M5

UNIT 14 DESIGN OF STEEL CHIMNEYS
Structure
14.1 Introduction
Objectives
14.2 Types of Steel Chimney
14.2.1 Self-supporting Steel Chimneys
14.2.2 Guyed Steel Chimneys
14.3 Factors
14.4 Design of Steel Plates for Self-supporting Steel Chimneys
14.5 Design of Joints for Self-supporting Steel Chimneys
14.6 Design of Flue Openings for Self-supporting Steel Chimneys
14.7 Fvrces Acting on Steel Chimney
14.7.1 Vertical Forces
14.7.2 Horizontal Forces
14.8 Bending Moment on Self-supporting Steel Chimneys
14.9 Bending Stress on Steel Chimney Due to Wind
14.10 Permissible Stresses
14.1 1 Design of Base Plate
14.12 Design of Anchor Bolts
14.13 Design of Foundation
14.14 Lining for Chimney
14.15 Stability of Steel Chimney
14.16 Design Problems
14.17 Summary
14.18 Answers to SAQs
14.1 INTRODUCTION
Steel Chimneys are frequently known as steel Stacks. The steel chimneys are made
of steel plants and supported on foundation. The steel chimneys are cylindrical in
shape. To provide larger base and greater stability, and to allow for easy entrance
of flue gases, the lower portion of the steel chimney is widened or flared out. The
widened section of the chimney at the base reduces the unit stresses in the steel at
the base of the chimney. The steel chimneys are constructed for the emission of
flue gases to such a height that the gases do not contaminate the surrounding
atmosphere. The cross-sectional area of the steel chimney is kept large enough to
allow the passage of burnt gases. The cross-sectional area of the steel chimneys
depends on the type and quantity of fuels to be used in plant, available draft for
carrying the burnt gases up the chimney. The height of the steel chimney is kept to
provide the required draft. "The draft is defined as the difference between the
absolute gas pressure at any point in the steel chimney and the ambient atmosphere
pressure." The draft depends on the height of the steel chimney above sea level,
the type of fuel to be burnt, the type of furnace and the temperature of the burnt
gases.
When the gases in a steel chimney are heated, then the gases expand. The hot
gases occupy larger volume than before. The weight of the gases per cubic metre
becomes less. As a result of this, the unit pressure at the bottom of chimney due to
weight of hot gases also becomes less than the unit pressure due to weight of cold
air outside the chimney. The difference between two pressures results in the flow
of the burnt gases up the chimney. For the purpose of structural design of steel
Steel Structures chimney, the height and the diameter of chimney at the top are known. The loads
acting on the steel chimney are transferred to the foundation easily by the widened
section. The base of the chimney may be made conical or bell-mouthed. But the
fabrication of bell-mouthed base does not have any advantage over the conical base
and the fabrication is costly. So, generally the conical base is provided.
The recommended height od flared portion of the chimney is 113rd of the height of
the chimney. The ratio of the diameter of the base of the flare to the diameter of
the cylindrical portion varies from 514 to 312. The plates in the conical flare should
not be thinner than the thickness of the lowest course in the cylindrical portion.
Objectives
After studying this unit, you should be able to
distinguish between various types of steel chimneys,
evaluate the forces acting on a steel chimney,
effect of bending moment and bending stress on self-supporting steel
chimneys,
design of flue openings, points and foundations,
obtain expression$ for bending moment, stresses and thickness of plates,
and
understand the stability concept of steel chimney
14.2 TYPES OF STEEL CHIMNEY

The slteel chimfieys are of two types:
i) Self-supporting smeel chimneys
ii) Guyed steel chimbeys
14.2.1 Self-supporting Steel Chimneys

A self-supporting steel chimney or stack is made of steel plates and supported on
foundations. When the laterlal forces (wind or seismic forces) are transmitted to the
foundation by the cantilevet action of the chimney, then the chimney is known as
self-supporting. The chimnay together with the foundation remains stable under all
working conditions, without any additional support. A self-supporting chimney is
shown in Figure 14.1. The self-supporting steel chimneys are made upto 10 m
diameter and from 50 m to 100 m in height.

