Manifold XX RCC Pit Design

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MANIFOLD #XX
#XX RCC PIT,
PIT, BEAM AND
COLUMN DESIGN.
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XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

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TABLE OF CONTENTS
Sr.
Description
No.
Page No.
Introduction
Scope
Manifold pit
1. Overall Geometry
2. Loads and load combinations
12
3. Column beam design.
35
4. Raft and wall design
79
5. Base pressure distribution.
107
6. BMD, SFD, AFD and Deflection Diagram,
109
7. Annexure
Annexure-A Staad-Pro Output.
116
Annexure-B Pump Drawings.
117

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1) Introduction
This document is proposed to provide the description of method of carrying out the design and
detailing works for the proposed . civil/ structural works, to . Civil structural
engineering team for the following facilities.
a) ManifoldXX Pit RCC slab, walls, beam and column design.
2) Scope
This document describes the general requirements and various design parameters that shall be
considered and agreed between . team and client for the design of Civil / Structural
works of above listed item pertaining to the project. Loads due to Crane, Steel
platform and Pipe supports are arrived from Doc No .. Also Refer Annexure-1,2 and 3 of
that document for the input from others.
3)
Manifold pit.
1 Overall Geometry: Refer design basis Doc .

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9.5m
Job No:

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Cross section (for Pipe rack design and dimensions refer Doc No. ..)
PlanPipe rack near White oil Manifold
PlanPipe rack near Black oil Manifold

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Middle column
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Plan:
EL +13.00M FMD
EL +12.10M FMD RAIL TOP
6.5m
EL +11.50M
FMD
EL +5.00M FMD FGL
EL +2.60M FMD PIT FFL
Foundation system: For 1 degree of rotation settlement of soil is = tan (1o) x 500 = 8.72mm.
Pressure due to this settlement is = 20/175 = 8.72 / x hence x = 8.72 x175 / 20
x = 76.36 kN/sqm.
Further Pressure due rotation = M x 6 /b x d2 Hence M = (P x b x d2 )/6 = 12.72kN-m.

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Foundation system is uniform soil spring of stillness (sub-grade modulus) of 20mm settlement at
175kN/sqm bearing pressure, Lateral stiffness is co-efficient of friction () x vertical stiffness = 8750 x
0.4 = 3500kN/m/m. Where () is as per soil investigation report of M/S Fugro for angle of repose of
( =2/3 x 1/tan ) Piperack footing consider 2m x2m footing with same soil stiffness = 8750 x 2 x 2 =
35000 kN/m/m. (Considered is 33.34% loss of contact for 3 x 3 m footing to get reduced size of 2 x
2m of footing.) Lateral stiffness is co-efficient of friction () x vertical stiffness = 35000 x 0.4 =
14000kN/m/m. (% loss of contact considered is 1/3 x 100 = 33.33%).
Rotational stiffness:
For 1 degree of rotation settlement of soil is = tan (1o) x 1000 = 17.45mm.

Pressure due to this settlement is = 20/175 = 17.45 / x hence x = 17.45 x175 / 20
x = 152.73
kN/sqm. Further Pressure due rotation = M x 6 /b x d2 Hence M = (P x b x d2)/6 = 203.64kNm/degree. Where P = 152.75 kN/sqm.

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Bracket for middle column is modeled to only transfer the crane load to RC col. detailed analysis is
carried out in Doc No ...
Also single RC beam is modeled as their moments are
balancing each other only uniform dead load considered.

Member properties:

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Only Property No 14 and 17 are used at crane extension bay, rest steel member are for pipe rack.
Wall 0.35 thk.
Middle Plates
0.5 thk.

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edge Plates
0.75 thk.
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2 Load and load combinations: 1) Dead load: SELFWEIGHT Y -1, as per densities of
material, steel 78.50, and concrete 25.00 kN/cum respectively. Clients Manifold layout and
Piping information is Basis for design. Pipe rack loads refer Doc No. ...

