DOC. NO.
PROJECT COAL & LIGNITE TRASNPORT
44PS5400-1101-VS-05A-00XX
Rev. No Page
STRUCTURE PRIMARY CRUSHER HOUSE
A
DESN CHKD
TITLE BASE PLATE DESIGN
JTP VETHA
1.0 BASE PLATE DESIGN
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery
Expansion (1.5MPTA to UAIL UAIL FLS-CVS-240-ED-0006 66-6703
2.0MPTA)
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
8.0 BASE PLATE
COLUMN : UB 457X191X67
REACTION SUMMARY FOR COLUMN
Horizontal Vertical Horizontal Moment
My Mz
Node L/C Fx kN Fy kN Fz kN Mx kNm
kNm kNm
Max Fx 1 219 DL+LL+E 80.644 183.841 15.398 0 0 0
Min Fx 7 218 DL+LL+ -67.564 200.487 -14.639 0 0 0
Max Fy 1 222 DL+LL+E -7.004 274.548 -15.012 0 0 0
Min Fy 6 207 DL+WL4 -5.488 -43.183 32.524 0 0 0
Max Fz 3 221 DL+LL+E 0.608 218.243 44.775 0 0 0
Min Fz 8 220 DL+LL+ -24.559 225.871 -45.271 0 0 0
Max Mx 1 200 DL+WL1 -32.387 132.456 -0.994 0 0 0
Min Mx 1 200 DL+WL1 -32.387 132.456 -0.994 0 0 0
Max My 1 200 DL+WL1 -32.387 132.456 -0.994 0 0 0
Min My 1 200 DL+WL1 -32.387 132.456 -0.994 0 0 0
Max Mz 1 200 DL+WL1 -32.387 132.456 -1 0 0 0
Min Mz 1 200 DL+WL1 -32.387 132.456 -0.994 0 0 0
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated,
disclosed or utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
BASE PLATE FOR COL. UB457X191X67 290
Size of the column
FORCE
Max. compn. 274.548 KN
457
600
Max. tension 43.183 kN
Max. shear 80.644 kN
Check For compression
Max. compn. = 274.5 KN
Hence base pressure = 1.58 N/mm2
Permisssible bearing pr. = 11.25 N/mm2
Hence safe
Grade of Base plate = 250 N/mm2
Moment on the base plate due to upward pressure = (1.58)*135^2*0.5
= 14397.75 N-mm/mm
Allowable stress on the plate = 250/1.1
= 227.3 N/mm2
Hence thickness of the plate = (6M/1.2*fy)^0.5
Required thickness of plate = 17.80 mm
Provided thickness of plate = 20 mm
Safe
Thickness of base plate as per 7.4.3.1 of IS 800: 2007
Allowable bending stress = 227.3 N/mm2
Thickness of flange = 13 mm
Thickness of plate required
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
97
50
a = 97 mm
b = 50 mm
Upward pressure,w = 1.58 N/mm2
ts = 12.87 mm < 13 mm (thk. of flange)
Safe
From Mukhanov's chart,
Edge condition - Plate supported on three sides.
