Hindalco Confidential

HIC/MOD/2016-17/17

01-04-2016

Hindalco Confidential – Internal Memo

To: Rajiv Parulekar Location: Hindalco, Everlast Marketing

From: Gautam Wagle HIC-SemiFab, Taloja

Copy: D K Das Hindalco Marketing

Ashish Nema Hindalco Marketing

Subhankar Gupta HIC-Semifab, Taloja

Technology Information Centre HIC-Semifab, Taloja

Subject: Load bearing capacity of Everlast Modern Troughed sheets (Kerala profile) & new
Profile under Development

Load Bearing Capacity Calculations

Hindalco Everlast Industrial Troughed profile (Ind-7) shown in Figure 1 below is typically
offered in thicknesses of 0.71mm and 0.91mm for Industrial project customers. AA3105-H18
and AA 8011-H18 are the more common alloys and tempers used for Industrial troughed
roofing. Mechanical properties of roofing sheet material are listed in Table 1.

Figure 1: Hindalco Everlast Industrial 7 troughed sheet profile

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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Table 1: Mechanical Properties for Everlast Industrial Troughed roofing sheet Alloys

Alloy Temper UTS (MPa) Yield Stress (MPa)

AA3003 H18 200 240 180

AA3105 H18 195 -- 160

AA8011 H18 175 -- 140

The Everlast brochure specifies the Permissible loading for various thicknesses of roofing
sheet for the industrial troughed roofing sheet. The permissible loading is dependent on the
purlin spacing and the support type (end supports or intermediate support) as shown in
Figure 2.

Figure 2: Permissible Loading for Everlast Industrial Troughed roofing sheet

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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01-04-2016

The permissible loading for various thicknesses was analyzed using beam theory calculations
considering a single pitch of troughed profile. The structural properties (Moment of Inertia)
for a profile were calculated using the Parallel Axis Theorem.

As per the beam theory for simply supported beam under uniformly distributed loading
(Figure 3) corresponding to sheet length supported by a single purlin, the maximum bending
stress as a result of uniformly distributed load is given by:

My max
 max 
I

wL2
where M  is the maximum bending moment due to a uniformly distributed load, w
8
(kg/m2), acting over a span L (purlin spacing).

Figure 3: Beam Theory for Simply Supported Beam under Uniformly Distributed Load

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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Table 2 lists the analyzed maximum bending stress due to the maximum permissible loading
listed for a single purlin support in the Everlast brochure.

Table 2: Maximum Bending Stress (single-purlin) for Permissible Loading (Ind-7 troughed)

Permissible Loading (kg/m 2) Max. Bending Moment (N-m) Max. Bending Stress, max (MPa)
Thickness
Purlin spacing, L (mm) Purlin spacing, L (mm) Purlin spacing, L (mm)
(mm)
914 1219 1524 1829 2134 914 1219 1524 1829 2134 914 1219 1524 1829 2134
1.22 1066 600 384 266 181 136.4 136.5 136.6 136.3 126.2 77.0 77.0 77.1 76.9 71.2

0.91 807 454 290 202 136 103.2 103.3 103.1 103.5 94.8 77.4 77.4 77.3 77.5 71.1

0.71 636 357 229 159 106 81.4 81.2 81.4 81.4 73.9 77.7 77.5 77.7 77.7 70.6

0.56 505 284 182 126 84 64.6 64.6 64.7 64.5 58.6 77.8 77.8 78.0 77.7 70.6

It is noted that the permissible loading for the current Everlast Industrial troughed roofing
sheets for single purlin support have been specified to keep maximum bending stress at
approximately 78 MPa. With material yield strength for AA3105-H18 of ~ 140-160 MPa, it
can be seen that the permissible loading results is a Factor of Safety of approximately 1.8 -
2.0 based on the maximum bending stresses.

The case of single sheet length supported by multiple purlin can be analyzed by considering
the beam theory for a continuous beam with two equal spans under uniformly distributed
load as illustrated in Figure 4. The maximum bending moment due to a uniformly distributed
9wL2
load, w (kg/m2), acting over a span L (purlin spacing) in this case is given by M  .
128

Table 3 lists the analyzed maximum bending stress due to the maximum permissible loading
listed for multiple purlin support in the Everlast brochure.

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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Figure 4: Beam Theory for Continuous Beam (Equal Spans) under Uniformly Distributed Load

Table 3: Maximum Bending Stress (multiple-purlin) for Permissible Loading (Ind-7 troughed)

Permissible Loading (kg/m 2) Max. Bending Moment (N-m) Max. Bending Stress, max (MPa)
Thickness
Purlin spacing, L (mm) Purlin spacing, L (mm) Purlin spacing, L (mm)
(mm)
914 1219 1524 1829 2134 914 1219 1524 1829 2134 914 1219 1524 1829 2134
1.22 1245 700 448 311 229 89.6 89.6 89.6 89.6 89.8 50.6 50.6 50.6 50.6 50.7

0.91 943 530 339 236 173 67.9 67.8 67.8 68.0 67.9 50.8 50.8 50.8 51.0 50.8

0.71 743 418 267 186 136 53.5 53.5 53.4 53.6 53.3 51.0 51.1 51.0 51.2 50.9

0.56 590 332 212 148 108 42.5 42.5 42.4 42.6 42.4 51.1 51.2 51.1 51.4 51.0

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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The permissible loading for the current Everlast Industrial troughed roofing sheets with
multiple purlin support have been specified to keep maximum bending stress at
approximately 51 MPa. For AA3105-H18 with yield strength ~ 140-160 MPa, it can be seen
that the permissible loading results is a Factor of Safety of approximately 3.0 based on the
maximum bending stresses.

