Blue Water Iron Ore Terminal Pvt Ltd

10 Mtpa Iron Ore Terminal at Paradip

Structural Design Basis Report

May 2010

Alok Baishya
Prepared by:

B H Sharma / Rajendra Tarali

Reviewed by:

R Jayaraman
Issued by:

2 18-05-10 CES comments incorporated AB HS / RT RJ

Generally revised as per CES
1 23-04-10 AB RJ
comments
0 20-01-10 Preliminary AB RJ
Project
Rev Date Issue By Checked
Manager

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purpose previously advised to Ausenco Sandwell. The contents of this document are not to be relied upon or used, in
whole or in part, by or for the benefit of others without prior adaptation and specific written verification by Ausenco
Sandwell.

Particular financial and other projections and analysis contained herein, to the extent they are based upon assumptions
concerning future events and circumstances over which Ausenco Sandwell has no control, are by their nature uncertain
and are to be treated accordingly. Ausenco Sandwell makes no warranties regarding such projections and analysis.

Sandwell and its corporate affiliates and subsidiaries and their respective officers, directors, employees and agents
assume no responsibility for reliance upon this document or any of its contents by any party other than Ausenco
Sandwell 's client.

Copyright to this document is wholly reserved to Ausenco Sandwell.

1 General Design Criteria ......................................................................................................... 1
1.1 General 1

1.2 Design Goals 1

1.3 Codes and Standards 1

1.4 References 3

1.5 Units 3

1.6 Site Datum 3

2 Site Conditions ...................................................................................................................... 4

2.1 Location 4

2.2 Temperatures 4

2.3 Rainfall 4

2.5 Seismic 4

3 Structural Design Criteria...................................................................................................... 5

4 Design Loads, Load Combinations& Deflection .................................................................. 8
4.1 Design Loads 8

4.2 Load Combinations

10

4.3 Design Strength and Deflection

10

5. Design Methodology ........................................................................................................ 12

5.1 Method of Analysis
12

5.2 Method of Design

12

6. Materials ............................................................................................................................ 12
7. Painting ............................................................................................................................. 13

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1 General Design Criteria

1.1 General

This Structural Design Criteria has been prepared for the detailed design of the Port and Stockyard
Facilities for the proposed 10 MTPA Iron Ore facilities at Paradip Port.

The design and construction of structures shall be in accordance with the codes and standards
referred to in Design Criteria. Where no specific requirement is stated, the design and construction
shall meet or exceed the requirements of the latest edition codes and standards listed in the
following subsections. In case of conflict between standards and this Design Criteria, the more
stringent requirements shall apply.

Unless specifically stated otherwise, the design and construction of all work shall be based on the
applicable sections and latest revisions of the following codes, standards and regulations or
approved equivalents.

Design and construction shall be completed with minimum disruptions to the ongoing operations.
Any interruption required during construction shall be planned and scheduled in coordination with
Paradip Port Trust and Independent Engineer.

1.2 Design Goals

All design goals shall be tested against the following criteria:

Critical facilities to have a design safety margin appropriate for the perceived risk;

Maximize safety;

Use proven methods and materials and;

Compatibility with the other facilities planned for the project;

Maintainable designs;

Design life of the structures is to be not less than 50 years

1.3 Codes and Standards

Unless specifically stated otherwise, the design and construction of all structural work shall be
broadly based on the applicable sections and latest revisions (including reaffirmations) of the
following codes, standards and regulations.

IS: 800-2007 General Construction in Steel – Code of Practice

IS: 806-1968 Code of Practice for Use of Steel Tubes in General Building Construction

IS: 807-2006 Code of Practice for Design, Manufacture, Erection and Testing (Structural Portion)
of Cranes and Hoists

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 IS: 814-2004 Covered Electrodes for Manual Metal Arc Welding of Carbon and Carbon
Manganese Steel – Specification

IS 816-1969 Code of Practice for use of Metal Arc Welding for General Construction

IS: 875-1987 Code of Practice for Design Loads (other than Earthquake) for Buildings and
Structures

Part 1: Dead loads - Unit weights of building material and stored materials

Part 2: Imposed loads

Part 3: Wind Loads

Part 5: Special loads and load combinations

IS:1161-1998 Steel Tubes for Structural Purposes - Specification

IS:1239-2004/92 Steel Tubes, Tubulars and other Wrought Steel Fittings ( Part 1 and 2)