a1 = =290/2-10 = 135 mm
d1 = =457/2-10 = 219 mm
Hence a1/d1 = 0.62
Hence coefficient = 0.081
Hence moment on the base plate = 0.081×1.58×135^2
= 2326.68 N-mm/mm
Grade of Base plate = 250 N/mm2
Allowable stress on the plate = 250/1.1
= 227.3 N/mm2
Hence thickness of the plate = (6M/1.2*fy)^0.5
treqd = = ((6×2326.68)/(1.2×227.27))^0.5
= 7.15 mm < 20mm
(From Compression only)
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
Check for tension
Support reaction = 43.2 kN
Assume 4 Nos 20 dia H.D bolts
According to clause 10.3.5 of IS800-2007
Tb < Tdb
Tdb = Tnb/gmo
Tnb =
fub = 410.00 N/mm2
An = 244.92 N/mm2
fyb = 250.00 N/mm2
Asb = 314.00 N/mm2
Tnb = 90.38 kN < 89.2 kN
Capacity of Single bolt under Tens = 72.3 kN
Tension Force per Bolt = 10.8 kN Ratio 0.15
Hence safe under tension
DESIGN OF SHEAR KEY:
Grade of concrete (M30) fck = 25 N/mm2
Yield strength of Base Plate fy = 250 N/mm2
Partial safety factor for material ƴm0 = 1.1
Thickness of Stiffener plate = 10 mm
HORIZONTAL LOAD
VERTICAL
JOINT NO LOAD CASE NO
LOAD X Z
1 219 DL+LL+EP-FL+WL2 - 88.7084 15.398 (10% additional load)
Considering the Vertical force as Zero, For worst Cae
Shear force to be resisted by Shear lug
F = max. Hori. Load - (Verti. Load * Co-eff. Of friction)
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
Co-efficient of friction = = 0.3
Considering the Vertical force as Zero, For worst Cae
Shear Key for Force F, F= 88.71 KN
Width of Shear Key , b = 175 mm
Depth of Shear Key , d = 175 mm
Depth of Grout , d' = 100 mm
Permissible Shear Stress = 131.22 N/mm²
(fy/(ƴm0* SQRT(3))
Check of Shear Key for Shear Stress,
Thickness of Plate required = 3.8631 mm
Thickness of Plate Provided = 25 mm
Safe
Comp. stress on conc. = 6.7587 N/mm²
Permissible comp. stress on conc. = 11.25 N/mm²
Safe
Two sides fixed,
a = 75 mm
b = 175 mm
a/b = 0.4286
Coefficient from REYNOLD's Table for stress and strain β= 0.50
Allowable Bending Stress = 227.27 N/mm²
Thickness required t Ö(bqb2/s) = 21.34 mm
Provided thickness of shear key = 25 mm
Safe
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
(10% additional load)
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery
Expansion (1.5MPTA to UAIL UAIL FLS-CVS-240-ED-0006 66-6703
2.0MPTA)
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
COLUMN : UB 533X210X82
REACTION SUMMARY FOR COLUMN
Horizontal Vertical Horizontal Moment
My Mz
Node L/C Fx kN Fy kN Fz kN Mx kNm
kNm kNm
Max Fx 9 219 DL+LL+E 68.559 343.737 19.669 0 0 0
Min Fx 12 218 DL+LL+ -73.589 402.396 -14.371 0 0 0
Max Fy 12 220 DL+LL+ -44.275 487.462 -64.43 0 0 0
Min Fy 11 206 DL+WL3 10.751 -107.497 -61.502 0 0 0
Max Fz 11 221 DL+LL+E -3.722 344.296 73.583 0 0 0
Min Fz 10 220 DL+LL+ -26.166 381.264 -73.583 0 0 0
Max Mx 9 200 DL+WL1 -41.402 69.984 0.119 0 0 0
Min Mx 9 200 DL+WL1 -41.402 69.984 0.119 0 0 0
Max My 9 200 DL+WL1 -41.402 69.984 0.119 0 0 0
Min My 9 200 DL+WL1 -41.402 69.984 0.119 0 0 0
Max Mz 9 200 DL+WL1 -41.402 69.984 0 0 0 0
Min Mz 9 200 DL+WL1 -41.402 69.984 0.119 0 0 0
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated,
disclosed or utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
BASE PLATE FOR COL. UB533X210X82 350
Size of the column
FORCE
Max. compn. 487.462 KN
533
650
Max. tension 107.497 kN
Max. shear 73.583 kN
Check For compression
Max. compn. = 487.5 KN
Hence base pressure = 2.14 N/mm2
Permisssible bearing pr. = 11.25 N/mm2
Hence safe
Grade of Base plate = 250 N/mm2
Moment on the base plate due to upward pressure = (2.14)*165^2*0.5
= 29130.75 N-mm/mm
Allowable stress on the plate = 250/1.1
= 227.3 N/mm2
Hence thickness of the plate = (6M/1.2*fy)^0.5
Required thickness of plate = 25.32 mm
Provided thickness of plate = 28 mm
Safe
Thickness of base plate as per 7.4.3.1 of IS 800: 2007
Allowable bending stress = 227.3 N/mm2
Thickness of flange = 13 mm
Thickness of plate required
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
45
61
a = 61 mm
b = 45 mm
Upward pressure,w = 2.14 N/mm2
ts = 8.98 mm < 13 mm (thk. of flange)
(Provided 36mm thick plate, hence safe)
Safe
From Mukhanov's chart,
Edge condition - Plate supported on three sides.
