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Calculation Sheet For Road and Paving - Rev 2 For Construction - 7 Agustus 2012
Calculation Sheet For Road and Paving - Rev 2 For Construction - 7 Agustus 2012
Calculation Sheet For Road and Paving - Rev 2 For Construction - 7 Agustus 2012
ALL RIGHTS
R RESERVED
D
FOR
R CONS
STRUCT
TION
THIS DOCUMENT T AND ANY DATA AND IN
NFORMATION CONTAINED THEREIN ARE CONFID DENTIAL
AND THE PROPERRTY OF MITSUBISHI HEAVY
H IND., APEX and REKIND AND THE COP PYRIGHT
THEREIN IS VEST
TED IN MITSUBISHI HE EAVY IND., APEX and REKIND
NO PART OF THIS B DISCLOSED TO OTHERS OR
S DOCUMENT, DATA OR INFORMATION SHALL BE
REPRODUCED IN ANY MANNER OR USED FOR ANY PURPOSE WHA ATSOEVER, EXCEPT WIT
TH THE
PRIOR WRITTEN PERMISSION OF MITSU UBISHI HEAVY IND., APEX
A and REKIND
C
CALCULAT
TION SHEET FOR
R
ROAD AND PA
AVING
DISTRI.
OWNER E
MHI E
APEX E
39 SHEETSS WITH COVER
REKIND 1
R
E
P
PROJECT
V QA/QC
I 7 A
AUG
S 2 2
2012 ISSUED FOR CONSTRU
UCTION P – PYMY – T – 1996
P3 P
PROCURE
I 19 JUNE S
SUBCONT
O 1 2
2012 ISSUEED FOR APPRO
OVAL P – PYMY – T – 1295
P3 DNM GB DWI SMP IWW
N APP’D APP’D COST
S NO
DA
ATE D
DESCRIPTION
N REFEREN
NCE SECTION PROJEECT TEAM SC
CHEDULE
MHI ORDER NO. CUSTOM
MER:
563420 P
PROCESS
PROJECT TEAM :
SAM
MUR PROJECTT EQUIP
APPROVED WA
AYAN WIJANA M
MACHINE
SA
AUT MAROLOP P PETRO
ONAS CHE
EMICALS FERTILISER
R SABAH SDN
S BHD F
FURNACE
PIPING
PROJEC
CT:
INSTRU
SECTION CIVIL S
SABAH AM
MMONIA UR
REA (SAMU
UR) PROJE
ECT
ELECT
APPROVED DW
WINOVIANTO S
CONTRA
ACTOR: ORIGINATOOR: MK (MHI-KL) CIVIL 1
MH
HI / APEX / REKIND DOC SIZE:: A (A4 SIZE
E)
CONST
PJT NO.: HC-T&C C/2010/0008
GA
ATOT BUDOYO
PCFSSB
B’S DWG. NO. : REV. SITE
SAM
MUR-REKIIND-CVS-C
CAL-91-00
0011 LICENSOR
DEESI NUR M
CONTRA
ACTOR’S DWG
G. NO. :
2 SPARE
TOTAL
DRAWN DATE 05‐‐MARCH‐2012
2 2
6419R
R C260-0
00011
JAPAN EXPORT CONTROL
On the conttrol List
9 Not on the control
c List
MH
HI – APEX – REKIND CO
ONSORTIUM
M
SHEET 2 OF 39
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6419R C260-00011
ROAD AND PAVING
Date By Chkd Apvd
07 – 08 - 12 DNM GB/ITF MDS/SMP
REVISION HISTORICAL SHEET
0 05 MARCH 2012 FOR APPROVAL
1 19 JUNE 2012 FOR APPROVAL
2 07 AUGUST 2012 FOR CONSTRUCTION
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CALCULATION SHEET FOR Doc. No. : 2
6419R C260-00011
ROAD AND PAVING
Date By Chkd Apvd
07 – 08 - 12 DNM GB/ITF MDS/SMP
Contents
1. GENERAL ............................................................................................................................................................................ 5
1.1. Outline Project and Scope ........................................................................................................................................ 5
1.2. Application Specification, Codes and Standards ...................................................................................................... 5
1.3. General Description ................................................................................................................................................. 5
1.4. Language .................................................................................................................................................................. 5
1.5. Unit of Measurement ............................................................................................................................................... 5
1.6. Computer Software .................................................................................................................................................. 5
2. ROAD AND PAVING GENERAL LAYOUT .............................................................................................................................. 5
3. HEAVY DUTY FLEXIBLE ASPHALT ROAD .............................................................................................................................. 5
3.1. Material Specification .............................................................................................................................................. 5
3.2. Traffic Load Data ...................................................................................................................................................... 5
3.3. Cumulative ESAL Traffic ........................................................................................................................................... 5
3.4. Thickness Design of Paving ...................................................................................................................................... 6
4. HEAVY DUTY RIGID CONCRETE PAVING ............................................................................................................................. 8
4.1. Material Specification .............................................................................................................................................. 8
4.2. Traffic Load Data ...................................................................................................................................................... 8
4.3. Thickness Design of Paving ...................................................................................................................................... 8
4.4. Material and Allowable Stress ............................................................................................................................... 10
4.5. Stress on Concrete Slab (σc) .................................................................................................................................. 10