IS: 1893-2002/05 Criteria for Earthquake Resistant Design of Structures (Part 1 and 4)

IS: 2062-1999 Hot Rolled Low, Medium and High Tensile Structural Steel

IS: 3502-1994 Steel Chequered Plates – Specification

IS: 3757-1985 Specification for High Strength Structural Bolts

IS: 4000-1992 Code of Practice for High Strength Bolts in Steel Structures

IS: 5624-1975 Foundation bolts - Specification

IS: 7205-1974 Safety Code for Erection of Structural Steelwork

IS: 7215-1974 Tolerances for Fabrication of Steel Structures

IS: 9595-1996 Metal Arc Welding of Carbon and Carbon Manganese Steels – Recommendations

IS: 11592-2000 Selection and Design of Belt Conveyors - Code of Practice

IS:12778-2004 Hot Rolled Parallel Flange Steel Sections for Beams, Columns and Bearing Piles

IS:12843-1989 Tolerances for Erection of Steel Structures

SP: 6(1)-1964 Handbook for Structural Engineers – Structural Steel Sections

IS: 456 – 2000 Plain and Reinforced Concrete – Code of Practice

AWS American Welding Society, Structural Welding Code-Steel

AISC American Institute of Steel Construction, Manual of Steel Construction

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 ASTM American Society for Testing and Materials, Applicable Standards for Various
Tests and Materials

1.4 References

Geotechnical Investigation Report by Fugro Survey India Pvt. Ltd.

Topographical Survey by Bharat Consultants.

1.5 Units

All dimensions and elevations shall be to the International Metric System.

1.6 Site Datum

All level shall be referred as CD (Chart Datum). Site level varies as per topographical survey report.

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2 Site Conditions

2.1 Location

Paradip port is located 210 nautical miles south of Kolkata and 260 nautical miles North of
Vishakhapatnam.

Latitude: 20°-15’-55.44” N

Longitude 86°-40’-34.62” N

2.2 Temperatures

Maximum temperature 41.4ºC

Minimum temperature 8.9ºC

Relative humidity maximum 90 %

2.3 Rainfall

Maximum monthly rainfall 577.9 mm

Annual average rainfall 1427 mm

2.4 Wind

Basic wind speed (Vb as described in IS: 875: Part 3) 55 m/sec

Mean probable design life of structures (as per IS: 875: Part 3) 50 years

Terrain Category (as per IS: 875: Part 3) 2

2.5 Seismic

Zone III as per IS: 1893 Part 1 & Part 4

The dynamic effect of seismic force on the Structure would be calculated on the basis of established
standard method of modal analysis as given in IS 1893.

The design horizontal seismic coefficient, Ah = Z*I*Sa / (2* R*g)

Where

Z = Zone Factor (Table 2), Seismic Zone III = 0.16

I = Importance Factor (Table 6) = 1.75

R = Response Reduction Factor (Table 7) = Varies

Time Period in X-Direction (From STAAD) =” x “sec (say)

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 Sa/g = Average Response Acceleration Coefficient (Fig. 2) = “y” (Say)

Design Horizontal Seismic Coefficient, Ah = 0.16*1.75*y/2*R

Hence, Loads on structure due to earthquake in the X-Direction = Ah*W

Time Period in Z-Direction (From STAAD) =” x1 “sec (say)

Sa/g = Average Response Acceleration Coefficient (Fig. 2) = “y1” (Say)

Design Horizontal Seismic Coefficient, Ah’ = 0.16*1.75*y1/2*R

Hence, Loads on structure due to earthquake in the Z-Direction = Ah’* W

3 Structural Design Criteria

3. 1 Co n v e yo r S u p p o rt s

Conveyor galleries shall be open type with hood except for conveyors at stockyard and along berth
which shall be without hoods. Galleries shall be truss type structures with clear walkways of 750 mm
on either side of the single conveyor galleries. For double conveyor galleries, walkway at the two
outer sides shall have clear width of 750 mm along with a central walkway of 1000 mm clear width.
The walkway floors shall be of serrated gratings supported on structural sections. Conveyor galleries
supported on transfer towers or other structural types, supports shall be such that one end of each of
the galleries is free to move in the longitudinal direction.

