Ma'Aden Engineering Manual: Structural Design Criteria-Process Buildings and Structures

MA’ADEN ENGINEERING MANUAL
Structural Design Criteria- Process Buildings And

Structures
MD-101- SMEM-E G- ST-CRT-0001
Rev. Rev. Date Revision Status Prepared By Reviewed By Approved By Approved By

No. (Employer)
CO1 22 Feb 2012 Issued for Use K H Chong D Kirkwood R Covella
(Hatch) (Hatch) (Hatc_h)l
PROPRIETARY & CONFIDENTIAL

This document and the information contained herein is Ma’aden proprietary know-how. This document or any
part thereof should not be reproduced, stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without prior written permission of Ma’aden.
PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

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CONFIDENTIAL Doc No: MD-101-SMEM-EG-ST-CRT-0001
Rev CO 1 prepared for Ma’ aden by Hatch Associates. H337201-0000-35-122-0001_C

Ma’aden Engineering Manual Rev. Date: 22 Feb 2011
Design Criteria Rev: C01
Table of Contents
1. Introduction ....................................................................................................................................... 5
1.1 Scope ........................................................................................................................................ 5
1.2 Purpose ..................................................................................................................................... 5
2. Key Terms and Definitions ................................................................................................................. 5
3. Referenced Documents ...................................................................................................................... 6
3.1 Statutory Regulations ................................................................................................................. 6
3.2 Industry Codes and Standards .................................................................................................... 6
3.2.1 Local Codes and Standards ............................................................................................ 6
3.2.2 International Codes and Standards ................................................................................. 6
3.2.3 Alternative Design Codes ............................................................................................. 11
3.3 Ma’aden Standards .................................................................................................................. 11
4. General Design Criteria ................................................................................................................... 11
4.1 Design for Safety ...................................................................................................................... 11
4.2 Units of Measurement.............................................................................................................. 12
4.3 Design Life .............................................................................................................................. 12
4.4 Provision for Future Expansion................................................................................................. 12
4.5 Site Data .................................................................................................................................. 12
4.6 Materials .................................................................................................................................. 12
4.7 Temperature Range .................................................................................................................. 12
4.8 Drawings ................................................................................................................................. 12
4.9 Protective Coatings .................................................................................................................. 13
4.9.1 General ........................................................................................................................ 13
4.9.2 Steel Flooring ............................................................................................................... 13
4.9.3 Bolts ........................................................................................................................ 13
4.10 Clean Plant Design .................................................................................................................. 13
4.11 Electrical Requirements............................................................................................................ 13
5. Design Load Criteria ........................................................................................................................ 14
5.1 Dead Loads ............................................................................................................................. 14
5.2 Equipment Loads ..................................................................................................................... 14
5.3 Live Loads ............................................................................................................................... 15
5.4 Material Loads ......................................................................................................................... 16
5.5 Wind loads .............................................................................................................................. 16
5.6 Seismic Loads .......................................................................................................................... 16
5.7 Crane and Monorail Loads ....................................................................................................... 17
5.8 Thermal Loads ......................................................................................................................... 17
5.9 Earth Loads .............................................................................................................................. 18
5.9.1 Soil Properties .............................................................................................................. 18
5.9.2 Lateral Earth Pressures .................................................................................................. 18
5.9.3 Surcharge to Retaining Walls ....................................................................................... 18
5.10 Bin Loads ................................................................................................................................. 19
5.11 Vibrating Loads ........................................................................................................................ 19
5.12 Conveyor Loads ....................................................................................................................... 19
5.12.1 Belt Tensions ............................................................................................................... 19
5.12.2 Services on Conveyor Gantries .................................................................................... 19
5.13 Dust Loads ............................................................................................................................... 19

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5.14 Piping Loads ............................................................................................................................ 20

5.14.1 General ........................................................................................................................ 20
5.14.2 Pipe Rack Loads ........................................................................................................... 20
5.14.3 Process Pipe Loads ....................................................................................................... 21
5.15 Cable Tray Loads ..................................................................................................................... 21
5.16 Blast Loads .............................................................................................................................. 21
5.17 Impact Load ............................................................................................................................. 21
5.18 Miscellaneous Loads ................................................................................................................ 21
5.19 Load Combinations .................................................................................................................. 22
5.19.1 General ........................................................................................................................ 22
5.19.2 Conveyor Gantries ....................................................................................................... 22
6. Concrete Design Criteria .................................................................................................................. 22
6.1 Design Method ........................................................................................................................ 22
6.2 Materials and Standard Specification........................................................................................ 22
6.2.1 Concrete ...................................................................................................................... 22
6.2.2 Reinforcing and Embedded Steel .................................................................................. 23
6.2.3 Anchor Bolts ................................................................................................................ 23
6.2.4 Grout ........................................................................................................................ 23
6.3 Footings ................................................................................................................................... 24
6.3.1 Soil Condition and General Requirement ..................................................................... 24
6.3.2 Stability ........................................................................................................................ 24
6.3.3 Lateral Loads on Footings ............................................................................................. 24
6.3.4 Pedestals ...................................................................................................................... 25
6.3.5 Depth of Embedment into Ground ............................................................................... 25
6.3.6 Uplift Resistance .......................................................................................................... 25
6.4 Slabs on Ground ...................................................................................................................... 25
6.4.1 Design Procedure ........................................................................................................ 25
6.4.2 Slab Thickness ............................................................................................................. 25
6.4.3 Reinforcement in Slabs................................................................................................. 25
6.4.4 Slab Panel Sizes ........................................................................................................... 25
6.4.5 Waterproof Membrane ................................................................................................. 26
6.4.6 Drainage Slopes ........................................................................................................... 26
6.4.7 Process Bunded Areas .................................................................................................. 26
6.4.8 Joints ........................................................................................................................ 26
6.5 Concrete Pile Design ............................................................................................................... 26
6.6 Foundations for Heavy Machinery ........................................................................................... 26
6.6.1 General ........................................................................................................................ 26
6.6.2 Design Guidelines ....................................................................................................... 27
6.6.3 Design Details ............................................................................................................. 28
6.6.4 Sizing and shape of Dynamic Foundation .................................................................... 29
6.6.5 Vibration Absorbers ..................................................................................................... 30
6.6.6 Frequencies ................................................................................................................. 30
6.6.7 Damping ...................................................................................................................... 31
6.6.8 Applied Forces from Machinery ................................................................................... 31
6.6.9 Reinforcement ............................................................................................................. 31
6.6.10 Anchor bolts and grouting ............................................................................................ 32
6.6.11 Ground Modeling ........................................................................................................ 32
6.6.12 Steel Structures ............................................................................................................ 32
6.6.13 Vibration Isolating Foundations .................................................................................... 32
6.6.14 Soil Bearing Foundations ............................................................................................. 34
6.6.15 Pile Foundations .......................................................................................................... 34

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7. Structural Steel Design Criteria ........................................................................................................ 34

7.1 Design Method ........................................................................................................................ 34
7.2 Materials and Standard Specifications ...................................................................................... 35
7.2.1 Grades ........................................................................................................................ 35
7.2.2 Coefficient of Thermal Expansion ................................................................................. 35
7.2.3 Grating and Handrails .................................................................................................. 35
7.2.4 Purlins and Girts .......................................................................................................... 35
7.3 Member Slenderness Ratios ..................................................................................................... 35
7.3.1 Tension and Compression Members ............................................................................ 35
7.3.2 Beams ........................................................................................................................ 35
7.4 Transportation and Constructability ......................................................................................... 36
7.5 Connections ............................................................................................................................ 36
7.5.1 Philosophy ................................................................................................................... 36
7.5.2 Bolting ........................................................................................................................ 36
7.5.3 Welding ....................................................................................................................... 37
7.5.4 Beam End Connections ................................................................................................ 37
7.5.5 Column Splices ............................................................................................................ 37
7.5.6 Beam Splices................................................................................................................ 37
7.5.7 Base Plates ................................................................................................................... 37
7.5.8 Connection Design Loads ............................................................................................ 37
7.5.9 Dynamically Loaded Connections ................................................................................ 38
7.6 Bracing .................................................................................................................................... 38
7.7 Lateral Restraint of Flexural Members ...................................................................................... 38
7.8 Deflection and Displacement................................................................................................... 39
7.8.1 Process Buildings ......................................................................................................... 39
7.8.2 Crane Runway Beams .................................................................................................. 40
7.8.3 Portal Frame Buildings ................................................................................................. 41
7.9 Corrosion Considerations......................................................................................................... 41
7.10 Structures Supporting Vibrating Equipment .............................................................................. 41
7.11 Cold Formed Steel Purlins and Girts ........................................................................................ 42
7.12 Steel Bins, Bunkers and Tanks .................................................................................................. 42
7.13 Design of Conveyor Structures ................................................................................................. 43
7.13.1 Conveyor Gantries ....................................................................................................... 43
7.13.2 Deflection Criteria........................................................................................................ 43
7.13.3 Connection of Conveyor Trusses to Buildings .............................................................. 44
7.13.4 Conveyor Trestles ........................................................................................................ 44
7.14 Cranes and Monorails .............................................................................................................. 44
7.15 Stacks and Chimneys ............................................................................................................... 45
7.16 Steel Pile Design ...................................................................................................................... 45

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1. INTRODUCTION
1.1 Scope
This document provides structural design criteria for process buildings and structures for all
Ma’aden projects.
This document is intended to be used in conjunction with the applicable documents listed
herein.
1.2 Purpose
The design criteria is to:
• Establish a common basis for structural discipline design of process building and
structures for all Ma’aden projects
• Set the minimum engineering standards and requirements.
2. KEY TERMS AND DEFINITIONS

Employer Saudi Arabian Mining Company (Ma’aden) and its authorized
representatives and respective affiliates
Contractor Party responsible for supplying engineering services, materials, plant,

labor and supervisory services
SBC Saudi Building Code
SASO Saudi Arabian Standards Organization
ACI American Concrete Institute
AISC American Institute of Steel Construction
API American Petroleum Institute
ASCE American Society of Civil Engineers
ASME American Society of Mechanical Engineers
ASSE American Society of Safety Engineers
ASTM American Society for Testing Materials
AWS The American Welding Society
BEDD Basic Engineering Design Data
BS British Standards
CMAA Crane Manufacturers Association of America
CICIND Comité International Des Cheminées Industrielles (International

Committee on Industrial Chimneys)
ISO International Organization for Standardization

