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MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

A. GENERAL
The purpose of this calculation sheet is for the determined basic engineering design of foundation system
for 5,000 tph TWIN BOOM BUTTERFLY STACKER & 9,000 tph BUCKET WHEEL RECLAIMER at Miang
Coal Terminal. The structural design in this report consists of :
- Basic Engineering Design of Foudation System for 5,000 tph TWIN BOOM BUTTERFLY STACKER
- Basic Engineering Design of Foundation System for 9,000 tph BUCKET WHEEL RECLAIMER

B. REFERENCES AND CODES


- SNI (Standar Nasional Indonesia ) 03-2847-2002
- ACI (American Concrete Institute ) 318-05
- SNI (Standar Nasional Indonesia ) RSNI 03-1726-201x
- UBC (Uniform Building Code ) 1997
- ISO 5049-1 : 1994 (Mobile Equipment for Continuous Handling of Bulk Materials )
- ASCE 7-05 (American Society of Civil Engineer )
- Design of Structures and Foundations for Vibrating Machines by Suresh C Arya, 1984

C. MATERIAL PROPERTIES
Material properties for the structure shown as follows :

a. Material of Concrete Element


Concrete material will be using requirements for concrete exposed to sulfate containing solution.
Cement = Portland Cement Type IV (ASTM 150), for use when low heat of hydration is desired
f'c = 25 MPa (Min. Compress. Strength at 28 Days and must be reached 46% of the strength in 3 days )
wc = 0.5 (Max. Water-cementious material ratio )

b. Rebars Specification
Fy = 235 MPa for Plained Bars
Fy = 390 MPa for Deformed Bars

D. LOADING DATA
1) Dead Load
2) Machine's/Equipment's Weight
3) Wind Force
4) Earthquake Load (Seismic Force)

E. ANALYSIS METHOD
Analysis method to analyze the foundation system and calculate detailed reinforcement of concrete will be
using manual calculation and MS Excel Spreadsheet. The foundation system for Stacker Equipment would
be modeled as strip footing foundation with expansion joint every 8 m long span but especially for Bucket
Wheel Reclaimer Equipment, the foundation system would be designed as Footing Mat Foundation.
Miang Besar Coal Terminal Project Page 1 of 11
TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

F. LOADING COMPUTATION
Loading computation for the foundation system shown as follows :

F.1 Loading Computation for 5,000 tph TWIN BOOM BUTTERFLY STACKER

F.1.1 Dead Load


Dead loads on the structure consists of :
- Rail Gauge Weight/10 m = 488 kg

F.1.2 Machine's/Equipment's Weight


Machine's/Equipment's weight and configuration shown in the following figure :

*) Detailed Point Load for Maneuver Condition :


- Fvertical = 13.125 tons (Multiplied by 1.25 Impact Factor as per ASCE 7-05)
- Flateral = 2.625 tons (20% of Vertical Impact Load as per ASCE 7-05)
- Flongitudinal = 1.969 tons (15% of Vertical Impact Load as per ISO 5049-1 : 1994)

for unbalanced position (Assumed that 2/3 total loads at one side of boogey wheels) :
- Fvertical = 17.500 tons (Multiplied by 1.25 Impact Factor as per ASCE 7-05)
- Flateral = 3.500 tons (20% of Vertical Impact Load as per ASCE 7-05)
- Flongitudinal = 2.625 tons (15% of Vertical Impact Load as per ISO 5049-1 : 1994)

*) Detailed Point Load for Operating Condition (Considering Total 2,200 RPM Machine's Frequency) :
- Fvertical = 11.174 tons (Fo*sin*(t + /2)) unbalanced force caused by rotating machinery
- Flateral = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery
- Flongitudinal = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery

for unbalanced position (Assumed that 2/3 total loads at one side of boogey wheels) :
- Fvertical = 14.674 tons (Fo*sin*(t + /2)) unbalanced force caused by rotating machinery
- Flateral = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery
- Flongitudinal = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery

Miang Besar Coal Terminal Project Page 2 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

F.1.3 Wind Force


Contact wind pressure on foundation will be using minimum wind pressure in accordance with
ISO 5049-1 : 1994. The minimum wind pressure shown as follows :

Min. Wind Speed and Aerodynamic Pressure (ISO 5049-1 : 1994)