a1 = =350/2-10 = 165 mm
d1 = =533/2-10 = 257 mm
Hence a1/d1 = 0.64
Hence coefficient = 0.080
Hence moment on the base plate = 0.080×2.14×165^2
= 4637.62 N-mm/mm
Grade of Base plate = 250 N/mm2
Allowable stress on the plate = 250/1.1
= 227.3 N/mm2
Hence thickness of the plate = (6M/1.2*fy)^0.5
treqd = = ((6×4637.62)/(1.2×227.27))^0.5
= 10.1 mm < 28mm
(From Compression only)
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
Check for tension
Support reaction = 107.5 kN
Assume 4 Nos 20 dia H.D bolts
According to clause 10.3.5 of IS800-2007
Tb < Tdb
Tdb = Tnb/gmo
Tnb =
fub = 410.00 N/mm2
An = 244.92 N/mm2
fyb = 250.00 N/mm2
Asb = 314.00 N/mm2
Tnb = 90.38 kN < 89.2 kN
Capacity of Single bolt under Tens = 72.3 kN
Tension Force per Bolt = 26.9 kN Ratio 0.37
Hence safe under tension
DESIGN OF SHEAR KEY:
Grade of concrete (M30) fck = 25 N/mm2
Yield strength of Base Plate fy = 250 N/mm2
Partial safety factor for material ƴm0 = 1.1
Thickness of Stiffener plate = 10 mm
HORIZONTAL LOAD
VERTICAL
JOINT NO LOAD CASE NO
LOAD X Z
11.00 221 DL+LL+EP-FL+WL4 - 73.589 14.371 (10% additional load)
Considering the Vertical force as Zero, For worst Cae
Shear force to be resisted by Shear lug
F = max. Hori. Load - (Verti. Load * Co-eff. Of friction)
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
Co-efficient of friction = = 0.3
Considering the Vertical force as Zero, For worst Cae
Shear Key for Force F, F= 73.59 KN
Width of Shear Key , b = 150 mm
Depth of Shear Key , d = 150 mm
Depth of Grout , d' = 100 mm
Permissible Shear Stress = 131.22 N/mm²
(fy/(ƴm0* SQRT(3))
Check of Shear Key for Shear Stress,
Thickness of Plate required = 3.7388 mm
Thickness of Plate Provided = 20 mm
Safe
Comp. stress on conc. = 9.8119 N/mm²
Permissible comp. stress on conc. = 11.25 N/mm²
Safe
Two sides fixed,
a = 65 mm
b = 150 mm
a/b = 0.4333
Coefficient from REYNOLD's Table for stress and strain β= 0.51
Allowable Bending Stress = 227.27 N/mm²
Thickness required t Ö(bqb2/s) = 22.26 mm
Provided thickness of shear key = 25 mm
Safe
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
(10% additional load)
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery
Expansion (1.5MPTA to UAIL UAIL FLS-CVS-240-ED-0006 66-6703
2.0MPTA)
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
COLUMN : UB 305X165X40
REACTION SUMMARY FOR COLUMN
Horizontal Vertical Horizontal Moment
My Mz
Node L/C Fx kN Fy kN Fz kN Mx kNm kNm kNm
Max Fx 226 205 DL+WL2 34.474 -15.531 0.327 0 0 0
Min Fx 226 200 DL+WL1 -34.53 69.467 -0.083 0 0 0
Max Fy 228 213 DL+LL+O 0.024 159.463 19.014 0 0 0
Min Fy 228 206 DL+WL3 -0.007 -79.969 -23.165 0 0 0
Max Fz 228 203 DL+WL4 0.019 148.737 23.478 0 0 0
Min Fz 224 202 DL+WL3 0.044 136.965 -23.478 0 0 0
Max Mx 224 200 DL+WL1 -1.872 4.652 -0.196 0 0 0
Min Mx 224 200 DL+WL1 -1.872 4.652 -0.196 0 0 0
Max My 224 200 DL+WL1 -1.872 4.652 -0.196 0 0 0
Min My 224 200 DL+WL1 -1.872 4.652 -0.196 0 0 0
Max Mz 224 200 DL+WL1 -1.872 4.652 0 0 0 0
Min Mz 224 200 DL+WL1 -1.872 4.652 -0.196 0 0 0
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated,
disclosed or utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
BASE PLATE FOR COL. U305x165x40 270
Size of the column
FORCE
Max. compn. 159.463 KN
305
400
Max. tension 79.969 kN
Max. shear 23.478 kN
Check For compression
Max. compn. = 159.5 KN
Hence base pressure = 1.48 N/mm2
Permisssible bearing pr. = 11.25 N/mm2
Hence safe
Grade of Base plate = 250 N/mm2
Moment on the base plate due to upward pressure = (1.48)*125^2*0.5
= 11562.5 N-mm/mm
Allowable stress on the plate = 250/1.1
= 227.3 N/mm2
Hence thickness of the plate = (6M/1.2*fy)^0.5
Required thickness of plate = 15.95 mm
Provided thickness of plate = 20 mm
Safe
Thickness of base plate as per 7.4.3.1 of IS 800: 2007
Allowable bending stress = 227.3 N/mm2
Thickness of flange = 10 mm
Thickness of plate required
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
47.5
52.5
a = 52.5 mm
b = 47.5 mm
Upward pressure,w = 1.48 N/mm2
ts = 6.10 mm < 10 mm (thk. of flange)
Safe
From Mukhanov's chart,
Edge condition - Plate supported on three sides.