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PCI Precast/Prestressed Concrete Institute
SDI Steel Deck Institute
SJI Steel Joist Institute
3. REFERENCED DOCUMENTS
This specification requires compliance with the provisions of the latest revision of the
relevant standards or codes of the following authorities and technical organizations, as
applicable, and specifications which shall be considered to form part of this specification,
where applicable.
3.1 Statutory Regulations
All work performed and materials furnished shall comply with the applicable statutory
regulations, codes and other requirements of the Kingdom of Saudi Arabia (including but not
limited to directives of the High Commission for Industrial Security, Royal Commission
regulations applicable to the Site, regulations of the Presidency of Meteorology and
Environment, Saudi Building Code and other applicable codes and regulations). The
Contractor shall ensure that he is fully aware and informed of all Government laws, local
ordinances, regulations and all orders and decrees of bodies or tribunals having any
jurisdiction or authority over the Project and/or Site, which in any manner affect the Project
and those engaged or employed on the Project, or which in any way affect the conduct of
the Work. The Contractor shall at all times observe and comply with all such Government
and/or Ministry laws, bylaws, ordinances, codes, regulations, orders and decrees.
3.2 Industry Codes and Standards
All equipment and systems shall conform to the following:
3.2.1 Local Codes and Standards
Saudi Building Code: SBC 301 Structural Loading and Forces
Saudi Building Code: SBC 302 Structural Testing and Inspection
Saudi Building Code: SBC 303 Structural Soil and Foundations
Saudi Building Code: SBC 304 Structural Concrete Structures
Saudi Building Code: SBC 305 Structural Masonry Structures
Saudi Building Code: SBC 306 Structural Steel Structures
SASO SSA 2 Steel Bars for the Reinforcement of Concrete
SASO SSA 224 Steel Fabric for Reinforcement of Concrete
3.2.2 International Codes and Standards
ACI 117 Standard Specifications for Tolerances for Concrete

Construction and Materials

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ACI 201.2R Guide to Durable Concrete
ACI 212.3R Chemical Admixtures for Concrete
ACI 301 Specifications for Structural Concrete
ACI 302.1R Guide for Concrete Floor and Slab Construction
ACI 304R Guide for Measuring, Mixing, Transporting and

Placing Concrete
ACI 304.2R Placing Concrete by Pumping Methods
ACI 305R Hot Weather Concreting
ACI 308 Standard Practice for Curing Concrete
ACI 308R Guide to Curing Concrete
ACI 309R Guide for Consolidation of Concrete
ACI 318M Building Code Requirements for Reinforced Concrete
ACI 318/318R Building Code Requirements for Structural Concrete
ACI 347 Guide to Formwork for Concrete
ACI 350 Code Requirements for Environmental Engineering

Concrete Structures
ACI 351.3R Foundation for Dynamic Equipment
ACI 360R Guide to Design of Slab on Grade
ACI 440.1R Guide for the Design and Construction of Concrete

Reinforced with FRP Bars
ACI 504R Guide to Sealing Joints in Concrete Structures
ACI 515.1R Guide to the use of Waterproofing, Damp-proofing,

Protective and Decorative Barrier Systems for
Concrete
ACI 530/ASCE 5/TMS402 Building Code Requirements for Masonry Structures
ACI SP-66 Detailing Manual – Details and Detailing of Concrete

Reinforcement
AISC LRFD Manual of Construction Load and Resistance Factor Design
API 650 Welded Steel Tanks for Oil Storage
ASCE 7-05 Minimum design loads for buildings and other

structures

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ASCE Guidelines for Seismic Evaluation and Design of

Petrochemical Facilities
ASCE 20-96 Standard Guidelines for the Design and Installation of

Pile Foundations
AISC Load and Resistance Factor Specification for Structural Steel Buildings
Design
AISC Manual of Steel Constructions Load Resistance Factor Design
AISC Manual of Steel Constructions Volume II Connections
AISC Specification for Structural

Joints Using ASTM A325 or ASTM
A490 Bolts
ANSI/AISC 341 Seismic Provisions for Structural Steel Buildings
AISI –SG 673, Part I Specification for the Design for Cold-Formed Steel
Structural Members
AISI –SG 673, Part II Commentary on the Specification for the Design for
Cold-Formed Steel Structural Members
AISI – SG 913, Part I Load and Resistance Factor Design Specification for
Cold-Formed Steel Structural Members
AISI – SG 913, Part II Commentary on the Load and Resistance Factor

Design Specification for Cold-Formed Steel Structural
Members
ANSI A1264.1 Safety Requirements for Workplace Walking/Working

Surfaces and Their Access – Workplace Floor, Wall
and Roof Openings – Stairs and Guardrails Systems
SEI/ASCE 37-02 Design Loads on Structures During Construction
ASME A17.1 Safety Code for Elevators and Escalators
ASME B30.2 Overhead and Gantry Cranes (Top Running Bridge,

Single Girder, Under Hung Hoist)
ASME B30.11 Monorails and Under Hung Cranes
ASME B30.17 Overhead and Gantry Cranes (Top Running Bridge,

Single Girder, Under Hung Hoist)
ASSE PROTECTION Introduction of Fall Protection
ASTM A36/A36M Standard Specification for Carbon Structural Steel
ASTM A123 Standard Specification for Zinc (Hot-Dip Galvanized)

Coatings on Iron and Steel Products
ASTM A153 Specification for Zinc Coating (hot-dip) on Iron and
Steel Hardware

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ASTM A193/A193M Standard Specification for Alloy-Steel and Stainless

Steel Bolting for High Temperature or High Pressure
Service and Other Special Purpose Applications
ASTM A307 Standard Specification for Carbon Steel Bolts and

Studs, 60,000 psi Tensile Strength
ASTM A325 Standard Specification for Structural Bolts, Steel, Heat

Treated, 120/105 ksi Minimum tensile Strength
ASTM A325M Standard Specification for Structural Bolts, Steel, Heat-

Treated 830 MPa Minimum Tensile Strength [Metric]
ASTM A354 Standard Specification for Quenched and Tempered

Alloy Steel Bolts, Studs, and Other Externally
Threaded Fasteners
ASTM A490 Standard Specification for Structural Bolts, Alloy Steel,

Heat Treated, 150 ksi Minimum Tensile Strength
ASTM A490M Standard Specification for High-Strength Steel Bolts,

Classes 10.9 and 10.9.3, for Structural Steel Joints
(Metric)
ASTM A572/A572M Standard Specification for High-Strength Low- Alloy
Columbium-Vanadium Structural Steel
ASTM A767 Standard Specification for Zinc-Coated (Galvanized)

Steel Bars for Concrete Reinforcement
ASTM A775 Standard Specification for Epoxy-Coated Reinforcing

Bars
ASTM A884 Standard Specification for Epoxy-Coated Steel Wire

and Welded Wire Fabric for Reinforcement
ASTM A992/A992M Standard Specification for Structural Steel Shapes
ASTM C39 Compressive Strength of Cylindrical Concrete

Specimens
ASTM C55 Specification for Concrete Brick
ASTM C90 Specification for Load Bearing Concrete Masonry

Units
ASTM C129 Specification for Non-Load Bearing Concrete Masonry

Units
ASTM C309 Standard Specification for Liquid Membrane-Forming

Compounds for Curing Concrete

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ASTM C618 Standard Specification for Coal Fly Ash and Raw or
Calcined Natural Pozzolan for Use in Concrete
ASTM C979 Standard Specification for Pigments for Integrally

Colored Concrete
ASTM C1240 Standard Specification for Silica Fume Used in

Cementitious Mixtures
ASTM D1751 Standard Specification Preformed Expansion Joint

Filler for Concrete Paving and Structural Construction
ASTM D1752 Preformed Sponge Rubber and Cork Expansion Joint

Fillers for Concrete Paving and Structural Construction
AWS D1.1/D1.1M Structural Welding Code – Steel
BS 11 Specification for Railway Rails
BS EN 13674 Railway Applications – Track – Rail
CMAA Spec No.70 Specification for Top Running Bridge and Gantry Type
Multiple Girder Electric Overhead Travelling Cranes
CMAA Spec No.74 Specifications for Top Running and Under Running
Single Girder Electrical Overhead Cranes Utilizing
Under Running Trolley Hoist
Guide to the Design of Concrete Structures in the
Arabian Peninsula
Guide to the Construction of Reinforced Concrete

Structures in the Arabian Peninsula
IBC International Building Code
Eurocode 3/BS EN 1993-4-1:2007 Design of Steel Structures Part 4-1: Silos
ISO 5048 Continuous mechanical Belt conveyors with carrying idlers -- Calculation of
handling equipment operating power and tensile forces
ISO 5049-1 Mobile Equipment for Rules for the Design of Steel Structures
Continuous Handling of Bulk
Materials
ISO 585:1997 Mechanical vibration and shock – Human Exposure –

Vocabulary.
ISO 2631-1 Mechanical vibration and shock -- Evaluation of

human exposure to whole-body vibration -- Part 1:
General requirements

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ISO 2631-2 Mechanical vibration and shock -- Evaluation of

human exposure to whole-body vibration -- Part 2:
Vibration in buildings (1 Hz to 80 Hz)
PCI - MNL 120 Design Handbook, Precast and Pre-Stressed Concrete
PCI - MNL 122 Architectural Precast Concrete
SDI Design Manual for Composite Decks, Form Decks and

Roof Decks
SJI Standard Specification and Load Tables for Steel Joists
and Joist Girders
3.2.3 Alternative Design Codes
Alternative design codes may be used for structural design if approved by Employer.
3.3 Ma’aden Standards
MD-101-SMEM-EG-ST-SPC-0001 Steel Fabrication

MD-101-SMEM-EG-ST-SPC-0002 Steel Erection
MD-101-SMEM-EG-ST-SPC-0004 Pre-Mixed Concrete
MD-101-SMEM-EG-ST-SPC-0005 Concrete Work
MD-101-SMEM-EG-ST-SPC-0006 Steel Reinforcing Bars and Wire Fabric
MD-101-SMEM-EG-ST-SPC-0007 Concrete Block Masonry
MD-101-SMEM-EG-ST-SPC-0008 Protective Coating of Structural Steelwork
MD-101-SMEM-EG-ST-SPC-0009 Protective Coating for Concrete
MD-101-SMEM-EG-CV-SPC-0002 Anchor Bolts
MD-101-SMEM-EG-AR-CRT-0001 Architectural Design Criteria
MD-101-SMEM-EG-CV-CRT-0001 Civil Design Criteria – General
MD-101-SMEM-EG-EL-CRT-0001 Electrical Design Criteria
4. GENERAL DESIGN CRITERIA

4.1 Design for Safety
The safe construction, operation, maintenance and demolition of structures shall be held as
paramount throughout the design process. The designer has a responsibility to provide a
design that is safe to construct/operate/dismantle/demolish.
Some safety in design principles to apply to structural design include:
1. Detailing structures to allow for safe construction and demolition, such as:
▪ Specifying temporary bracing requirements and support requirements

▪ Including a minimum number of bolts per column base to enhance stability
during erection
▪ Using bolted joints instead of welded joints where a structure is to be
dismantled.

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2. Inclusion of restraints/anchorages for fall arrest systems, designed in accordance with

ASSE PROTECTION. The required locations for such restraints shall be investigated
by the Design Engineer in consultation with other discipline engineers. Anchorages
are typically required on all structural columns above each floor level, and also at
roof high-points.
3. Provision of tested lifting lugs on large pre-assemblies to facilitate safe cranage and
installation.
4. Thorough multi-discipline 3D layout reviews to ensure that adequate access/egress

routes are provided, required clearances are achieved, and to generally identify and
mitigate as much as possible any potential safety issues.
5. Provision of walls/barriers with acceptable fire ratings in appropriate locations.