In high steel chimneys, the mild steel wire ropes or guys are attached to transmit
the lateral forces. Such stedl chimneys are known as "guyed steel chimneys." In
guyed steel chimneys, all the externally applied loads (wind, seismic force etc.) are
not totally carried by the chimney shell. These attached guys or stays do share
these applied loads. These chimneys may be provided with 1, 2, or 3 sets of guys.
In each set of guys 3 or 4 m sometimes 6 wires are attached to the collars. A
particular type of steel chimney is selected depending on the advantage and
disadvantages with referenae to economy.
Design of Steel Chimneys
tCylip
n odrrt i ocna l
a (I((I
Breech
or
F l u e opening
liigure 14.l(a) : Self-supporting Steel Chimney
Figure 14.l(b) : Guyed Steel Chimneys
14.3 FACTORS
A choice between self-supporting steel chimney and guyed steel chimney is made
by considering some of the important factors : Number of units, type of equipment,
and type of fuel to be used are considered. In case the chimney to be used for
boilers, the surface area, output efficiency, draft requirements etc. are taken into
account. The mode of operation of the equipment shall also be considered.
The type of lining is decided knowing the composition of the flue gases. The
temperature of the flue gases before entering the chimney and its likely variation
are studied. The local statutory regulations, relating to height, dispersion of ash,
Steel Structures provision for earthing aviation warning lamps. The quantity of dust and data about
the aggressiveness of the flve gases etc. are the factors which should be considered
for selecting a type of steel chimney.
- - - - -
14.4 DESIGN OF' STEEL PLATES FOR SELF-

SUPPORTING STEEL CHIMNEYS
Generally the plate width of 1.5 m is used for chimneys. The thickness of plates
should not be less than 6 mm and in upper portions one or two plates should be
8 mm thick as it is subjected to maximum corrosion. The thickness of steel plates
in the flared portion should not be less than the thickness at the lowest section of
the cylindrical portion. The steel plates are available in thickness of 2, 6, 8, 10, 12,
14, 16 & 20 mm. The saeel plates of chimneys are caulked from the inner side of
chimney so they are sheared or planned to proper levelling. The thickness of steel
chimney obtained from stress calculations and deflection consideration shall be
increased by permitting an allowance for corrosion determined from the
considerations of the deslign life of the chimneys and aggressiveness of the flue
gases. The steel plates are painted in order to avoid corrosion. The corrosion
resistant steel plates may be used in chimneys. Copper bearing steel plates may be
used for self-supporting steel chimney. The allowance for corrosion permitted is
decided depending upon the amount of internal corrosion of steel plates. For 10
years of design life the allowance for slight, normal, and exceptional internal
corrosion is 2 mm, 3 m$, and 5 mm respectively also for 20 years, the above said
steel is 4 mm, 5 mm and 8 mm respectively.
The windward side of steel chimney is subjected to tensile stress due to the
combined effect of the qind and the weight of steel chimney. The weight of lining
is omitted in calculating (the maximum tension, since the maximum wind pressure
may act on the steel chimney before the lining is done. The maximum wind may
also act, when the chimqey is under repair and the lining has been removed for
renewal. The maximum dotal tensile stress on windward side.
where, o,= permissible stress in tension in steel plates

ql = efficiency of the point on the tension side
Thus the thickness of the steel plates from tension side
The leeward side of the $tee1 chimney is subjected to maximum compressive stress
due to the combined effect of wind, weight of steel chimney and weight of lining.
The maximum total compressive stress on leeward side.
1 where, oc= permissible stress in compression in steel plates

I
I q2= efficiency of the joint on the compression side
,
= 1 (:. q2=100%)
Thus the thickness of the steel plates from compression side
The thickness of the steel plates at various horizontal sections are found. The
thickness of steel plates o f the flared portion should not be less than the thickness
of steel plates in the cylindrical portion. The thickness of steel plates of chimney is
kept in excess than what is necessary (in order to protect them from corrosion) by
allowance for corrosion, which depends upon the design life of the steel chimney.
14.5 DESIGN OF JOINTS FOR SELF-SUPPORTING STEEL

