane: Total weight of the cranes, but excluding the lifted loads shall

be considered as a dead load.• Storage tanks : 75% of snow load

The distribution of the total lateral earthquake load over the height of the building and other structures

shall be based on the following procedures:

• Buildings: as per INBC Part: 6

• Vertical vessels, stacks, storage tanks, Horizontal vessels, Heat exchangers (single & Multi

level) and the other Equipment: as per UBC 97.

• Flat-bottomed, vertically orientated storage tanks and their foundation shall be in accordance

with Appendix E of API 650, with an importance factor I =1.0.

2.1.15 Pipe Rack and Pipe Support Design Load

For design of pipe racks and pipe supports in the absence of definite loading provided by Piping

Department, the following minimum loads can be used.

2.1.15.1 Ver t ica l Loads

The following vertical loads shall be considered in design:

• Pipe Bundle:

For pipes diameter < 12 inches, a uniformly distributed load shall be applied to the considered pipe rack

level on the total area including free space for future use. For minimum values see table below:

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Average Diameter

(Inches)

Empty Weight

(Kg/m2

Full of Water Weight

) (Kg/m2

2

)

40 60

3 70 100

4 80 120

6 110 180

8 120 220

10 140 28012 150 320

For pipes diameter > 12 inches, piping load shall be considered as concentrated loads. In static

calculation, fluid loads shall be considered as dead loads.

• Single Pipe:

Piping loads shall be considered as concentrated loads

2.1.16 Vibration Load (VL)

.

Vibration loads are those forces and moments caused by rotating or reciprocating machinery such

as compressors, turbines, fan, blowers, and pumps.

The evaluation of such loads shall be done on the base of Manufacturer’s documents and as

indicated in the following paragraph 5 "Foundations and Structures for Vibrating Machines".

2.1.17 Construction load (CL)

Construction loads are temporary forces due to the erection of structures or equipment. In static

calculations it shall be considered as live loads.

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2.1.18 Earth Load (HL)

Earth loads are those loads due to soil, and ground water pressure when necessary, against

structures and foundations.

2.2 Loading Combinations

All loading combinations shall be done in accordance with the referenced design codes. For loads not

specified in ACI 318-05, but referred to in this Design Criteria, the load factor shall be taken as 1.4.

Combination of loads and forces shown in the following table shall be considered to determine the

critical loading condition for the design of the structural elements (columns, beams, slabs, bracings,

anchor bolts, foundations) and to check the stability of the structure. when inclusion of fluid loads, live

loads or snow load results in a less critical loading condition, these loads shall be excluded.

However safety of persons and structures shall be assured during all transient phases of construction.

All civil works including equipment structures, pipe racks, shelters, process equipment and foundations

shall be designed for the following scenarios:

2.2.1 Fixed Equipment

Supports and foundations for vertical and horizontal heat exchangers and vessels shall be designed on

the basis of UBC chapter 16 requirements summarised in 14.3.4 and the following specific conditions:

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Table2-3: Load Combination for Equipment Structure Design

ERECTION TEST OPERATION SHUTDOWN BUNDLE

PULL

ACCIDENTAL

Vessels dead

weight

100 % 100 % 100 % 100 % 100 % 100 %

Internals

weight

0 % 100 % 100 % 100 % 0 % 100 %

Platforms and

ladders

0 % 100 % 100 % 100 % 0 % 100 %

Piping, valves 0 % 100 % 100 % 100 % 0 % 100 %

Cables 0 % 100 % 100 % 100 % 0 % 100 %

Insulation 0 % 100 % 100 % 100 % 0 % 100 %

Fire proofing 0 % 100 % 100 % 100 % 0 % 100 %Live loads 100 % 100 % 100 % 100 % 0 % 25 %

Operating 0 % 100 %

(test)

100 %

(operating)

100 % 0 % 100 %

(operating)

Ambient

Thermal loads

0 % 0 % 100 % 100 % 0 % 0 %

Impact loads 0 % 0 % 100 % 100 % 0 % 0 %

Vibration loads 0 % 0 % 100 % 0 % 0 % 0 %

Surge loads 0 % 0 % 0 % 100 % 0 % 0 %

Wind 100 % 33 %

***

100 %* 100****% 0 % 0 %

Bundle pull

load

0 % 0 % 0 % 0 % 100% 0 %

Seismic 0 % ** 0 % *** 100 %* 100****% 0 % 100 %

* Wind and Earthquake are not considered simultaneously. Refer to UBC 97 section 1612 for

applicable load combinations.

** It is assumed that erection of equipment is too short a period to take into account seismic loads.

*** It is assumed that the testing of equipment or pipes is too short a period to take into account seismic

loads or the full wind loads.