Wharf Conveyors (ISC 9 & 10) at Ship loading berth will be supported on beams or truss type
framework, supported on trestles. Walkways for these shall be of serrated gratings and shall have
minimum 750 mm clear width. Ship loader tripper shall move on rails supported on the conveyor
structure. (One tripper on each conveyor)

Elevated conveyor galleries will rest on trestles. Trestles (including boxed type, as required as per
codal provisions) would be truss type with legs adequately braced for transferring the horizontal
forces to concrete pedestals/foundation on the ground.

Staircases shall be provided between side walkways from ground to ground for crossing over.
These crossovers on the conveyors will be provided at no more than 100 m intervals for conveyor
lengths more than 250 m. However, this will not be applicable for wharf conveyors. For Wharf
conveyors, access to walkways from the berth level shall be at the two ends of the conveyors.
Clearance between crossover platform on conveyor gallery and hood shall be minimum 150 mm.
Ladders (minimum width of 400 mm) shall extend from walkway floor to crossover platform level and
bolted to both the supporting frames. Rungs of ladder shall be of minimum 25 mm diameter rod (Tor
or Rebar). Crossover platform above conveyors shall have 750 mm clear width with hand railing and
kick plates with serrated gratings on floor. Crossover platform shall have adequate stiffness and
braced; and supported on posts at four corners which in turn would rest on conveyor walkway
supporting members. Clear width of conveyor walkway in the crossover zone shall not be less than
500 mm.

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 When conveyor galleries are supported on transfer towers or other structures, supports shall be such
that one end of each of the galleries is free to move in the longitudinal direction. All elevated
conveyors shall have hand railings (on outer faces) with kick plates for fall protection. Expansion
joints (due to temperature variation) in galleries shall be provided at appropriate intervals, wherever
applicable as per codal provisions.

All conveyors shall have deck plate of 10G (3.15 mm thk.), mild steel galvanised sheet, 6 m long at
the feed and discharge ends. Deck plates shall to be located on top of the stringer beam/supporting
frame and between carrying and return idlers. Seal plates shall be minimum 8 mm thick and shall
extend at a distance of minimum 3 m on either side beyond road width. It shall be located below the
return belt.

3. 2 T ran sf e r T o w ers

Transfer towers basic frame shall be double sloped (1:2.5) roof structure, adequately braced in the
longitudinal direction to transfer the horizontal forces to the foundation. Roof and side cladding
including trim and flashings, shall be fabricated from roll formed pre-finished zinc aluminum metal
2
sheeting to ASTM A653 structural quality grade, yield strength of 240 N/mm or better. Colour coated
trapezoidal profile steel sheet having bare thickness of 0.76 mm (0.8 mm TCT) and having minimum
depth of ribs as 35 mm. Side cladding would extend from underside of roof to the nearest working
floor from ground. Roof cladding shall sufficiently extend beyond the side cladding (not less than 300
mm) face to prevent ingress of water.

Translucent sheets, having the same width and profile as the steel sheets shall be provide at about 5
m intervals on roof for natural light during day time. Fixed louvers of size about 500 mm x 500 mm
shall be provided at 5 m intervals (on each side) on the side sheeting starting at about 1.2 m above
floor level, on all working floors for proper ventilation. Louver blades should be sloped to prevent
ingress of rain water inside the transfer tower. Any louver items having thickness less than 5 mm
shall be galvanised.

A minimum clear access of 1500 mm would be provided around the equipment on the floors.
Working Floors shall be covered with chequered plates which in turn would be fixed to supporting
members by using countersunk screws. Access to floor members from ground/grade slab shall be
by stairs having clear width of minimum 1000 mm. Slope of stairs shall not exceed 45° with
horizontal. Treads shall be of gratings (bolted to stringers) having 250 mm width and with riser not
exceeding 200 mm. Landing for stairs shall not exceed 3500 m in height and clear width shall not be
less than 1000 mm. Clear headroom at all places shall not be less than 2.2m. Columns and vertical
bracings would transfer all the loads (vertical and horizontal) to the foundation through base plates.

Monorails shall be supported from roof members to facilitate travel of hoists. Monorail shall
sufficiently extend outside the transfer tower side cladding for easy lowering and lifting of the biggest
equipment proposed.

