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INDEX
1.0 INTRODUCTION 4
1.01 SCOPE OF WORK 5
1.2 DESCRIPTION OF FACTORY BUILDING 5
1.2.1 FUTURE EXPANSION OF MAIN FACTORY BUILDING 6
1.3 FUTURE EXPANSION OF LPC BUILDING 6
1.4 PHASE -1 WORK OF FACTORY BUILDING 7
1.5 TESTING BUIDING 9
1.6 TRANS BORDER 10
1.7 TRACK PIT 13
1.8 RAIL TRACK 14
1.9 DYNAMIC TEST TRACK 16
1.10 MOBILE SPRAYING RAMP 17
1.11 Bogie Load Test Bench 17
1.12 Wheel press: 17
1.11 ABOVE ROOF TYP. DETAILS 19
1.12 LIFE LINE 19
1.12.1 TURBO FAN FIXING DETAILS 20
1.12.2 POLYCARBONATE SHEET 20
1.12.3 ROOF SEALANT 20
1.13 ANALYSIS 21
2 LOADS 22
3 STRENGTH OF MATERIALS 23
4 METHOD OF DESIGN 23
5 LOAD COMBINATIONS 25
6 GRADE OF REINFORCEMENT STEEL 26
7 GRADE OF CONCRETE 26
8 NOMINAL COVER TO MEET DURABILITY REQUIREMENTS 27
9 MATERIAL SAFETY FACTORS 27
10 SERVICEABILITY CHECKS 28
11 TYPE OF SOFTWARE AND VERSION 29
12 EARTHQUAKE ANALYSIS 29
13 WIND ANALYSIS 33
14 DESIGN 33
15 DETAILING 35
16 FIRE RATING 35
17 SPECIAL NOTES FOR PEB 36
18 FLOORING AND EXPANSION JOINTS 37
19 ROADS 40
20 LIST OF CODES AND REFERENCES 41
ANNEXURE-A 42
ANNEXURE-B 44
ANNEXURE-C 46
ANNEXURE-D 49
REVISION/VERIFICATION HISTORY:
REVISIO
N DATE PREPARED BY CHECKED BY APPROVED BY
NUMBER
R0 10.06.2016 SRIKANTH RAMARAO R.B. RAJESHA
R1 30.06.2016 SRIKANTH RAMARAO R.B. RAJESHA
R2 5.07.2016 SRIKANTH RAMARAO R.B. RAJESHA
R3 6.07.2016 SRIKANTH RAMARAO R.B. RAJESHA
R4 8.07.2016 SRIKANTH RAMARAO R.B. RAJESHA
R5 13.10.2016 SRIKANTH RAMARAO R.B. RAJESHA
R6 28.10.2016 SRIKANTH RAMARAO R.B. RAJESHA
1.0 INTRODUCTION:
Refer Architectural
2 Building Characteristics -----
DBR
3 Architectural Drawings T3
Technical Specifications R1 Revised R1 dated
a) Civil and list of approved on 29-06-2016
makes
4 b)PEB and list of approved
makes
c) Civil bill of materials
d) PEB bill of materials
-------
5. Rail track DBR
MAIN FACTORY Building will be expanded in future towards east side .The cladding
covered in the east will be dismantled & used in the future expansion area. Only
substructure will be common for future expansion.
LPC Building consist of 2/3 bays depending upon the cost proposals and further
bay wise expansion refer key plan
Temporary sheeting for segregating construction area (phase-2) from production area
(phase-1)
INDICATIVE SECTION
Each of the Electrified lines ( with 25 KV catenaries) shall have provision of
switch controls to disconnect the power supply and have appropriate LOTO
and Interlocking provisions with the platform access. Kindly refer the attached
Reference document on Test buildings provided by Employer.
Specifications:
This specification is for several trans borders.
The location of the transborders is presented on the site layout.
All transborders will move independently.
The displacements will be on rails
All trans borders will move the transit + the handling tractor which pushes
or pulls the transit
Refer document number:
The purpose is to move the cars from one station to another one. Total weight of
locomotive is 100MT and Tracks designed shall be 25MT Axial load. Accordingly sub
structure shall be designed based on the soil report.