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2) Pump Load: Pump drawings are attached in Annexure-C, Pedestal height of 124 to 130mm is
required. The slab below pump is locally thickened to 1000 or 1500mm respectively as shown in
the table below. The pumps are not having dynamic load so overall weight of 3 times (min)
provided to that of Pumps weight. Staadpro. input is shown on next page.
White oil Manifold Pump details: (by Piping)
Black oil Manifold Pump details:

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Pump load Notes:

Manifold Pumps are long lead Items and above details are available, so the detailing is done as
per criteria given below,
a. As the pumps are dynamically, balanced rotating equipment the foundation size will be
decided on the general guidelines of code using weight of foundation equal to 2.5 to 3
times of weight of pump. Actual loading will be updated when final data will be available
from mechanical department.
b. The pumps are proposed to be provided anti vibration bearing so that all the vibration will
be absorbed in anti-vibration pads.
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c. Now in the detailing although the pump loads are considered on the raft slab physically the
pumps will be isolated from surrounding slab, so no transfer of loads will be due to pump
on manifold integral slab so the assumption is conservative.
3) Side wall load: Soil load: Refer design basis Doc No ..
Ph =
(1 sin )
soil h
(1 + sin )
where = is angle of repose of soil = 30o
P h = 0 . 334 2 h
P h = 0 . 667 h
Pipe Trunion loads (resting directly on Pedestal on bottom raft slab.) Refer Annexure A and C.

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Plan-White Oil.
White oil Manifold- Pipe trunion loads:

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Plan-Black Oil.
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Direct pipe supports: (refer Piping Document Number .)

Note:
All loads are applied at nearer to 1000 interval and dimensions are rounded to nearest
1000mm.
All Reactions are at pedestal bottom level, so no moment has been added due to shear.
Where Structural Pipe support Frame load and Direct pipe support loads are very close to
each other (less than 1000mm) the load is added on single node which will result in more
conservative and safer design.
Load transferred from Structural Pipe support Frame (at un-braced bays)
White oil Manifold Loads: Reaction summary taken from Doc No- .

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Overview:
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Platforms

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Pipe supports
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Pipe frame support loads overview.

(Refer Doc .)
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White oil Manifold
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Black oil Manifold
Braced and un-braced support (Refer Doc No- ..)

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Braced bay Nodes: high reactions
Un-braced Nodes:
White Oil Manifold-Braced bay:
White Oil Manifold-Un-braced bay:
Black Oil Manifold-Braced bay:
Black Oil Manifold- Un-braced bay:
Shear force at Pedestal top is transferred at raft top equal to Mx and MZ as shown above.
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Access platform support braced and un-braced bays are considered to be in one group of un-braced
columns as the reactions are less compared to braced bays.

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Platform reaction on crane column:
These loads include:

1. Platform reaction:
2. Stair Reaction:
3. Fire Monitor platform Reaction:
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Stair and fire monitor reaction is considered equal to platform reaction conservatively although they
light structures.
Raft Live load: 500 kN/sqm all over the slab:
Crane loads: Refer .
Two load locations are selected each at 6mc/c wheel-base one at centre of manifold and one near to
pipe-rack columns. Load of 40m crane applied on 30m span conservatively.
Lower value of crane wheel-base is considered to get more closer distribution of reactions and most
adverse condition (40m crane and 30m cranes are having 6.6m and 6m wheelbase respectively.
Moment due to crane reaction at corbel location is considered and applied at middle column.
In crane parking bay only unloaded weight of crane is considered:
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Live load of platform 600 wide at

middle rail beam = 0.6 x
0.5kN/sqm = 0.3 say 0.45 kN/m

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At north end and at crane parking bay, a wheel load is considered to check column members.
Wind load: Wind load will act on pipe rack, Gantry girder and supporting beams/columns for wind load
on pipe rack refer .. pit wall and piping inside the pit no wind load is considered to be acting.
Refer BS 6399 Part -2,
Wind load on side beam and vertical column of 300 deep wide,
= 2 x 0.3 x 0.971 = 0.583 kN/m
Refer piping Drawing No .,

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Largest pipe is 24in ~ 600mm so wind load for 5m span is = 0.6 x 1.2 x 0.971 x 5 = 3.5kN per 5 m
bay
Crane column wind load = 0.5 x 2 x 0.971 = 0.971kN/m.
Crane beam wind load = 0.6 x 2 x 0.971 = 1.16kN/m.

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Wind load on crane supporting beam and columns is shown here for wind load on pipe rack refer
.
Seismic load: Seismic load will act on pipe rack, Gantry girder and supporting beams/columns. The
reaction of pipe support platform inclusive of wind/seismic loads are applied on base raft.

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UBC 97 Seismic load will be divided by 1.4 and multiplied by factor of 1.2 as per BS8110.
Loading combination: Loading combination shall be as per clause Doc No ..
Additionally following table from BS8110 part 1 is referred.
Notes:
Crane load is considered as imposed load factor is 1.6.
Piping load in manifold pit is considered as imposed load factor is 1.6.
Platform Loads in manifold pit are considered as imposed load factor is 1.6.
For Live load (General live load/Pipe loads etc)reduction of 50% is considered in EQ case.

