CALCULATION

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PBA-CAL-CVL-001-A4

Conveyor T-1022

CALCULATION REPORT FOR CONVEYOR STRUCTURE T-1022

OWNER CONTRACTOR PROJECT NAME LOCATION CONTRACT DATE

: PT ANTAM (PERSERO) Tbk : PT WIJAYA KARYA (PERSERO) Tbk : CONVEYOR MOPP FeNi-1 : POMALAA, SULAWESI TENGGARA : 17 January 2012

09-05 2012

31

Approval

DRP

SMS

AP

BR

AA

Originator REV DATE Page Number STATUS

Reviewed By

Approved By

Reviewed By

Approved By

PT. WIJAYA KARYA (PERSERO) Tbk

PT ANTAM (PERSERO) Tbk

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Conveyor T-1022

CALCULATION REPORT FOR CONVEYOR STRUCTURE T-1022

REV

DATE

REVISION DETAIL

ORIGINATOR DRP

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TABLE OF CONTENT

Conveyor T-1022

1. 1.1. 1.2. 1.3. 1.4.

GENERAL SCOPE CODE AND STANDARD REFERENCES BASIC DESIGN 4 4 4 4

2. 2.1 2.2 2.3

STRUCTURAL MODEL 3D STRUCTURAL MODEL LONGITUDINAL AND TRANSVERSAL SECTION LOADS APPLIED IN STRUCTURE MODEL 6 7 7

3. 3.1 3.2 3.3 3.4

EXTERNAL LOADING CALCULATION DEAD LOAD (D) LIVE LOAD (L) EARTHQUAKE LOAD (E) WIND LOAD (W) 9 11 12 16

4. 4.1 4.2

MEMBER DESIGN CHECK CODE DEFLECTION CHECK 22 29

5.

MEMBER TAKE OFF

31

ATTACHMENT ATTACHMENT 1 STAAD INPUT MODEL ATTACHMENT 2 STAAD OUTPUT ANALYSIS

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1. 1.1. GENERAL SCOPE

Conveyor T-1022

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

1.2.

CODE AND STANDARD

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

1.3.

REFERENCES

1.3.1. PBASP50001A4 Structure Design Specification 1.3.2. PBASP50005A4 Fabrication and Construction of Steel Structure Specification

1.4. 1.4.1 a.

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

b.

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

c.

Anchor Bolt : ASTM A-307

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1.4.2 LOADING DATA

Conveyor T-1022

Loading data shall refer to PBASP50001A4 Structure Design Specification document.

1.4.3

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

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2. 2.1 STRUCTURAL MODEL 3D STRUCTURAL MODEL

Conveyor T-1022

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

(a)

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

2.2

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

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Conveyor T-1022

Fig 2.2 Longitudinal and transversal section in STAAD PRO Program Analysis

2.3

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

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

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Conveyor T-1022

EZ WZ

(a)

(b)

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

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

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3. 3.1 EXTERNAL LOADING CALCULATION DEAD LOAD (D)

Conveyor T-1022

Dead loads are the self weight of structures or foundations and all permanent facilities, such as floor, roof, joist, stairways, etc. 3.1.1. Structure Self-weight The Dead Load is the load of the structure itself (calculated by STAAD-PRO). with command "Selfweight Y-1.0", and other dead load as describes below. 3.1.2. Equipment Load

conveyor belt Frame Idler (carry) Idler (return) corrugated sheet belt cover 4 kg/m x 1 m pipe total equipment load (exc. Pipe) subjected to idler supports
2

= = = = = = = =

0,29 0,27 0,33 0,25 0,04 0,16 1,20

kN/m kN/m kN/m kN/m kN/m kN/m kN/m kN/m

30 28 34 26 4 16

kg/m kg/m kg/m kg/m kg/m kg/m

0,60

3.1.3. Walkway Platform

Platform Area Load span 0.8 m Handrail at 1.5 m interval cable tray 1

= = =

0,08 0,10 0,30

kN/m kN/m kN/m

19,5 10 30

kg/m2 kg/m kg/m

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Conveyor T-1022

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

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3.2 LIVE LOAD (L)

Conveyor T-1022

3.2.1. Ore/Bulk Material Load

bulk material on conveyor belt width 1

m x 2.35 kN/m
2

= = =

2,35 2,35 1,18

kN/m2 kN/m kN/m

240

kg/m2

subjected to idler supports

3.2.2. Walkway Live Load

Inspection Platform subjected at 100 kg/m2 x 0.8 m span = = 0,98 0,80 kN/m2 kN/m 100 80 kg/m2 kg/m

