COAL HANDLING PLANT AND SILO

LOADING ARRANGEMENT AT
ANANDA SIDING V & IV

SEMI UNDERGROUND BUNKER

DESIGN BASIS REPORT

 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

Table of Contents

1. INTRODUCTION ..................................................................................................................................... 3
2. DESIGN PHILOSOPY ............................................................................................................................... 4
3. MATERIAL SPECIFICATION .................................................................................................................... 4
3.1.CONCRETE STRUCTURE ............................................................................................................... 4
3.2.STEEL STRUCTURE ....................................................................................................................... 4
4. PROPERTIES OF STORED MATERIAL ...................................................................................................... 5
5. STRUCTURAL DESIGN CRITERIA ............................................................................................................ 5
5.1.NATURAL PHENOMENA .............................................................................................................. 5
5.1.1.Wind Speed .......................................................................................................................... 5
5.1.2.Seismicity ............................................................................................................................. 5
5.1.3.Temperature ........................................................................................................................ 5
6. DESIGN LOADS ...................................................................................................................................... 6
6.1.Dead Load ................................................................................................................................... 6
6.2.Live load ...................................................................................................................................... 6
6.3.Stored Material load ................................................................................................................... 7
6.4.Wind Load ................................................................................................................................... 7
6.5.Seismic Load................................................................................................................................ 8
6.6.Temperature loads...................................................................................................................... 8
6.7.Hydrostatic pressure and Earth pressure ................................................................................... 9
7. LOAD COMBINATIONS ........................................................................................................................ 10
8. ANALYSIS and DESIGN OF STRUCTURAL ELEMENTS ........................................................................... 10
8.1.ANALYSIS ................................................................................................................................... 10
8.1.1.Bunker ................................................................................................................................ 10
8.1.2.Roof structure .................................................................................................................... 11
8.1.3.Tunnel ................................................................................................................................ 11
8.2.DESIGN OF STRUCTURAL ELEMENTS ........................................................................................ 11
8.2.1.CONCRETE STRUCTURES .................................................................................................... 11

1
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

Table of Contents

8.3.STEEL STRUCTURES ................................................................................................................... 12

9. CODES AND STADARDS ....................................................................................................................... 13

2
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

1. INTRODUCTION
JTP Consulting Engineers Pvt Limited is asked to do the (CIVIL) Design and
Detailed engineering of Coal handling Plant and Silo loading arrangement at Ananda
Siding V & VI. The Design and detailing of the coal handling plant include 15000MT
capacity of Semi underground bunker which includes main tunnel, Escape tunnel,
Maintenance Bay, Pent house etc.

The semi-underground bunker consists of steel roof at top to cover the tipper conveyors,
material storage bunker with underground conveyor tunnel, Plough feeder maintenance
bay at both the ends etc. In which, the design of roof structure above bunker will be
designed using structural steel and all other part of bunker will be designed using
reinforced concrete. The bunker and the roof structure will be supported by the RCC
columns and RCC wall provided to cover the conveyor C7 & C8 to retain the earth fill
outside tunnel. Both RCC columns and walls are supported on RCC raft which is resting
on soil.

There are two conveyors C5 & C6 located at top of bunker as a feeder to bunker through
tippers, which moves along the length of bunker in the longitudinal direction. The plough
feeders are mounted on the rail running along the conveyors at bottom of the bunker, to
extract the material and supply to the conveyors C7 & C8 which is going to TH 10.

The underground tunnel (Clear width = 10.5m) has been provided for the conveyors (C7
& C8) from bunker to the Pent House. The tunnel consists of top slab, earth retaining
wall and raft at base. The top slab is supported by a concrete beam, columns at middle
and by walls at ends.

There is a small escape tunnel near the tail pulley coming from underground conveyor
tunnel to top of ground level. This tunnel has to be designed to carry the 2t capacity
monorail along with air supply and exhaust duct.

3
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

This report deals with the analysis, design and detailing of semi-underground RCC
Bunker with detailed Load Calculation.