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Concrete design parameters:

Column effective lengths:

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ELY Minor axis effective length 1.5 times unsupported length.
ELZ Major axis effective length 2 times unsupported length.

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Column beam Design: Crane supporting Beams

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Critical design for bending is for beam 11473.

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Provide 5 Nos. T25 top main bars throughout 2450sqmm > 1808mm OK.
Provide 5 Nos. T20 top main bars throughout 1570sqmm > 628mm OK.

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Area of stirrups of T8 dia. 2 Legged is 50.3 x 2 = 100.6 sqmm. Actual area provided is 113 x 5 =
565sqmm so stirrups spacing can be increased to 565/100 x 60 = 339mm c/c Provide T12-5L @
140c/c
T25- 5 Nos. Top
T20- 5 Nos
Design of TB2: Pipe rack Tie beam on Manifold side:

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Force envelope (Bending and Shear)
Force envelope (Bending and Shear)

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Moment at face of column 750 wide (P3) is = (917 0) x 1.625 / 2 + 11.4 = 745kNm

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Area per meter of beam of links = 50.3 x 2 x 7 = 704sqmm provided is 78.5x 2 x 5.55 = 871sqmm OK.

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Crane Column Design:
load combinations for Min Fx, Max My and Min Mz are critical from the table above:

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Crane column height above raft top is (lo) 9.5m (cantilever) 60b =60 x 0.5 =30m > 9.5m. Also 100 x
b x b/h = 100 x 0.5 x 0.5/0.75 = 33.34 > 9.2m hence column is not slender. (BS-8110 Part-1)

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Stress ratio for Crane column projection members (middle col. Bracket is not designed here):
Crane column footings outside Manifold Pit (for Crane parking Bay)
Column Node Numbers:

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*****
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Crane Parking Bay Bracket insert Plate design:
Per Insert plate 263kN ~ 60kips force.
Middle Column 2 IPs at top (in Tension)

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Side Columns 1 IP at top (in Tension)
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Crane column deflection check: (Un-factored operating load combinations only)
Vertical deflection:
North.
Vertical deflection Allowable as per BS 8110 = Span/600 = 1500/600=2.5mm ~ 3 (11-8mm)
Cantilever at South end. Ok.
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Vertical deflection Allowable as per BS 8110 = Span /600 = 4000/600=6.66mm > 6 (8-5mm) Next to
cantilever span from south side. Ok. Also in this case crane will be unloaded so it is conservative.
North.
Operating Load Deflection:

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Soil Load Deflection:
Lateral deflection Allowable as per BS 8110 = Span/600 = 9500/600=15.83mm > 11 (25-14mm)

Difference in Soil load and operating load. Crane erection will be after soil backfilling around manifold.
Design of pipe-rack column resting on Manifold slab:
All columns:
Pipe rack Unbraced columns Design:

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Base plate design:
Moment y as shown above at top is not considered as it is generated due to shear force and does not
acts on base plate.

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Resultant Shear = Sqroot ( Fy2 + Fz2) =31 kN

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Pipe Rack columns braced bays:
Combinations Max Fx, Min Fx and Min My are critical.

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Column Design members
Base plate design nodes:
Base plate design members:
Base pate reaction: only top nodes of considered for base plate design.

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Resultant Shear = Sqroot ( Fy2 + Fz2) =386.87 kN

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Anchor bolt design is done for total tensile force and shear: tension = 1368 x 1.2 = 1641 kN ~ 369
kips (seismic case combination 24) and shear 386 kN ~ 138.84 kips. Note that moment is negligible.

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Design of Pedestals Inside of Pit:

Un-braced Nodes:
1. White Oil Manifold-Braced bay:
2. White Oil Manifold-Un-braced bay:
3. Black Oil Manifold-Braced bay:
4. Black Oil Manifold- Un-braced bay:
As the force is tensile force and Bolt is directly anchored in Raft slab pedestal is not designed. Only
anchor bolt is designed. For Pedestal only 0.4 % nominal steel is provided = 1440 Sqmm Provided is
8 Nos T 20 = 2512 Sqmm.
Anchor bolt design is done for factored force of 725 x 1.2 = 870 kN and shear resultant of 367 kN.

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4) Raft and wall Design: Base raft: Pump foundation will be left with construction joints:
Considerations:
1. Local stresses and forces (moments) are averaged between the highest of that plate to next
plate element highest stress/force adjacent to it. This is done because generally in finite
element analysis some local stress/force concentration is always there and shall be corrected.
2. Maximum Mx or My is combined with Mxy using Wood's Armer principle i.e.
Mx' = Mx + 0.7 x Mxy
Or My' = My + 0.7 x Mxy.

