epc structure

Kingdom of Saudi ArabiaRoyal Commission for Jubail & Yanbu

Royal Commission in JubailJubail Industrial City

CONTRACT NO. 122-C01

EPC OF PACKAGE SANITARY WASTE WATER TREATMENT PLANT

DESIGN BASIS REPORT(REVISED STRUCTURE)

FEBRUARY, 2011REV.NO. REV. DESIGNED BY DATE SIGNATURE CHECKED BY DATE SIGNATURE

B Rev.10% IRFAN FEB-2011 KAMAL DEC-2010

A 10% IRFAN JAN- 2011 KAMAL JAN-2011

Document Number122-C01-G80-SA-001

P.O. Box 2341, Riyadh 11451Tel : +966 1 4659975 Fax : +966 1 4647540

Kingdom of Saudi Arabia

P.O. Box 14911, Jeddah, 21434Tel : + 966 920006300 Fax : +966 2 6067858

Kingdom of Saudi Arabia

CONTRACT NO. 122-C01- REVISED 10% STAGEEPC OF PACKAGE SANITARY WASTEWATER TREATMENT PLANT

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DESIGN BASIS REPORTSTRUCTURAL WORKS

Prepared By Irfan AliReviewed By Mohamed KamalDate February, 2011

TABLE OF CONTENTS

5. STRUCTURAL WORKS...................................................................................................................... 5-1

5.1 INTRODUCTION.......................................................................................................................................5-15.2 STRUCTURAL SCOPE OF WORK............................................................................................................5-1

5.2.1 Description of the Buildings and Structural System...................................................................5-15.2.2 Design Criteria for Special / Other Structures.............................................................................5-2

5.3 APPLICABLE CODES, STANDARDS AND PUBLICATIONS........................................................................5-65.3.1 Loading............................................................................................................................................5-65.3.2 Concrete..........................................................................................................................................5-65.3.3 Masonry...........................................................................................................................................5-75.3.4 Structural Steel...............................................................................................................................5-85.3.5 Corrosion control............................................................................................................................5-85.3.6 Thermal Protection.........................................................................................................................5-85.3.7 Calculations.....................................................................................................................................5-95.3.8 Safety...............................................................................................................................................5-9

5.4 MATERIALS SPECIFICATIONS.................................................................................................................5-95.4.1 Concrete..........................................................................................................................................5-95.4.2 Cement..........................................................................................................................................5-105.4.3 Reinforcing Steel..........................................................................................................................5-105.4.4 Concrete Masonry Units..............................................................................................................5-115.4.5 Pre-Engineered Structural Steel.................................................................................................5-11

5.5 DESIGN CRITERIA................................................................................................................................5-125.5.1 Dead loads....................................................................................................................................5-125.5.2 Live Load.......................................................................................................................................5-135.5.3 Rain Load......................................................................................................................................5-135.5.4 Crane Load....................................................................................................................................5-135.5.5 Wind Load.....................................................................................................................................5-135.5.6 Earthquake Load..........................................................................................................................5-145.5.7 Temperature Load........................................................................................................................5-155.5.8 Load Combinations......................................................................................................................5-155.5.9 Stability against Overturning, Uplift, Sliding, and Buoyancy...................................................5-165.5.10 Deflection..................................................................................................................................5-175.5.11 Concrete Cover........................................................................................................................5-175.5.12 Slab on Grade..........................................................................................................................5-185.5.13 Soil Bearing Capacity..............................................................................................................5-195.5.14 QA/QC Implementation...........................................................................................................5-19

5.6 SAFETY................................................................................................................................................5-195.6.1 Safety Issues............................................................................................................................5-195.6.2 Safety Improvement Solutions...............................................................................................5-19

5.7 CORROSION PROTECTION...................................................................................................................5-19

CONTRACT NO. 122-C01-10% STAGE(REVISED)EPC OF PACKAGE SANITARY WASTEWATER TREATMENT PLANT

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5. STRUCTURAL WORKS

5.1 Introduction

The following report is intended to outline the criteria and basis of design that will be used in the calculations for the design of structural works involved in this project. This design criteria complies with all relevant Royal Commission Codes and Standards, latest editions of engineering codes and Saudi Arabian Government Codes.

5.2 Structural Scope of Work

Structural scope of work for this project is intended for the structural design of structures as described in section 5.1.1.

5.2.1 Description of the Buildings and Structural System

5.2.1.1 Treated Effluent Storage Tank (2 Nos)

The treated effluent storage tanks shall be of diameter 30.0 m and height of 10.0 m having storage capacity of 6500 cubic meter. These tanks shall be made up of welded steel and designed as per API 650 (refer to section 5.1.2.1 of this report). Steel tanks shall be above ground and supported on concrete foundation.

5.2.1.2 Cross Clarifier (3 Nos) (CC)

Cross Clarifiers shall be of size 40.0m x 10.80m in plan. It is reinforced concrete structure having concrete wall supported on concrete foundation; one concrete wall in contact with water on both sides and other walls are contact with water from inside and soil outside.

5.2.1.3 Micro screen Filter (MSC)

Micro screen filter is reinforced concrete structure having size of 9.25 m x 7.10 m. The structural system is comprises reinforced concrete walls supported on mat foundation.