4.6. Concrete Reinforcement ........................................................................................................................................ 11
4.7. Joint Connection Design ......................................................................................................................................... 12
5. LIGHT DUTY RIGID CONCRETE PAVING ............................................................................................................................ 12
5.1. Material Specification ............................................................................................................................................ 12
5.2. Traffic Load Data .................................................................................................................................................... 13
5.3. Thickness Design of Paving .................................................................................................................................... 13
5.4. Material and Allowable Stress ............................................................................................................................... 14
5.5. Stress on Concrete Slab (σc) .................................................................................................................................. 14
5.6. Concrete Reinforcement ........................................................................................................................................ 16
5.7. Joint Connection Design ......................................................................................................................................... 16
6. ATTACHMENTS ................................................................................................................................................................ 17
6.1. Attachment A – Road and Paving General Layout ................................................................................................. 17
6.2. Attachment B – Engineering Drawing (Road and Paving Detail Drawing) .............................................................. 18
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6.3. Attachment C – CBR Value For Each Layer Based on Soil Investigation Report and Traffic Data ........................... 19
6.4. Attachment D – Traffic Data .................................................................................................................................. 21
6.1. Attachment E – Correlation Between Standard Deviate (ZR) and Reliability (R).................................................... 23
6.2. Attachment F – The Value of Terminal Serviceability Level from PTS .................................................................... 24
6.3. Attachment G – Coefficient Layer for Flexible Paving ............................................................................................ 25
6.4. Attachment H – Drainage Coefficient for Flexible Paving ...................................................................................... 26
6.5. Attachment I – Detail Calculation for Flexible Pavement ....................................................................................... 29
6.6. Attachment J – Modulus Subgrade Reaction, k ..................................................................................................... 31
6.7. Attachment K – Formula Japan Road Association for CBRm ................................................................................... 32
6.8. Attachment L– K Value For Concrete Modulus of Rupture .................................................................................... 33
6.9. Attachment M – Load Transfer Coefficient ............................................................................................................ 34
6.10. Attachment N – Drainage Coefficient for Rigid Paving ...................................................................................... 35
6.11. Attachment O – Graphical Method For Determining Concrete Slab Thickness (D) – Heavy Duty Rigid Paving 36
6.12. Attachment P – Typical Axle Loads and Vehicle Dimension .............................................................................. 37
6.13. Attachment Q – z, Coefficient of Shrinkage ...................................................................................................... 38
6.14. Attachment R – Climate Condition, Normal Maximum and Minimum Temperature ....................................... 39
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6419R C260-00011
ROAD AND PAVING
Date By Chkd Apvd
07 – 08 - 12 DNM GB/ITF MDS/SMP
1. GENERAL
1.1. Outline Project and Scope
Project : SABAH AMMONIA UREA (SAMUR) PROJECT
Client : PETRONAS CHEMICALS FERTILISER SABAH SDN BHD
Location : SABAH, MALAYSIA
1.2. Application Specification, Codes and Standards
(1) Project Specification
6419M C200‐00100 : Design Criteria for Civil, Structure, Building, and Jetty Work
(2) Codes and Standards
PTS 34.13.20.31 : Petronas Technical Standard‐Roads, Paving, Surfacing, Slope Protection And Fencing
AASHTO GDPS 1993 : Guide Design of Paving Structure
ASTM : American Society for Testing and Material
1.3. General Description
This calculation covers the design of road and paving, which is consisting of heavy duty flexible road; heavy duty
concrete and light duty concrete paving. These road and paving are designed for design life with traffic load data
from Petronas Technical Standard.