4.2 Units of Measurement
All calculations, drawings and other structural engineering deliverables for the project shall
be carried out using the Standard International (SI) unit system.
4.3 Design Life
The design life shall be as specified in the Project Basis of Design.
4.4 Provision for Future Expansion
Provision for future expansion shall be as specified in the Project Basis of Design.
4.5 Site Data
For general site conditions refer to Project Site Data Specification.
4.6 Materials
The selection of appropriate materials of construction is critical in facilities with corrosive
environments, and appropriate selections must be made to ensure durability and minimal
site works, and to facilitate future demolition.
In general, above-ground structures shall be fabricated from structural steel and foundations
constructed from reinforced concrete, except for the possibility of using steel piles. Flooring
shall be steel grating or floor plate, with grating preferred except where material containment
is required. Suspended concrete slabs shall be avoided.
4.7 Temperature Range
Temperature range, as specified in the site data specification, shall be adopted for structural
design, unless approved otherwise by the Employer.
4.8 Drawings
Design uniform floor live loads shall be clearly indicated on the general arrangement
drawings as kPa (kN/m2).
Reference shall be made, on the general arrangements or the general notes drawing to the
appropriate protective coating system to be used. Note that this applies to concrete as well
as structural steel.

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4.9 Protective Coatings

4.9.1 General
Protective coatings and surface treatments for all steel and concrete works shall be in
accordance with the following specifications:
• MD-101-SMEM-EG-ST-SPC-0008 Protective Coating of Structural Steelwork
• MD-101-SMEM-EG-ST-SPC-0009 Protective Coating for Concrete

4.9.2 Steel Flooring
Plate flooring shall be shop painted, using the applicable paint specification. Where a floor
plate is specified as requiring site perimeter welding, its edges shall be covered with tape so
as to prevent painting for a width of approximately 50 mm. This tape shall be removed prior
to installation of the plate, and painting touched-up after completion of site-welding.
Likewise, the weld zones on the support beams shall be left unpainted in the shop.
4.9.3 Bolts
All bolts shall be supplied galvanized or zinc coated, as per ASTM A153.
4.10 Clean Plant Design
The main emphasis of Clean Plant Design (CPD) for structural engineering is to minimize
horizontal flat surfaces where dust will accumulate and become entrained. The following
summarizes the recommended structural design features and details:
a) To contain spills and facilitate clean up, generally steel plate floors shall be used under
all equipment that has the potential to spill material.
b) High strength steel shall be used to minimize flange widths and number of members.
c) Preference should be given to larger column spacing so as to have fewer members and
therefore less dust accumulation.
d) Process areas shall be individually bunded for containment.
e) Floors beneath process areas shall be appropriately sloped to collect spills and wash
water.
f) Stairwells are to be located outside of buildings in order to isolate them from the main
process areas.
g) Sumps shall be designed to allow for the collection and recycling of spills.
4.11 Electrical Requirements
The Electrical Engineer shall advise requirements for earthing and lightning protection for all
buildings and structures. This may include the provision of lugs at the bases of steel
columns, and/or bonded concrete reinforcement. The requirement shall comply with
MD-101-SMEM-EG-EL-CRT-0001, Electrical Design Criteria.

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5. DESIGN LOAD CRITERIA

5.1 Dead Loads
Dead loads shall be determined using SBC 301 Structural – Loading and Forces, and shall be
considered in two categories:
• Dead loads unable to be removed from the structures
• Superimposed dead loads.
Superimposed dead loads are defined as the weight of all materials forming static loads on
the structure, that are not structural elements, and which are likely to vary or be removed
during operation or construction. Superimposed dead loads such as weight of fluid or solids
in tanks, piping, chutes and equipment including cranes, lay down loads, equipment
handling, lateral earth pressure, overloads due to blocked pipes, chutes and equipment shall
be considered. Provision shall be made for spillages and equipment overload.
The design engineer shall assess the possibility of the removal of superimposed dead loads
which will result in the most severe combination of design actions on the structure. The
designer shall also consider the possibility of adding temporary dead loads during a repair.
Process piping, ducts or major electrical runs shall be individually assessed in each case,
with their design information obtained in writing from the respective discipline engineers.
The loads associated with hydrostatic pressure may be considered as dead load provided that
the full head (i.e. height of tank including freeboard or top of retaining wall) is used in
calculating the pressure.
5.2 Equipment Loads
Equipment load means the weight of equipment and its appurtenances supported by a
structure and shall be classified as follows:
a) Equipment load for erection means the load of the equipment during erection and, in
many cases, does not include the weights of internals, fluids and solids within the
equipment, nor the insulation, platforms and piping to be attached to the equipment.
b) Equipment load for operation means the load of the equipment during normal operating
conditions and includes weights of internals, fluids and solids within the equipment, and
the insulation, platforms and piping (with insulation and contents thereof) attached to the
equipment. Vibration caused by operation of the equipment shall be handled separately
as vibration loads.
c) Equipment load for testing or flushing shall mean the load of the equipment during
hydraulic testing or during flushing with water, and includes weights of internals,
insulation, platforms and piping attached to equipment, insulation of attached piping
and all water within the equipment and piping.

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Dead and live loads associated with mechanical, electrical and vendor supplied equipment
shall be incorporated into the structural design loading. The source of the loading
information shall be clearly indicated in the structural calculations. Equipment loads shall be
certified prior to issuing drawings for construction, indicating all possible loading
combinations (e.g. vessel at normal and abnormal operating conditions, allowance for scale
build-up, and dynamic effects). Any maximum allowable deflections of support structures
specified by the equipment vendor shall be adhered to.
Dynamic loads shall be obtained from the equipment vendor and applied in accordance
with the appropriate structure design code. In the absence of Vendor supplied dynamic
loads specific for the Project, the static mass of the equipment shall be multiplied by the
following factors to determine a static equivalent of the dynamic or impact loads:
• Reciprocating machinery, crushers and pumps 3.0
• Rotating machinery 2.0
• Mobile equipment 1.2
• Forklifts, other cranes 1.6
• Carry idlers at loading points 2.0
• Carry idlers elsewhere 1.1
Such conversion to static mass equivalent shall be vetted by the vendor.

5.3 Live Loads
Floor design shall be based on probable area loading. Design engineer shall check for
heaviest equipment/maintenance load. Live load reduction shall not be used.
The floor area live load shall be omitted from areas occupied by equipment where the
weight of such is specifically included in dead load.
Minimum live loads to be used in design shall be in accordance with SBC 301 Structural –
Loading and Forces or as per Table 5-1, whichever is greater, unless directed otherwise by
the Employer.
Table 5-1 identifies common structural loading. Special loads such as those from specific
types of cranes and forklifts, or special heavy storage loads shall be considered when
appropriate in consultation with the discipline engineer.
Table 5-1 : Minimum Live Loads
Location Live Load

Operating platforms, control rooms and assembly 5.0 kPa or a moving concentrated load
rooms of 4.5 kN
Conveyor walkways 4.0 kPa
Conveyor walkways ore spillage load 4.0 kPa
Stairways, landings and walkways 4.0 kPa
Offices and amenities 3.0 kPa

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Location Live Load

General storage areas not accessible by vehicle or 7.5 kPa
crane
Heavy storage areas accessible by vehicle or crane 30.0 kPa (for special requirements
refer to Discipline Engineers)
Ground floor areas not accessible to trucks 10.0 kPa
Ground floors accessible to trucks Specified Truck Wheel Loading
Trench covers not for vehicle traffic 5.0 kPa
Electrical switchgear areas To be provided by the Electrical
Engineer but not less than 10.0 kPa
Roofs not accessed for maintenance 0.5 kPa or a point load of 0.8kN
Storage tank roofs 1.2 kPa
5.4 Material Loads

For stored and handled material densities and other characteristics refer to the Process
Design Data Sheets and/or the Process Design Criteria. Values shall only be adopted after
confirmation from the Process Engineer that they are suitable for structural design.
Blocked chute loads shall be calculated from the maximum expected bulk density of
materials and the volume of the chute with free surface in contact with the lowest rotating or
oscillating machinery component. For column design, the simultaneous effects of live loads
on other floors need to be considered with the blocked chute load.
5.5 Wind loads
Wind loading shall be in accordance with SBC 301 Structural – Loading and Forces and the
parameters sourced from the project Site Data Specification.
Wind load is obtained by multiplying the effective velocity pressures by the wind pressure
coefficient described below:
• Basic wind speed and the type of exposure shall be set forth in Basic Engineering Design
Data (BEDD)
• Effective velocity pressure shall be in accordance with “Structural Code” of Royal

Commission
• Wind pressure coefficient for ordinary buildings and structures shall be in accordance
with “Structural Code” of Royal Commission, relevant site data specification and
SBC 301.
For special shapes, the value shall be determined by wind tunnel tests.
5.6 Seismic Loads
Seismic loading shall be in accordance with SBC 301 Structural – Loading and Forces and
the parameters sourced from the project Site Data Specification. Earthquake loading shall be
calculated in accordance with Royal Commission Structural Code, relevant site data
specification and SBC 301.

Page 16 of 45
5.7 Crane and Monorail Loads

The design of crane girders and monorail beams shall be in accordance with SBC 301
Structural – Loading and Forces. Crane and equipment supplier’s information shall be used
for wheel loads, equipment loads and weights of moving parts.
The impact forces affecting a monorail shall be deemed to work vertically and be 20% of the
sum of the lift load and the weight of the hoist of the chain block. For weights of hoists and
chain blocks, the standard weight furnished by the crane manufacturer shall be used. The
impact forces affecting a monorail shall comply with AISC, ASME B30.11 and CMAA.
5.8 Thermal Loads
Forces caused by expansion or contraction due to a change in temperature from the erection
condition shall be taken into account. Such forces shall include those caused by:
• Partial or complete anchorage of piping or equipment
• Sliding or rolling friction of piping or equipment
• Expansion or contraction of the structure
• The above forces shall be calculated depending on the actual condition
• For exposed steel frame structures not exceeding 40 m in length, or reinforced concrete
structures and steel frame buildings covered with exterior walls not exceeding 60 m in
length, loads due to thermal expansion of structural material need not be considered
• For structures exceeding the above lengths, appropriate expansion joints shall be
provided. However, when an expansion joint cannot be provided because it would foul
a conveyor line, crane, or other similar equipment, the thermal force shall be calculated
as follows:
N = AEα (t – to)
Where:
N = axial force in tonnes
A = cross section of material in cm2
E = Young’s modules in tons/cm2
α = coefficient of thermal expansion, per oC
t = temperature when thermal forces are considered in oC
to = standard temperature (normally temperature during erection in oC)
Friction loads caused by thermal expansion shall be determined using the appropriate
static coefficient of friction. The coefficient shall be as following:
• Steel to Steel = 0.4
• Steel to Concrete = 0.6
• Proprietary Sliding Surfaces or Coatings (e.g. “Teflon”) = Based on manufacturer’s

specification.