5.2.1.4 Chlorination Building (CB)

Chlorination building is reinforced concrete structure (beam, column and slab) having size of 6.0 m x 10.0 m. outer and inner walls shall be concrete masonry hollow block units. All columns shall be supported on conventional isolated spread foundation.

5.2.1.5 Chlorination (CL)

Chlorination is reinforced concrete structure having size of 12.0 m x 12.0 m. The structural system is comprises reinforced concrete walls supported on mat foundation.

CONTRACT NO. 122-C01-10% STAGE(REVISED)EPC OF PACKAGE SANITARY WASTEWATER TREATMENT PLANT

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5.2.1.6 Outlet Pumping Station (OPS)

Outlet pumping station is reinforced concrete structure having size of 3.0 m x 6.5 m. The structural system is comprises of beams, column and slab. All columns shall be supported on conventional isolated spread foundation.

5.2.1.7 Operational Building (OB)

Operational Building is reinforced concrete structure. The structural system is comprises of beams, column and slab. All columns shall be supported on conventional isolated spread foundation. The building size in plan is 30.60 m x 6.50 m.

5.2.1.8 Inlet Pumping Station (IPS)

Inlet pumping station is reinforced concrete structure having size of 3.0 m x 6.5 m. The structural system is comprises of beams, column and slab. All columns shall be supported on conventional isolated spread foundation.

5.2.1.9 Primary Settling Tank (3 Nos) (PST)

Primary settling tanks are reinforced concrete structure having internal diameter of 3.80 m. These tanks are above ground structure supported on concrete foundation. The walls of tank are in contact with soil (outside) and water (inside).

5.2.1.10 Sludge Storage Tank (SST)

Sludge storage tank is reinforced concrete structure having size of 10.0 m x 6.5 m. The walls of tank are in contact with soil (outside) and water (inside). This structure is supported on concrete foundation.

5.2.1.11 Neutralization Zone (NZ)

Neutralization zone is reinforced concrete structure having size of 3.90 m x 3.75 m. The walls of tank are in contact with soil (outside) and water (inside). This structure is supported on concrete foundation.

5.2.2 Design Criteria for Special / Other Structures

5.2.2.1 Steel Effluent Storage Tank

Material Comparison

Description Concrete Tanks Steel TanksInitial Cost Medium Cost 20- 40% HigherRunning Cost (Maintenance)

High Low


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Description Concrete Tanks Steel TanksLife Time About 50 Years About 100 YearsConstruction Time Longer Time Shorter TimeQuality Control Need more control High Quality can

be achieved

Regarding to the above comparison steel water takes is recommended from our side.

Steel Water Tanks Design Criteria

Steel Shell Tank

The Shell plate to be provided for the steel tank shall have a maximum width of 2.5m per course and varying thickness depending on the lateral pressure to be imposed by the tank content (water) as calculated in conformance to clause 5.6.3 or 5.6.4 of the API, 11th Edition.

Steel Shell Tank Annular Plate

The annular plate to be provided has a minimum width of 600 mm and shall be as calculated in conformance to clause 5.5.2 & Table 5-1 of API 650, 11th Edition.

Steel Tank Bottom Plate The Bottom Sketch plate to be provided shall be in conformance to clause 5.4.1 of API 650, 11th Edition.

Steel Tank Roof Cone Plate

The thickness of roof cone plate to be provided shall be as calculated in conformance to clause 5.10.2.2 or 5.10.5.1 of API 650, 11th Edition.

Wind Girders

Wind Girders to be provided shall satisfy conditions mentioned in clause 5.9.7 of the API 650, 11th Edition, while sizing will be calculated in conformance to clause 5.9.7.6 of API 650, 11th Edition.

Curb Angles

Size of Curb Angle to be provided shall satisfy conditions mentioned in clause 5.10.2.2 of API 650, 11th Edition.

Rafters

Rafter Size shall be designed depending on the loads imposed by the cone roof plate & roof live load acting along its tributary area and the rafter’s self weight. The length of the


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rafters shall be 7.25m passing from the center column to the outer rings as proposed in this design. It shall be spaced not more 0.6p m apart along the circumference in conformance to clause 5.10.4.4 of API 650, 11th Edition.

Assumptions considered in the design are:

Effect of roof slope is negligible. Loads acting on rafters are considered as uniformly distributed.

Girders

Girder Size shall be designed depending on the loads imposed by the Rafters on both sides of its tributary area and its own self weight. The length of girders shall vary on the outer ring as proposed in this design. It is also assumed that the load acting on the girder shall be uniformly distributed.

Columns

Intermediate and center columns size shall be designed depending on the load to be imposed by half of the girder loads on both sides that it supports and its own self weight. The length of the columns shall vary from center column to the outer rings. Eccentricity load shall be assumed negligible in the design columns.

Base Plate

Base plate sizes for all columns shall be designed depending on the load acted upon the column and contracted by the allowable soil bearing pressure underneath the column resisting the load. Size to be provided shall be adequate enough to resist maximum bending moment.

Dead Load

Dead loads are the permanent loads imposed by the structure. These are primarily the self weights imposed by the tanks shell, bottom and roof plates, rafters, girders, columns, etc.