CHIMNEYS
Single riveted lap joints are used for vertical seams, and single, double, or triple
riveted lap joints are used for the horizontal seams of the upper part or cylindrical
portion of the steel chimney i.e. flared portion, butt joints are used in the
horizontal seams with the heavy plates. Butt joints are also used in the vertical
seams in the bell-mouthed flare of large chimney. The recommended types of
riveted joints and diameter of rivets necessary for different thickness of plates are
given in Table 14.1.
Table 14.1
Thickness of Steel Plates Diameter of Steel Type of Riveted Joint
(mm) (mm)
6 16 Single riveted lap joint
1
8-10 18 Double riveted lap joint
12-16 22 Triple riveted lap joint
Thicker than 16 24 Butt joint
The spacing of the rivets along the caulked edges of plates shall not be greater
than 10 times the thickness of plates. The spacing of the rivets shall not be less
than 2.5 times the diameter of rivet.
The steel plates more than 16 mm thick and not more than 22 mm thick are
sub-punched with a punch 5 mm smaller than the nominal diameter of rivet, and
reamed to a diameter of 1.5 mm larger than the rivet. The plates thicker than
22 mm are drilled.
Steel Structures
14.6 DESIGN OF FLUE OPENING FOR
SELF-SUPPORTING CHIMNEYS
The flue opening is also khown as breech opening. The flue opening is provided
for the entrance of flue gases. The flue gases come from furnaces of the boilers.
A flue opening or breech opening is provided in the steel chimney as shown in the
Figure 14.l(a). The area of the flue opening is kept about 20% larger than the
internal cross-sectional area of the chimney. The maximum width of the flue
opening should not be greater than two-thirds of the diameter. In order to
compensate the removed materials, the reinforcement should be provided all around
the flue opening. The vertical reinforcement provided should be 20% larger than
the material removed in the ratio of diameter to the long chord perpendicular to the
face of the opening.
( a) One bndch opening ( b) Two bkecn openings
[c Two breech openings (d 1 Three breech openings

a t right1 angles
Figure 14.2
The horizontal reinforcement provided at the top and bottom of the opening is kept
equal to the vertical reihforcement. The reinforcing material provides sufficient
vertical stiffness. In order to transfer and distribute the stress into the steel of the
chimney, the reinforcing material should be extended above and below the opening.
In the self-supporting steel chimney the flue opening is kept well above the flared
or conical base, so that it does not extend in the flared base.
The steel chimneys may have one or two breech openings, in the same direction,
two breech openings at right angles and three breech openings as shown in
Figure 14.2 (a), (b), (c), and (d), respectively. The number of flue openings may
be 1, 2, 3, or 4 depending upon the requirement. It is suggested that a maximum
of two flue-openings may be provided at one level so that the chimney remains
safe enough to resist the applied forces at the plane of the openings. However, it is
possible to provide thr$e openings in one plane. This is done only when the
number of the openings is three only. The width of openings does not exceed
one-third of the diameter of the chimney at that plane. A clean-out door as shown
by dotted lines in Figure 14.1 is provided preferably on the opposite side of the Deslgn of Steel Chimneys
breech opening near the base. The minimum size of clean-out door shall be
300 mm x 800 mm clear. The clean-out door serves the purpose of removal of ash
and for the inspection of inside of steel chimney clean-out doors are also properly
reinforced.
14.7 FORCES ACTING ON STEEL CHIMNEY

The various forces acting on the self-supporting steel chimney are as follows.
14.7.1 Vertical Forces
1) Self-weight of the Chimney
The self-weight of steel chimney Ws acts vertically. Consider a
horizontal section XX as shown in Figure 14.1 The thickness of steel
plates of chimney above the section XX, may be assumed constant. The
self-weight of chimney is given by
p = unit weight of steel = 79 k ~ / r n ~

d = diameter of chimney in metres
t = thickness of steel plates in metres
h = height of steel chimney above the section XX in metres

.: W, = 79 ( n dt.h) kN ...(14.5)
The compressive stress in the steel plates at the section XX due to the
self-weight of chimney is given by
= 0.079 h N/mm2 ...( 14.6)