1.4. Language
All drawings, calculations and documents shall be written in English
1.5. Unit of Measurement
Unit of measurement shall be in Metric and Imperial Units.
1.6. Computer Software
Applied computer software in this calculation :
(1) MS Excel
2. ROAD AND PAVING GENERAL LAYOUT
See Attachment A ‐ B.
3. HEAVY DUTY FLEXIBLE ASPHALT ROAD
3.1. Material Specification
a. Paving : Asphalt Concrete, EAC = 450000 psi
b. Base Course : Crushed Stone, compacted CBR 75% (see Attachment C)
c. Sub Base Coarse : Sandy Gravel, compacted CBR 30% (see Attachment C)
d. Sub grade : Compacted Soil to 95% max dry density
CBR = 5 % (see Attachment C)
3.2. Traffic Load Data
The traffic load data is based on data from process and from daily activity of office man (who using vehicle to
work). Especially for the data that is obtained from process engineering, the data as a production of chemical
substance. To obtain the daily traffic of truck (chemical vehicle), the production of chemical is divided by the
capacity of truck. So, it’s obtain the count of vehicle per day or month or year. (see Attachment D)
3.3. Cumulative ESAL Traffic
For cumulative ESAL traffic, it is used the formula below :
1
1
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365
Where :
LHR0 = daily traffic during construction period (n = 1 year, i = 1%)
LHR20 = daily traffic during analysis period (n = 20 year, i = 10%)
Wkip18 = the cumulative two directional 18‐kip ESAL units predicted for a specific section of highway
during the analysis period.
DD = a lane distribution factor
DL = a directional distribution factor
This is the summary of traffic data and cumulative ESAL :
3.4. Thickness Design of Paving
For thickness design of paving, it has to be designed :
Structural Number (SN) first. Based on AASHTO GDPS – 1993, the structural number can be obtained from the
equation below,
∆
9.36 1 0.20 4.2 1.5 2.32 8.07
1094
0.40
1 .
a. Reliability/Surface Condition (R)
For heavy duty roads, based on PTS it’ used R = 75%
b. Standard Normal Deviate (ZR)
From AASHTO GDPS 1993, there are relation between Reliability factor and standard normal deviate. It can
be used ZR = ‐ 0.674 (see Attachment E)
c. Combined Standard Error (S0)
From AASHTO, flexible paving has value S0 between 0.4 – 0.5.
It was taken S0 = 0.45
d. Serviceability Index (ΔPSI)
To determine the serviceability index, it has to be known initial serviceability (p0) and terminal serviceability
(pt). From AASHTO GDPS 1993 and PTS, for flexible paving, can be used p0 = 4.2 and pt = 2.5 (see Attachment
F). So, the serviceability index are ΔPSI = p0 ‐ pt = 1.7.
e. Resilient Modulus (MR)
Based on AASHTO GDPS 1993, to obtain resilient modulus of sub grade, can be used relation between CBR of
the sub grade. From the soil investigation, CBR value for sub grade = 5%.
MR = 1500 x CBR
MR = 7500 psi
Resilient Modulus for base and sub base layer also using the equation above.
So,
MR base = 112500 psi
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MR sub base = 45000 psi
f. Drainage Coefficient (m)
Based on AASHTO GDPS 1993, there are drainage coefficients for several condition. For good condition
(water removed within 1 day), and the percent of time pavement structure is exposed to moisture levels
approaching saturation greater than 25% (based on rainfall intensity on Sabah, Malaysia). It was taken m = 1.
(see Attachment H).