**** Design for whichever the greater, 100% wind or 100% seismic.

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2.2.2 Pipe-Racks, Shelters, Structures and Pipe Supports

Pipe-racks, structures and pipe supports and their foundations shall be designed on the basis of UBC

chapter 16 requirements summarised in 14.3.4 and the following specific conditions:

Table2-4: Load Combination for Pipe Rack

* Wind and Earthquake are not considered simultaneously. Refer to UBC 97 section 1612 for applicable loadcombinations.

** It is assumed that erection of equipment is too short a period to take into account seismic loads.

*** It is assumed that the testing of equipment or pipes is too short a period to take into account seismic loads or

the full wind loads.

**** Consideration shall also be given to the erection case without live loading.

ERECTION TEST OPERATION ACCIDENTAL

Structural 100 % 100 % 100 % 100 %Piping weight 100 % 0 % 0 % 0 %Cables 0 % 100 % 100 % 100 %Fireproofing 0 % 0 % 100 % 100 %Equipment 100 % 100 % 100 % 100 %Live loads 100 %**** 25 % 100% 25%Operating Load 0 % 100 %

(test)

100 %

(operating)

100 %

(operating)Wind loads 100 % 33 % *** 100 % * 0 %Seismic loads 0 % ** 0 % *** 0% - 100 % * 100 %Anchor loads 0 % 0 % 100 % 0 %Friction loads 0 % 0 % 100 % 0 %Ambient ThermalLoad

0 % 0 % 100 % 0 %

Impact Load 0 % 0 % 100 % 0 %Crane/Lifting Hoists 0 % 0 % 100 % 0 %

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2.2.3 Load Combination for Steel Structure design and Soil

pressure Check.

Table2-5: Load Combination for soil pressure check

Normal

(%)

Wind

(%)

Normal

(%)

Wind

(%)

Normal

(%)

Tempera

ture(%)

Wind

(%)

1 Structural dead weight 100 100

2 Piping weight 100 100 100 100 100 100 100 100 90

3 Cables 100 100 100 100 100 100 90

4 Fireproofing 100 100 100 100 90

5 Equipment 100 100 100 100 100 100 100 100 906 Live loads 100 100 25 25 100 100 100 25

7Operating loads

100

(test)

100

(test)100 (OP) 100 (OP)

100

(OP)

100

(OP)

90

(OP)

8 Wind loads (±) 100 33 100

9 Seismic loads (±) 72 72

10 Piping Thermal loads(±) 100 100

12Ambient Thermal load(±) 100

13 Impact loads 100 100 100

14 Bundle Pull load 100

Allowable increase factor 1.000 1.333 1.200 1.333 1.000 1.333 1.333 1.333 1.333

Test Operation

Seismic (%)Load Description

Erection

Item

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2.2.4 Load Combination for Equipment Foundation Design

Table2-6: Load Combination for equipment foundation design

Wind

(%)

1 Structural dead weight 140 120 120 90 140 120 120 140 120 120 90 120 90

2 Piping weight 140 120 120 90

3 Cables 140 120 120 140 120 120 90 120 90

4 Fireproofing 140 120 120 90 120 90

5 Equipment 140 120 120 90 140 120 120 140 120 120 90 120 90

6 Live loads 160 100 40 25 160 100 25

7 Operating loads 140 120 120 140 120 120 90 120 90

8 Wind loads (±) 130 130 53 130 130

9 Seismic loads (±) 100 100

10 Piping Thermal loads(±) 140 120 120

11

Piping Friction

loads(Local design) 140 120 120

12 Ambient Thermal load(±) 140 120 120

13 Impact loads 160 100

14 Bundle Pull load 160

Wind (%)

Erection

Seismic

(%)

Operation

Item Normal

(%)

Test

Normal

(%)Wind (%)

Load Description Normal

(%)

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3 GENERAL DESIGN CRITERIA

3.1 Allowable vertical deflection

Design deflections of structural steel members shall not exceed the following values:

• Purlins, building floor joists and girders not supporting plastered ceilings L/200

• Floor beams without equipment L/300

• Building floor joists and girders supporting plastered ceilings L/300

• Pipe rack

• Main supporting beams L/400

• Combined deflection of intermediate beams and longitudinal tie-beams L/200

(L =span of intermediate. beam)

• Floor beams supporting equipment

• Operating state L/500

• Hydraulic test L/250

• Crane runways and monorails (vertical) For class services SA,SB&SC L/400

• For class services SD L/800

• For class services SE &SF L/1000

• Crane runways and monorails (horizontal) L/400

• Crane runways and monorails (horizontal) L/400

• Conveyer support for pulleys and drive units under live load +belt tension L/800

• Conveyer support under dead + live load L/400

• Relative lateral deflection of runway rails due to gravity loads 25mm

Where: L =theoretical span of beam.