Roof Live Load

Live load of 1.0 kPa (20 psf) is considered on the roof as recommended in section 5.2.1 API 650, 11th Edition.

Wind Load

Wind load acting on structure are calculated as per clause 5.11 of the API 650, 11th Edition.


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Seismic Load

Seismic Design of tank shall be carried out as per Appendix-E of the API 650, 11th Edition.

Material Data

Structure steel shall conform to ASTM A36 having yield stress of 250 MPa and Tensile strength of 400 MPa. Galvanization shall be as per ASTM A123.

Connecting BOLTS shall conform to ASTM A325. Galvanization shall be as per ASTM A153.

Foundation Design

The foundation for steel tank shall be designed as per recommendation of API 650, 11th edition, Appendix-E “Recommendations for design and construction of foundations for aboveground oil storage tanks”.

5.2.2.2 Foundation Design Criteria for Dynamic Equipments

All foundations that support machinery i.e. Pumps, Motors, Mixers or Compressor shall be as per recommendation of ACI 351.3R and R.C Engineering Manual Chapter-9, section 9.11.B.6. The anticipated dynamic and static loads shall be taken from manufacturer recommended data.

5.2.2.3 Concrete Masonry Wall Design

All interior and exterior walls shall be non load bearing walls. The exterior wall will be designed to resist the wind load as per recommendation of ACI 530. The wall thickness shall be calculated as per ACI 530 “Building Code Requirements for Masonry Structure” table 5.5.1 i.e. Maximum L/T OR H/T shall be 18 for exterior wall and 36 for interior walls.

5.2.2.4 Foundation Design for Light Poles

All foundations for lighting poles shall be designed to resist both axial and lateral loads employing posts or poles as columns embedded in earth or in concrete footings in earth shall be in accordance with IBC-2009, Sections 1807.3.

5.2.2.5 Thrust Block Design

Thrust block shall be provided where necessary and shall be designed (as per R.C Engineering Manual; Chapter-9, section-) to resist thrust force by sheer weight and friction only (without passive soil pressure) at working pressure and to consider passive soil pressure at pipe hydro test pressure.


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5.2.2.6 Fence Boundary

The security fence boundary shall be chain link fabric as per R.C guidelines specifications section 02820 “Guidelines and specifications for fence and gates” and R.C standard drawings.

5.2.2.7 Overhead Cranes

The capacity of overhead cane used in inlet and outlet pump rooms will be 2.0 Ton. The overhead clearance shall be 5.50 m from finish floor level. The supporting for cranes shall be designed as per R.C Engineering Manual, Chapter-9 and section 9.07-G.

5.2.2.8 Utility/Drainage underground Culverts

Utility Culver (if required) shall be precast or cast in situ structure; designed as per recommendations of Ministry of Transportation (MOT) and AASHTO. Utility culverts shall be so sized that they easily accommodate the utilities/drainage water.

5.2.2.9 Valve Chamber Design

Valve chambers shall be designed for the dead, live, earth pressure and loads transfer through the pipes liquid. Loads criteria for vehicles shall be as per MOT and AASHTO. Valve chamber size shall be as per requirement and will be made up cast in situ concrete as per requirements of ACI 350.

5.2.2.10 Pipe Support Structure

Pipe supports shall be designed for the service loads as per requirement. These pipe supports will be made up of structural steel and will be designed as per recommendations of AISC ASD.

5.3 Applicable Codes, Standards and Publications

5.3.1 Loading

Code ReferenceGeneral Design RequirementsChapter-9; Structural Design CriteriaLatest Revision

Royal Commission Engineering manual

SEI/ASCE 7-05 Structural Engineering Institute/American Society of Civil Engineering:Minimum Design Loads for Buildings andother Structures

IBC-09 International Building CodeSBC Saudi Building Code

5.3.2 Concrete


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Code ReferenceRoyal Commission GuidelineSpecifications Division-31. Structural Concrete2. Portland Cement3. Reinforcement for Concrete4. Cast in place Concrete Forms & Accessories5. Precast Concrete

Section 03310Section 03310-1Section 03205Section 03105

Section 03430ACI 318m-08 American Concrete Institute

Building Code Requirements for Structural Concrete and Commentary

ACI 315-99 American Concrete InstituteDetails and Detailing of Concrete Reinforcement

ACI 350 Code Requirements for Environmental Engineering Concrete Structures and Commentary

ACI 350.2R Concrete Structures for Containmentof Hazardous Materials

ACI 350.4R Design Considerations for EnvironmentalEngineering Concrete Structures

ACI 351.3R Foundations for Dynamic Equipment

5.3.3 Masonry

Code referenceRoyal Commission GuidelineSpecifications Division-41. Masonry Mortar2. Masonry Grout3. Masonry Anchorage & Reinforcement4. Masonry Accessories5. Concrete Masonry Unit6. Unit Masonry Assemblies

Section 04060Section 04070Section 04080

Section 04090Section 04220Section 04810

ACI 530m-05 American Concrete InstituteBuilding Code Requirements for Masonry Structures and Commentary

ACI 530.1-05 American Concrete InstituteSpecifications for Masonry Structures and Commentary