2) Weight of Lining
The weight of the lining in the steel chimney W L , also acts vertically.
The thickness of brick lining may be assumed as 100 mm. The weight
of lining
W, = p, . m i . (O.l).h
pl = unit weight of brick lining
The compressive stress in the steel plates at the section XX, due to
weight of lining
Steel Structures
14.7.2 Horizontal Forces
1) Wind Pressure
The wind pressure acts horizontally. The wind pressure acting on the
structure depends on the shape of the structure, the width of the
structure, the height of the structure, the location of the structure, and
the climatic condition The wind pressure per unit area increases with the
height of the structure above the ground level. In order to simplify the
design, the steel chimney is divided into number of segments of equal
height. The height of each segment may be kept 10 m. The intensity of
wind pressure over each segment may be assumed as uniform. The
intensity of wind pressure corresponding to the mid-height of each
scgment may be noted from IS : 875-1984. The wind pressure on the
flared portion may be found by using average diameter. The wind
pressure is assumed to act at the mid-height of each segment and also in
the flared portion. It has also been practised to take uniform wind
pressure over the full height of chimney.
The wind pressure
P = K.P1 x (Project area of chimney)
where, K = shape factor

It accounts for the shape of thc structure. p e shape factor for the
cylindrical portion is 0.7
P, = Intensity of wind pressure
:. P = 0.7 x (P,x d l x h) kN ...(14.9)
where, dl = outer diameter of chimney.

In addition to overturning effect due to wind pressure, the wind has also
aerodynamic effect. The aerodynamic effect of wind has not been taken
into consideration for the design of steel chimney.
2) Seismic Forces
The seismic forces also act horizontally. The seismic forces act on a
structure, when the structures are located in the seismic area.
The following load combinations for calculation of stresses at any point
of steel chimney are considered.
i) Dead load + wind load
ii) Dead load + Earthquake load

iii) Dead load + Earthquake seismic load
+ Temperature effect + live load.
Under these loads the chimney behaves as a cantilever and the chimney
may be designed by conventional beam and column theories and the
maximum stress .is limited to the allowable stress given by the chimney
code. The worst combination out of the effect due to seismic
(Earthquake) forces and wind effect is only taken into consideration and
only one effect is considered for the design of the structure.
-- - - - - - - - - - - - - - - -

14.8 BENDING MOMENT ON SELF-SUPPORTING STEEL
CHIMNEYS
The wind force acts as uniformly distributed load on the self-supporting steel
chimney. For the purpose of determining bending moment at any section XX
Figure 14.1 the wind force is assumed to act at the middle height above the
section. The bending moment due to wind at section XX, h metres below the top is
given by
where, p = total wind force

Substituting the value of P from Eq. 14.9.
...(ii)
/'
Sometimes the self-supporting steel chimney is erected between the constructed
buildings. A portion of the chimney extends over the roof of the building as shown
in Figure 14.3. The remaining portion of the chimney remains protected from the
wind. The bending moment for the part of chimney above the roof is calculated in
accordance with the expression (ii) above, the bending moment of chimney below
the roof (protected from the wind) shall be determined as follows:
When the chimney is not fixed at the roof
F 7
When the chimney is fixed at the roof
Case(A) Case (El I
Figure 14.3
The maximum bending moment occurs at the base of the chimney

This bending moment acts as overturning moment on the steel chimney. The
overturning moment Md, due to the wind pressure causes compressive stress on the
leeward side of the steel chimney and the tensile stress on the windward side of
the steel chimney. The maximum compressive stress and tensile stress on the
extreme fibre of steel chimney due to wind are equal.
14.9 BENDING STRESS ON STEEL CHIMNEY DUE TO

WIND
The bending stress fw at the extreme fibre of steel chimney due to overturning
moment, Mw (moment due to wind in kN-m) is given by
I = Moment of inertia of circular ring section of the steel chimney
Z = Modulus section OF chimney ring section with no flue opening

t = thickness of steel plate (viz., without corrosion allowance)
IS : 6533-1971 'Code of practice for design and construction of steel chimney

recommends the value of section modulus of steel chimney ring with no flue
opening as
The modulus of section of chimney cross-section with flue opening as shown in