From equation above and axle movement equal to 3091 (W18), can be used goal seek to obtain structural number
(SN). It’s obtained SN = 0.116. (that is the structural number for sub base layer, for base course and surface layer
were in detail calculation, see Attachment I).
Asphalt concrete layer, total
Then, the thickness can be calculated after SN was obtained.
thickness, T=70 mm
Divided by 2 layers (1st layer,
during const. and 2nd layer as
final layer)
.
SN and D* units are in the imperial unit (inch).
D*1 was the thickness of flexible paving (asphalt concrete)
D*2 was the thickness of base course
m1,m2,m3 was drainage coefficient for each layer (surface, base course and sub base)
Layer Coefficient (a) for :
Paving : a1 = 0.44; EAC = 450000 psi (see Attachment G)
Base Course : a2 = 0.135;
Sub Base Course : a3 = 0.11;
Summary :
D1 = 1 in = 70 mm
D2 = 4 in = 100 mm
D3 = 4 in = 100 mm
Detail calculation, see Attachment I.
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ROAD AND PAVING
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4. HEAVY DUTY RIGID CONCRETE PAVING
4.1. Material Specification
2
a. Paving : Reinforced Concrete C‐25, fc’ = 210 kg/cm
b. Base Course : none
c. Sub Base Coarse : Sandy Gravel, CBR = 30% ; with thickness = 150 mm (see Attachment C)
d. Sub grade : Compacted Soil to 95% max dry density
CBR = 5 %
4.2. Traffic Load Data
The traffic load data for heavy duty paving is determined as :
• Production capacity of Loory Loading = 60 ton/hour
• Loory capacity = 10 ~ 15 ton, used 10 ton
• Traffic of loory = production capacity/loory capacity = 6 loory/hour
• For daily operation (assume operation hour = 12 hours) :
Traffic per day = 6 x 12 = 72 loory/day
Traffic for 20 years = 72 x 360 x 20 = 518400 cycle ≈ 600000 cycle
4.3. Thickness Design of Paving
Based on AASHTO GDPS – 1993, the thickness of concrete slab (D) can be obtained from the equation below,
∆ .
4.5 1.5
1.132
7.35 1 0.06 4.22 0.32
1.624 10 . 18.42
1 215.63
1 . / .
a. Reliability/Surface Condition (R)
For heavy duty roads, based on PTS it’ used R = 75%
b. Standard Normal Deviate (ZR)
From AASHTO GDPS 1993, there are relation between Reliability factor and standard normal deviate. It
can be used ZR = ‐ 0.674 (see Attachment E)
c. Combined Standard Error (S0)
From AASHTO, rigid paving has value S0 between 0.3 – 0.4.
It was taken S0 = 0.35 (average).
d. Serviceability Index (ΔPSI)
To determine the serviceability index, it has to be known initial serviceability (p0) and terminal
serviceability (pt). From AASHTO GDPS 1993 and PTS, for rigid paving, can be used p0 = 4.5 and pt = 2.5. So,
the serviceability index are ΔPSI = p0 ‐ pt = 2.
e. Modulus of Sub Grade Reaction (k)
The modulus of sub grade reaction was obtained from correlation with CBR value and Modulus Resilient
(see Attachment J), this correlation was based on plate test 30 in. This CBR value was representative CBR
for more layer below concrete slab. It was used the equation from Japan Road Association (see
Attachment K for detail equation) :
∑
∑
%
Where :
CBRi = CBR value in layer thickness hi
Σhi = taken up to a depth of 1.0 m
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ROAD AND PAVING
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CBRm = 10.3%
Modulus Resilient, MR = 2555 x CBR0.64 = 11365.585 psi
Modulus Subgrade Reaction,
= 585.855 pci = 16.216 kg/cm3
.
f. Concrete Modulus of Rupture (Sc’)
(psi)
where :
K = 7.5 ~ 10, it’s used K = 8 (see Attachment L)
Sc’ = 437.22 psi
= 30.74 kg/cm2
g. Concrete Elastic Modulus (Ec)
(psi)
6
Ec = 3.1 x 10 psi
= 2.18 x 105 kg/cm2
h. Load Transfer Coefficient (J)
From AASHTO GDPS 1993, the load transfer coefficient for continuously reinforced concrete paving
without tied joint (dowel bars) , it’s recommended J = 2.9 – 3.2. It was taken J = 3. (see Attachment M)
i. Drainage Coefficient (Cd)
Based on AASHTO GDPS 1993, there are drainage coefficients for several condition. For good condition, it
was taken Cd = 1. (see Attachment N)
From equation above and axle movement equal to 6 x 105 (W18), can be used goal seek to obtain thickness of slab
concrete (D). It’s obtained D = 131.4 mm (= 5.17 in).