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5.3.4 Structural Steel

Code Reference

Section 05820

Section 05120Section 05580Section 05210Section 05310Section 05520

1 .Non-Royal Commission Guideline

Specifications Pre-Engineered Metal

Buildings2 .RC Guideline Specifications

Structural Steel Formed Metal Fabrications

Steel Joists Steel Decks

Hand Rails and RailingsAmerican Institute of Steel ConstructionManual of Steel Construction – Allowable Stress Design; 13th edition

AISC

American Iron and Steel InstituteSpecifications for the Design of Cold-formed Steel Structural Members with Commentary

AISI

American Petroleum Institute Welded Steel Tanks for Oil Storage

API 650

American Welding SocietyStructural Welding Code

AWS

American Society for Testing and MaterialsASTM

5.3.5 Corrosion control

Code referenceRoyal Commission Engineering ManualDesign Criteria; chapter-12


Royal Commission Guideline Specifications

1 .Damp Proofing & Waterproofing

2 .Damp Proofing3 .Sheet Waterproofing4 .Preformed Joint Seal

5 .Joint Seal

5.3.6 Thermal Protection

Code ReferenceRoyal Commission Guideline Specifications

1 .Thermal Protection2 .Building Insulation

Section 07200Section 07210


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3 .Metal Roof and Wall Panels4 .Sheet Metal Roofing

5 .Sheet Metal Flashing and Trim6 .Roof Accessories

7 .Manufactured Roof Specialties


5.3.7 Calculations

Code Reference

Royal Commission Engineering ManualStructural Design Criteria; Chapter-9Section 9.12, 9.13, 9.14

Jubail Management ProcedureJMP

5.3.8 Safety

Code ReferenceOccupational Safety & Healt Administration; Latest Edition

OSHA

Part 1910 – GeneralPart 1926 – Construction

Standards CFR 29

5.4 Materials Specifications5.4.1 Concrete

TABLE – 4

Structure Class of ConcreteMinimum Cylinder

Compressive Strength

at 28 DaysDesign Concrete cylinder compressive strength at 28 days for all cast in situ reinforced structural concrete elements in contact with soil or exposed to weather, salt, salt water, brackish water, seawater or spray from these sources.

C30 minimum with Type I Portland cement and pozzolanic replacement as per GS 03310, Table 1C

30 MPa

Design Concrete cylinder compressive strength at 28 days for all cast in situ reinforced structural concrete elements and precast walls not in contact with soil or exposed to weather, salt, salt water, brackish water, seawater or spray from these

C30a or C30b minimum with Type I Portland cement and pozzolanic replacement as per GS 03310, Table 1C

30 MPa


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TABLE – 4

Structure Class of ConcreteMinimum Cylinder

Compressive Strength

at 28 Dayssources.Design Concrete cylinder compressive strength at 28 days for all precast/prestressed reinforced structural concrete elements

C40 minimum with type-I Portland cement as per GS 03310, table 1C

40 MPa

Blinding Slabs, Mud Mats, and Lean Concrete

C20 with Type V Portland cement as per GS 03310, Table 1C

20 MPa

5.4.2 Cement

1. Cement shall be ASTM C150 type-I portland cement with silica fume pozzolanic replacement as per RC GS section 03310, table 1c for structural concrete in contact with soil or exposed to weather, salt, salt water, brackish water, seawater, or spray from these sources.

2. Cement shall be ASTM C150 type-I portland cement as per RC GS section 03310, table 1c for structural concrete not in contact with soil and not exposed to weather, salt, salt water, brackish water, seawater, or spray from these sources. Silica fume or fly ash pozzolanic replacement complying with RC GS section 03310 table 1c can be used at the contractor’s option and expense.

3. Cement shall be ASTM C150 type v Portland cement as per RC GS section 03310, table 1c for blinding slabs, mud mats, and lean concrete.

5.4.3 Reinforcing Steel

1. All reinforcing steel shall conform to the following:a. Deformed bar reinforcing; ASTM A706 grade 60 (420 MPa);b. Deformed welded wire reinforcing (WWR) sheets; ASTM A497. Plain steel

(WWR) ASTM A185 and rolled WWR shall not be used.2. Reinforcing steel bars and WWR in concrete that is in contact with soil or exposed

to weather, salt, salt water, brackish water, seawater, or spray from these sources shall be FBECR conforming to the following:a. Deformed bar reinforcing; ASTM A755;b. Deformed welded wire reinforcing (WWR) sheets; ASTM A884.c. Damaged FBECR shall be repaired in accordance with ASTM A775 and A884

and the material manufacturer's recommendations.3. All reinforcing, including column and pedestal ties, shall be detailed in accordance

with ACI 315 "manual of standard practice for detailing reinforced concrete structures".


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5.4.4 Concrete Masonry Units

Concrete Masonry units shall be Type-1, Grade N with minimum assembly strength at 28 days f’m = 13.80 MPa; ACI 350-99; table 2.2.3.2. Mortar shall be Type N for interior walls and Type S for exterior walls. Grout shall have a minimum compressive strength at 28 days f’g = 13.80 MPa.

Concrete Masonry Units grout and mortar shall be according to the ASTM standard.

The interior masonry walls are non-load bearing walls and shall be designed with minimum steel.

Maximum L/T OR H/T shall be 18 for exterior wall and 36 for interior walls as per ACI 530 “Building Code Requirements for Masonry Structure” table 5.5.1.