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3.2 Allowable horizontal displacement

Maximum horizontal displacements of structures shall not exceed the following values:

• Single floor walkways and shelters without bridge-cranes H/150

• Frames without equipment H/200

• Pipe-racks H/200

• Frames with equipment

o Total Displacement H/200

o Displacement between floors h/300

• Shelters with bridge-cranes at runway beam elevation

o for structural classes of services SA&SB&SC H/240 Max 50mm

o for structural classes of services SD&SE H/400 Max 50mm

where H = total height of structure

For allowable horizontal displacement of building due to earthquake loads, refer to the INBC Part: 6

and UBC provisions of section 1630.

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3.3 REINFORCED CONCRETE WORKS

3.3.1 General

All concrete design shall be in accordance with the requirements of ACI standards and guides and

project specification 418/200-B00-C1-002, ‘Specification for Concrete Works ’.

All bar arrangement such as spacing, lapping, anchorage, and concrete cover shall be carried out

according to ACI requirements.

Reinforcement details not shown on standard and design drawings shall be carried out in accordance

with the requirements of ACI 315 "Details and Detailing of concrete Reinforcement".

3.3.2 Concrete Grades

Concrete works shall be designed using following minimum compressive strength at 28 days age for

cylindrical specimen (ASTM C39):

• Lean concrete Cement =150 Kg/m

• Concrete for duct bank and anchor blocks f’c =150 Kg/cm

3

2

• Foundation concrete f’c = 280 Kg/cm

• Machine foundation concrete f’c =350 Kg/cm

2

2

• Elevation concrete (cast in situ) f’c =250 Kg/cm

2

• Prefabricated concrete f’c = 280 Kg/cm

2

• Paving f’c =210 Kg/cm

• Basins and water retaining structures f’c = 250 Kg/cm

2

2

• Fireproofing concrete ( density :20 kN/m3) f’c = 210 Kg/cm

2

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3.3.3 Reinforcing Steel

Deformed High Tensile Strength Steel Bars, Grade III, in accordance with DIN 488 Specification with a

minimum yield stress of 4000 Kg/cm2 or approved equivalent. Diameters to use are : 8, 10,12, 16 ,20,

22, 25, 28 & 32mm.

Reinforcing Fabric Mesh in accordance with BS 4483 or approved equivalent as follow:

• 100 × 100 × 6 × 6 mm

• 200 × 100 × 8 × 8 mm

• 200 × 200 × 8 × 8 mm

• 150 × 150 × 8 × 8 mm

3.3.4 Anchor Bolts, Plates and Steel Inserts

3.3.4.1 Mater ia l

Material for steel plates and steel shapes for inserts shall be:

• A36 according to ASTM, or approved equivalent with minimum yield strength of 235 N/mm2 or

ST-37-2 in accordance with DIN 1025, 1050 and 17100 Specifications or approved equivalent

with a minimum yield stress of 2400 Kg/cm2.

Material standard anchor bolts shall conform or be equal to the following:

• ASTM A 307 Grade C or DIN ST-37-2 for Anchor bolts or approved equivalent. Minimum

anchor bolts diameter for structural steel foundations shall be 20 mm.

• Hexagonal nuts shall be in accordance with DIN 555 or ASTM A 563M or approved

equivalent for anchor bolts in foundations.

• Circular washers shall be in accordance with DIN 7989 specification or ASTM F 436M .

3.3.4 .2 Des ig n Requ i rement

• Allowable stress for anchor bolts shall be the following (ASD Part. 5, Table J 3.2):

• Tensile stress Ft, all =N/A =110 N/mm2(1)

Shear stress Fv, all = T/A =70 N/mm2(1)

Where:

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A =Gross (nominal) area of bolt

N = axial force on bolt;

T = shear force on bolt.

All anchor bolts shall be hot dip galvanized

1. Allowable stresses may be increased 1/3 if loading conditions includes wind or earthquake.

In principle shear stress should not be transferred on foundation by anchor bolts. Shear design of

Steel structure base-plates shall meet the following criteria:

_ Shear-keys shall be provided under columns which transfer important shear loads (such as

Braced frames, shelters with bridge-crane and pipe rack braced bays). Shear-key consists of

steel profile welded under column base-plate.

_ Shear can be transferred to foundation by friction for minor structures, such as walkways,

shelters without bridge-crane, pipe-racks, etc.

In these cases the effective compressed area shall be calculated based on actual vertical load and

moment.

If the effective shear load exceeds the maximum shear transferred by friction, shear-key shall be

• foreseen.