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This is to account the twisting moment acting to at an angle to the orthogonal reinforcement
axis. Similar method is followed for two way slab corner where the cracking due to twisting
(torsion is in diagonal direction)
The angle of such moment is considered as 45 Degrees.
3. Crack width calculations are done as per BS 8007 provisions for un-factored load combination
including seismic and wind.
4. Strength design is done for all factored load combinations.
5. Sign convention for plate stresses and forces is as shown is sketches below, which is
obtained from staad-pro manual.
6. Local Z direction face moments are always +ve. (tension face) and shear force along local Z is
+ve.
[[

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A. Side Wall Design

1. Strength Design. Wall Maximum force summary:

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Shear forces:
Design is done for Maximum SQX (+ve- Wall inside face) and Minimum SQX (-ve-Wall outside face)

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Maximum SQX is average of forces of Plate 1789 and 1790
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Minimum SQX is average of forces of Plate 1721 and 1651
Bending Moment:
Design is done for Maximum My (+ve - Wall inside face) and Minimum My (-ve-Wall outside face)
Maximum My is average of forces of Plate 1263 and 1343

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Minimum SQX is average of forces of Plate 1048 and 1128
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Check for crack width: Wall Maximum force summary: (un-factored Loads)
Shear forces are not required for crack width check:

Bending Moment:
Check is done for Maximum My (+ve - Wall inside face) and Minimum My (-ve - Wall outside face)
Maximum My is average of forces of Plate 1044 and 1124

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Minimum My is average of forces of Plate 61 and 141
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B. Raft Slab Design:

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500 THK Plates
750 THK Plates
Plate thicknesses.

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Stress contour for factored Loads: (shown for Load comb. 15)

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Design of 500 Thk Raft slab:

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Maximum SQX is average of forces of Plate 6043 and 6143
Force Summary

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Minimum SQY is average of forces of Plate 6216 and 6146
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These two plates are located exactly at the Pedestal locations. Shear force at 'd' will be outside the
element boundary, so average value is considered sketch below and values marked as *.
Pedestal
locations
Maximum Mx is average of forces of Plate 4321 and 4322

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Minimum My is uniform in E-W direction so no average is taken.
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Crack width check: only moments are considered. (un-factored load summary)

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Force summary for crack width :

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Design of 750 Thk strips below piperack columns:

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Crack width Check:

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Check is done for Max My as it is highest moment at bottom and top and bottom same steel is
provided.

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5) Base pressure distribution:

All reactions are less than 175kN/sqm and are within the limit.

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Two groups are identified of plates:

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6) BMD, SFD and AFD and deflection diagram.

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Deflection Diagram:
The deflection visible is scaled up for better visibility: actual deflection is just in some mm.
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7) ANNEXURE

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A. Staad pro Output

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B. Pump Drawings:

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Manifold XX RCC Pit Design

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Revised and resubmitted for approval after incorporating clients comments.

Issued for construction.

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

2. Loads and load combinations

3. Column beam design.

4. Raft and wall design

5. Base pressure distribution.

6. BMD, SFD, AFD and Deflection Diagram,

Annexure-B Pump Drawings.

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

1 Overall Geometry: Refer design basis Doc .

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

PlanPipe rack near White oil Manifold

PlanPipe rack near Black oil Manifold

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

EL +12.10M FMD RAIL TOP

EL +5.00M FMD FGL

EL +2.60M FMD PIT FFL

Further Pressure due rotation = M x 6 /b x d2 Hence M = (P x b x d2 )/6 = 12.72kN-m.

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

For 1 degree of rotation settlement of soil is = tan (1o) x 1000 = 17.45mm.

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Also single RC beam is modeled as their moments are

balancing each other only uniform dead load considered.

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Wall 0.35 thk.

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Black oil Manifold Pump details:

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Pump load Notes:

where = is angle of repose of soil = 30o

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

White oil Manifold- Pipe trunion loads:

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Direct pipe supports: (refer Piping Document Number .)

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Pipe frame support loads overview.

White oil Manifold

Black oil Manifold

Braced and un-braced support (Refer Doc No- ..)

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Braced bay Nodes: high reactions

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc

Platform reaction on crane column:

These loads include:

Crane loads: Refer .

Live load of platform 600 wide at

XX-X-XXXX-XX-XXXX-REV XX - Manifold #XX RCC design.doc