5.4.5 Pre-Engineered Structural Steel

All structural steel shall confirm to the following codes and specifications.

1. All steel for hot-rolled structural shapes, plates and fittings shall confirm to ASTM A572 Grade 50 (fy = 50ksi or350 MPa).

2. All primary built up members shall confirm to ASTM A572 grade 50 (fy = 50ksi or 350 MPa) high grade steel plates.

3. All round steel rod members shall confirm to ASTM A615 Grade 300 (fy = 40ksi or300 MPa) round bars.

4. All cold-formed secondary steel members shall confirm to ASTM A607 or A653 fy = 50ksi or 350 MPa.

5. All primary bolted connections shall furnished with 20mm minimum diameter high strength bolts confirming to ASTM A325M, type-N; all hot dipped galvanized in accordance with ASTM A153 to a minimum weight of 915 g/m2 (130 micron). All bolts shall be tightened by procedure outlined in RCSC “Specifications for Structural joints using ASTM A325 or A490 Bolts”.

6. All high strength bolts shall be furnished with nuts and washers hot dipped galvanized in accordance with ASTM A153 to a minimum weight of 915 g/m2

(130 micron). Nuts for hight strength bolts shall confirm to ASTM A563M Grade DH. Washers for high strength bolts shall confirm to ASTM F436M.

7. All Anchor bolts shall confirm to ASTM F1554 Grade 36; double nut confirming to ASTM A563 Grade DH; and plate washers confirming to ASTM A436. All items shall be hot dip galvanized in accordance with ASTM A153 to a minimum weight of 915 g/m2 (130 micron). Nuts shall be tapped oversize as per ASTM A563M and shall be re-tapped and lubricated after galvanizing to provide the proper fit. All anchor bolts shall be furnished with nuts that confirm to ASTM A563 and washers confirming to ASTM F436M, or F844; all hot dip galvanized in accordance with ASTM A153 to a minimum weight of 915 g/m2 (130 micron).


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5.5 Design Criteria

5.5.1 Dead loads

Dead loads acting on a structure or a portion thereof shall consist of the vertical load due to the weight of all permanent structural and nonstructural components such as insulation, beams, bracing, fireproofing, and all fixed service equipment. Refer to ASCE 7, Chapter 3 for descriptions of dead loads and values of lateral soil loads.

Retaining walls shall have a minimum 15 kPa construction surcharge pressure applied to the high side (i.e., over the heel) of the wall. Refer to the Geotechnical Engineering Report(s) for lateral soil loads and design parameters and to ASCE 7, Chapter 3 for minimum values of lateral soil loads.

Refer to Royal Commission Engineering Manual, Chapter 9, Table 9A, 9B and ASCE 7, Chapter C3, Table C3-1 for weights and densities of various construction materials.

Following are the dead loads used in the design of building.

TABLE – 1Unit Weight of different Building MaterialsREINFORCEMENT CONCRETE 24.0 kN/m3

STEEL 77.32 kN/m3

Floor and Roof FinishesFloor Finish 2.00 kN/m²Roof Finish 3.50 kN/m²CMU Wall150 mm Masonry Wall 2.25 kN/m²200 mm Masonry Wall 3.00 kN/m²Roofing systemOverhanging Loads 0.75 kN/m²Rigid insulation — 1 50 mm thk. (13 mm thick @ 0.04 kN/m3)

0.48 kN/m²

PVC single ply sheet (0.06 in. thick) 0.03 kN/m²Gravel 50 mm thick layer 0.815 kN/m²Sloped screed (foam concrete) 2.36 kN/m²Sandwich Panel (109 mm thk) 0.113 kN/m²Sandwich Panel (84 mm thk) 0.108 kN/m²Sandwich Panel (74 mm thk) 0.105 kN/m²Ceiling (Suspended Ceiling)Acoustical fiber board 0.05 kN/m²Suspended steel channel sys. 0.10 kN/m²Provision for mechanical duct 0.19 kN/m²Provision for elec. lighting 0.05 kN/m²Fire sprinkler system 0.15 kN/m²


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Floor CoveringsCeramic or Quarry Tile (9 mm thk) on 25 mm thk mortar bed

0.52 kN/m²

Vinyl tile (6 mm thk) 0.05 kN/m²

5.5.2 Live Load

Live loads acting on a structure consist of loading not permanently fixed, but superimposed by use and occupancy. Live loads include those uniformly distributed and concentrated on floors, handrails, guardrails, vehicle barrier systems, ladders, and stairs from use, occupancy, operation, impact, and vibration. Refer to ASCE/SEI 7-05, Chapter 4 for descriptions and values of live loads for various uses, occupancies, and other conditions.

Following are the live loads used for the design of this building.

TABLE – 2Offices 2.40 kN/m²Halls & Prayer Area 5.00 kN/m²Corridors, Stairs, Balconies 5.00 kN/m²Mechanical & Electrical Rooms 7.50 kN/m²Roof (accessible) 2.00 kN/m²Roof Flat (inaccessible) 1.00 kN/m²Roof Sloped (inaccessible) 0.60 kN/m²PACU Units As per Manufacturer’s

5.5.3 Rain Load

Each portion of a roof shall be designed to sustain the load of all rainwater that will accumulate on it if the primary drainage system for that portion is blocked plus the uniform load caused by water that rises above the inlet of the secondary drainage system at its design flow. Refer to ASCE 7, Chapter 8 for descriptions of rain loads.