Page 17 of 45
5.9 Earth Loads

5.9.1 Soil Properties
The relevant soil properties for design shall be sourced from the Project Geotechnical Report.
For preliminary design (where geotechnical report is not available), the following values may
be adopted, in consultation with the Employer:
3
• Density for applied loading = 20.0 kN/m
3
• Density for stability = 18.0 kN/m
• Allowable bearing pressure = 200 kPa
• Modulus of sub-grade reaction: design for upper and lower bound cases of 5 kPa/mm
and 50 kPa/mm.
All preliminary design assumptions shown above shall be approved by a qualified

geotechnical engineer.
Water table level shall be taken into account for any soil- structure interaction design.
5.9.2 Lateral Earth Pressures
Active pressures shall be used to design flexible structures, such as cantilever retaining walls.
At rest pressures shall be used to design rigid structures, such as tied retaining walls and
concrete tunnels. The “at rest” pressure coefficient, ko, shall be taken as not less than 0.50.
Passive pressures shall not be assumed to resist lateral forces unless substantial movement
can be accommodated (e.g. free standing retaining walls).
Lateral earth pressure coefficients on retaining structures subject to repeated traffic loads shall
take into consideration the resulting long term compaction, which in some cases has been
measured as giving coefficients as high as the passive coefficient kp.
5.9.3 Surcharge to Retaining Walls

All retaining walls shall be designed for the actual surcharges applied, or the effect of either
(i), (ii), or (iii) below, as applicable or whichever gives the worst effect for design.
(i) Minimum Surcharge
The minimum surcharge for which a retaining structure shall be designed is 10 kPa. (or as
agreed with the Lead Structural Engineer).
(ii) Normal Road Traffic
Where the edge of a road is within a horizontal distance from the top of a retaining structure
equal to one half of its clear height, the wall shall be designed for a road vertical surcharge of
20 kPa in addition to normal earth pressures.
(iii) Abnormal Axle or Point Load
Where high axle load vehicles or other items are able to apply point surcharge loads to
retaining structures, the effect of this load shall be calculated using established methods
approved by the Employer.

Page 18 of 45
5.10 Bin Loads

Bin loads shall be determined in accordance with SBC 301 and API 351.3 and shall take into
account the effects of pressures developed during filling and emptying operations.
5.11 Vibrating Loads
Certified vendor drawings giving design parameters and operating frequencies shall be
obtained from the manufacturer.
5.12 Conveyor Loads
5.12.1 Belt Tensions
Belt tensions shall be treated as a live load to the support beams and the appropriate load
combination applied except that the factor φc shall be taken as 1.5 for belt tension.
The belt tension used in the design of conveyor support structures shall be as follows:
• For general structures: maximum of 1.5 x Tr and 1.0 x Ts
• For connection of head/drive frame to support steelwork, support steelwork and the
connections out to the nearest columns: 2.0 x Ts
where Tr = normal operating belt tension load
Ts = drive start tension load
5.12.2 Services on Conveyor Gantries
Unless advised otherwise by the discipline engineer, load allowances for services on
conveyor gantries shall be as follows:
• Electrical cable loads of minimum 75 kg/m connected to one handrail
• A piping load of minimum 150 kg/m connected to the same handrail.

5.13 Dust Loads
Dust loads are based on local operating experience. The magnitude and applicability of dust
loading must be discussed with the Employer and discipline engineers. The density of the
dust is to be supplied by the discipline engineer.
Ducts for fume systems and their supports shall be designed for an accumulation of dust
equal to a minimum of 30% of the duct volume. An accumulation of 50% of the duct
volume shall be used if warranted by operating conditions such as:
• Sticky dust
• Possibility of dust becoming wet
• Duct conditions that promote settling of dust (such as reduction in gas velocity in the
duct).
In addition to dust loading on ducts, the design of roofs and roof gutters shall take into
consideration the possibility of dust accumulation.

Page 19 of 45
The dust loadings in general and dust accumulation in ducts for fume systems and their
supports shall be treated as live loads for analysis but should not be included in the
allowable live loads specified on the drawings.
5.14 Piping Loads
5.14.1 General
Piping load means the weight of pipe, fittings, valves, insulation and the fluid contents of
piping and shall be classified as follows:
a) Piping load for erection means the weight of prefabricated piping and consists of weights
of pipe, fittings and valves but does not include insulation and the fluid contents.
b) Piping load for operation means the weight of piping during normal operating conditions
and consists of total weight of pipe, fittings, valves, insulation and the contents of piping
during operation.
c) Piping load for testing or flushing means the weight of piping during hydraulic testing or
flushing with water and consists of total weight of pipe, fittings, valves, insulation and
the water contents therein.
Piping load should normally be assumed and calculated as a certain weight per horizontal
unit area of the pipe rack. However, concentrated loads of large diameter pipes and valves
shall be calculated separately.
For gas piping where loads may increase only during hydraulic testing, the load shall be
considered depending on the actual condition, such as section of piping to be tested. The
load of such piping shall not be considered to increase over its entire length.
For high pressure piping, forces due to internal pressure shall be considered in addition to
the above loads.
5.14.2 Pipe Rack Loads
5.14.2.1 Vertical Loads
Vertical pipe loads shall be calculated and used for the pipe rack design. Any unused areas
of pipe rack shall be designed for a load allowance of 2.5 kPa. Cable tray loads shall also be
included if applicable.
5.14.2.2 Transverse Wind Loads
For a typical pipe rack, transverse wind loading shall be calculated by assuming a bluff area
height that increases with pipe rack width, as per Table 5-2.
Using this method, an allowance is already included for structural steel, and the shape factor,
Cd, shall be taken as 1.2.
Table 5-2 : Effective Heights of Piperack Levels for Transverse Wind Load Calculations
Width of pipe rack B<4m 4m<B<6m 6m<B<8m 8m<B<9m
Height of wind 1.5 m 2.0 m 2.5 m 2.75 m
load per level of
pipe rack

Page 20 of 45
5.14.2.3 Longitudinal Loads

Longitudinal loads on pipe racks due to thermal expansion and longitudinal wind shall be
allowed for as follows:
• Horizontal loads equal to 15% of vertical loads of all lines shall be applied at each
transverse frame and the longitudinal steelwork immediately adjacent to the frame on
each side
• Horizontal loads equal to 10% of all vertical pipe loads shall be accumulated at braced
bays and carried down to the foundations.
5.14.3 Process Pipe Loads
Forces caused by the major process piping, together with a clear instruction of the location
and type of pipe anchor/support shall be supplied by the Piping Engineer. Pipe loads shall
be given as individual load cases together with assumptions made by the Piping Engineer on
coefficients of friction used for sliding and structural rigidity at each support.
The Structural Engineer shall advise the Piping Engineer of expected structural deflections, so
that realistic assumptions are made during pipe stress analysis with regards to fixity and
deflections of support members.
5.15 Cable Tray Loads
Cable tray loading shall be obtained in writing from the Electrical Engineer. For preliminary
design, a unit load of 0.75 kN/m may be adopted.
5.16 Blast Loads
Blast load is the load on a structure caused by overpressure resulting from the ignition and
explosion of flammable material or by overpressure resulting from a vessel burst.
Control houses or other buildings housing personnel and control equipment near processing
plants may need to be designed for blast resistance.
Blast load shall be computed and applied in accordance with the ASCE Design of Blast
Resistant Buildings in Petrochemical Facilities.
5.17 Impact Load
The following impact loads shall be used in addition to those listed in the AISC Specification:
• Vertical impact on monorail beams: 25% of the hoist capacity
• Longitudinal force on monorail beams: 10% of the hoist capacity
• Vertical impact on davits and hitch points: 25% of the lifted load
• Lateral force on davits and hitch points: 20% of the lifted load
5.18 Miscellaneous Loads
A single point load of 2300 kg (22.5 kN) shall be allowed for at any one panel point of roof
trusses, main roof and floor girders to cover miscellaneous hoisting operations. This load
shall not be cumulative through the structure.
Any loads that are not noted here shall determined from SBC 301.

Page 21 of 45
5.19 Load Combinations

5.19.1 General
Combinations of loads together with the appropriate load factors for strength, stability and
serviceability limit states shall be determined in accordance with SBC 301, Chapter 2.
In determining the loading combinations, material loads, crane loads and belt tensions shall
be treated as live loads. Tanks and pipes shall be assumed to be full and operating during
ultimate wind events, unless otherwise instructed by the discipline engineers.
Structures and their parts shall be designed to withstand the results of the following
combinations of loads and forces within the limits of stress specified herein. Wind and
seismic loads shall not be considered to occur simultaneously.
1. Erection: structural dead load, piping dead load, and equipment erection dead load
combined with or without wind or seismic load.
2. Test: structural dead load, piping dead load, equipment test dead load, equipment
and piping test contents load, and the applicable live loads combined with 1/3 of
design wind pressures. Seismic load shall not be combined with the test load.
3. Operation: structural dead load, equipment operating load, piping operating load,
the applicable live loads, and impact loads combined with or without wind or
seismic load.
4. Empty: structural dead load, piping dead load, equipment operating dead load less
the operating contents weight combined with wind or seismic load.
5. Maintenance: structural dead load, piping dead load, equipment operating load less
the operating contents weight, maintenance loads combined, without wind or
seismic load.
5.19.2 Conveyor Gantries
The load combinations and load multiplying factors given in ISO 5049.1 shall be considered
in the design of conveyor trusses and machine structures. Longitudinal wind drag on rising
conveyors shall be considered in the appropriate load combinations as applicable.
6. CONCRETE DESIGN CRITERIA

6.1 Design Method
All concrete structures shall be designed in accordance with SBC 304 Structural – Concrete
Structures. The limit state method of design shall be used and appropriate serviceability
checks shall be made.
6.2 Materials and Standard Specification
6.2.1 Concrete
6.2.1.1 Compressive Strengths
For preliminary design purposes, the characteristic compressive strengths of concrete shall be
taken as 32 MPa for general structural concrete, and 15 MPa for blinding and block-work
infill. The concrete criteria shall comply with the Concrete Specification,
MD-101-SMEM-EG-SPT-0004 and MD-101-SMEM-EG-SPT-0005. Project specific
requirements may vary and shall be confirmed by the Employer.

Page 22 of 45
6.2.1.2 Concrete Durability

Concrete cover shall generally be in accordance with Section 7.7 of SBC 304. Additional
concrete durability measures would be required in areas with aggressive conditions. This
shall be assessed on a case by case basis. Some concrete may require a protective coating, as
detailed in MD-101-SMEM-EG-ST-SPC-0009: Protective Coating for Concrete.
6.2.1.3 Coefficient of Thermal Expansion
-6
The coefficient of thermal expansion for concrete shall be taken as 10.0 x 10 /°C.
6.2.2 Reinforcing and Embedded Steel
6.2.2.1 Grades
The following steel grades (yield strengths) shall be used for reinforcing and embedded steel.
Employer’s approval for alternative steel grade, if proposed, shall be secured:
• Plain bars: 280 MPa (Grade 40)
• Deformed bars: 420 MPa (Grade 60)
• Wire & welded wire mesh: 420 MPa (Grade 60)
• Embedded steel: 280 MPa (Grade 40)
All reinforcing steel shall in accordance with MD-101-SMEM-EG-ST-SPC-0006.

6.2.2.2 Sizes
The following reinforcement sizes shall be used:
• Round Bars: R6, R8, R10 (fitments only)
• Deformed bars: D10, D13, D16, D19, D22, D25, D29, D32
• Square meshes: MW40, MW50, MW65, MW80
• Wire: W6, W8 (fitments only).