Refer document number: MAD-appendix 2.100-b Tracks-V2.
Internal Track:
External Track:
The external tracks are resting on ballasts to refer the layout for detailed
junctions.
Column Reaction, Anchor bolt template & Design ( Autocad) , Staad model
analysis and design shall be provided by the bidder along with their
proposal
2mm thick polycarbonate sheet is resting on two purlin and with all round frame work
with safety weld mesh as per technical specifications
.
1.12.4 Roof sealants:
We are recommending DEKS Roof sealants.
Product Name: DEKSTRIP
1.13 Analysis
The above Buildings are analysed as a Space Frame. The modelled space
frame are analysed for dead loads (DL), live loads (LL), wind loads (WL) and seismic
loads (EQ) and their combinations (as per IS: 875) using STAAD Pro/ ETABS and
designed for limit states of Strength, serviceability including load combinations as per
IS: 1893(part-1). Effective lengths of columns are considered as per the standard
codes of practice. This structure are designed and detailed as per Indian codes of
practice only.
The Support Condition considered as follows:
Main Factory Building/LPC support considered as Fixed.
RCC Buildings support considered as Fixed.
2. LOADS
Note: Wherever reference to IS Code is made, the same shall be
taken as the latest revision (with all amendments issued.)
Dead load - The Dead Load in a Building shall comprise the weight of all walls,
partitions, floors and roofs and shall include the weights of all permanent
constructions in the buildings. The unit weight per mass of the materials and
parts or components of the building that are applicable to the determination of
dead load calculations are obtained by considering complying with IS-875 (Part 1)-
1978 and according to densities of the possible dead loads. (Ref. Annexure. A
Table-1).
Live load - Live loads on floors comprise all loads other than dead loads
produced by intended use or occupancy of a building including the weight of
movable partitions, distributed and concentrated loads, loads due to impact and
vibrations and dust load but excluding wind, seismic loads, etc. The minimum live
load on different floors for different purposes of usage are taken from IS 875:1987
(Part-2). (Refer Table -2).
Wind Load- Wind load calculation to be made by taking into account the random
variation of wind speed with time. Large majority of structures suffer wind induced
oscillations and are examined for such effects. Wind Loads are considered
according to IS-875 (Part 3)-2015 [Code of Practice for Design Loads (Other than
Earthquake) For Buildings and Structures].
Earthquake Load- Earthquakes cause random motion of ground, which can be
resolved in any three mutually perpendicular directions. This motion causes the
structure to vibrate. The response of the structure to the ground vibration is a
function of the nature of foundation soil, materials, form, size and mode of
construction of the structure, and the duration and the intensity of ground motion.
IS 1893: 2002 has been used for the earthquake analysis of the present structure.
As per IS 1893: 2002, Madhepura region falls under Zone V Relevant
earthquake parameters as per Zone V will be considered in the design.
3. STRENGTH OF MATERIAL
Purlins and Girts = 345 Mpa.
Hot rolled sections = 250Mpa.
Tube sections = 210/310 Mpa.
GalvalumeSheet = 550 Mpa.
Built up Plates: = Fe 490 B
RCC for the building shall be complying with concrete of Grade M25.(Fck-25 Mpa). All
reinforcement is high yield strength deformed bars of Grade Fe- 500 D.
4. METHOD OF DESIGN
All the structural elements in the building are designed with LIMIT STATE METHOD as
per Indian standards for R.C.C members& for Structural Steel members.
General Construction in Steel Code of Practice: IS 800-2007
Plain & Reinforced Concrete Code of Practice: IS 456-2000
Note: For design of structural steel members chapter 12 shall be included as per
IS800:2007.