5.5.4 Crane Load

Strength and serviceability design criteria for crane loading shall be in accordance with the Royal Commission Engineering Manual, Chapter 9, Section 9.07.G and ASCE 7, Section 4.10.

5.5.5 Wind Load

All structures and foundations shall be designed and constructed to resist the wind effects determined in accordance with ASCE 7-05, Chapter 6, Method 2 – Analytical Procedure. The design wind load, F, on structures and elements thereof shall be


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assumed to act normal to the surfaces and shall be determined for any height and from any direction by the following formula:

F=qz G Cf Af, o Where the product of qz G Cf shall not be less than in 500 N/m2 Where:

qz= Velocity pressure at height z above the adjacent terrain at the centroid of Afqz= 0.613 Kz Kzt Kd V2 I in N/m2Exposure Category DKz= Velocity pressure coefficient = as per table 3-6 ASCE 7-05Kzt= Topographic factor=1Kd= Wind directionality factor =0.85I= Importance factor =1.15 determined from the Occupancy Category IIIV= Velocity = 43 m/s (155 kph)G= Gust-effect factor =0.85Cf= Force coefficient Af= Projected area normal to the wind, m2

o Displacements of the structures shall be considered using the displacements determined in an elastic analysis.

o The design story drift (Δi) shall be computed as the difference of the displacements at the center of mass at the top and bottom of the story under consideration.

o Δi/Li < 0.0025, where Li = Story height under consideration o Acceptable story drift shall also consider the parameters used in the design of the

cladding. Coordination between the structure design and cladding is critical.

5.5.6 Earthquake Load

All structures and foundations shall be designed and constructed to resist stresses produced by inertia forces induced by seismic ground motion in accordance ASCE 7 11.7 and the applicable provisions in Chapters 12, 14, and 15.

o Given data for Jubail Industrial City:I = Importance factor = 1.25 from Occupancy Category IIISite Class DSS = 0.15gS1 = 0.04gSeismic Design Category (SDC) = A

o Fx, the design lateral force applied at story x, shall be determined as:Fx = 0.01wx, where wx is the portion of the total dead load of the structure, D,

located or assigned to Level x.o Displacements of the structures and the potential for interacting effects shall be

considered using the amplified displacements obtained from the following formula: δx = Cdδxe/I Where: δx =Amplified deflectionCd =Deflection amplification factor


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δxe =Deflections determined in an elastic analysis using the strength level seismic forces (i.e., 1.0E, not 0.7E) of of ASCE 7 even when allowable stress design is used

I =Importance factor from Occupancy Categoryo The design story drift (Δi) shall be computed as the difference of the amplified

displacements at the center of mass at the top and bottom of the story under consideration. Δi/Li < 0.015, where Li = Story height under consideration.

o Acceptable story drift shall also consider the parameters used in the design of the cladding. Coordination between the structure design and cladding is critical.

5.5.7 Temperature Load

Self-restraining and Thermal Expansion and Contraction Loads: Building structures shall be designed with consideration for the loads and effects caused by restraining supports, contraction or expansion resulting from temperature changes, shrinkage, moisture changes, creep in component materials, differential settlement, and combinations thereof. Ambient temperatures range from a high of 50 degrees C to a low of 0 degrees C. In direct sunlight, the temperature of structures and components shall be assumed to rise a minimum of 15 degrees C above ambient. As a minimum, the temperature gradient for thermal loads should be +25 degrees C and -15 degrees C with the most severe condition governing the design.

5.5.8 Load Combinations

Building structures shall be designed and constructed to resist stresses produced by load combinations in accordance with ASCE/SEI 7-05, Chapters 2 and 12.

o Symbols and Notations:.D = Dead load, including load of empty piping and equipmentE = Seismic load effect, which shall include both Eh and Ev with ρ = 1.0 for

SDC = AF = Load due to fluidsH = Lateral earth pressure; groundwater pressureL = Live loadLr = Roof live loadR = Rain loadT = Self-restraining and thermal expansion and contraction loadW = Wind load

o Load Combinations for Factored Loads Using Strength Design: 1.4(D + F) 1.2(D + F + T) + 1.6(L + H) + 0.5 (Lr or R) 1.2D + 1.6(Lr or R) + (L or 0.8W) 1.2D + 1.6W + L + 0.5(Lr or R) (1.2 + 0.2SDS)D + 1.0E + L 0.9D + 1.6W + 1.6H (0.9 – 0.2SDS)D + 1.0E + 1.6H


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o Load Combinations for Nominal Loads Using Allowable Stress Design: D + F D + H + F + L + T D + H + F + (Lr or R) D + H + F + (0.75 (L + T) + 0.75(Lr or R) D + H + F + W (1.0 + 0.14SDS)(D)+ H + F + 0.7E D + H + F + 0.75W + 0.75L + 0.75(Lr or R) (1.0 + 0.105SDS)(D + H + F)+0.75(0.7)E+0.75L+0.75(Lr or R) 0.6D + W + H (0.6 – 0.14SDS)D + 0.7E + H

o Exceptions to Factored and Nominal Load Combinations: For Factored Load Combinations 3, 4, and 5, the load factor on L is permitted to

equal 0.5 for those occupancies in which L0 in Table 4-1 is less than or equal to 4.79 kPa, with the exception of garages or areas occupied as places of public assembly

Effects of one or more loads not acting in whole or in part shall be investigated. This includes patterning transient loads in continuous and cantilever framing.