From graphical method, the concrete thickness can be obtained with the value approximately same as with using
formula. (see Attachment O)
Used, D = 150 mm (minimum thickness of heavy duty paving based on design criteria)
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ROAD AND PAVING
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4.4. Material and Allowable Stress
4.5. Stress on Concrete Slab (σc)
Stress on concrete slab due to Wheel Load in any position (Westergaard Formula) :
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N SHEET
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64419R C260-000011
RO D PAVING
OAD AND
Date By Chkd A
Apvd
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DS/SMP
(Seee Attachment P
P)
4.6. Concrete Rein nforcement
Basically the steel wire funcction is to prevvent uncontrolle
ed cracking duee to stresses reesulting from su
uch effects as
shrinkage or thermal variations.
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ROAD AND PAVING
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The required percentage of steel are :
• Shrinkage Controlled
Minimum required ratio rebar to control shrinkage is :
100%
Where :
Es = Modulus of Elasticity Steel = 2.9 x 107 psi
6
Ec = Modulus of Elasticity Concrete = 3.12 x 10 psi
n = Equivalent Concrete Ratio, Es/Ec = 9.3
z = Coefficient of Shrinkage = 0.0008 (see Attachment Q)
Tc’ = Tensile Strength of Concrete = 0.4 to 0.5 Sc’, used Tc’ = 0.4 Sc’ = 174.886 psi
Used wiremesh for reinforcement,
Ts = Tensile Strength of Steel = 5100 kg/cm2 = 73969.23 psi (φ7 – 200#, British Standard)
So, ρs = 0.18031% → GOVERN
• Temperature Drop Controlled
Minimum required ratio rebar to control temperature drop is :
100%
∆
Normal Maximum condition = 36⁰C = 100 F Based on Basic Engineering Design Data
Normal Minimum condition = 10⁰C = 64 F (see Attachment R)
Total Temperature Drop, Δt = 36 F
Coefficient of Thermal Change, ε = 0.000005 in./in. per F
So, ρt = 0.12719%
• Slab Reinforcement
ρ = 0. 18031%
b = 1000 mm
So, the minimum required rebar :
As req. = ρ x b x h
As req. = 270 mm2
Provide :
Wiremesh M7 – 200 (two layers)
As = 385 mm2 (>As req.) → OK
4.7. Joint Connection Design
Transversal Joint Connection, no "Dowel Bar" is required (based on PTS and design criteria)
a. Expansion Joint
No need to put dowel for Expansion Joint, but just filling opening width with flexible jointing material.
Opening width, z = 20 mm
b. Contraction joint
No need to put dowel for Contraction Joint, but just using 25 x 25 mm timber crack inducer.
5. LIGHT DUTY RIGID CONCRETE PAVING
5.1. Material Specification
a. Paving : Reinforced Concrete C‐25, fc’ = 210 kg/cm2
b. Base Course : none
c. Sub Base Coarse : Sandy Gravel, CBR = 30%; with thickness = 30 mm (see Attachment C)
d. Sub grade : Compacted Soil to 95% max dry density
CBR = 5 %
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5.2. Traffic Load Data
For light duty paving, the traffic load is not calculated because the function of paving is for maintenance.
Therefore, just the forklift load that is calculated for paving load and there’s no traffic load.