6.2.3 Anchor Bolts
Anchor bolt shall be fabricated as specified in MD-101-SMEM-EG-CV-SPC-0002.
All major anchor bolts (e.g. for building columns, trestle columns, tank columns, pipe racks)
shall be cast into concrete. The minimum size shall be 20 mm diameter.
Chemical anchors (16 mm minimum) may be used for minor items. (stair stringers, ladder
stringer, minor pipe supports. Mechanical anchors shall not be used.
6.2.4 Grout
Standard thickness allowances of non-shrink grout shall be as follows:
• 30 mm under steel column base plates
• 50 mm under machine bases.

Page 23 of 45
6.3 Footings
6.3.1 Soil Condition and General Requirement
Sufficient soil investigation shall be performed to obtain soil data necessary for designing
concrete structures and foundations. The time of the soil investigation shall be subject to the
prior approval of Employer.
Based on the soil investigation by the soil consultant/engineer, foundation type shall be
determined.
The maximum foundation settlement for the recommended soil bearing pressures shall be
limited to 25 mm, and maximum differential settlement between two adjacent foundations
shall be limited to 20 mm. These requirements may vary depending on any special
requirement due to equipment functions.
The allowable soil bearing capacity and pile bearing capacity can be increased by 33% for
temporary loads such as wind load, earthquake load and bundle pulling force and by 25%
for testing loads.
When the foundation is within 300 mm of the water table or below the water table, the soil
bearing capacity shall be reduced taking into consideration buoyancy and loss of cohesion.
All footing shall have a 100 mm layer of blinding concrete unless the footing is based on
rock, in which case the rock shall be air-cleaned prior to placing of reinforcement.
6.3.2 Stability
Concrete structures and foundations shall be designed so that the safety factors nominated in
Table 6-1 are satisfied.
Table 6-1 : Concrete Design Safety Factors
Failure Mode Safety Factor
Sliding 1.5
Overturning (temporary load) 1.5
Overturning (Permanent load) 2.0
Buoyancy 1.2
6.3.3 Lateral Loads on Footings

6.3.3.1 Load Transfer from Steel Structure to Pedestal
The preferred methods of transferring shear loads from base plates to concrete pedestals are:
a) Shear keys for major columns and shear loads.
b) For minor columns and wind posts, the friction between the column base plate and the
concrete shall be included in combination with the bolt shear resistances. A friction
coefficient of 0.30 shall be used. Any combined tension and shear cases shall also be
considered, which will have zero friction. As a good design practice, only 50% of the
anchor bolts shall be assumed as being effective in resisting the shear, due to the
oversize holes in the base plates and misalignments.

Page 24 of 45
6.3.3.2 Load Transfer from Footing to Soil

Lateral loads on footings shall be transferred to the soil by friction and passive resistance.
The calculated passive resistance shall be reduced by 0.5 to ensure that the lateral
displacements are kept to acceptable limits.
Where rock anchors have been used to resist uplift, the residual ground pressure may be
included in sliding resistance calculations.
The co-efficient of friction between the rock and the footing shall be taken as 0.40.
6.3.4 Pedestals
The top of the pedestal shall be 300 mm minimum above nominal floor/ground level, with
all major pedestals in the one facility/building being at the same level. The pedestal height
may be reduced with the approval of the Employer if it is deemed that sufficient clearance is
maintained above any containment levels, and operational requirements are not adversely
affected.
6.3.5 Depth of Embedment into Ground
All footings shall be located such that:
• Where possible and within reason the underside of all footings within the one
facility/building shall be located at the same elevation
• If the top of the footing is to be below the finished surface level then it shall be a
minimum of 500 mm below finished surface level
• The top of the footing shall be located a minimum of 300 mm below the underside of
any slab on ground.
6.3.6 Uplift Resistance
Where footings are located on rock, the preferred method of resisting uplift on footings shall
be the use of rock anchors. Corrosion protection shall be provided to all rock anchors.
Where footings are not located on rock, the preferred method of resisting uplift shall be by
the mass of the reinforced concrete footings. Other options may be applicable with the
approval from the Employer.
6.4 Slabs on Ground
6.4.1 Design Procedure
The design method for slabs on ground shall be in accordance with SBC 304 and ACI 360R.
6.4.2 Slab Thickness
The minimum thickness of slabs shall be 150 mm.
6.4.3 Reinforcement in Slabs
The reinforcement to be provided in ground slabs shall be calculated in accordance with the
requirements of ACI 360R.
6.4.4 Slab Panel Sizes
Slabs shall be detailed so as to limit the area of any slab between joints to 50 m2, with the
ratio of longest side to shortest side of a panel not to exceed 1.5.

Page 25 of 45
6.4.5 Waterproof Membrane

A 0.2 mm polythene membrane shall be provided under all slabs.
6.4.6 Drainage Slopes
Drainage slopes shall be provided to all slabs exposed to the weather or subject to
wash-down water. The slope provided shall be within the range of 1 in 50 to 1 in 100.
6.4.7 Process Bunded Areas
Concrete slabs or rafts that form containment bunds in process areas shall be considered to
be liquid retaining structures and shall have suitable water-stop sealed joints. The joint
design and layout shall reflect the goal that no contained liquids shall leak from the bunds
into the surround ground. The concrete mix design is to ensure a low permeability concrete
(<10-12 m/s) through high strength, low water content or additives, or a combination of these
measures.
Bunded area dimensions and levels shall not be reduced below the area and wall levels as
laid out in the Drawings. For reference, bunded areas shall be designed for the capacity
requirements as set out in the Civil Design Criteria.
Process sumps shall be circular with a single sump pump. The pump motor platform and
access walkway shall to be located above bund wall to allow maintenance access to the
sump pump in the event of pump failure during a flooded bund.
Steel lined process drains may be used in various Process Areas to direct process flows to
local Area sumps. The extent and arrangement of these drains are indicated in the Drawings
for each Process Facility.
Steel lined process sumps and drains used in concrete rafts and slabs shall be as detailed in
the Drawings. All other sumps and tundishes indicated in the Drawings shall be constructed
of steel plate.
6.4.8 Joints
Joints shall be positioned to suit the process equipment requirement and minimize cracking.
Generally joints shall be set out on a square pattern and located along high point concrete
ridge lines. Specific joint design details shall be taken from the Project Standard Drawings.
6.5 Concrete Pile Design
All concrete pile design shall be in accordance with ASCE 20-96.
6.6 Foundations for Heavy Machinery
6.6.1 General
The design of ground bearing foundations supporting rotating and reciprocating machinery
including pumps and compressors shall be in accordance with the guidelines given below.
Multiple machines shall only be installed on a common foundation where the manufacturer’s
approval for this has been obtained.
The design of foundation for specialist machinery shall be as per the Manufacturer’s
guidelines and recommendations.

Page 26 of 45
Design of foundations for heavy machinery shall encompass the following activities:
• Investigating physical properties of machinery
• Determining geotechnical parameters and characteristic of the supporting soil
• Determining spring constant of soil and allowable amplitude of machinery
• Determining type, number and layout of piles, if required
• Determining shape and dimensions of foundations/footings
• Determining vibration absorbers and type thereof
• Calculating natural frequency and amplitude of machinery, and foundations supported

by springs or set directly on ground
• Calculating amplitude and force transmitted to foundations or ground via springs, or

other vibration absorbers
• Determining stresses and reinforcing steel arrangement for foundations.

6.6.2 Design Guidelines
In the absence of Project specific Supplier design information for equipment or machine
footings the following general guidelines shall apply:
• Equipment footings for centrifugal machinery shall be sized to weigh three times as
much as the machine as a minimum
• Equipment footings for reciprocating machinery shall be sized to weigh five times as
much as the machine as a minimum
• Large machinery footings (compressors, pumps, blowers etc) shall be designed on the
basis of a frequency comparison. Machine operating frequency will be compared with
the natural frequency of the combined machine and its footings (refer to Section 6.6.6).
Finite Element Analysis may be used to reasonably predict the response of the footing.
• If pump plinths are not integral with a raft, the plinth shall be sized and laid out so that
suction and discharge pipe supports immediately adjacent to pump volute can be
attached to and form part of the pump plinth. This can be achieved by extending the
concrete directly under the suction and discharge piping to allow support points to be
mounted on the same concrete as the main pump base frame.
• For machinery, six degrees of freedom exist. Analysis of all six degrees of freedom or
natural frequencies (vertical, horizontal and rocking in a vertical plane) shall be
undertaken, depending on the availability of Supplier information.
• The machine footing shall be isolated from any adjacent footings and structures, where
ever possible, including steel associated with walkways and platforms. If the steel is
attached to the footing, the effect of this additional mass on the footing’s response to
vibration shall be included in the design.

Page 27 of 45
• The clear distance in any direction between adjacent foundations for heavy machinery
shall be large enough to avoid transmission of detrimental vibration amplitudes through
the surrounding soil, otherwise the adjacent foundations shall be protected in other
ways. Transmissibility of amplitudes shall be limited to 20% between adjacent
foundations, unless otherwise agreed by the project engineer.
• The footing thickness for vibrating machines shall be at least 600 mm, unless a lesser
thickness is allowed by the machine manufacturer.
• Where practical and economical, the machine foundation system shall be proportioned
to be low-tuned. High-tuned machine foundation systems shall be used only when a
low tuned system is not practical or economical; e.g. for low-speed or variable-speed
machinery.
6.6.3 Design Details
Foundation shall be designed considering the following:
• Normal revolutions per minutes (for machinery and motors). Maximum continuous
operating speed. Maximum and minimum speed for trip and/or alarm setting.
• Horsepower
• Allowable amplitudes for machinery
• For elevated machinery, the flexibility of the entire support structures must be
considered in the dynamic analysis
• Unbalanced inertia forces in X, Y and Z directions (primary and secondary)
• Unbalanced inertia moments in X, Y and Z directions (primary and secondary)
• Diagrams showing origin and direction of all axes
• Weight and gravity center of each machinery component, and location of the center of
gravity of the machinery
• Shop drawings or outline drawing of machinery
• Mass and eccentricity of rotors
• Critical speed of rotors
• Space restrictions
• Maximum maintenance lift load
• Maximum static deformation allowed on the structure (if any) by the Vendor
• Geotechnical parameters of the supporting soil
• Steady state continuous dynamic force at long term normal operational speeds based
purely on an out-of-balance vibration level. This value should not be the static force
equivalent of a dynamic force.

Page 28 of 45
The foundation design shall be capable of resisting all applied dynamic and static loads
specified by the machinery manufacturer, loads from thermal movement, dead and live loads
as applicable, wind or seismic forces, any loads that may be associated with installation or
maintenance of the equipment, and fatigue. For fatigue, the dynamic loads shall be increased
by a factor of 1.5.
The design should take into account the general guidance given by ISO 2631-1 and
ISO 2631-2 on human response to building vibration and weighting curves of frequency
responses for equal annoyance of humans together with measurement methods to be used.
Methods of quantifying whole body vibration in relation to human health and comfort, the
probability of vibration perception, and the incidence of motion sickness are presented in
these standards.
The design method shall be based on either static or dynamic analysis approach depending
on the power rating of the machinery. The following Table illustrates these requirements:
Notes:
1. Weight Ratio = weight of foundation/(weight of machine + driver)
2. Packaged equipments such as generators and compressors with built-in anti-vibration
mountings may be exempt from Dynamic analysis. Example of such machinery is the Essential
Diesel Power Generators (EDPGs). A confirmation from the Vendor is required to ensure anti-
vibration mountings are installed for the equipment in question. A raft foundation should be
provided thus.
3. Dynamic design shall be based on the dynamic forces resulting from a full Finite Element
analysis.
6.6.4 Sizing and shape of Dynamic Foundation

Foundations shall have a simple rectangular shape. Projections shall be avoided wherever
possible. The foundation should be symmetrical about the axis parallel to the shaft of the
machine. The underside of the foundation shall be at a constant level. For rock bearing
foundations, any difference between the underside of the foundation and the rock level shall
be made up with mass concrete.
a) Foundation minimum thickness: the base thickness shall not be less than any of the
following:
▪ Larger plan dimension/10
▪ Smaller plan dimension/5
▪ 0.6 m + larger plan dimension (m)/30.