Above-ground height of the Wind Speed Aerodynamic Press.
structural element involved (vw) (q)
2
m m/s km/h kN/m
2-20 36 130 0.8
20-100 42 150 1.1
Above 100 46 165 1.3

- Eff. Area of TWIN BOOM BUTTERFLY STACKER (Ae) = 255.00 2


m (Assumed)
- Total pressure on structure caused by wind (Pwind) = 140.25 kN
- Wind pressure acting on boogey wheel (P'wind) = 7.01 kN/boogey wheel

Wind Pressure Acting on 5,000 tph TWIN BOOM BUTTERFLY STACKER

F.1.4 Seismic Load


Earthquake load or seismic analysis on the structure would be calculated according to RSNI 1726-201x
and Indonesia Earthquake Zone Map 2010 in which the code refer to IBC 2009. Earthquake load on the
structure would be analyzed by using static equivalent method. Spectral acceleration of seismic load
would be defined by using the following parameters :

Data Input
1. Risk Category of Structure = 3 see table 1, RSNI 1726-2010 sect. 4.1.2
2. Soil Acceleration Parameter
SS = 0.7 g see figure 9 (map) RSNI 1726-2010
S1 = 0.25 g see figure 10 (map) RSNI 1726-2010
3. Site Classification = 4 see table 3, RSNI 1726-2010 sect. 5.3

Miang Besar Coal Terminal Project Page 3 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

Data Output
1. Occupancy Importance (I) = 1.25 see table 2, RSNI 1726-2010 sect. 4.1.2

2. Site Coefficient
Fa = 1.24 see table 4, RSNI 1726-2010 sect. 6.2
Fv = 1.9 see table 5, RSNI 1726 sect. 6.2
So :
S MS = 0.868 g see eq. 5, RSNI 1726-2010 sect. 6.2
S M1 = 0.475 g see eq. 6, RSNI 1726-2010 sect. 6.2

3. Parameter Spectral Acceleration Design


S DS = 0.58 g see eq. 7, RSNI 1726-2010 sect. 6.3
S D1 = 0.32 g see eq. 8, RSNI 1726-2010 sect. 6.3

4. Response Spectrum Design


T0 = 0.11 s see eq. 11, RSNI 1726-2010 sect. 6.4
TS = 0 55
0.55 s see eq
eq. 12
12, RSNI 1726-2010
1726 2010 sect.
sect 66.4
4

T Sa
0.00 0.23
0.11 0.58
0.55 0.58
0.75 0.42
0.95 0.33
1.15 0.28
1.35 0.24
1.55 0.20
1.75 0.18
1.95 0.16
2.15 0.15
2.35 0.13
2.55 0.12
2.75 0.12
2.95 0.11
3.15 0.10
3.35 0.09
3.55 0.09
Response Spectrum Graph For Seismic Analysis

Elastic fundamental period of vibration would be calculated such as follows :


Ta = Ct*(hn)x
0.256 s
Miang Besar Coal Terminal Project Page 4 of 11
TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

Where :
Ct = 0.02 for all type structural system
hn = 30.00 m ; height of TWIN BOOM BUTTERFLY STACKER
x = 0.75

Parameters which would be used to calculated earthquake force shown as follows :

I = 1.25 ; importance factor for industrial facilities


R = 2.9 ; non-building structure(all other self supporting structure)
SDS = 0.58 g
SD1 = 0.32 g

Spectral coefficient would be calculated such as follows :


Cs1 = SDS/(R/I) = 0.249
Cs2 = SD1/[T*(R/I)] = 0.532
Cs_min = 0.158
Cs_req. = 0.532

Base shear (Caused by Max. Weight) would be calculated such as follows :


CS*W tot
Vtot.seismic =
3,726.8 kN
Vtot.seismic.1 = 93.17 kN/boogey wheel at strong axis
Vtot.seismic.2 = 27.95 kN/boogey wheel at weak axis
Vtot.seismic.3 = 18.63 kN/boogey wheel at vertical axis

F.2 Loading Computation for 9,000 tph BUCKET WHEEL RECLAIMER

F.2.1 Dead Load


Dead loads on the structure consists of :
- Rail Gauge Weight/10 m = 366 kg/m

F.2.2 Machine's/Equipment's Weight


Machine's/Equipment's weight and configuration shown in the following figure :

*) Detailed Point Load for Maneuver Condition :