Finished levels of all grade slabs shall be at least 200 mm above the FGL (finished ground level).
FGL shall be minimum 200 mm above the highest flood level. Underside of base plates of columns
at grade shall be 300 mm above the grade slab level.

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 Sheeting shall be provided in a manner to prevent ingress of rain water. At least one and a half
trapezoidal profile should overlap on each side. Silicon sealant tapes or better to be provided for all
joints. Connections to members shall be preferably with self tapping screws or better.

Penthouse between tunnel conveyors IRC-03 and IRC- 04 (from wagon tipper building) and transfer
tower shall be steel framed with roof and side (partial) side cladding as shown in GA drawing of the
relevant conveyors.

3. 3 W ag o n T ip p le r S h e d

A double bay steel superstructure shed of overall size of about 34m width x 36m long (to
accommodate 2 wagon tipplers) is envisaged. EOT cranes of 15 Tonne capacity shall be installed
inside the shed, one each in each of the bays. For details Wagon Tippling station GA may be
referred.

Roof shall have double sloped (1:2.5) framed structure with pre-finished zinc aluminium coated steel
2
sheeting to ASTM A653 structural quality grade 230 N/mm or better. Colour coated trapezoidal
profile steel sheet shall have bare thickness of 0.76 mm (0.8 mm TCT) and having minimum depth of
ribs as 35 mm. Side cladding would extend from underside of roof to a distance of about 0.9 m
above FFL(finished floor level) along the length of the building. Brick work would used as walling up
to 1 m height from floor level. On the gable ends side sheeting shall extend up to crane girder bottom
level from top of roof.

Translucent sheets, having the same width and profile as the steel sheets to match, and with
adequate thickness to withstand the forces shall be provided at 10 m intervals on roof for natural light
during day time.

Wind louvers shall be provided all along the length of building one each on each outer side at about
1.5 m from floor level, for proper ventilation and the projection should be in downward slope to
prevent ingress of rain water inside the wagon tippler shed.

The building frame shall comprise of roof supporting members which shall support roof sheeting,
purlins. It shall be either portal or truss/space truss type along with columns as pitch portal type
matching with roof slope of 1:2.5. Spacing of bays shall be decided on the most optimum design and
constructability of the structure and equipments located inside the building.

Roof members shall be adequately braced in plan for transfer of lateral forces. Columns along with
vertical bracings would transfer all the loads (vertical and horizontal) including crane wheel loads
from the crane girders to the pedestal through base plates and foundation bolts.

Ladders shall be provided at a suitable location in the building for access to EOT cranes. The ladder
shall extend from building floor to crane girder level and should be bolted at both ends. Safety hoops
shall be provided from 2.5 m above floor level

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3. 4 M ech an ic a l W o r ks h o p Sh ed
2
Wokshop shed shall be single bay having a minimum 840 m covered area. An EOT crane of 15 T
capacity is envisaged. Structural details almost similar to wagon tippler shed above except that the
gable ends shall be mostly covered. For location and size of the shed relevant G.A. drawing is to be
referred.

4 Design Loads, Load Combinations& Deflection

4.1 Design Loads

4.1.1 Dead Loads

Dead Loads shall include the weights of all permanent structural and non-structural components.
The weight of major permanent equipment, conveyor belting, idlers, cables, piping shall be treated
as dead load.

Conveyor Belting:

1.0 m wide polyester chord 0.25 kN/m

1.0 m wide steel chord 0.35 kN/m

1.4 m wide polyester chord 0.45 kN/m

1.4 m wide steel chord 0.50 kN/m

Conveyor Idlers:

1.0 m wide, carrying idler 0.40 kN @ 1 m spacing

1.0 m wide, return idler 0.3 kN @ 3 m spacing

1.4 m wide, carrying idler 0.72 kN @ 1 m spacing

1.4 m wide, return idler 0.45 kN @ 3 m spacing

Any other dead load not covered shall be considered as per IS: 875 – Part 1

4.1.2 Imposed Loads

Imposed Loads include the weights of the iron ore material, floor area loads, live loads, crane wheel
loads, equipment handling loads, and mobile equipment (e.g. Tripper). Impact loads shall be taken
as per relevant IS standards or from vendors data supplied. The floor area live load shall be omitted
from areas occupied by equipment whose weight is specifically included in dead load. Live load
shall not be omitted under equipment where access is provided.