2. DESIGN PHILOSOPY
Control of the Structural Analysis and Design on this project has been completed in
accordance with various predetermined standard practices and project-specific programs.
The purpose of this document is to summarize the code, standards and standard design
criteria and form the basis of the design for the structural components and systems for the
project. More specific design information has been developed during detailed design to
support equipment procurement and construction specifications.

3. MATERIAL SPECIFICATION
3.1. CONCRETE STRUCTURE
Reinforced concrete structures accordance with the provisions given in IS456:
2000.
Grade of Concrete for Raft M25
Grade of Concrete for Beams,
Columns and Slab M25
Concrete Grade for Bunker Wall M25
Grade of Mass concrete M10

Reinforcing steel: High strength deformed steel bars conforming to IS 1786.

Grade of Reinforcement Steel Fe415

3.2. STEEL STRUCTURE

The hot-rolled steel members and fasteners confirming to IS2062:1984 and
IS226:197. The Steel framed structures are designed in accordance with IS: 800.

Yield strength of Structural Steel fy = 250 MPa

4
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

4. PROPERTIES OF STORED MATERIAL

Material Stored Coal
Density (MCL-NIT doc) 12 kN/m3

Angle of Internal Friction 30
Internal Temperature 100o C
External Temperature 6.7oC
Co-efficient of Friction 0.5
Co-efficient of hzl. Pressure of material 0.5

5. STRUCTURAL DESIGN CRITERIA

5.1. NATURAL PHENOMENA
5.1.1. Wind Speed
Wind loads have been determined from IS875 (Part 3). The design wind speed
used as 44m/s to determine wind loads for all structures.

5.1.2. Seismicity
The Plant is located in Seismic zone III as determined from ANNEX E of IS1893
(Part 1): 2002.

5.1.3. Temperature
The basic thermal load of outdoor air temperature is based on the 100 year-return
period value of the annual highest and lowest temperature. The heat source from the
warm storage material (Coal) is also considered for the design. The internal temperature
of the bunker wall is considered as 80oC and the external temperature of wall is 30oC.

5
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

6. DESIGN LOADS
Design loads for all structures have been determined according to the criteria
described below.

6.1. Dead Load

Dead load is the weight of the structural elements and all equipment of a permanent or
semi permanent nature including wall panels, partitions, roofing, piping, drains, lifting
equipments, rails, and content of tanks and bins measured at full operating capacity. The
unit Weight of Materials considered for design as follows,

Unit Weight of RCC 25 kN/m3

Unit Weight of Brick 20 kN/m3
Unit Weight of weathering course 20 kN/m3

6.2. Live load

Live loads consist of uniform live loads and equipment live loads. Uniform live loads
are considered as per IS 875 (Part 2) including weight of peoples, portable equipment and
tools. Equipment live loads are calculated based upon the actual weight and size of the
equipment and parts to be placed on floors during operations.

Equipment loads have been specially determined and located based on the equipment
suppliers specification. For major equipment, structural members and bases have been
specially located and designed to carry the equipment load into the structural system. For
equipment weighing less than the uniform live load, the structural system has been
designed for the live load.

The live load on roof is recommended in the Table 2 of IS 875(Part II): 1987.
Live loads on Structural roof with profile sheeting 0.75 kN/m2
(According to Table 2 of IS 875 Part III, The Imposed load taken for slopping roof with slopes up to 10o
(Access not provided) is 0.75k N/m2.)
Live load on RCC Floors 5 kN/m2

6
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

Live loads on Steel Platform 5 kN/m2

Live loads on Maintenance bay floor 10 kN/m2

6.3. Stored Material load

The stored material load of coal is considered as per the provision given in IS: 4995
(Part 2) 1974 standards. The detailed load calculations of stored material in the bunker
have been done as per standard practice and enclosed in the design report.

The following cases have been considered to find the maximum forces in the
structural elements

1. The bunker is full (100%) There is no extraction under the bunker and stored
with the full capacity of bunker.
2. Partially extracted condition (approx 75% material in the bunker) - Partly
extracted as shown in the sketch below.
The following details are considered for the design of structure;

Unit weight of coal 12 kN/m3

Co-eff. Of Horizontal pressure at rest condition 0.5

6.4. Wind Load

Wind loads for all structures have been calculated based on IS 875(Part 3) and
Explanatory handbook of SP64.