3.3.5 Concrete Cover

Minimum net cover shall be as follows:

A Formed concrete cast against and permanently exposed toground and sea water, for all diameter 70 mm

BFormed concrete exposed to weather and underside of

foundation for all diameters60 mm

CConcrete not exposed to weather or not in contact with

ground : Walls, slabs40 mm

DConcrete not exposed to weather or not in contact with

ground : Beams, Columns40 mm

The net cover is the distance from the outer edge of any reinforcement or other metal items to the

concrete external face.

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Minimum distance of reinforcing bars shall be 2 times the maximum diameter of bars.

Above mentioned figures for concrete cover and bar distance shall be checked against maximum size

of available aggregate and enough free space for vibrator.

3.4 Steel Structure

3.4.1 Material

3.4.1 .1 St ru ctu ra l S teel

Material for structural steel shall be Mild Steel Grade ST 37-2 in accordance with DIN 1025, 1050 and

17100 with a minimum yield stress of 2400 kg/cm2 or approved equivalent. Single or double sections of

European profiles such as I-sections (IPE), channels and angles shall be used in the design. In the

case of buildings, application of built-up sections is allowed. Structural steelworks fabrication and

erection shall be in accordance with project specification 418/D00-200-T1-001, ‘Specification for

Fabrication & Erection of Steelwork’.

3.4.1 .2 Bo l t s , Nu ts and Washers .

The following types of bolts may be used for design of connections.

Hexagonal head bolts grade 4.6 or 5.6 or A307 in accordance with DIN 7990, hexagonal nuts in

accordance with DIN 555, and circular washers in accordance with DIN 7989, square taper washers in

accordance with DIN 434 for connections of steel channels and DIN 435 for connection of steel I-

sections or approved equivalent.

Bolts grade 4.6 or 5.6 or A307 may be used only for walkways, joists, girts, stair stringers, handrails

and other secondary steel connections. The minimum diameter of bolt for these secondary members

shall be 12 mm.

Hexagonal head bolts grade 8.8 in accordance with DIN 6914, hexagonal nuts in accordance with DIN

6915, circular washers in accordance with DIN 6916, square taper washers in accordance with DIN

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6918 for connections of steel channels and DIN 6917 for connection of steel I-sections or approved

equivalent.

High strength bolts grade 8.8 or 10.9 shall be used for structural steel connections. The minimum

diameter of bolts for structural steel connections and main members shall be 16 mm and for secondary

members shall be 12 mm. Not less than two bolts shall be used in end connections.

3.4.2 Chequered Plates

Steel for chequered plates shall be ST 37-2 or approved equivalent. Minimum thickness shall be 6 mm

for plate plus 2 mm for raised pattern height.

Chequered plates shall be welded unless otherwise specified in related drawings.

3.4.3 Steel Gratings

Steel grating shall be a 30 x 50 mm mesh, with 30 x 3 mm bearing and 6X6 mm twisted transverse bars

or deformed Φ8 mm. Steel shall be in compliance with ST-37-2 or approved equivalent. Gratings shall

be hot dip galvanized as per ASTM A 123. Maximum span between supports of the gratings is 1.5 m.

3.5 Foundation Design

3.5.1 General Design Criteria and Details

The following design criteria shall be applied:

• The depth of foundation with respect to adjacent foundation has to be determined so that the

ground slope between the foundations is not steeper than 45°. This may require a lean

concrete fill below the higher foundation.

• Foundations next to pipe lines are to be founded at the bottom of pipe level. This applies up to

a distance of 1.5 m between foundation and pipe. In case of bigger distances, the slope of 45°

has to be kept at distance of 1.0 m from the foundation.

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• Foundations shall be cast on a minimum 60 mm thick lean concrete layer.

• Top of concrete pedestals shall be at least 150 mm (including grout thickness of 25 mm) above

the high point of paving or finished grade level, unless noted otherwise in related drawings.

• In order to facilitate the adjustment of equipment and steel structure, top of concrete level in

foundations shall be set at least 25 mm below the final level. Possible gap shall be filled bygrout after installation. Underside surface of the base plates of equipment and structures shall

be rough enough to increase grout bonding.

• Foundation pedestal for structural columns and equipment legs shall extend at least 50 mm

from edges of the base plates.

• Foundation for equipment such as pump and compressors shall extend at least 100 mm from

the edges of the base plates, unless otherwise specified on manufacturer’s drawings.

• Anchor bolts shall be positioned within the reinforcing bar cage. As a general rule, anchor bolts

shall be installed before concrete casting. If necessary, adequate pockets shall be provided in

the foundation when anchor bolts will be installed later. Pockets shall be filled using non-

shrinking grout.