5.3. Thickness Design of Paving
a. Modulus of Sub Grade Reaction (k)
The modulus of sub grade reaction was obtained from correlation with CBR value and Modulus Resilient
(see Attachment J for detail equation). This CBR value was representative CBR for more layer below
concrete slab. It was used the equation from Japan Road Association (see Attachment K for detail
equation) :
∑
∑
Where :
CBRi = CBR value in layer thickness hi
Σhi = taken up to a depth of 1.0 m
CBRm = 6.2 %
Modulus Resilient, MR = 1500 x CBR = 9298.614 psi
Modulus Subgrade Reaction,
= 479.31 pci = 13.2673 kg/cm3
.
b. Concrete Modulus of Rupture (Sc’)
(psi)
where :
K = 7.5 ~ 10, it’s used K = 8 (see Attachment L)
Sc’ = 437.22 psi
2
= 30.74 kg/cm
c. Concrete Elastic Modulus
(psi)
6
Ec = 3.1 x 10 psi
= 2.18 x 105 kg/cm2
Because there’s no traffic load, the light duty paving can’t be treated as a heavy duty paving. So, the thickness of
light duty paving was taken as a design criteria by PTS, minimum thickness of light duty paving = 100 mm.
So, used D = 100 mm.
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5.4. Material and Allowable Stress
5.5. Stress on Concrete Slab (σc)
Stress on concrete slab due to Wheel Load in any position, will be checked by Westergaard Formula :
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(See Attachment P)
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5.6. Concrete Reinforcement
Basically the steel wire function is to prevent uncontrolled cracking due to stresses resulting from such effects as
shrinkage or thermal variations.
The required percentage of steel are :
• Shrinkage Controlled
Minimum required ratio rebar to control shrinkage is :
100%
Where :
Es = Modulus of Elasticity Steel = 2.9 x 107 psi
Ec = Modulus of Elasticity Concrete = 3.12 x 106 psi
n = Equivalent Concrete Ratio, Es/Ec = 9.3
z = Coefficient of Shrinkage = 0.0008 (see Attachment Q)
Tc’ = Tensile Strength of Concrete = 0.4 to 0.5 Sc’, used Tc’ = 0.4 Sc’ = 174.886 psi
Used wiremesh for reinforcement,
2
Ts = Tensile Strength of Steel = 5100 kg/cm = 73969.23 psi (φ7 – 200#, British Standard)
So, ρs = 0.18031% → GOVERN
• Temperature Drop Controlled
Minimum required ratio rebar to control temperature drop is :
100%
∆
Normal Maximum condition = 36⁰C = 100 F Based on Basic Engineering Design Data
Normal Minimum condition = 10⁰C = 64 F (see Attachment R)
Total Temperature Drop, Δt = 36 F
Coefficient of Thermal Change, ε = 0.000005 in./in. per F
So, ρt = 0.12719%
• Slab Reinforcement
ρ = 0. 18031%
b = 1000 mm
So, the minimum required rebar :
As req. = ρ x b x h
As req. = 180 mm2
Provide :
Wiremesh M7 – 200 (single layer)
2
As = 192 mm (>As req.) → OK
5.7. Joint Connection Design
Transversal Joint Connection, no "Dowel Bar" is required (based on PTS and design criteria)
c. Expansion Joint
No need to put dowel for Expansion Joint, but just filling opening width with flexible jointing material.
Opening width, z = 20 mm
d. Contraction joint
No need to put dowel for Contraction Joint, but just using 25 x 25 mm timber crack inducer.