Figures 14.2 (a, b, c, & d) are given by the following expressions respectively
..(i)
It is to note that these expressions are applicable for thickness of the plane less Design of Steel Chimneys
than 0.015d.
14.10 PERMISSIBLE STRESSES

The windward side of the steel chimney is subjected to tensile stress due to
combined effect of the wind and the weight of steel chimney. The leeward side of
the steel chimney is subjected to compressive stress due to combined effect of
wind, weight of steel chimney and weight of lining. In order to control buckling in
steel chimneys the compressive stress caused by the combination of extreme
stresses due to bending and direct load should not exceed the values given in
Tables 14.3 and 14.4.
On the compressive side the chimney, the efficiency of the joint depends on the
strength of the rivets in shear, and in bearing, and does not depend on the tensile
strength of the plate. The efficiency of the joint on the compression side is 100%.
The efficiency of the joint on the tension side is less than the efficiency on the
compressive side say 70%. The permissible stresses in steel chimney in axial
tension, shear and bearing shall be adopted as specified in 18:800-1984. The
allowable stress in axial compression and in bending for circular chimneys depends
upon the effective height of the steel chimney h,, the radius of gyration, k (0.707 x
radius), the diameter and the thickness 't' of the chimney to be considered for
different types of steel chimneys are shown in the Table 14.3.
I
I
1
I Figure 14.4: Self-supporting Chimney
stress
Axial h , = 2L
I Bending h , = L
where, h , = effective height of chimney
The allowable stress in axial compression and in pending for circular steel chimney
are as per IS 6533-1971 ('Code of practice for design and construction of steel
chimneys). The combined stress shall comply with the requirements of IS:800-1984.
The member of the steel chimney reasonably exposed to adverse temperature shall
be considered. The allowable stresses are obtained by multiplying the basic stresses
the appropriate temperature coefficient, k,.The value of k, may be noted from
Table 14.2 as specified in IS:6533-1971.
Coefficient, kt
Temperature 0.20 250 300 350 40O0C
kt 1.OO 0.75 0.67 0.60 0.50
for Circular Steel Chimneys

Allowable Stress in N/-'
hlk (dlt)
Ratio Ratio
100 125 150 175 200 225 250 300 350 400 450 500 550 600
and less
0 125.0 125.0
10 125.0
20 125.0
30 125.0 125.0 *
40 125.0 125.0 125.01125.0
50 125.0 125.0 125.0 125.0 125.0 125.0 125.0
60 125.0 125.0 125.0 125.0 125.0 124.0
70 116.0 116.0 107.0

80 103.5 103.5 92.8
90 90.6 I ** 90.6 85.8
100 78.6 78.6 78.3 71.8
110 68.0 68.0 68.0
120 58.9 58.9
Table 14.4: Allowable Stresses in Bending for Circular Steel Chimneys Dcalp of Steel Chhnaeys
hlflr Allowable Stress in k ~ / m m ~

Ratio (dlt) rado
100 and 125 150 175 200 225 250 300 350 400 450 500 550 600
Less
upto 130 165.0 157.5 153.0 149.5 146.5 145.0 143.5 140.0 137.0
140 159.0 157.5 153.0
150 151.0 151.0 151.0 149.5 146.5 145.0 143.5 140.0
160 145.0 145.0 145.0 138.0 138.5 138.5 137.0
170 138.0 132.0
180 132.0 132.0
190 126.0 ** 118.0 116.5
200 118.0 113.5
210 116.5 112.0
220 113.5 108.0
230 112.0 *** 107.0
240 108.5 105.0
250 107.0 104.0
260 105.5 102.5
270 104.0 104.0
280 102.5 102.5
290 101.0 101.0
300 9912 99.2 94.5 86.6 78.17
Note : For Tables 14.3 and 14.4

* For ratios of d/t and hllk in zone above zig-zag line, the stresses from the top line may be noted.
** For ratios of a% and hllk in zone below zig-zag line, the stresses from the column headed 100 and less may
be noted.
*** Above values of stresses have been converted into SI Units from those given in m.k.s. Units.
In case, the increase in stresses is solely due to wind forces, the allowable stresses
may be exceeded by 25%. However, the thickness of steel plates shall not be less
than that needed if the wind forces were neglected.
Similarly, when the effect of seismic load is considered, the allowable stresses may
be exceeded by 25 percent. The thickness of steel plate shall not be less than that
required if the seismic forces were not taken in to account. The permissible
stresses in rivets are adopted as per IS : 800-1984.
14.11 DESIGN OF BASE PLATE