• Foundation for vertical equipment on skirt shall have the top surface sloped for drainage

purposes. Accordingly, an embedded drain pipe shall be provided in the foundation.

3.5.2 Tank foundations

Tank Diameter (D) Foundation Type

D > 3 m Reinforced Concrete Slab Foundation

D <3m Solid octagon or solid square reinforced concrete foundation

The design of ring wall ( if any ) shall conform to requirement of paragraph 4 of this specification,

or

as required by tank vendor. Minimum width of ring wall = 300 mm

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3.5.3 Elevations of foundation plinths

The minimum elevation of foundation plinths (top of grout) above high point of paving / finishing floor

level for steel structures and equipment shall be as follows:

• Structural steel columns : 200 mm

• Stairs and ladders : 150 mm

• Equipment (general) : 150 mm

• Equipment (pumps) : 300 mm

3.5.4 Soil Check

Foundations shall be designed according to the following criteria:

• Maximum soil pressure which shall be lower than the allowable figure (as determined from the

complimentary geotechnical investigation) for all non-factored loading combinations. Allowable

soil pressure may be increased by 33 % for any loading combination that includes wind or

earthquake loads.

• Total and differential settlements due to dead and live loads shall be lower than the maximum

values described in this specification (as detailed in 3.5.5).

• Minimum factor of safety against overturning (as detailed in 3.5.6).

• Minimum factor of safety against sliding (as detailed in 3.5.7)

Friction coefficients between soil and foundation shall be based on the soil report recommendations.

Should this information be unavailable it shall be assumed equal to tan Ø (where Ø is the soil’s angle

of friction) and shall not exceed the following values:

• 0.6 in the case of course or gravel soils.

• 0.45 in the case of fine to medium sand or stiff clay soils.

• 0.35 in the case of clay soils.

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In sandy soils (without cohesion) foundations of vertical equipment higher than 30 m and have a total

height/diameter ratio of greater than 10 shall be designed as follows:

• 85 % of the soil under the foundation shall be under compression for all load combinations in

erection.

• 100 % of the soil under the foundation shall be under compression for all loading combinations

in operation.

• Minimum factor of safety against flotation shall be 1.2 in all loading conditions/combinations.

3.5.5 Allowable Settlements

Allowable settlements, due to permanent loads are shown in the following table:

Maximum differential settlement between two adjacent equipment shall not exceed 15 mm.

Special care shall be taken for heavy permanent loads (storage tanks and storage buildings) with

regard to long term settlements.

Table 3-1: Foundation Allowable Settlement

FOUNDATION TYPEMAXIMUM TOTALSETTLEMENT

MAXIMUM DIFFERENTIALSETTLEMENT

Towers and vertical equipment 25 mmDeviation from vertical linedue to differential settlement

shall not exceed 0.2%Horizontal equipment 25 mm 15 mm

Vibrating machinery 10 mm 5 mm

Process structures 25 mm 10 mm

Buildings 25 mm 15 mm

Mat Foundation 50mm 15 mm

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3.5.6 Stability Ratios

The following minimum factors of safety against overturning shall be applied in the design of

foundations:

Table 3-2: Overturning Safety Factor

Design Condition Stability Ratio

Erection condition 1.5

Test condition 1.5

Operating condition 2

Shutdown condition 2

Accidental condition 1.5

3.5.7 Sliding Stability

The minimum factor of safety against sliding shall be 1.5 in all loading conditions/combinations except

the accidental condition when the factor may be reduced to 1.2.

Passive soil resistance may be used in calculating the factor of safety against sliding.

The coefficient of friction of concrete on soil shall be in accordance with clause 3.5.3 of this

specification.

The resisting force against sliding shall be taken as either the full frictional force between foundation

and the sub-soil strata plus 50% of the earth's passive resistance or 50% of the frictional force plus

100% of the earth's passive resistance, whichever is greater. The weight of the earth superimposed

over the foundations may be included in the loads causing the resisting frictional force.

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3.6 Foundation and Structures for Heavy Vibrating Machinery

Heavy vibrating machinery is any equipment having reciprocating or rotary masses as the major

moving parts (such as reciprocating or rotary compressors, pumps, turbines) and having a gross plan

area exceeding 2.5 m², or a total weight of greater than 25 kN.

Light vibrating machinery is any equipment having reciprocating or rotary masses as the major moving

parts (such as reciprocating or rotary compressors, pumps, turbines) and having a gross plan area less

than 2.5 m² and total weight of less than 25 kN.

For light vibrating machinery dynamic design is not required. Static design shall be carried out

according to the criteria of sections 8. In addition it shall be checked that the foundation weight shall

not be less than 3 times the total rotary machine or 5 times the total reciprocating machine weight.