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

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3.3 EARTHQUAKE LOAD (E)

Conveyor T-1022

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

Design spectral = Spectral acceleration / R R (structural system factor) = 4.5 (ordinary moment resisting ftrame) Importance factor = 1 Design response spectra for return period 500 years. Dead Load (Self-weight + permanen equipment load) is used for seimic load calculation Seismic Load is calculated based on V Rx = Rz = 3.3.1 4.5 4.5

Cv I W RT

(Ordinary moment resisting frame) (Ordinary moment resisting frame)

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

3.3.2

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

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Conveyor T-1022

Table 3.1 Maximum Dead Load Support Reaction

Table 3.2 Maximum Dead Load Support Reaction for convetor side without walkway 3.3.3 Structure Natural Periode Based on UBC 1997, steel moment resisting frame can be determined with T=Ct(hn)3/4 Where, Ct Hn = 0.0853 = structure height (meter)

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

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3.3.4 Base Shear Force

Conveyor T-1022

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

Cv I W = RT

Maximum total base shear

2 .5 C a I W = R

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

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

Cv I W = RT

Maximum total base shear

2 .5 C a I W = R

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

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3.4 WIND LOAD (W)

Conveyor T-1022

Wind loads shall be generally as ASCE 7-05 Building category = III Exposure C V = I = Kz = Kd = 68,351 mph 1 1.005 0,85 10.21 m lattice framework 110 km/h Basic wind speed Importance factor (see table 3.1) (see table 3.2)

qz = 0.00256*Kz*Kd*(V*I)2 = = Gust factor G = 10.14 lb/ft2 0,489 kN/m2 0,85

Structure Properties Longitudinal dimension = 24 m

Transversal dimension = 2,6 m Height = 10.21 m

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Conveyor T-1022

Transversal direction

Longitudinal direction

Table 3.3 Kz coefficient based in structure height and exposure

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Conveyor T-1022

with z= zg = = Kz = 1.00532 33.497 900 9,5 ft ft

Table 3.4 Kd Coefficient based on structure type

Table 3.5 product of internal pressure coefficient and gust effect factor

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Conveyor T-1022

Table 3.6 Wall pressure coefficient

Table 3.7 Roof pressure coefficient

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Transversal direction L/B h/L = = 0,144 12.884

Conveyor T-1022

Fig 3.5 Wind Load applied to structural

contact surface direction windward roof leeward side wall code 1 2=3 4 5

Cp 0,8 -1,3 -0,5 -0,7

Table 3.8 Wind direction coefficient

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F = Af*(qz*G*Cp)
wind direct 1 trestle 1 4 trestle 4 2=3 5 trib. area Af (m) 1.5 0.5 1.5 0.5 1.5 0.65 0.68 0.68 -0.425 -0.425 -1.105 -0.595 GCp

Conveyor T-1022

qz 0.489 0.489 0.489 0.489 0.489 0.489

Fz kN/m 0.50 0.17 -0.31 -0.10 -0.81 -0.19

Table 3.9 Wind Force on Gallery Structure

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4. MEMBER DESIGN

Conveyor T-1022

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

4.1

CHECK CODE BASED ON AISC ASD FOR UNITY RATIO

4.1.1. BOTTOM CHORD UNITY RATIO

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

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4.1.2. TOP CHORD UNITY RATIO

Conveyor T-1022

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

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4.1.3. VERTICAL SHEAR WEB UNITY RATIO

Conveyor T-1022

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

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4.1.4. DIAGONAL SHEAR WEB

Conveyor T-1022

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

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4.1.5. TRESTLE COLUMN

Conveyor T-1022

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

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4.1.6. TRESTLE BRACING

Conveyor T-1022

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

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4.2 DEFLECTION CHECK

Conveyor T-1022

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

Fig 4.1 Vertical deflection at top chord member

Fig 4.2 Vertical deflection at bottom chord member

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Conveyor T-1022

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

4.2.2

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

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

OK!

In X axis direction or longitudinal section, maximum longitudinal deflection is 13.278 mm < 52.64 mm OK! This longitudinal deflection doesnt represent proportional structure behaviour because at start and end point of conveyor, the structures are tied in transfer tower with pinned and rolled support respectively. However, lateral deflection in longitudinal direction shall be less than 2 span 12 meters model.

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5. MEMBER TAKE OFF

Conveyor T-1022

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

Table 4.8 Conveyor structure Member Take Off