Conveyors (material weight on carrying belts)

1.0 m wide belt 1.8 kN/m

1.4 m wide belt 4.2 kN/m

Stairs and Gratings/Chequered Plate platforms/walkways 5 kN/m2

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 Conveyor gallery walkways – for overall gallery design only 3.5 kN/m2

Allowance for piping & electrical 1.0 kN/m

Roof Live Load 0.5 kN/m2

Dust Load (on roof) 0.4 kN/m2

Any other imposed load not covered above shall be considered as per relevant Indian codes as
applicable.

Equipment Loads will include the weight given by the equipment supplier and the weight of product
as follows:

Equipment weight including piping, lining, monorails and platforms supported from the equipment
shall be treated as dead load.

Weight of product or material on conveyors, pipes etc and operating belt tension shall be treated as
operating live load

Clogging of chutes at transfer point and buffer effects shall be taken into consideration as per codal
provisions

Structures supporting conveyor pulleys shall be designed for the following:

- start-up belt tension = 1.5x operating belt tension

- stalled belt tension = 2.5 x operating belt tension

Tripper, Overhead Cranes and Hoist Loads

Critical wheels loads will be taken from vendor data considering lifting load, trolley weight and crane
weight for the cranes to be located in the wagon tippler building and mechanical workshop shed. For
the hoists, wheel load from vendor to be considered for design of supporting members.

Tripper wheel loads would be obtained from the ship loader vendor for design of the tripper and
conveyor supporting structures beside the berth.

4.1.3 Wind Loads

Same as 2.4

4.1.4 Seismic Loads

Same as 2.5

Temperature Loads would also be taken into consideration as applicable.

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4.2 Load Combinations

All structures shall be designed using the appropriate load factors and combinations as per relevant
codal provisions specified, not limited to the combinations indicated below as per Table 4 of IS: 800.

Limit State of Strength Limit State of Serviceability

Combination
1 1
DL LL WL/EL AL DL LL WL/EL

Leading Accomp- Leading Accomp

anying -anying

DL+LL+CL 1.5 1.5 1.05 - - 1.0 1.0 1.0 -

DL+LL+CL+ 1.2 1.2 1.05 0.6 - 1.0 0.8 0.8 0.8

WL/EL 1.2 1.2 0.53 1.2

DL+WL/EL 1.5 - - 1.5 - 1.0 - - 1.0

2
(0.9)

DL+ER 1.2 1.2 - - - - - - -

2
(0.9)

DL+LL+AL 1.0 0.35 0.35 - 1.0 * * - -

where, DL = Dead Load ; LL = Live Load ; WL = Wind Load ; CL = Crane Load (Vertical/Horizontal);
EL = Earthquake/Seismic Load ; ER = Erection Load ; AL = Accidental Load
1
When actions of different Live Loads are simultaneously considered, the leading Live Load shall be
considered to the one causing the higher load effect in the member/section.

Above Imposed/Live Loads can include: floor or walkway load + material load + belt tension + wheel
load, etc. – combination depending on the appropriate application.

4.3 Design Strength and Deflection

The structures shall be designed to have adequate design strength to withstand safely all loads likely
to act on it throughout its life in accordance with Limit State Design method as defined in IS: 800 &
good engineering practice.

Vibration check shall be done to ensure the separation of the fundamental mode structural frequency
from the machine frequency such as conveyor supporting trusses or beams, structures supporting
vibrating equipments, etc.

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 The recommended values are as follows:
2
Structural frequency ≤ /3 x machine frequency
1
Structural frequency ≥ 1 /2 x machine frequency
All structures shall be designed to accommodate the effects of thermal load.

Consideration would be undertaken for moving heavy items of equipment into place and consider
loading when mounting or replacing heavy items of equipment.

Deflections, stability shall be checked as per limit state of serviceability, using partial safety load
factors as mention in the table under 4.2.

Deflections of members due to dead load, live load, crane load and wind/seismic load shall not
exceed the following as applicable:

Monorail beams (lifting load and beam self wt.) span / 500

Floor grating (live load only) 6 mm (max.)