The dynamic modulus of elasticity (E’) of concrete to be used in the dynamic analysis is indicated in the

following table:

Table 3-3: Module of Elasticity

Characteristic Compressive

Strength, F’c

(N/mm

2

Dynamic Modulus of

Elasticity, E’

) (kN/mm

2

)

25 30.0

35 34.0

45 37.0

55 39.0

Soil pressure, considering dead and live loads, shall not exceed 50% of the allowable figure. The

effects of shrinkage and thermal expansion shall be taken into account. In order to prevent cracking

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the minimum amount of reinforcement shall be 50 kg/m³. The minimum diameter of the main

reinforcing bars shall be 16 mm. All reinforcement shall be triaxially arranged.

The following rules shall be considered in foundation design:

• Foundation shall consist of clean, simple lines.

• Pockets where vapour could accumulate are not permitted.

• The shape of beams and columns shall be uniform and rectangular.

All parts of the machine supports shall be independent from the adjacent foundations and buildings.

Concrete floor slabs, adjacent to machine foundations, shall be spaced a minimum of 20 mm from the

foundation. The space between slab and foundation shall be filled with a flexible joint filler and sealer.

Thickness of foundation slab, in meters, shall not less than:

Thk = 0.6 +L/30

where:

• for one machinery train:

• L = longest dimension of the foundation slab (m);

• For two or more machinery trains supported on a common foundation (only where cannot

be avoided):

• L = greater of:

• Width of the common slab;

• Maximum slab segment length assigned to any train.

The minimum thickness of the foundation base slab shall not be less than 1/10 of its maximum

dimension.

Foundations and supporting structures for heavy vibrating machinery shall be designed as per CP2012

such that the natural frequency of the supporting structure including soil/structure interaction is either

less than 0.7 or greater than 1.3 times the operating frequency of the machine.

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The factor of safety against overturning shall be greater than or equal to 3.

The manufacturer of the machine shall provide the following basic information:

• An arrangement drawing showing overall dimensions of the required concrete support

specification for the machines, with location and size of opening, holes and grooves; location of

base plate, pads, anchor bolts and relevant pocket sizes.

• A layout showing location of auxiliary equipment and miscellaneous, such as condenser, piping

supports and service platform legs

• A drawing showing distribution lines to be connected to the footing or passing through it.

• Maximum operating temperature at the machine-foundation contact surface

• The operating speed range of each machine.

• The shaft position, both in plane and in elevation.

• Weight and centre of gravity for every machine and base plate and the static load acting on each

support

• Weight and centre of gravity of each rotating mass (for rotating machinery only)

• For each machine, the standard dynamic forces and moments with relevant point of application

and phase angle.

• Indication of supports where dynamic load acts

• Full load torque and force produced upon each support.

• Short circuit moment and force produced upon each support

• Depression on the condenser and type of connection (rigid or flexible)

• Permissible amplitudes of vibration, allowable settlements and any other information, according

to the supplier, is to be taken into account.

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3.6.1 Design Criteria for Reciprocating Machinery

Design of foundations for reciprocating machinery shall be carried out in accordance with the following

criteria:

• The total foundation weight shall be at least 5 times the total weight of the machine.

• The horizontal eccentricity in any direction between the centroid of the machine + foundation

system and the centroid of the base contact area shall not exceed 5 % of the respective base

dimension.

• The centre of gravity of the machine-foundation system should be as close as possible to the

lines of action of unbalanced forces.

• Groups of reciprocating machinery could be tied together with a common foundation slab when

allowed by their location and service and the combined foundation results in reduced

amplitudes.

3.6.2 Dynamic analysis shall be carried out as follows:

• Natural frequencies in the modes being exited shall preferably be out of 0.7 to 1.3 times the

disturbing frequencies of any machine on the foundation. If it is not possible to meet this

requirement, frequencies within the above mentioned range may be accepted if the maximum

calculated amplitudes are within the limits listed in the following point e).

• Damping shall not be higher than 3 %.

• Primary forces, couples and moments shall be applied at machine speed for calculation of primary

amplitudes.

• Secondary forces, couples and moments shall be applied at twice the machine speed for

calculation of secondary amplitudes.

• Total amplitude shall be calculated by combining, in the worst conditions, primary and secondary

amplitudes.

• Exciting forces arising under fault condition shall also be considered

• Total peak to peak amplitudes on foundation shall not exceed 0.05 mm, unless specified otherwise

by the manufacturer.

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3.6.3 Design Criteria for Rotary Machinery

Rotary machines may be supported either on a direct foundation or on an elevated structure.