New Everlast Profiles

New Everlast troughed roofing profiles have been developed for specific marketing segments.
The Modern Troughed profile for the Kerala Market to be in domestic applications shown in
Figure 5(a) is currently offered in AA3105-H18 in 0.4 and 0.46mm as colour coated roofing
sheets. This profile was developed with lower load bearing capacity than existing Ind-7
profile to provide a cost-effective offering in the domestic market.

A new stronger Industrial troughed profile for applications in industrial construction shown in
Figure 5(b) is under development at Renukoot and is proposed to be offered in AA3105-H18
in 0.56 – 0.71mm thickness. This new profile has been developed to increase the load
bearing capacity in order to compete with the inherently stronger GI roofing sheet offerings
in industrial segments.

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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(a) Modern Troughed (Kerala Profile)

(b) Strong Industrial Troughed (New Renukoot Development)

Figure 5: New Everlast Troughed Roofing Sheet Profiles Developed

Load Bearing Capacity for New Profiles

Load bearing capacity for the different Everlast roofing profiles to be offered in different Alloy
& Temper grades for commonly used purlin spacing are calculated. Cases of single and

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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multiple purlin to support the roofing sheet length are considered with appropriate beam
theory calculations described in previous section.

The load bearing capacity of the roofing sheet in kg/sq-m for length of sheet supported with
a single purlin and multiple purlin are summarized in Tables 4 and 5 respectively. For the
single purlin, a slightly higher factor of safety 2.0 – 2.2 (Maximum bending stress ~ 100
MPa) is taken for AA3104-H18 alloy since variability due to Hot rolled gauge under
development trials at Hirakud FRP and variability in coating process are yet to be
established.

Table 4: Load Bearing Capacity (kg/m2) for Single Purlin (ΔˉˉˉˉˉΔ) in Various Thicknesses

Profile Ind-7 Troughed Modern Troughed (Kerala Profile) Ind. Strong (New Rkt Development)
Alloy-Temper AA3105-H18 AA3105-H18 AA3104-H18 AA3105-H18 AA3104-H18
Purlin spacing Purlin spacing Purlin spacing Purlin spacing Purlin spacing
Thickness (mm) (mm) (mm) (mm) (mm)
(mm)
914 1219 1524 914 1219 1524 914 1219 1524 914 1219 1524 914 1219 1524
1.22 1066 600 384 695 390 250 900 505 322 1493 840 535 1970 1105 705
0.91 807 454 290 525 295 189 680 380 245 1130 635 405 1480 830 530
0.71 636 357 229 412 232 148 535 300 192 890 495 320 1165 650 415
0.56 505 284 182 326 184 118 425 238 152 705 395 250 920 515 330
0.46 415 234 149 270 152 97 350 196 126 580 325 205 760 425 270
0.4 356 202 129 235 132 85 305 171 110 500 280 180 660 370 235

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204

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Table 5: Load Bearing Capacity (kg/m2) for Multiple Purlin (ΔˉˉΔˉˉΔ) in Various Thicknesses

Profile Ind-7 Troughed Modern Troughed (Kerala Profile) Ind. Strong (New Rkt Development)
Alloy-Temper AA3105-H18 AA3105-H18 AA3104-H18 AA3105-H18 AA3104-H18
Purlin spacing Purlin spacing Purlin spacing Purlin spacing Purlin spacing
Thickness (mm) (mm) (mm) (mm) (mm)
(mm)
914 1219 1524 914 1219 1524 914 1219 1524 914 1219 1524 914 1219 1524
1.22 1245 700 448 800 450 290 1120 630 405 1750 985 630 2440 1370 875
0.91 943 530 339 605 340 220 847 476 305 1320 740 475 1835 1030 656
0.71 743 418 267 480 270 170 670 375 239 1035 580 370 1435 806 515
0.56 590 332 212 380 215 135 532 298 189 820 460 295 1140 640 410
0.46 485 272 173 310 175 112 434 245 156 670 375 240 935 525 336
0.4 419 236 151 270 152 98 378 213 136 585 325 209 815 455 291

Summary
The load bearing capacity for Everlast troughed profiles (existing and new developed) have
been evaluated for various roofing sheet thicknesses supported either with single and
multiple purlin.

Keeping similar Factors of Safety in design for load bearing capacity of various troughed
roofing profiles it is seen that:

 For the same alloy and temper, the Modern Troughed profile (Kerala profile) has
approximately 1.5 times less load bearing capacity than the Ind-7 troughed profile.
 For the same alloy and temper, the Industrial Strong profile (New development) has
approximately 1.4 times higher load bearing capacity than the Ind-7 troughed profile.
 For the same profile, AA3104-H18 (Yield Strength ~ 220 MPa) has approximately 1.35 –
1.4 times higher load bearing capacity than AA3105-H18 (Yield Strength ~ 160 MPa).

HINDALCO INDUS TRIES LTD. REGISTERED OFFICE Website www.hindalco.com

Plot # 2, MIDC Taloja, Century Bhavan, 3 rd Floor, Email hindalco@adityabirla.com
Navi Mumbai, Maharasthra – 410 208 Dr. Annie Besant Road,
Corporate
Worli, Mumbai - 400 030
Identity No. L27020MH1958PLC011238
Telephone +91-(22) 66292252 Telephone +91-(22) 6662 6666
Fax +91-(22) 66292204