Page 29 of 45
b) The centre of gravity of the machine shall coincide with the centre of gravity of the
foundation within ±5% of the relevant dimension.
c) The centre of gravity of the machine-foundation system shall coincide with the centre of
bearing pressure within ±5% of the relevant dimension.
d) The relevant dimension in rocking mode (normally the base width) shall be greater than
the vertical distance from the underside of the base to the centre of gravity of the
machine (in normal operation) or the rotating shaft axis, whichever is the greater. For
reciprocating machines this dimension shall be not less than 1.5 times the same vertical
distance.
e) The maximum bearing pressure shall not exceed 0.5 times the allowable bearing
pressure.
The shape and principal dimensions of foundations shall be determined from the following,
in addition to machinery dimensions:
a) The height from the ground or the floor to the top of the foundation shall be as little as
possible, provided that operational efficiency and drainage are maintained.
b) Foundations for machinery shall be isolated from other foundations and floors wherever
possible.
c) Generally, cantilevered beams shall not be used for frame foundations.
d) Common or combined footing shall not be advisable for reciprocating and rotating
machinery.
When the revolution of a machine changes within a certain range, the foundation shall be
designed so that is will not resonate within the range of revolution.
6.6.5 Vibration Absorbers
Rubber vibration absorbers shall not be used where the ambient temperature is constantly
below 10°C or above 70°C.
When using rubber vibration absorbers, rubber which may deteriorate within its modulus of
elasticity due to vibration shall not be used.
Preventive measures against aging of the rubber and the method for its replacement shall be
considered. Direct sunlight onto the rubber vibration absorbers shall be avoided in
particular. The absorber installation shall be accordance with manufacturer’s
recommendations.
Rubber vibration absorbers shall not be used for machinery that is anticipated to leak oil.
When use of air springs, metal coil springs, dampers or others are to be considered, approval
of Employer shall be required.
6.6.6 Frequencies
The foundations shall be designed on the basis of a frequency comparison. The equipment
operating frequency shall be compared with the natural frequency of the combined
equipment-foundation system. Foundations supporting rotating machinery shall have a
fundamental natural frequency of greater than 2.0 times or less than 0.5 times the frequency
of the disturbing force.

Page 30 of 45
The calculated amplitude of vibration at any point on the foundation shall not exceed the
lesser of the following:
• Maximum allowable amplitude specified by the equipment manufacturer
• Amplitude (single amplitude) which causes the effective velocity of vibration to exceed:
a) 3.0 mm/s for centrifugal and rotating machine and foundation.
b) 3.8 mm/s for reciprocating machine and foundation.
Note: The effective velocity is defined as the square root of the average of square of the
velocity, velocity being a function of time. In the case of a pure sinusoidal function,
the effective is 0.71 times the peak value of the velocity.
6.6.7 Damping
Rigid Foundation: Soil geometric and material damping ratios of 50% of that calculated from
the elastic half-space models as recommended by Novak (1970) or other proven values may
be used but not more than 25% as per DIN4024 Part 2. (ACI 351.3R, Clause 4.2.2).
Flexible Foundation: Damping ratio of the entire system shall be assumed to be 2% as per
DIN4024, Part 1; unless a more accurate value is available.
6.6.8 Applied Forces from Machinery
a) Dynamic forces: Operational forces are usually supplied by the Vendor. These normally
include out-of-balance and emergency forces. However, in the absence of such data
dynamic oscillating forces may be calculated using the empirical formula as follows
(ACI 351.3R, Clause 3.2.2.1d):
b) Malfunction (Emergency) forces: Unless otherwise given by the Vendor forces due to
machine malfunction shall be obtained from DIN 2024 Part 1 where these are specified
as six times the normal operating forces and shall be used for static design and stability
check of the foundation.
c) Psuedo static forces: In the absence of detailed calculations of member forces due to
dynamic loads an equivalent static load shall be used for static design. These forces are
additive to normal gravity loads and considered to act at the centerline of the machine
shaft. They shall not be considered to act concurrently with one another:
 Vertical Force equal to 50% of the total weight of each machine
 Horizontal Force equal to 25% of the total weight of each machine applied in the
transverse direction
 Horizontal Force equal to 25% of the total weight of each machine applied in the
longitudinal direction.
6.6.9 Reinforcement
Reinforcing bars shall be provided on all faces in both directions using a minimum bar size
of 16 mm and spaced at 200 mm centers.

Page 31 of 45
An intermediate tri-axial arrangement of reinforcement is required when the foundation

thickness exceeds 1.0 m in order to account for concrete shrinkage. This should be placed at
600 mm centers in all three directions using a minimum bar size of 16 mm.
Earthing of the foundation shall be accounted for in accordance with Electrical

recommendations.
6.6.10 Anchor bolts and grouting
Anchor bolts and grouting shall be as specified by machine vendor and in accordance with
MD-101-SMEM-EG-ST-SPC-0003 and MD-101-SMEM-EG-CV-SPC-0002.
For large reciprocating machinery, the anchor bolts shall be designed to carry the full
horizontal and vertical loads specified by the equipment manufacturer with none of the
horizontal load assumed to be resisted by friction on the underside of the base plate, unless
specific shear keys are provided.
6.6.11 Ground Modeling
Foundations under vibrating equipments shall be modeled as structures supported on springs
the stiffness of which is based upon the weighted dynamic shear modulus of the ground.
Ground dynamic properties shall be based on the findings of the Geotechnical study taken
down to a sufficient depth below the foundation.
6.6.12 Steel Structures
Where structures are not properly isolated from vibrating equipment the relationship
between the natural frequency of the supporting members and their columns should be
checked against the frequency of the vibrating equipment. The structural supports shall be
so proportioned that excessive vibration of the supports and other parts of the structure
cannot take place.
The ratio of the natural frequency of the supporting member to the operating frequency of
the equipment shall not be below 2 for reciprocating equipment and below 1.5 for rotating
equipment.
Where practicable, miscellaneous steel structures, such as operator platforms, shall be

independent from the main machinery carrying structure(s), to avoid operator discomfort.
Steel structures shall be designed for the actual dynamic loads generated by the equipment
as supplied by the vendor of the equipment. Documentary proof of these loads shall be
included in the design calculations.
Dynamic loads derived from factoring the weight of the equipment shall not be used unless
every other avenue of dynamic load assessment has been exhausted.
6.6.13 Vibration Isolating Foundations
If adjacent nearby buildings and equipment are liable to be affected by vibration due to
utilization of rigid foundations, vibration isolating foundations using rubber, metal coil
springs or other vibration absorbers may be used.

Page 32 of 45
Since machinery resting on vibration isolating foundations vibrates violently when such
machinery passes its resonant point between start of operation and normal operating speed,
piping and other appurtenances attached thereto shall be installed in such manner that they
will not be adversely affected. The operating floor shall be isolated from the machinery.
The gravity centers of machinery and the height of their points of support shall be as close as
possible.
The allowable amplitudes of machinery shall be in conformance with values prescribed in

the Job Specification.
The allowable amplitudes of foundations shall normally be values obtained from Figure 1
below:
Figure 6-1 : Allowable Amplitude of Machinery – Reiher – Meister Chart (Ref: ACI 351.3R)
Minimum block thickness should be one-fifth the short plan dimension, one-tenth of the long
plan dimension, or two feet, whichever is greater.
Minimum width should be 1.5 times the vertical distance from the machine centerline and
the bottom of the foundation block.

Page 33 of 45
Length and width should be adjusted so the center of gravity of the machine plus the
equipment coincides with the center of gravity of the foundation. Also sufficient area should
be available for maintenance.
6.6.14 Soil Bearing Foundations
When the permanent allowable bearing capacity of the ground is not less than 100 kPa, and
where strata, such as silt layers, or loose sand layers liable to cause settlement do not exist to
a depth of two times the width of the footing from the bottom of the foundation, a soil
bearing pressure shall not exceed 60% of the allowable bearing capacity.
For grounds where the soil type and the bearing capacity are not as mentioned above, soil
bearing foundations may be used on condition that the ground is improved by replacing the
surface soil with sand or by taking other appropriate methods to meet the above provision.
The depth and shape of the bottom of the foundation shall be determined by considering the
frost line and adjacent foundations.
Positive soil bearing over the entire base of the foundation shall be required.
If the ground water table is close to the bottom of the foundation, the condition of
liquefaction of soil has to be checked. Also the bearing capacity should be reduced taking
into consideration cohesion loss and buoyancy.
The foundation should be at least three times the mass of a centrifugal machine and five
times the mass of a reciprocating machine.
6.6.15 Pile Foundations
Pile foundations shall be used for machinery where the soil bearing foundations cannot be
used.
Types and dimensions of piles shall be determined by considering depth of bearing strata,
depth of underground water, weight of equipment to be supported, type of surface soil,
construction period, construction cost, and direction and magnitude of unbalanced inertia
forces.
Batter piles may be used when horizontal unbalanced forces are of great magnitude.
Pile shall extend not less than 100 mm into the footing of the foundation and the reinforcing
steel thereof shall be anchored to the foundation.
Pile cap should be at least two and a half times the mass of a centrifugal machine and four
times the mass of a reciprocating machine.
7. STRUCTURAL STEEL DESIGN CRITERIA

7.1 Design Method
All steel structures shall be designed in accordance with AISC. The limit state method of
design shall be used and appropriate serviceability checks shall be made.