Location = Bhubaneswar
Basic wind speed, Vb = 44 m/s
Category = 3
Class = C
Total Height of structure = 25m
Design Wind Speed, Vz = V b k1 k2 k3
Probability factor, k1 = 1.07

7
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

Terrain, height and structure factor, k2 = 0.935

Topography factor, k3 = 1
Design wind pressure, Pz = 0.6 Vz2 = 1.163 kN/m2

The detailed wind load calculations are shown in the design report.

6.5. Seismic Load

Seismic loads have been determined in accordance with the requirements specified in
Section 6.4, of IS 1893 (Part 1): 2002
Place = Bhubaneswar
Zone = III
Zone factor Z = 0.16
Importance factor I = 1.5
Reduction factor R = 3 (Considered as Ordinary RC Moment resisting system)

Hzl. seismic coefficient

6.6. Temperature loads

The structure containing hot materials are subjected to temperature stresses. The
thermal stresses and the corresponding additional reinforcement shall be calculated and
added to the wall reinforcement. The temperature loads are calculated based on cl. 5.8 of
IS4995 (Part II) 1974.

The temperature difference, T

Where,
K- Coefficient of heat transmission in kcal/m2hC
t - Thickness of wall in m
Ca - Surface conductance of concrete to air = 15.00 in kcal/m2hC
Cc - Thermal conductivity of reinforced concrete = 1.75 in kcal/m2h
hC

8
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

Cs - Surface conductance of concrete to stored material = 2.0 in kcal/m2hC

Bending moment across the section due to change in temperature

MT = t T Ec I/t
Where,
t - Coefficient of thermal expansion of concrete = 1.10E-05 /C /cm
Ec - Modulus of elasticity of concrete = 2.50E+05 kg/cm2
I- Moment of inertia of section in cm4

6.7. Hydrostatic pressure and Earth pressure

The lateral earth pressure have been calculated and used in the analysis for the
structures or part of the structures below ground level such as retaining walls in the
Tunnel below bunker and for main, escape tunnel walls etc. Check for overturning, uplift
have been carried out as per standard.

The coefficient of active earth pressure at rest condition 0.5 has been taken for the
analysis and design of the structure.

The ground water table has been considered at the existing ground level near bunker
locations. The existing ground level is at EL (+) 107.114m based on soil report and the
finished ground level is considered at EL (+) 109.0m for the soil pressure on the retaining
walls.
The surcharge load of 20kN/m2 has been considered near the retaining structures
and above the tunnel locations wherever applicable.

9
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

7. LOAD COMBINATIONS
The loading combinations are considered in the design of structures in accordance
with the stipulations in the relevant design codes. The simultaneous occurrence of
maximum values of WL and EL is not likely.

a. DL
b. DL+LL
c. DL+WL
d. DL+EL
e. DL+TL
f. DL+LL+WL
g. DL+LL+EL
h. DL+LL+TL
i. DL+WL+TL
j. DL+EL+TL
k. DL+LL+WL+TL
l. DL+LL+EL+TL

(DL Dead Load, LL Live Load, WL Wind Load, EL Earthquake load, TL

Temperature load)

8. ANALYSIS and DESIGN OF STRUCTURAL ELEMENTS

8.1. ANALYSIS
8.1.1. Bunker
The Semi Underground Bunker has been divided into three parts based on the
expansion joint requirement and modeled separately and analyzed using Staad Pro V8i
software. The load calculations have been done as per Standards of IS 4995. The bunker
has been analyzed for the various load combinations mentioned in section 7.0. The
critical load combinations with material fill for 100% and 75% has been carried out along

10
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

with the dead, live, temperature and wind or seismic loads and the design is carried for
the critical load combinations.
8.1.2. Roof structure
The steel roof structure above bunker has been modeled as portal frame for the
span of 15m and spacing of frame is 9m in the maintenance bay portion and 6m for all
other locations. The structural analysis has been carried out along with the bunker using
STAAD Pro.
8.1.3. Tunnel
The main tunnel has been dived in to two part; i) Below ground level near bunker
and ii) above ground level near pent house.