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6. ATTACHMENTS
6.1. Attachment A – Road and Paving General Layout
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6.2. Attachment B – Engineering Drawing (Road and Paving Detail Drawing)
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6.3. Attachment C – CBR Value For Each Layer Based on Soil Investigation Report and Traffic Data
Reference : Draft Geotechnical Investigation Report by IKRAM,page 28
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Crushed Stone
Sandy Gravel
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6.4. Attachment D – Traffic Data
vehicle/day
B Disposal WWT 345 lt/day Tank Truck cap. (lt) 4000 1
Lubricant 200 lt / day Tank Truck cap. (lt) 4000 1
2
C Entrance to Plant
Commissioning vehicle/3month
-MDEA 808,920 kg/3month Tank Truck (kg) 8000 127
-enriched aMDEA - kg/3month Tank Truck (kg) 8000 0
-Anti-foam 980 kg/3month Tank Truck (kg) 8000 1
-Pottasium Carbonate 112,000 kg/3month Tank Truck (kg) 8000 18
-Granule Urea 210,000 kg/3month Tank Truck (kg) 8000 33
-UF80 6,700,000 kg/3month Tank Truck (kg) 8000 1047
-Sulphuric Acid 741,960 kg/3month Tank Truck (kg) 8000 116
-Caustic Soda 1,653,728 kg/3month Tank Truck (kg) 8000 259
-Liquid Ammonia 560,000 kg/3month Tank Truck cap. (lt) 4000 175
-Liquid Nitrogen 200,000 kg/3month Tank Truck (kg) 8000 32
-Ethylene Glycol 5,600 kg/3month Tank Truck (kg) 8000 1
-Silicagel 1,720 kg/3month Tank Truck (kg) 8000 1
-Ammonium Sulfate 136,640 kg/3month Tank Truck (kg) 8000 22
-Diesel Oil 608,800 kg/3month Tank Truck (kg) 8000 96
-18% PAC 6,814 kg/3month Tank Truck (kg) 8000 2
-10% NaOCL 6 kg/3month Tank Truck (kg) 8000 1
-Sulphuric Acid for WWT 1,458,000 kg/3month Tank Truck (kg) 8000 228
-Caustic Soda for WWT 58,320 kg/3month Tank Truck (kg) 8000 10
-Alumunium Sulfate for WWT 1,678,320 kg/3month Tank Truck (kg) 8000 263
-Phosphoric Acid for WWT 1,296 kg/3month Tank Truck (kg) 8000 1
-Methanol 149,040 kg/3month Tank Truck (kg) 8000 24
-Polymer for Clarifier 3,888 kg/3month Tank Truck (kg) 8000 1
-Polymer for Dehydrator 38,880 kg/3month Tank Truck (kg) 8000 7
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Operation vehicle/year
-MDEA 50,400 kg/year Tank Truck (kg) 8000 8
-enriched aMDEA 16,380 kg/year Tank Truck (kg) 8000 3
-Anti-foam 500 kg/year Tank Truck (kg) 8000 1
-Pottasium Carbonate - kg/year Tank Truck (kg) 8000 0
-Granule Urea - kg/year Tank Truck (kg) 8000 0
-UF80 9,800,000 kg/year Tank Truck (kg) 8000 1532
-Sulphuric Acid 589,980 kg/year Tank Truck (kg) 8000 93
-Caustic Soda 1,386,864 kg/year Tank Truck (kg) 8000 217
-Liquid Ammonia - kg/year Tank Truck cap. (lt) 4000 0
-Liquid Nitrogen - kg/year Tank Truck (kg) 8000 0
-Ethylene Glycol - kg/year Tank Truck (kg) 8000 0
-Silicagel - kg/year Tank Truck (kg) 8000 0
-Ammonium Sulfate - kg/year Tank Truck (kg) 8000 0
-Diesel Oil - kg/year Tank Truck (kg) 8000 0
-18% PAC 2,920 kg/year Tank Truck (kg) 8000 1
-10% NaOCL 2 kg/year Tank Truck (kg) 8000 1
-Sulphuric Acid for WWT 972,000 kg/year Tank Truck (kg) 8000 152
-Caustic Soda for WWT 38,880 kg/year Tank Truck (kg) 8000 7
-Alumunium Sulfate for WWT 1,118,880 kg/year Tank Truck (kg) 8000 175
-Phosphoric Acid for WWT 864 kg/year Tank Truck (kg) 8000 1
-Methanol 99,360 kg/year Tank Truck (kg) 8000 16
-Polymer for Clarifier 2,592 kg/year Tank Truck (kg) 8000 1
-Polymer for Dehydrator 25,920 kg/year Tank Truck (kg) 8000 5
2213
To find the cycle of vehicle, the chemical production capacity is divided by capacity of vehicle (the efficiency of vehicle
capacity is not 100%, but just 80%). So it is obtain the cycle in vehicle/day.
The traffic data that is not in vehicle/day should be converted to vehicle/day. For commissioning, there is divided by 90
days and for operation, there is divided by 365 days.