Page 34 of 45
7.2 Materials and Standard Specifications

7.2.1 Grades
Structural steel shall comply with the grades that specified in the Standard Specification
MD-101-SMEM-EG-ST-SPC-0001.
7.2.2 Coefficient of Thermal Expansion
-6
The coefficient of thermal expansion for steel shall be taken as 11.7 x 10 /°C.
7.2.3 Grating and Handrails
The following proprietary types shall be used unless approved otherwise by the Employer:
• Grating: Grating shall be conform to ASTM 569/A569M, galvanized in accordance with

ASTM A123 and NAAMM MBG 531
• Handrails: Handrail shall comply to requirements of ASTM E985 and ASSE A1264.1.
7.2.4 Purlins and Girts
Purlins and girts shall conform to ASTM 1008 Grade 50. Steel purlins and girts of C and Z
profile shall be designed in accordance with the manufacturers design guides. The full
specifications, including required laps and bridging, shall be clearly specified in the relevant
calculations and drawings.
7.3 Member Slenderness Ratios
7.3.1 Tension and Compression Members
Table 7-1 : Maximum Slenderness Ratios for Tension and Compression Members
Member Type Max. Slenderness

Columns supporting vibrating equipment 100
Other columns and trestle legs 180
Compression bracing subject to permanent loads or belt tensions 180
Tension bracing subject to permanent loads or belt tensions 250
Tension bracing subject to transient loads (e.g. wind or seismic 300

loads)
7.3.2 Beams
Table 7-2 : Depth/Span Ratios for Preliminary Sizing
Member Type Depth : Span

Beams supporting heavy or vibrating equipment, gearboxes or drives 1:10
General platform and frame line beams 1:20
Walkways and minor access decks 1:25
Steel lattice beams (in trusses) 1:12
Roof purlins 1:30
Girts 1:50

Page 35 of 45
7.4 Transportation and Constructability

Careful consideration shall be given to the size of fabricated members and sub-assemblies to
ensure that they are suitable for transportation to the site by road. Any design of a sub-
assembly shall be made in consultation with the construction manager and the design
coordinator early in the design process to agree on the extent, number of units, load factors
and loading conditions.
Refer to the Ministry of Transport Guidelines for load size limits for transportation.
All details shall be arranged to facilitate handling of sub-assemblies, such as not including
any welded cleats that protrude proud of the overall member. Consideration shall be given
to cranage requirements and site connections/splices.
7.5 Connections
7.5.1 Philosophy
Connections shall be designed in accordance with AISC with simplicity of fabrication and
erection given high importance. Connections must be designed to resist the applied load,
however over designed connections can add significantly to the cost of a structure, therefore
economical design principles shall be followed.
Standard connections shall be used wherever possible, however where applied forces
exceed the capacity of the standard connections, the connection shall be individually
designed.
Care shall be taken in connections involving members in three dimensions. Geometry and
clearances shall be thoroughly checked to avoid clashes and to allow for erection
requirements. Floor bracing shall avoid connecting into columns where possible.
Site welding shall be minimized, but not excluded if no other connection is practical.
Any single load shall be carried either entirely by bolting or entirely by welding, but not a
mixture of both.
7.5.2 Bolting
All bolting shall be in accordance with AISC, with installation procedures defined as follows:
• ST = Snug Tight Joints
• PT = Pre-tensioned Joints
• SC = Slip Critical joints.
Bolts shall be M20 except where loads are such that it is necessary to use larger bolts. All
bolt holes (with the exception of anchor bolts) shall have a diameter 2 mm greater than the
bolt. Mild steel bolts of sizes M12 or M16 may only be used in minor connections such as
purlins, girts, door frames, etc.
All bolts shall be designed, assuming thread projecting into the shear plane. All connections
shall have a minimum of two bolts with the exception of minor connections such as fly
bracing.
Slotted holes may be designed to allow thermal expansion and contraction.

Page 36 of 45
7.5.3 Welding
All welding shall be in accordance with AWS D1.1. Welding electrodes shall be specified as
E60XX.
Manual fillet welds should be limited to a maximum size of 10 mm if possible, as this is the
limit on a one-pass weld.
7.5.4 Beam End Connections
Beam end connections shall be either:
• Beam to column connections: flexible end plates
• Beam to beam connections: web side plates. The exception to this is where the
connection must carry substantial axial loads in which case the connection shall be
individually designed.
• Beam to existing beam: welded web side plate.

7.5.5 Column Splices
Column splices shall be located 800 mm above a floor level to ensure no clashing of bolts at
the intersection of floor beams. These splices shall be fully bolted for bending and prepared
for bearing for axial loads as described in the AISC Connection Design Guides.
7.5.6 Beam Splices
Beam splices shall be fully bolted and preferably located at a position where moment is low.
This does not preclude the use of bolted connections at other locations where moment is
high, but in such a case, comprehensive calculations are required for bolts details, prying
forces, end plate/flange bending strengths, and stiffener requirements.
7.5.7 Base Plates
Overall, base plate dimensions for relevant column size shall be chosen from the range
provided on the Standard Drawings.
Shear keys shall be either single or cruciform arrangement to suit the loading conditions and
force directions in accordance with the Standard Drawings.
Bolt holes in base plates shall have a diameter 6 mm greater than the nominal diameter of
the bolt (e.g. an M20 bolt shall be provided with a 26 mm diameter hole). Anchor bolts
shall be designed in accordance with Section 7.5.2.
7.5.8 Connection Design Loads
Connections shall be designed for the greater of the design action in the member, or the
minimum actions specified in Table 7-3.
Table 7-3 : Minimum Design Actions for Connections
Type of Connection Minimum Design Action

Rigid construction 0.5 x member design moment capacity
Simple construction 40 kN shear force or 0.15 x member shear
capacity
Axially loaded members 0.3 x member design capacity

Page 37 of 45
Type of Connection Minimum Design Action

Full contact bearing splices in compression 0.15 x member design capacity
Other splices 0.3 x member design capacity
Threaded rods 1.0 x member design capacity
7.5.9 Dynamically Loaded Connections

Equivalent design loads for connections subject to dynamic loads shall be taken as:
Fequiv = Fstatic + 3 Fdyn
where Fequiv = Equivalent static design load
Fstatic = Reaction due to static loads
Fdyn = Reaction due to dynamic loads
7.6 Bracing
As far as possible, vertical and horizontal systems are to be designed as a triangulated
concurrent system, with a preference to the ‘K’ brace configuration where access is a design
requirement, using circular hollow sections. If the loads are beyond the strength capacity of
circular hollow sections, consideration should be given to use rolled column sections.
Structural members, steel flooring and items of equipment connected to, but not directly part
of a triangulated bracing system, shall not be taken into account in the design of the bracing
system.
The preferable horizontal bracing arrangement for all structures shall be diagonal single
angle or circular hollow sections. Choice of steel section type shall be dependent on the
size of the loads to be transmitted. Roof bracing shall be designed for tension only and
where necessary may be fastened to underside of purlin in order to prevent sag.
Floor plate that is to be welded to deck secondary steel may be assumed to laterally restrain
the top flange of the secondary deck steel. Primary steel must rely on secondary steel or
bracing for lateral restraint. Floor grating shall not be assumed to offer lateral restraint to
deck beams.
Bracing members that are directly connected to beams supporting vibrating equipment shall
have a member length to radius of gyration ratio (l/r) not greater than 100.
Bracing members that are indirectly connected to beams supporting vibrating equipment but
are part of that structural framework or system shall be designed as compression members
with an l/r ratio not greater than 120.
Floor bracing shall not be connected to beam/column intersections where possible.

7.7 Lateral Restraint of Flexural Members
The following criteria apply to the assumed lateral restraint of members subject to flexure:
1. Open grid flooring shall be deemed to offer no lateral restraint to the top flange.

Page 38 of 45
2. Plate flooring that is bolted to the floor beams shall be deemed to offer no lateral
restraint to the top flange.
3. Plate flooring that is welded to the floor beams may be deemed to offer effective
lateral restraint to the top flange. The welds shall be designed to transfer the
required restraint forces.
4. Floor beams of a permanent nature only may be assumed to provide effective lateral
restraint to top flange of main beams. For global restraint to a floor a bracing system
shall be used.
5. Where a floor is constructed with an in-situ or precast reinforced concrete slab the
effective lateral restraint will depend on the physical connection between the slab
and the top flange of the beams.
6. Roof deck attached by screws shall generally be assumed to provide lateral restraint
to purlins that are perpendicular to the corrugation of the roof deck.
7. Siding, placed with corrugations vertically, in combination with sag rods shall be
assumed to provide lateral restraint to girts.
Note: Items 3, 6 and 7 shall apply in portions of the plant where corrosion is not expected
to be severe. If severe corrosion is anticipated, floor plate and roof/wall cladding
shall be assumed to provide no lateral restraint.
7.8 Deflection and Displacement
7.8.1 Process Buildings
Unless otherwise specified, deflections of structures subjected to serviceability loading (dead
load + live load) shall be limited as detailed in Table 7-4, in conjunction with the member
depth/span and slenderness ratio constraints detailed in Section 7.3.
Table 7-4 : Deflection Limits for Process Buildings
Deflection or Member Type Deflection Limit

Building drift Height/400 for overall height and between
floors
Wall columns Height/300
General floor beams Minimum of span/360 or 25 mm whichever
is less
Concrete process floors Span/360
Primary beams supporting equipment or Minimum of span/500 or 20 mm whichever
critical items is less
Purlins, girts and other secondary members Minimum of span/180 or 30 mm whichever
is less
Purlins with ceilings (plasterboard or Minimum of span/220 or 25 mm whichever
suspended) is less
Roof beams Span/360 for pitch > 3°

Page 39 of 45
Deflection or Member Type Deflection Limit

Span/500 for pitch ≤ 3°
Grating/floor plate Minimum of span/180 or 5 mm whichever is

less
For Monorail:
• Support at both ends L/500 or less
• Cantilevered L/300 or less
For girder supporting cranes:
• For motor-driven cranes L/800 or less
• For hand-operated cranes L/600 or less
For beam supporting equipment (Live Load
only):
• For heat exchanges (including air- L/400 or less and not more than 25 mm
cooled exchangers)
• For towers and vessels L/600 or less and not more than 20 mm
• For rotating or vibrating equipment L/800 or less and not more than 20 mm
• For other equipment L/400 or less and not more than 25 mm
Conveyor trusses – Span
• Vertical static operating loads Span/500
• Lateral dynamic operating loads Span/600
Conveyor trusses – Cantilever
• Vertical static operating loads Span/300
• Lateral dynamic operating loads Span/400
Pipe Racks and equipment structures Height/150
(Lateral)
7.8.2 Crane Runway Beams

The deflection limits given in Table 7-5 apply to crane runways and monorails, in
combination with ASME B30.11.
Table 7-5 : Deflection Limits for Crane Runways
Deflection Type Deflection Limit

Vertical Span/500 between supports
Span/300 for cantilevers/overhangs
Lateral Minimum of span/600 or 10 mm
Column bay span/400 for crane beam, between two columns,
supporting a crane beam span

Page 40 of 45
7.8.3 Portal Frame Buildings

Total horizontal displacement of portal frames at the knee shall not exceed 1/250 of the
height under influence of the worst load combination. Consideration shall be given to
differential deflection between sheeted end portal frames, which will behave as rigid
diaphragms, and intermediate portal frames in the building. Columns with cranes shall have
lateral deflections limited to height/400.
7.9 Corrosion Considerations
Generally all steelwork structures shall be designed to approximately 90% of capacity with
no corrosion allowance. Refer to MD-101-SMEM-EG-ST-SPC-0009 for protective coating
requirements. Detailing of the steelwork shall take into consideration the following items:
• In general, the minimum thickness of angles, tees, plates and flanges of sections shall be
6 mm
• The ends of all hollow sections shall be sealed to prevent moisture ingress
• Avoid details or arrangements that are inaccessible for inspection and plant maintenance
• Rolled steel structural shapes shall not be positioned in such a way as to retain moisture.
Provision shall be made for drainage where necessary
• Adequate space shall be maintained between components to facilitate painting
• Shedder plates or a suitable infill grout shall be considered in aggressive environments to

protect beam/column and column/footing connections from collecting moisture or
process liquids or other corrosive agents. Vibrations shall be considered when choosing
this method.
• For steel bins the stiffeners shall have all edges fully seal welded.
7.10 Structures Supporting Vibrating Equipment
Design parameters and operating frequencies of vibrating equipment shall be obtained in
writing from manufacturers or clients for each piece of equipment.
Loads due to vibrating machines, which will set up excessive building vibrations, shall be
isolated from the main structural framing. Where it is not possible to isolate such equipment,
all steelwork supporting the vibrating equipment shall be analyzed for fundamental natural
frequency of vibration and dynamic amplitude of vibration at the equipment operating
frequency. Care shall be taken to guard against resonant structures. For floor beams, the
ratio of natural frequency divided by equipment operating frequency shall not be less than
the values provided in Table 7-6.
Dynamic analysis shall be performed considering all appropriate dead loads and excluding
live loads. Areas subject to dynamic loading shall be checked for dynamic response against
limits for workers as specified in ISO 585:1997.