Floor beams (live load only) span / 300

Lateral deflection (gallery ) span / 500

Building drift height / 400

Lateral deflection (trestle) height / 1000 **

Vertical deflection (conveyor gallery and tripper) span / 500

Vertical deflection (Crane girder) span / 750

Cladding (wind load or live load) span / 180

Purlin and Girt (wind load or live load) span / 150

Equipment supports as specified by the equipment manufacturer

** However this can be relaxed per Conveyor vendor performance guarantees.

For any other deflection requirements, values indicated in IS: 800 or other relevant Indian Standards
would be taken into consideration.

All trusses shall be fabricated with a camber equal to the sum of the dead load and 50% of Imposed
load deflections.

Minimum factors of safety shall be provided as follows:

Overturning & sliding 1.5 under operating conditions.

1.2 under upset conditions including clogged chute and start-up or

stalled belt tension.

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 where, dead load provides restoring forces, the dead load factor shall be taken as 0.9

Any restoring forces due to Imposed Loads, Wind or Seismic action shall be ignored.

5. Design Methodology

5.1 Method of Analysis

Analysis shall be carried out by STAAD Pro or equivalent reputed software or by manual methods.

5.2 Method of Design

All steel members shall be designed by IS: 800 in Limit State Method. In case of any particular
requirement not available is Indian Standards, then AISC or other reputed Standards will be
consulted.

All structures/members shall be considered for the worst design load combinations for arriving at the
appropriate size satisfying strength and deflection requirements. Foundation Design shall be carried
as specified in the Civil Design Basis Report based on the worst Load Combination at the base plate
level (on top of pedestal) of the steel superstructure.

All foundation bolts shall be designed and selected considering concrete grade of M40 as per IS:
456, unless otherwise stated in Civil Design Basis Report.

6. Materials

Members and elements shall meet the following minimum thickness requirements unless indicated
otherwise:

Item Minimum Steel Thickness

Plates, stiffeners and gussets 8 mm

(Accessible to cleaning and repainting)

Plates, stiffeners and gussets 10 mm

(Not accessible to cleaning and repainting)

Flanges of rolled shapes, stems of tee and legs 8 mm

of angles, pipes.

Chequered plates (galvanised/ painted as per painting spec) 6 mm (galvanised)

7 mm (if painted)

Gratings - serrated (non-skid type) 5 mm thk x 30 mm depth (bearing bars)

(40 mm x 50 mm openings)

Colour coated (aluminium zinc alloy) steel sheets for cladding 0.76 mm (bare thk.)

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 Concrete (for pedestal) grade shall be M40 or as indicated in Civil Design Basis for relevant structure
under consideration.

Kick plates having minimum height of 100 mm above floor and shall be provided around all openings
on floors and edges. Stair treads shall be made of gratings. Posts and handrails shall be made from
minimum 32 NB (M) pipe. The height to the top of the handrail shall be 1,070 mm above finished
floor level. Two horizontal rails, shall be provided, one at top and the other 560 mm above finished
floor level. Posts shall be provided to resist 1 kN horizontal load applied at any point along to top rail
and spacing of vertical posts at a maximum spacing of 1500 mm.

Structural steel shapes, plates and bars shall be minimum ASTM A36 / IS: 2062 E 250 (Fe 410 W) or
approved equivalent.

Foundation bolts and minor connections (like hand railings) shall be minimum ASTM A307 / IS: 1367
(Cl. 4.6)

Main structural bolts shall be to ASTM A325 / IS: 1367 (Cl. 8.8).

In general, connections would be shop welded and site bolted. Bolted connections shall be of
bearing type only.

Pipes shall be to IS: 1161 / IS: 1239 with minimum 240 MPa yield strength.

Colour coated sheets for cladding shall have minimum 240 MPa yield strength.

All grating and chequered plates shall be of mild steel quality.

7. Painting

Surface preparation: Sa 2 ½

Primer coat: Inorganic Zinc Silicate 50 microns

Tie coat: Epoxy/Polyamide 25 microns
Intermediate coat 1:
Epoxy/Polyamide HB, Micaceous Iron Oxide 125 microns
Intermediate coat 2: Epoxy Polyamide HB 125 microns
Finish coat: Two component polyurethane 50 microns
Total minimum DFT 375 microns
Paint colour shall be Blue (greyish) conforming to RAL 7001 or equivalent as defined in IS: 5-1994
Shade 631.

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