Weight of basement (foundation and elevated structure) shall be at least three times the weight of the

machinery.

If evaluation of damping of concrete is not carried out, the damping factor of system machine +

foundation shall be assumed as 0.02.

Higher values of damping factor shall be considered in loading condition in which the loads are

significantly higher than that during normal operation.

3.6.3 .1 Dynamic Ana lys i s

Dynamic analysis may be dispensed if the mass of rotating elements is less than 1/100 of the mass of

the whole system (machine +foundation).

Model shall be defined in such a way to correctly describe the foundation behaviour up to 1.5 fmax,

where fmax is the maximum operating speed.

3.6.3 .2 Natura l F requenc ies

Natural frequencies of the system, machine + foundation, shall be calculated in accordance with the

following criteria:

Number of natural frequencies to be calculated shall be defined so that the highest natural frequency

calculated is at least 10 % higher than the operating frequencies. This prescription may be neglected in

the case of machines having operating frequency higher than 75 Hz.

However, depending on the analysis model, the number of natural frequencies to be calculated, n, shall

meet the following:

• n = 10 for two dimensional models in which only displacements out of the plane are considered and in

which vibration in one direction has influence in other directions.

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• n = 6 for two dimensional models in which only displacements out of the plane are considered and in

which vibration in one direction has only secondary influence in other directions ( the system may be

represented by independent models).

The assessment of vibration behaviour shall be checked as follows:

First order natural frequency (lowest frequency):

f1 ≥ 1.25 fm

or

f1 ≤ 0.8 fm

where fm is the lowest service frequency.

Higher order natural frequencies:

a) fn ≤ 0.9 fm and fn+1 ≥ 1.1 fm

b) If condition a) is not met it shall be suffice that fn is less than fm where n is equal to 6 or 10.

3.6.4 Analysis of Vibrations Due to Unbalanced Forces

3.6.4 .1 Exc i t in g Forces

Unbalanced forces are provided by the machine manufacturer and shall be used for the dynamic

response of the foundation.

In case of absence of such information unbalanced forces may be calculated on the basis of nominal

quality of balance of machine as follows:

a) Operating state

The balanced quality of machine shall be assumed one grade lower than that for the relevant machine

group.

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F = M ω² e = F(ω e)ω

Where:

ω = speed in rad/sec

(ω e) = quality of balance of machine

All forces shall be considered applied at the bearings.

b) Malfunctioning state.

Forces due to malfunctioning shall be assumed 6 times the values for operating state and shall be used

for the static design and stability checks of the structure.

3.6.4 .2 A l lo wab l e Disp l acements

If allowable displacements are given by the machine manufacturer they shall be used for the check of

the structure.

In the absence of such information the maximum amplitudes, effective at the bearings, may be

assumed for the particular machine group as follows:

a) Operating state

The value associated with the operating frequency which is one grade higher than that guaranteed by

the manufacturer shall be taken as the amplitude under service conditions.

b) Malfunctioning state

The amplitude in case of malfunctioning shall be assumed to be 6 times the values used for the

operating state.

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4 CIVIL WORKS

4.1 Paving

4.1.1 Types of paving

4 .1 .1 .1 L igh t du ty pav ing

Light duty paving will be used in areas not subjected to vehicle traffic, or occasionally subjected to

transit of light movable equipment with maximum axial load equal to 10 kN.

Concrete slab shall be of uniform thickness of 100 mm and shall be designed to withstand a maximum

axial load of 10 kN plus impact.

Reinforcement consists of single welded wire mesh or equivalent reinforcement.

4.1.1 .2 Med iu m Duty Pav in g

Medium duty paving is provided for areas subjected to light and medium traffic and to transit of

maintenance vehicles.

Concrete slab shall be 150 mm thickness with thicken edges and designed to withstand a maximum

load of 60 kN per axle.

Reinforcement consists of single welded wire mesh or equivalent reinforcement

4.1.1 .3 Heavy du ty pav in g

Heavy duty paving is provided for areas subjected to heavy vehicle traffic including the areas from

loading arms to outlet road.

Paving shall be designed to withstand a maximum load per axle of 120 kN (4 tyres)

Concrete heavy duty paving shall be 250 mm thickness in central area and 300 mm along the edges.

Reinforcement consists of double welded wire mesh or equivalent reinforcement

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4.1.2 Paving Elevation

High point of the paving shall be near the center if the process operation areas and it shall be sloped a

minimum of 1% to drain. Paving shall slope away from all equipment foundations to prevent water

damage to foundation and preserve bearing capacity.

Cable Trenches shall be located on high point of paving as much as possible to prevent water damage.