5. LOAD COMBINATIONS
Load cases/definition:
DL Dead Load including crane dead weight
LL Live Load
CL Collateral Load
CR Crane lifting load
EQX, EQZ Seismic load in X & Z directions
WL Wind load
TL Temperature load
Load combinations for Limit state of collapse for Steel design:
1.5 (DL + LL)
1.5 (DL + LL + CL) TL
1.5 (DL + LL + CL) + 1.05 CR TL
1.5 (DL + CR + CL) + 1.05 LL TL
1.5 (DL EQX)
1.5 (DL EQZ)
1.5 (DL + CL EQX) TL
1.5 (DL + CL EQZ) TL
1.2 (DL + LL + CL EQX) + 0.53 CR TL
1.2 (DL + LL + CL EQZ) + 0.53 CR TL
1.5 (DL WL)
1.5 (DL WL) TL
1.2 (DL + LL WL) + 0.53 CR TL
1.2 (DL + LL + CL) + 1.05 CR 0.6 EQX TL
1.2 (DL + LL + CL) + 1.05 CR 0.6 EQZ TL
1.2 (DL + LL) + 1.05 CR 0.6 WL TL
0.9 (DL + CL) 2.5 EQX TL (only for design of columns where Pr / Pd> 0.4)
0.9 (DL + CL) 2.5 EQZ TL (only for design of columns where Pr / Pd> 0.4)
1.2 (DL + CL) + 0.5 LL 2.5 EQX TL
(Only for design of columns where Pr / Pd> 0.4)
1.2 (DL + CL) + 0.5 LL 2.5 EQZ TL
Foundations - M25/M30
Columns & Pedestals: - M25
Beams & Slabs: - M25
Walls M25
Minimum cement content shall be as per provisions of IS: 456: 2000, for a
moderate environmental exposure condition.
Vertical Deflections
Live/Wind Load Deflections
Purlins (Elastic Cladding) Span /150
Rafter (Elastic cladding) Span /180
Crane load (Electric operated up to 50T) Span /750
For Lateral Deflections
Wind load deflections (Elastic cladding) Height/150
Earth quake deflections Height/250
Crane + Wind ----Gantry (Lateral) 10mm
(Relative displacement between rails supporting crane)
Crane + Wind ---Column/Frame (Elastic cladding) Height /200
The storey drift in any storey due to minimum specified design lateral force, with
partial load factor of 1, shall not exceed 0.004 times the storey height.
d. For cracking:
Surface crack width shall not exceed 0.3 mm in general and for water retaining
structure it is limited to 0.1 mm.
11.0 SOFTWARES USED:
STAAD Pro. V8i
STAAD Pro is comprehensive structural engineering software that addresses all
aspects of structural engineering including model development, verification, analysis,
design and review of results. Here STAAD Pro is mainly used for analysis & design
of steel Structures.
ETABS (Version 9.7.4)
ETABS stands for Extended Three Dimensional Analysis of Building System.
ETABS is an engineering software product that caters to multi-story building analysis
and design. Modelling tools and templates, code-based load prescriptions, analysis
methods and solution techniques, all coordinate with the grid-like geometry unique to
this class of structure. Here ETABS are mainly used for analysis & design of RCC
Structures.
AUTODESK - AUTOCAD 2016
AUTOCAD software used for drafting of 2D structural drawings.
Being located in the high seismic zone perched on the boundary of the tectonic plate
joining the Himalayan tectonic plate near the Bihar-Nepal Border and having six sub-
surface fault lines penetrating through its Gangetic planes in four directions,
Madhepura is vulnerable to the worst kind of disaster caused by earthquake of near
maximum intensity. Out of eleven districts in Zone V ,Dharbhanga,
The earthquake analysis shall be carried out for dead loads (DL), live loads
(LL), piping, crane and equipments.
And refer Allianz document.
The proposed structure in this site shall be analyzed for seismic forces. Earthquake
analysis shall be carried out using STAAD-pro V8i for Steel Structures & ETABS for
RCC Structures as per the provisions of IS-1893: 2002 (Part 1 and 4). The nodal
mass shall be obtained as per the recommendations of IS-1893: 2002 regarding the
load combinations. The Response reduction factor shall be taken 4.5 for Steel
structures
As per IS 1893 base shear shall be calculated as
Vb = Ah x W
Where, Ah is base shear co-efficient and W is the nodal mass of all the floors.