- Fvertical = 30.625 tons (Multiplied by 1.25 Impact Factor as per ASCE 7-05)
- Flateral = 6.125 tons (20% of Vertical Impact Load as per ASCE 7-05)
- Flongitudinal = 4.594 tons (15% of Vertical Impact Load as per ISO 5049-1 : 1994)

Miang Besar Coal Terminal Project Page 5 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

for unbalanced position (Assumed that 2/3 total loads at one side of boogey wheels) :
- Fvertical = 40.838 tons (Multiplied by 1.25 Impact Factor as per ASCE 7-05)
- Flateral = 8.168 tons (20% of Vertical Impact Load as per ASCE 7-05)
- Flongitudinal = 6.126 tons (15% of Vertical Impact Load as per ISO 5049-1 : 1994)

*) Detailed Point Load for Operating Condition (Considering Total 2,200 RPM Machine's Frequency) :
- Fvertical = 25.174 tons (Fo*sin*(t + /2)) unbalanced force caused by rotating machinery
- Flateral = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery
- Flongitudinal = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery

for unbalanced position (Assumed that 2/3 total loads at one side of boogey wheels) :
- Fvertical = 33.344 tons (Fo*sin*(t + /2)) unbalanced force caused by rotating machinery
- Flateral = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery
- Flongitudinal = 0.337 tons (Fo*sin t) unbalanced force caused by rotating machinery

F.2.3 Wind Force


Contact wind pressure on foundation will be using minimum wind pressure in accordance with
ISO 5049-1 : 1994.

- Effective Area of BUCKET WHEEL RECLAIMER (Ae) = 340.00 m2 (Assumed)


- Total pressure on structure caused by wind (Pwind) = 187.00 kN
- Wind pressure acting on boogey wheel (P'wind) = 9.35 kN/boogey wheel

F.2.4 Seismic Force

Elastic fundamental period of vibration would be calculated such as follows :


Ta = Ct*(hn)x
0.318 s
Where :
Ct = 0.02 for all type structural system
hn = 40.00 m ; height of BUCKET WHEEL RECLAIMER
x = 0.75
Miang Besar Coal Terminal Project Page 6 of 11
TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

Parameters which would be used to calculated earthquake force shown as follows :

I = 1.25 ; importance factor for industrial facilities


R = 2.9 ; non-building structure(all other self supporting structure)
SDS = 0.58 g
SD1 = 0.32 g

Spectral coefficient would be calculated such as follows :


Cs1 = SDS/(R/I) = 0.249
Cs2 = SD1/[T*(R/I)] = 0.429
Cs_min = 0.158
Cs_req. = 0.429

Base shear (Caused by Max. Weight) would be calculated such as follows :


CS*W tot
Vtot.seismic =
7,009.0
, kN
Vtot.seismic.1 = 175.23 kN/boogey wheel at strong axis
Vtot.seismic.2 = 52.57 kN/boogey wheel at weak axis
Vtot.seismic.3 = 35.05 kN/boogey wheel at vertical axis

G. LOADING COMBINATION
Loading combinations for basic engineering design of the stacker/reclaimer foundation will be using
unfactored loading combinations.

- 5,000 tph TWIN BOOM BUTTERFLY STACKER


1 .1D (Permanent Condition)
2 . 1 D + 1 MM (Permanent Condition)
3 . 1 D + 1 MM + 1 W (Permanent/Imposed Condition)
4 . 1 D + 1 MM + 0.7 E (Temporary Condition)
5 . 1 D + 1 MO (Permanent Condition)
6 . 1 D + 1 MO + 1 W (Permanent/Imposed Condition)
7 . 1 D + 1 MO + 0.7 E (Temporary Condition)

- 9,000 tph BUCKET WHEEL RECLAIMER


1 .1D (Permanent Condition)
2 . 1 D + 1 MM (Permanent Condition)
3 . 1 D + 1 MM + 1 W (Permanent/Imposed Condition)
4 . 1 D + 1 MM + 0.7 E (Temporary Condition)
5 . 1 D + 1 MO (Permanent Condition)
6 . 1 D + 1 MO + 1 W (Permanent/Imposed Condition)
7 . 1 D + 1 MO + 0.7 E (Temporary Condition)

Miang Besar Coal Terminal Project Page 7 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

Where :
D = Dead Load
MM = Machine Weight in Maneuver Condition
MO = Machine Weight in Operating Condition
E = Earthquake Load/Seismic Force
W = Wind Load