Increases in allowable stress shall not be used with the load combinations given for allowable stress design.

E and W are permitted to be applied independently in each of two orthogonal directions and orthogonal interaction effects are permitted to be neglected.

Minus E and minus W directions shall be investigated. H shall be set equal to zero (-0-) if the structural action due to H counteracts that due

to W or E. When lateral earth pressure provides resistance to structural actions from other

forces, it shall not be included in H, but shall be included in the design resistance.

5.5.9 Stability against Overturning, Uplift, Sliding, and Buoyancy

Stability analyses shall demonstrate the ability of the structures to resist overturning, uplift, sliding, and buoyancy, and that the allowable soil bearing values are not exceeded. Stability shall be provided solely by dead load plus permanent mechanical anchorages. In determining the safety factors, allowance shall be made for the potential removal of resisting dead loads (i.e., excavation, erosion, etc.).

Retaining wall sliding resistance shall be developed by friction (and passive soil pressure where necessary) utilizing particularly detailed shear keys to engage the friction-resistance plane below the plane of the waterproofing and protection.

Following are the minimum factor of safety to be considered in design:

Sliding = 1.50 Overturning = 2.00 Uplift = 1.25


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5.5.10 Deflection

Structural systems and members shall be designed to have adequate stiffness to limit deflections and lateral drift.

The deflections of structural members shall not exceed the more restrictive of the limitations of IBC-2009, Sections 1604.3.2 through 1604.3.5 or that permitted by Table 1604.3.

5.5.11 Concrete Cover

5.5.11.1 Concrete Cover for Cast in situ Concrete

The table below defines minimum concrete cover measured from outermost rebar (tie bar) that shall be provided for reinforcement of cast in-place concrete structure.Concrete Exposure

Concrete in contact with soil;exposed to sea water; potableor treated water

Concrete exposed to weather:Columns, Walls and Beams

All sizes of barsSlab & Joists

All sizes of barsShells & Folded Plates

All sizes of barsAll welded Wire Fabric (WWF) Concrete exposed to interior, non-

air-conditioned environments below grade (e.g. interior of underground manhole)

All sizes of bars Concrete not exposed or not in

contact with soil or water:Columns and Beams

All sizes of barsSlab. Walls & Joists

All sizes of’ barsShells & Folded Plates

16 mm and larger barsAll Welded Wire Fabric (WWF)and bars smaller than 16 mm dia.

Minimum Cover(mm)

75

50

40

3030

75

40

25

25

20

Royal Commission Guideline Specification, Section 03205.


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5.5.11.2 Concrete Cover for Precast Concrete

The table below defines minimum concrete cover measured from outermost rebar (tie bar) that shall be provided for reinforcement of precast concrete.

Concrete Exposure Minimum Cover(mm)

Royal Commission GuidelineSpecification, Section 03205.

Concrete in contact with soil;exposed to sea water; potable or treated water

All sizes of bars Concrete exposed to weather:

Walls and Slab Panels;

75

30


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All sizes of barsAll other members

All sizes of bars Concrete exposed to interior,

non-air conditioned environmentsbelow grade;

All sizes of bars Concrete exposed to whether

and concrete not in contact with soil orwater of any type:

Slab, Walls and Joist;All sizes of bars

Beams and Columns;All sizes of bars

Shells and Folded Plates;1 6 mm and largersmaller than 16 mm and allWWF

High Strength Polymer GridAll exposure conditions

50

50

20

30

2020

20

5.5.12 Slab on Grade

Slab on grade shall be designed in accordance with Royal Commission Engineering Manual; Design Criteria Structural; chapter-9 (section 9.08 G.1.a) and ACI 360.

5.5.13 Soil Bearing Capacity

Maximum allowable soil bearing capacity for all types of footing shall be as per recommendations of geotechnical investigation report.

5.5.14 QA/QC Implementation

The quality control in all design phases shall be done in accordance the R.C Engineering Manual Chapter-9.

5.6 Safety

5.6.1 Safety Issues


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Emphasis is to be placed on safety both in designs and in constructions. Contractors, subcontractors, fabricators, suppliers, laborers, operators, drivers, and A/E's shall comply with the OSHA standards 29 CFR part 1910 - general industry, part 1917 - marine terminals, and part 1926 - construction industry.

General safety and health provisions - subpart 'C'. Occupational health and environment controls - subpart 'D'. Personal protective and life saving equipment - subpart 'E'. Fire protection and prevention - subpart 'F'. Safety signals and site access - subpart 'G'. Materials handling, storage, use, and disposal - subpart 'H'. Welding and cutting - subpart 'I'. Scaffolds - subpart 'L'. Fall protection - subpart 'M'. Crane, derricks, hoists, elevators, and conveyors- subpart 'N'. Excavation, embankment stability and temporary works - subpart 'P'. Concrete and masonry construction - subpart 'Q'. Overhead protection from power transmission services - subpart 'W'.