Three-Dimensional finite element modeling has been created using STAAD Pro.
For the first one and the Structural elements are treated as linear elastic and this method
of modeling and analysis can more closely represent the actual conditions. The response
of the foundation for the tunnel structure is modeled in STAAD Pro as an elastic mat with
the modulus of sub grade value of 30000kN/m2 as per soil report.

The surcharge load on tunnel top slab considered is equivalent to 1.2m height of
earth filling above ground level. The side walls will be subjected by the earth pressure
and overburden pressure due to earth fill.

The second one is partially covered with the soil and there is no soil and surcharge
on top roof slab. This one is analyzed and designed using conventional method
conforming to IS456:2000.

8.2. DESIGN OF STRUCTURAL ELEMENTS

8.2.1. CONCRETE STRUCTURES
All RCC structural elements have been designed as per Limit state method of
design and checked for serviceability conditions confirming to IS456:2000
The design is carried out using staad pro software for the ultimate load
combinations and with the following criteria;

11
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

Clear cover to reinforcement shall

Raft - top & bottom = 50mm
Tunnel wall (Earth - Outside) = 50mm, Inner face = 40mm,
Column = 50mm, BEAM = 40mm, SLAB = 30mm
Expansion joint is provided to allow expansion due to temperature changes. It is limited
to 45m as per cl 27.2 of IS 456: 2000.

8.3. STEEL STRUCTURES

The portal frame has been designed to support the purlins and roof sheets,
monorail and chain pulleys (2t) at specified locations as per requirements. Purlins are
provided at a spacing of 1.4m (max) centre to centre to support GI Sheets.

The Deflection and Sway under the serviceability loads of frame is checked for the
most adverse and critical load combinations, the maximum allowable deflection is
conforming to the standard.

The column member has been designed for the combined axial and bending
moments and checked as per cl 7.1.1 of IS 800:1984. The limiting slenderness ratio of
250 is considered for the loads due to wind/ seismic.

12
 COAL HANDLING PLANT AND SILO LOADING ARRANGEMENT AT DOC. NO.
PROJECT
ANANDA SIDING V & VI 01-CHP01-BUNKER-DC-CE001
DESIGN CHECKED
TITLE SEMI UNDERGROUND BUNKER - DESIGN BASIS REPORT
SK JTP

9. CODES AND STADARDS

The design and specification of work carried in accordance with all applicable
standards. The following Codes and Standards have been identified as applying to
structural Analysis, Design and detailing etc.

TABLE - LIST OF CODES AND STANDARDS

Sl.
Codes
No
1 IS: 875 (Part 1) - 1987
2 IS: 875 (Part 2) - 1987
3 IS: 875 (Part 3) - 1987
4 IS: 456 - 2000
Description
Code of Practice for Design Loads (other
than earthquake) for Buildings and structures
- Unit weight of building materials
Code of Practice for Design Loads (other
than earthquake) for Buildings and structures
- Imposed Load
Code of Practice for Design Loads (other
than earthquake) for Buildings and structures
- Wind load
Code of Practice for Plain and Reinforced Concrete

5 IS: 1893 (Part 4) - 2005 Criteria for Earthquake Resistant

Design of Structures
6 IS: 4995 (Part 1) - 1974 Criteria for Design of Reinforced concrete bins for the
storage of Granular and Powdery materials
- General requirements and assessment of bin loads.

7 IS: 4995 (Part 2) - 1974 Criteria for Design of Reinforced concrete bins
for the storage of Granular and Powdery materials
- Design Criteria

8 DIN 1055-6 :2005-03 Design loads for buildings and loads in Silo bins
9 IS 800 - 1984 Indian Standard Code of Practice for General
Construction in Steel.
10 SP-16 Design Aids for Reinforced Concrete
to IS:456-1978

13