For Steel Building
Analysis Parameters Clause/Table of
IS-1893:2002(part 1 & 4)
Zone factor, Z 0.36 Table 2 (P.No. 16)
Importance factor, I 1.75 Table 5 (P.No. 13) Part4
Steel building 4 or 5
Response factor, RF Table 23 (P.No. 87)
depending on connections
SS 2 -
ST 2 -
DM 0.02 for Steel -
To be calculated for each Clause 7.6.2 of IS 1893
Px
structure individually Part I
To be calculated for each Clause 7.6.2 of IS 1893 of
Pz
structure individually Part - I
DT As per soil report analysis -----
Where:
SS = Rock or soil sites factor (=1 for hard soil, 2 for medium soil, 3 for soft
soil). Depending on type of soil, average response acceleration coefficient
S a /g is calculated corresponding to 2% damping. Refer Clause 6.4.5 of IS:
1893 (Part 1) -2002.
ST = Optional value for type of structure (=1 for RC frame building, 2 for Steel
frame building, 3 for all other buildings).
DT= Depth of foundation below ground level = 2 to 3.5 meters as per soil
report
Px&Py= 0.085 x( h ) 0.75 for Steel and Px & Py= 0.09 x h /( D ) 0.5
Clause 7.6.2 of
IS:1893(Part 1)-2002 for RCC buildings .
13.0 WIND ANALYSIS
The proposed structure shall be analyzed for wind forces as per IS: 875-2015.
Analysis is carried out by using Staad Pro and the coefficients and wind pressure are
calculated as per the provisions made by IS: 875-2015.
14.0 DESIGN:-
Super Structure: Steel
All the structural steel elements shall be designed as per IS 800-2007. All the
frames and beams shall be checked for deflection as per the allowable limits.
Super Structure: R.C.C Frames (Beams & Columns):
All the structural R.C.C elements shall be designed as per IS 456-2000. All the
columns and beams shall be check for deflection as per the allowable limits. All the
slabs shall be designed using Spread Sheets and checked for deflection as per the
allowable limits.
Sub Structure:-
However, EPC contractor refer this soil report & satisfy himself with new set of
geotechnical tests if required at his cost.
Cover
The Clear Cover is the distance from the outer face of the structural element from
outer reinforcing rods. It is essential to avoid the exposure of reinforcing rod to the
environment.
SL Cover(mm)
Member
No Simply supported Continuous
1. Beams 35 35
2. Slabs 25 25
3. Columns 40 40
10. Proof checking cost of PEB structure under EPC scope & shall be from IIT
vetting like Mumbai, Delhi &Chennai.
11. PEB structure shall be earth connected.
12. PEB structure shall protected against lighting.
GENERAL NOTES:
1. All Rail Maintenance platform columns are resting on VDF with HILTI
connection.
2. Top of rail should match with finished floor level.
3. Pit and track in the floor shall be designed as per document number: MAD-
appendix 2.101-b-pit specifications
Roads
For the design of BTroads the CBR to be considered as per soil report.