H. FOUNDATION DESIGN
Foundation system would be design based on Soil Characteristic of BH 5 (GWS Soil Investigation Report)
or Preasumptive Load Bearing Pressure on Soil Based on IBC 2009 for Clay Soil. Especially for stacke
foundation, every span would be supported by transverse beam. The summary of total working loads based
on loading combinations shown as follows :

- 5,000 tph TWIN BOOM BUTTERFLY STACKER (6 Boogey Wheels per Long Span)

No. Load Comb. Loads & Directions


Fvertical = 4.88 kN
1 1D Flateral = - kN
Flongitudinal = - kN
Fvertical = 1,055 kN
2 1 D + 1 MM Flateral = 147 kN
Flongitudinal = 110 kN
Fvertical = 1,055 kN
3 1 D + 1 MM + 1 W Flateral = 176 kN
Flongitudinal = 140 kN
Fvertical = 1,133 kN
4 1 D + 1 MM + 0.7 E Flateral = 421 kN
Flongitudinal = 192 kN
Fvertical = 885 kN
5 1 D + 1 MO Flateral = 14 kN
Flongitudinal = 14 kN
Fvertical = 885 kN
6 1 D + 1 MO + 1 W Flateral = 44 kN
Flongitudinal = 44 kN
Fvertical = 964 kN
7 1 D + 1 MO + 0.7 E Flateral = 288 kN
Flongitudinal = 96 kN

Miang Besar Coal Terminal Project Page 8 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

- 9,000 tph BUCKET WHEEL RECLAIMER (4 Boogey Wheels per Long Span)

No. Load Comb. Loads & Directions


Fvertical = 4.88 kN
1 1D Flateral = - kN
Flongitudinal = - kN
Fvertical = 1,638 kN
2 1 D + 1 MM Flateral = 229 kN
Flongitudinal = 172 kN
Fvertical = 1,638 kN
3 1 D + 1 MM + 1 W Flateral = 255 kN
Flongitudinal = 198 kN
Fvertical = 1,737 kN
4 1 D + 1 MM + 0.7 E Flateral = 572 kN
Flongitudinal = 275 kN
Fvertical = 1,339 kN
5 1 D + 1 MO Flateral = 9 kN
Flongitudinal = 9 kN
Fvertical = 1,339 kN
6 1 D + 1 MO + 1 W Flateral = 36 kN
Flongitudinal = 36 kN
Fvertical = 1,437 kN
7 1 D + 1 MO + 0.7 E Flateral = 353 kN
Flongitudinal = 112 kN

All lateral loads would be defined using friction coefficient ( = 0.7).

H.1 Detailed Calculation for Foundation System of Stacker Equipment


Detailed calculation for Foundation System of Stacker Equipment shown in Attachment 1.

H.2 Detailed Calculation for Foundation System of Reclaimer Equipment


Detailed calculation for Foundation System of Reclaimer Equipment shown in Attachment 2.

I. BASIC DETAILED REINFORCEMENT


Basic detailed reinforcement of foundation system shown as follows :

Miang Besar Coal Terminal Project Page 9 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

I.1 Basic Detailed Reinforcement for Foundation System of Stacker Equipment


Basic drawing of detailed reinforcement for Stacker's Foundation shown as follows :

Front View of Reinforcement Design of Stacker's Foundation

Cross Section of Detailed Reinforcements of Stacker's Foundation

Miang Besar Coal Terminal Project Page 10 of 11


TTE033-2204-04-11-A0 Rev : A0
MIANG BESAR COAL TERMINAL PROJECT

Doc. No : TTE033-2204-04-11-A0
Job. No : TTE033
BASIC ENGINEERING DESIGN OF STACKER/RECLAIMER FOUNDATION
Rev. No : A0
Date : 29/06/2013
Reference Specs. : Civil and Structural Specification Engineer : FS

I.2 Basic Detailed Reinforcement for Foundation System of Reclaimer Equipment


Basic drawing of detailed reinforcement for Reclaimer's Foundation shown as follows :

Front View of Reinforcement Design of Reclaimer's Foundation

Cross Section of Detailed Reinforcements of Reclaimer's Foundation

Miang Besar Coal Terminal Project Page 11 of 11


TTE033-2204-04-11-A0 Rev : A0