The final traffic load data is summary from each activity (office building, disposal, entrance to plant). This summary is
multiplied by 2 because the assumption the production cycle of vehicle is back and forth. The traffic load data is given
below :
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6419R C260-00011
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6.1. Attachment E – Correlation Between Standard Deviate (ZR) and Reliability (R)
Reference : AASHTO GDPS – 1993; page I‐62
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6.2. Attachment F – The Value of Terminal Serviceability Level from PTS
Reference : Petronas Technical Standard, PTS 34.13.20.31; page 10
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6.3. Attachment G – Coefficient Layer for Flexible Paving
Reference : AASHTO GDPS – 1993; page II‐22
Reference : AASHTO GDPS – 1993; page II‐25
Based on rainfall intensity on
Sabah was 50% per year. And
the ground water level nears
the ground surface
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6.4. Attachment H – Drainage Coefficient for Flexible Paving
0.44
450000
Reference : AASHTO GDPS – 1993; page II‐18
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0.135
Reference : AASHTO GDPS – 1993;
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0.11
Reference : AASHTO GDPS – 1993;
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6.5. Attachment I – Detail Calculation for Flexible Pavement
Growth Rate, g = 10 %
Analysis Period = 20 years
DD = 50 % (2 Direction)
DL = 100 % (1 Lane)
W18 = 3.9E+03
CBR subgrade = 5 % (soil investigation)
CBR subbase = 30 %
CBR base = 75 %
R = 75 % (heavy duty roads‐PTS)
ZR = ‐0.674 (AASHTO)
S0 = 0.45 (AASHTO‐PTS)
p0 = 4.2 (AASHTO‐PTS)
pt = 2.5 (AASHTO)
MRbase = 112500 psi =1500*CBRbase
MRsubbase = 45000 psi =1500*CBRsubbase
MR subgrade = 7500 psi =1500*CBRsubgrade
log10W18 = 3.5911
by using formula from AASHTO, it can be obtained structural number for each layer (SN1, SN2 and
SN3) :
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a1 = 0.44 m1 = 1
a2 = 0.135 m2 = 1
a3 = 0.11 m3 = 1
SN1 = 0.116 in
D1* (asphalt concrete) = 0.3 in
used D1* = 0.8 in 20.32 mm (with minimum requirement from AASHTO that D1 = 1 in = 25.4, take used D1* = 70 mm based on standard drawing)
SN1* = 0.352 in
D2*(base course) = 0.4 in
used D2* = 3.0 in 76.2 mm (with minimum requirement from AASHTO that D2 = 4 in = 100, take used D1* = 100 mm )
SN2* = 0.405 in
Source : AASHTO GDPS‐1993 page II‐35
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6.6. Attachment J – Modulus Subgrade Reaction, k
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6.7. Attachment K – Formula Japan Road Association for CBRm
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6.8. Attachment L– K Value For Concrete Modulus of Rupture
Note :
MR in the formula above was equal to Sc’ in the calculation (Concrete Modulus of Rupture).
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6.9. Attachment M – Load Transfer Coefficient
Reference : AASHTO GDPS – 1993; page II‐26
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6.10. Attachment N – Drainage Coefficient for Rigid Paving
Reference : AASHTO GDPS – 1993; page II‐26
6.11. Attachment O – Graphical Method For Determining Concrete Slab Thickness (D) – Heavy Duty Rigid Paving
ATTACHMENT O
k = 585.85 pci R = 75%
Ec = 3.12 x 106 psi S0 = 0.45
Sc’ = 437.22 psi W18 = 6 x 105
J = 3 ΔPSI = 2
Cd =1
D = 5.6 in (≈ D from formula = 5.17 in)
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6.12. Attachment P – Typical Axle Loads and Vehicle Dimension
Reference : Petronas Technical Standard, PTS 34.13.20.31; page 15
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6.13. Attachment Q – z, Coefficient of Shrinkage
Tensile Strength of Concrete at 28 Days Shrinkage Coefficient,z
(PSI) (in/in)
≤ 300 0.0008
400 0.0006
500 0.00045
600 0.0003
≥ 700 0.0002
Reference : AASHTO GDPS 1993, page II‐29
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6.14. Attachment R – Climate Condition, Normal Maximum and Minimum Temperature
Reference : Basic Engineering Design Data, 6491M B212 – 00100 page 5