ANNEXURE-A
A BUILDINGS
1 MAD-appendix 2.10-b-Carbodyshell building - V3
2 MAD-appendix 2.10-e-carbodyshell building photos - V1
3 MAD-appendix 2.11-b-detail power trap door
4 MAD-appendix 2.11-b-fitting building - V5
5 MAD-appendix 2.11-b-trap door-V1
6 MAD-appendix 2.11-e-fitting building photos-V1
7 MAD-appendix 2.13 - EHS_WMS_006 - safety requirements for
static testing activities
8 MAD-appendix 2.13-b-lock out tag out - V1
9 MAD-appendix 2.13-b-testing building specification-V4
10 MAD-appendix 2.13-e-testing building photos
11 MAD-appendix 2.14-b-dynamic test track specification V5.3
12 MAD-appendix 2.14-b-EHS_WMS_007 - safety requirements for
dynamic testing activities V1.2
13 MAD-appendix 2.14-e-dynamic test track photos - V1
14 MAD-appendix 2.15-b-warehouse building - V2
15 MAD-appendix 2.17-b-standard chemical storage workshop - V5
16 MAD-appendix 2.17-e-chemical storage photos
17 MAD-appendix 2.18-b-Office-facilities building - V2
18 MAD-appendix 2.19-b-Environment - Waste Management V3
19 MAD-appendix 2.19-e-environment - waste area - V1
20 MAD-appendix 2.23-b-socials building - V2
21 MAD-appendix 2.24-bcolor coding of rigid pipe V1
22 MAD-appendix 2.24-blighting of work places V2.2
23 MAD-appendix 2.24-b-Technical Data general-V3
24 MAD-appendix 2.100-b-Tracks - V2
25 MAD-appendix 2.101-b-Pit specification - V5
26 MAD-appendix 2.101-e-photos of existing pits
27 MAD-appendix 2.101-g-protection pit solutions - V5
28 MAD-appendix 2.104-b-technical data industrial doors - V3
29 MAD-appendix 2.105-b-catenary specification - V1
30 MAD-appendix2.200-5S - factory marking - V8
Madhepura Electric Locomotive Pvt. Ltd Rev: 06 Page 44 of 49
Structural DBR Date: 28-10-2016
MADHEPURA ELECTRIC LOCOMOTIVE PVT. LTD.
THE EMPLOYER MADHEPURA E-LOCO PROJECT
Tender Package: Fixed Price Lump Sum EPC Turnkey Contract
31 DRAFT EHS-WMS-001 V2
32 DTZ SPECIFICATION
33 SITE SPECIFICATIONS
ANNEXURE - B
DEAD LOADS
1. Bare Galvalume Sheets with insulation (single skin)
=0.0005x7850x1=0.003925kN/m2
2. Bracings = 0.05 kN/ m2
3. Purlins = 0.08 kN/ m2
All together Dead load of 0.25 KN/ m2 shall be considered
Table-1 Density of Materials:
N
Description Unit Value Remarks
o
1 RCC kN/m3 25 -
2 Steel kN/m3 78.5 -
3 Saturated soil kN/m3 20 -
4 Brick work 230 thk. kN/m3 20 Including plastering
Collatral Loads:
ANNEXURE - C
A) Wind Loads for Production Block:
Design wind Speed (vz) = Vb* K1* K2 *K3 m/sec
Basic wind speed (Vb) = 55 m/sec
Probability Factor (K1) = Refer Table-1, page 11, IS 875-Part 3
Terrain Height and Structure size factor (K2) = Table-2, page 12, IS: 875-part 3
Topography factor (K3)=Refer clause 5.3.3.1, IS 875- part 3
Vz=55*K1*K2*K2
Design wind Pressure Pz = 0.6 * Vz2
Wind load on individual members F= (Cpe +/- Cpi) * A * Pz
Cpe = External Pressure Coefficients
Cpi = Internal Pressure Coefficients = +/- 0.5 (for Medium openings)
A = Surface Area of Structural elements or Cladding units
B) Calculation of Pressure Coefficients for Production Block:
IS: 875 Part (3) we can obtain external pressure coefficients from the following data
H = Height of Building
W=The lesser horizontal dimension of Building
L= The greater horizontal dimension of Building
Roof slope = 1 in 10
B) Calculation of Pressure Coefficients for Production Block:
IS: 875 Part (3) we can obtain external pressure coefficients from the following data
H = Height of Building
W=The lesser horizontal dimension of Building
L=The greater horizontal dimension of Building.
ANNEXURE - D
Madhepura Electric Locomotive Pvt. Ltd Rev: 06 Page 48 of 49
Structural DBR Date: 28-10-2016
MADHEPURA ELECTRIC LOCOMOTIVE PVT. LTD.
THE EMPLOYER MADHEPURA E-LOCO PROJECT
Tender Package: Fixed Price Lump Sum EPC Turnkey Contract