The contractor shall develop an emergency response and evacuation plan to the satisfaction of royal commission's ES&H staff.

5.6.2 Safety Improvement Solutions

Orientation seminars for all workers and equipment screening shall be initiated prior to commencement of work. Daily Tool Box meetings regarding work safety shall be held to update the personnel on the importance of safety issues.

5.7 Corrosion Protection

Reference Royal Commission Engineering Manual, Chapter 12 – Corrosion Control and Royal Commission Guideline Specification Sections 07130 – Sheet Waterproofing, 09970 – Coatings for Steel, and 09980 – Coatings for Concrete and Masonry. The atmosphere, soil, and water conditions in RAZMIC are severely corrosive. The

design and construction of foundations and superstructures shall include competent corrosion mitigation measures to achieve long-term durability. Contractors are obligated to adopt all Royal Commission-published corrosion-related documents.

Steel at interior, dry environments where the steel is not embedded in or connected to concrete:o Steel shall be cleaned in accordance with SSPC-SP6 "Commercial Blast

Cleaning" to produce sharp angular surface profiles as recommended by the paint manufacturer.

o Steel shall receive one shop coat of a two-component poly-amide cured epoxy primer containing zinc phosphate corrosion-inhibiting pigment applied as per the manufacturer’s instruction to produce a dry film thickness of 75 microns (3 mils) minimum. Omit shop primer at the following conditions:

o Within 75 mm of field welds, including field welded shear studs.


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o Faying surfaces of slip-critical (sc) connections.o Surfaces to receive spray-on-fireproofing.

Exterior steel, interior steel in wet environments, high-strength bolts, nuts, and washers for joints, anchor rods, nuts, and plate washers, and steel parts and accessories attached to or embedded in concrete:o Steel shall be cleaned in accordance with SSPC-SP8, "Pickling".o Steel shall be hot-dip galvanized (HDG) after fabrication to a minimum

weight of 915 g/m2 (130 microns) as per ASTM A123 and A153 as applicable.o For HDG steel intended to receive finish paint, the steel shall then be

cleaned in accordance with SSPC-SP7 "Brush off Blast Cleaning" to produce surface profiles recommended by the finish paint manufacturer.

Field Touch-Up: Primer and HDG coatings at all field weld areas, abraded areas, and all interior and exterior high-strength bolts, nuts, and washers shall be cleaned and coated as follows:o Steel cleaned as per SSPC-SP3 - Power-Tool cleaning or as

recommended by the paint manufacturer.o Steel shall receive one shop coat of a two-component poly-amide cured

epoxy primer containing zinc phosphate corrosion-inhibiting pigment applied as per the manufacturer’s instruction to produce a dry film thickness of 75 microns (3 mils) minimum.

Wherever possible, restrict the framing to eliminate steel-to-steel contact as described in the Royal Commission Engineering Manual, Chapter 12, Figures 12A and 12B.o Field welding is not permitted without specific Royal Commission approval

and only where bolting is not possible.o Superstructures shall be detailed to shed precipitation by toeing flanged

sections down and closing the ends of open sections. Structural concrete in contact with soil or exposed to weather, salt, salt water,

brackish water, seawater, or spray from these sources:o Comply with Royal Commission Guideline Specification Section 03310 –

Structural Concrete, Table 1C, Type C35 (as a minimum), and utilize silica fume as pozzolanic replacement.

o Reinforcing steel shall comply with Royal Commission Guideline Specification Section 03205 - Reinforcement for Concrete, fusion-bonded epoxy-coated reinforcing (FBECR).

o The concrete cover for reinforcing shall be 75 mm. Structural concrete formed against soil, including, but not limited to, slabs, footings,

walls, and grade beams, shall be cast on a 50 mm minimum thick blinding slab complying with Royal Commission Guideline Specification Section 03310 – Structural Concrete, Table 1C, Type C20 utilizing Type V Portland cement. The top surface of the blinding slab shall be waterproofed and the waterproofing protected prior to commencing any work on the structural concrete.o Blinding slabs under slabs-on-grade shall be cast on a 200 micron

minimum thick polyethylene vapor retarder with overlapped and waterproof-taped joints.


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As required by the Royal Commission Corrosion Specialist, structural concrete in contact with soil shall be protected by providing either:o Sheet membrane waterproofing and protection, sand-cement screed,

counter flashing, reglets, sealants, outside corner chamfers, and inside corner fillets for complete “tanking” of the concrete to comply with Royal Commission Guideline Specification Section 07130 – Sheet Membrane Waterproofing; or

o Coated to comply with Royal Commission Guideline Specification Section 09660 – High-Performance Coatings, Section 2.04.D.9b and as follows: Primer (two-component, solvent-free, amine-cured epoxy sealing primer),

which shall be thinned on-site as per the manufacturer’s recommendations; and

Intermediate and top coats (two-component, solvent-free, amine-cured coal tar epoxy), each coat 200 microns minimum thick with the total coating to result in a dry-film thickness (DFT) of 400 microns minimum.


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epc structure

Documents

structural steel

structural system

date contract

kamal kamal date

irfan irfan date

date irfan ali mohamed

jubail yanbu royal commission

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