4.1.3 Paving Design

• Static design of reinforced concrete paving shall be carried out according the criteria indicated

in manual PCA-Portland Cement Association-Concrete Pavement Design.Final design

thickness of pavements shall be appropriate to vehicular or other acted loadings.

• Paving slabs adjacent to foundation pedestals columns. Etc. shall be separated by joint filler

and sealer.

• In the case of large areas covered by pavement slabs, the slabs shall be subdivided into

square, rectangle or other convenient shapes by use of expansion joint. Such expansion joint

should be placed at the high points of the slab in order to discourage infiltration of water below

the slab Other Kinds if joints such as contraction construction, control and etc. should be used

as necessary.

• The contraction joints in reinforced paving shall be not more than 6m apart and expansion

joints not more than 24 m apart.

• A maximum allowable difference in elevation of paving 150mm shall be limited for slope

paving.

• Concrete paving may support minor equipment (small pumps, staircase, and light skid

mounted packages) provided that the local strengthening results in max 10 kN/m2 soil

pressure.

• In correspondence of expansion joints shall be foreseen dowel bars for transferring at least

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20% of the load across the joint. Generally these dowel bars consist of smooth steel bar 20

mm diameter,500 mm long every at a spacing of 500 mm. Half dowel bar shall be oiled to

prevent bond between two section of r. c. slab.

• Construction joints shall extent to the full depth of concrete paving. Construction joints shall

be 8 mm width and shall be filled with hot bitumen or with suitable material hydrocarbon

resistant. Lower part of joint shall be filled with polystyrene or with suitable non extruding

material.

4.2 Sidewalks

J ustification of sidewalks in rural areas depends upon the volume of pedestrian and vehicular

traffic, their relative timing, and the speed of vehicular traffic.

Sidewalks are accepted as integral part of streets, but few are provided in roads.

Sidewalks shall be laid parallel to streets and as walkways to building entrances, and shall be provided

in accordance with operational and/or pedestrian traffic requirements. Walkways adjacent to and

between buildings, and other facilities in built-up areas, generally are accepted as integral parts of

these areas.

4.2.1 Walkways

Walkways along roads in open areas, between certain isolated locations, can be as necessary as inbuilt-up areas.

4.2.2 Location of sidewalks

Sidewalks shall be placed adjacent to the curb, and widened as necessary to satisfy operational

requirements.

4.2.3 Cross slope

Allow 2 percent in the direction of natural drainage.

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4.2.4 Widths

Sidewalks shall be having minimum 1.0 m width.

The width of a planted strip between the sidewalk and travel way, if provided, should be a minimum of

0.60 m to allow maintenance activities.

4.2.5 Grades

The use of steps in walkways shall be avoided, if possible. Single risers, in particular, are hazardous

and are prohibited. When steps are required they should have a minimum of three risers. Grade

limitations are:

• Minimum allowable: none, flat grades are permissible

• Maximum allowable: 6 percent, however, 5 percent maximum is preferred.Build steps for steeper grade.

4.2.6 Ditch Crossings

Where sidewalks cross open drainage channel hold the underside of the walkway above the design

high water surface.

4.3 Pipe Crossings

Piping below roads shall be run in sleeves or culverts, as applicable direct burial for non-process lines

is usually the rule. Pipe crossings shall be installed so that the angle between the road way axis and

the axis of the crossing is as near 90 degrees as is practicable. After pipe has been installed the trench

shall be backfield with approved material and compacted to the base course and surface coat shall be

installed according to the original road specifications.

4.4 Cable Trenches

The main cables are placed in covered reinforced concrete trenches. There will be a layer of fine sand

on top of the cables in the trenches.

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Smaller cables, lighting cables and off sticks from the main trenches that width is smaller than 60 Cm,

can be put directly in excavated trenches Roughly a half of the depth a concrete warning slab shall be

put wherever needed.

The cable trenches will have a certain slope for dewatering.

4.5 SURFACE DRAINAGE SYSTEM

The surface drainage system of the Plant shall be based mainly on open drainage ditches and nullah

drains. The use of catch basins, storm drains and culverts shall be minimized. The system shall be

designed for rainfall intensity as per specific Site conditions. In special process areas sewer system

with catch basin and manholes shall be used, as required.

The surface storm water runoff shall be determined by rational method from the following equation.

Q = 2.778 C.I.A.

Where

Q = Rate of runoff (liters/sec)

C = Runoff coefficient

I = Design rainfall intensity (mm/hr)

A =Area of the drained surface (hectares)

The design rainfall intensity " I " shall be taken as per specific site conditions.

The runoff coefficient C shall be taken as follows:

Paved areas and roof surfaces, C=1.00

Graveled areas, C = 0.50

Landscaped areas, C = 0.40

U d C 0 50

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