Page 41 of 45
Table 7-6 : Minimum Natural/Operating Frequency Ratios for Floor Beams
Beam Location Minimum Natural/Operating Frequency Ratio

Span < 5.0 m Span > 5.0 m
Directly connected to column 1.5 2.0
Not directly connected to column 2.0 2.5
7.11 Cold Formed Steel Purlins and Girts

Steel purlins and girts of C and Z profile shall be designed in accordance with the
manufacturers design guides. The full specifications, including required laps and bridging,
shall be clearly specified in the relevant calculations and drawings.
Special attention shall be paid to the vicinity of corners and perimeters of roofs and walls for
local pressure effects (refer to SBC 301). The capacity of purlin bolts shall be verified.
The maximum length of section without lapping shall be approximately 9.0 m. This is to
ensure that lengths of purlins can be handled manually once stacked on a roof, unless roof
sections are pre-assembled on the ground.
7.12 Steel Bins, Bunkers and Tanks
The design of steel bunkers and bins shall be in accordance with the following publications:
• Australian Steel Institute (ASI) “ Structural Design of Steel Bins for Bulk Solids”
• Eurocode 3/BS EN 1993-4-1:2007 “Design of Steel Structures Part 4-1: Silos”
• WTIA TN14 “Design and Construction of Welded Steel Bins”
• API 650 “Welded Steel Tanks for Oil Storage”.
One of the most important aspects of design of a bin (circular or rectangular) is to ensure that
loads are correctly carried into the columns, and that the columns are not loaded with
undesirable eccentricities. The design should begin at this detail, as it determines the final
position and orientation of the columns. The concentration of load in the bin plates from
column upwards must be carefully checked. Fabrication tolerances for the proper bearing at
the column cap must be specified. All bins shall be designed and detailed in such a way as
to minimize the site erection component of the work, and hence maximize the shop
fabrication. Consideration shall be given to the construction sequence and the possibility of
pre-fabricating sections of the bin either in the shop or on the ground at site, and then lifting
into place.
Design of bins, bunkers and tanks shall comply with the following requirements:
a) Wall plates shall have a minimum of a 2 mm wear allowance added to the theoretically
required thickness unless wear plates are being installed in the wear areas.
b) Only standard plate thicknesses shall be used.
c) Buckling shall be considered.

Page 42 of 45
d) For rectangular bins, wall stiffeners shall be designed for composite action. The
slenderness ratios shall be no greater than the plasticity limit to allow for a compact
action (Ref. AISC). For all welded elements the slenderness limits shall not exceed the
values for heavily welded sections.
e) For circular tanks, the eccentricity of plates at wall splices shall be minimized by
ensuring plate centre lines coincide.
f) The corrosion considerations of Section 7.9 shall apply. The need for a corrosion
allowance to be added to the theoretically required wall thickness must be investigated.
7.13 Design of Conveyor Structures
7.13.1 Conveyor Gantries
Conveyor gantries and trusses shall be designed to meet the following criteria:
1. Gantry spans shall be arranged such that the standard span is 24.0 m and the closing
span, which shall occur at the lower end of the conveyor, may be less than 24.0 m.
Where existing conveyors are to be extended, the gantry span shall be the same as
the existing.
2. Where high-level conveyors are greater than 200 m long, a stabilizing anchor tower
shall be provided to take out longitudinal loads generated between sliding joints.
3. Sliding joints shall be provided at spacing not greater than 100 m for high-level
conveyors, and 30 m for low-level conveyors.
4. Sliding joints at conveyor gantry end frame to trestle connections shall only be
provided at the lower end of a sloping gantry, unless stated otherwise on the
drawings.
5. No belt tensions shall be carried along the length of conveyors unless specific
allowance is made in the design.
6. If the mechanical arrangement or conveyor equipment supplier drawings do not
show walkways on both sides of the conveyor, this shall be brought to the attention
of the discipline engineer.
7.13.2 Deflection Criteria
Table 7-7 provides deflection limits that shall apply to the design of conveyor trusses and
trestles.
Table 7-7 : Deflection Limits for Conveyor Structures
Deflection Type Load Condition Deflection Limit

Vertical deflections of G Span/1000
gantries/trusses
G + Qn + Mn Span/700
G + Qs + Mf Span/240
Horizontal deflections of Wo Span/500

gantries/trusses
Ws Span/240
FP Refer to SBC 301

Page 43 of 45
Deflection Type Load Condition Deflection Limit

#
Horizontal deflections at Wo Minimum of height /500 and
tops of trestles 50 mm
#
Ws or FEQ Height /250
#
The height of a trestle shall be taken as the vertical distance between the underside of base
plate and the top-of-steel level of the crossbeam.
where: G = Weight of steelwork + idlers + belt + permanent dead loads
Qn = Live load on walkway/s without material spillage
Qs = Live load on walkway/s including material spillage
Ws = Serviceability wind load
Wo = Wind load during a shutdown
Mn = Normal operating material weight *
Mf = Flooded belt material weight *
FP = Seismic force acting on a component of a structure
* Live loads on a conveyor (Mn and Mf) shall be determined in accordance with ISO 5049.
7.13.3 Connection of Conveyor Trusses to Buildings
In the situation where a conveyor truss is connected to a building using a theoretically
pinned connection it is necessary to consider the horizontal sway of the first trestle out from
the building and take into account the resulting horizontal couple set up in the supporting
beam at the building as it attempts to resist this sway.
7.13.4 Conveyor Trestles
Conveyor trestles shall be designed for the loads originating from the gantry/truss design.
Generally conveyor trestles shall be standardized for the project and each trestle shall be
chosen from these standard trestles for rationalized heights ranges.
7.14 Cranes and Monorails
The design of crane girders, monorail beams and lifting device support structures shall be in
accordance with ASME B30.11.
Crane rail supporting steelwork (runway or girder) shall be designed to have adequate
strength to resist bending, shear, torsion and local effects. Interaction between global
bending, shear, torsion and local effects shall be included in the design considerations.
Crane rail supporting steelwork shall have supports designed to transmit reactions under the
least favorable loading condition. Crane rail supporting steel shall also be designed for
possible eccentric loads caused by inexact steelwork shapes, fabrication and construction.

Page 44 of 45
The application of crane and monorail loads, load factors and the design of the steel framing
shall be in accordance with this Criteria and AISC publication, Steel Design Guide 7,
Industrial Buildings.
Serviceability deflections shall be limited to the requirements of Table 7-5.
Cranes shall be installed and operated in accordance with ASME B30.2 or ASME B30.17.
Monorails shall be installed and operated in accordance with ASME B30.11.
Crane rails shall be supplied in accordance with BS 11 or BS EN 13674 and secured to the
crane beam by a proprietary crane rail fastening system approved by the Employer.
Monorail end stops to be at least as wide as monorail flanges.
All lifting equipment with a rated load capacity in excess of 1 tonne must be certified by the
crane manufacturer. It is the Design Engineer’s responsibility to check that this has been
carried out in accordance with the code requirements.
7.15 Stacks and Chimneys
The design of stacks and chimneys shall be in accordance with the International Committee
on Industrial Chimneys (Comité International Des Cheminées Industrielles - CICIND) Model
Codes and Manuals.
7.16 Steel Pile Design
All steel pile design shall be in accordance with ASCE 20-96.

Page 45 of 45

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MA’ADEN ENGINEERING MANUAL

Structural Design Criteria- Process Buildings And

MD-101- SMEM-E G- ST-CRT-0001

Rev. Rev. Date Revision Status Prepared By Reviewed By Approved By Approved By

PROPRIETARY & CONFIDENTIAL

PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

Rev CO 1 prepared for Ma’ aden by Hatch Associates. H337201-0000-35-122-0001_C

PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

5.14 Piping Loads ............................................................................................................................ 20

PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

7. Structural Steel Design Criteria ........................................................................................................ 34

PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

• Set the minimum engineering standards and requirements.

2. KEY TERMS AND DEFINITIONS

Contractor Party responsible for supplying engineering services, materials, plant,

SBC Saudi Building Code

SASO Saudi Arabian Standards Organization

ACI American Concrete Institute

AISC American Institute of Steel Construction

API American Petroleum Institute

ASCE American Society of Civil Engineers

ASME American Society of Mechanical Engineers

ASSE American Society of Safety Engineers

ASTM American Society for Testing Materials

AWS The American Welding Society

BEDD Basic Engineering Design Data

CMAA Crane Manufacturers Association of America

CICIND Comité International Des Cheminées Industrielles (International

ISO International Organization for Standardization

PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

PCI Precast/Prestressed Concrete Institute

SDI Steel Deck Institute

SJI Steel Joist Institute

Saudi Building Code: SBC 301 Structural Loading and Forces

Saudi Building Code: SBC 302 Structural Testing and Inspection

Saudi Building Code: SBC 303 Structural Soil and Foundations

Saudi Building Code: SBC 304 Structural Concrete Structures

Saudi Building Code: SBC 305 Structural Masonry Structures

Saudi Building Code: SBC 306 Structural Steel Structures

SASO SSA 2 Steel Bars for the Reinforcement of Concrete

SASO SSA 224 Steel Fabric for Reinforcement of Concrete

3.2.2 International Codes and Standards

ACI 117 Standard Specifications for Tolerances for Concrete

PROPRIETARY & Structural Design Criteria - Process Buildings and Structures

ACI 201.2R Guide to Durable Concrete

ACI 212.3R Chemical Admixtures for Concrete

ACI 301 Specifications for Structural Concrete

ACI 302.1R Guide for Concrete Floor and Slab Construction

ACI 304R Guide for Measuring, Mixing, Transporting and

ACI 304.2R Placing Concrete by Pumping Methods

ACI 305R Hot Weather Concreting

ACI 308 Standard Practice for Curing Concrete

ACI 308R Guide to Curing Concrete

ACI 309R Guide for Consolidation of Concrete

ACI 318M Building Code Requirements for Reinforced Concrete

ACI 318/318R Building Code Requirements for Structural Concrete

ACI 347 Guide to Formwork for Concrete

ACI 350 Code Requirements for Environmental Engineering

ACI 351.3R Foundation for Dynamic Equipment

ACI 360R Guide to Design of Slab on Grade

ACI 440.1R Guide for the Design and Construction of Concrete

ACI 504R Guide to Sealing Joints in Concrete Structures