a1 = =270/2-10 = 125 mm
d1 = =305/2-10 = 143 mm
Hence a1/d1 = 0.88
Hence coefficient = 0.113
Hence moment on the base plate = 0.113×1.48×125^2
= 2617.75 N-mm/mm
Grade of Base plate = 250 N/mm2
Allowable stress on the plate = 250/1.1
= 227.3 N/mm2
Hence thickness of the plate = (6M/1.2*fy)^0.5
treqd = = ((6×2617.75)/(1.2×227.27))^0.5
= 7.59 mm < 20mm
(From Compression only)
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
Check for tension
Support reaction = 80.0 kN
Assume 4 Nos 20 dia H.D bolts
According to clause 10.3.5 of IS800-2007
Tb < Tdb
Tdb = Tnb/gmo
Tnb =
fub = 410.00 N/mm2
An = 244.92 N/mm2
fyb = 250.00 N/mm2
Asb = 314.00 N/mm2
Tnb = 90.38 kN < 89.2 kN
Capacity of Single bolt under Tens = 72.3 kN
Tension Force per Bolt = 20.0 kN Ratio 0.28
Hence safe under tension
DESIGN OF SHEAR KEY:
Grade of concrete (M30) fck = 25 N/mm2
Yield strength of Base Plate fy = 250 N/mm2
Partial safety factor for material ƴm0 = 1.1
Thickness of Stiffener plate = 10 mm
HORIZONTAL LOAD
VERTICAL
JOINT NO LOAD CASE NO
LOAD X Z
(10% additional
224 200 DL+WL1 - 34.53 0.083 load)
Considering the Vertical force as Zero, For worst Cae
Shear force to be resisted by Shear lug
F = max. Hori. Load - (Verti. Load * Co-eff. Of friction)
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Plant: Client Contract Code Document ID Contract No.
Alumina Refinery Expansion
(1.5MPTA to 2.0MPTA) UAIL UAIL FLS-CVS-240-ED-0006 66-6703
DESIGN CALCULATION FOR PIPE
RACK PR1
Rev 0 Page of
Co-efficient of friction = = 0.3
Considering the Vertical force as Zero, For worst Cae
Shear Key for Force F, F= 34.53 KN
Width of Shear Key , b = 125 mm
Depth of Shear Key , d = 125 mm
Depth of Grout , d' = 100 mm
Permissible Shear Stress = 131.22 N/mm²
(fy/(ƴm0* SQRT(3))
Check of Shear Key for Shear Stress,
Thickness of Plate required = 2.1052 mm
Thickness of Plate Provided = 20 mm
Safe
Comp. stress on conc. = 11.05 N/mm²
Permissible comp. stress on conc. = 11.25 N/mm²
Safe
Two sides fixed,
a = 52.5 mm
b = 125 mm
a/b = 0.42
Coefficient from REYNOLD's Table for stress and strain β= 0.48
Allowable Bending Stress = 227.27 N/mm²
Thickness required t Ö(bqb2/s) = 19.1 mm
Provided thickness of shear key = 20 mm
Safe
The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or
utilized without written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
Contract No.
66-6703
and confidential property of FLSmidth and may not be duplicated, disclosed or
written consent from FLSmidth