Self-supporting steel chimney may be provided with structural steel, cast iron, cast
steel circular base plates. It is preferable to use cast steel base plates as compared
to the cast iron base plate. The structural steel base plates are even better than cast
steel base plates for high steel chimneys.
The width of steel plate should be sufficient to transmit the compressive stresses to
the foundation. The allowable bearing pressure on a good cement concrete
foundation is 4 ~ / m m Thickness
~. of base plate should be such that the bending
stress and shearing stress in the base plate do not exceed the allowable bending
and shearing stresses. There are two methods of connecting the flared portion of
Steel Structures the steel chimney with the, base plates. These methods are shown in Figure 14.5.
The maximum compressive stress at the base plate on the leeward side of the
chimney
where, d l = diameter of the steel chimney at the base of the flared portion.
The maximum compressive stress per unit circumferential length at the base plate
on the leeward side of the chimney.
The width of the base plate
where, obcr
= permissible bearing stress on the foundations.
In case the anchor bolts are provided on inside and outside of the steel chimney,
c / l of
anchor
bolts
1.X
b =width of base plate
I_ b = widk of base plate 4
( aI (b)
Figure 14.5
then the base plate may be kept symmetrical with chimney, as shown in
Figure 14.5(a). The unsuppor'ted length of the base plate 1, measured from the
extreme edge upto the critical section XX, are equal. In case the anchor bolts are
provided on the outside only, then the unsupported length I, would be kept more
than the inner unsupported length. The critical section is marked under the root of
angle section. The thickness bf base plate is found as under :
The maximum bending moment at the critical section XX
The moment of resistance of unit length of base plate at the critical section
M k = -1( 1 . a 2 .ob,) ...(ii)

6
where, a = thickness of the base plate at the critical section
It is to be noted that this includes the thickness of the angle section used for the
connection
crbc = permissible bending stress in the base plate
(0.75 f, where, f , is the yield stress for steel)
Equation (i) & (ii)
The thickness of the base plate found by deducting the thickness of the angle
section from the total thickness obtained as per Eq. 14.18. The critical section may
be checked for shear stress. It is to note that the total thickness of the base plate a,
has been found by using permissible bearing stress on the foundation instead of
actual bearing stress. This provides comparatively more thickness in case the
unforseen wind pressure increases.
I
I
14.12 DESIGN OF ANCHOR BOLTS
The anchor bolts (holding down bolts) are provided to resist the uplift pressure due
to the overturning effect of the wind on the windward side of the stress chimney.
The uplift pressure is found by considering the combined effect of wind pressure
and the weight of chimney only. The weight of lining is omitted. It is assumed that
all the anchor bolts are drawn up tight. Further it is assumed that the line of
rotation is perpendicular to the direction of wind and passes through the centre of
the horizontal base section of the steel chimney as shown in Figure 14.1. The
initial tension in the anchor bolt, if any, is neglected.
The maximum tensile stress at the base plate on the windward side of the chimney
The maximum tensile stress per unit circumferential length at the base plate on the
windward side of the chimney
F2 = ofx ( t x 1) kN/m ...(14.20)
The maximum uplift force in one anchor bolt
= F , . g = o , x ( t x 1)xg kN
where, g = spacing of the anchor bolts in metres.

Steel structures The number of anchor bolts may be found by dividing the circumference of anchor
bolt ring by the spacing of anchor bolts. The permissible stress in axial tension at
the root of the threads of the anchor bolt is adopted from IS:800-1984.
Figure 14.6
14.13 DESIGN OF FOUNDATION

I
A plain cement concrdte or reinforced cement concrete foundation is used for

self-supporting steel chimney. The following types of foundation are generally
a) full raft (circular slab)

b) annuldr raft
ii) Pile founddtion
iii) Truncated cone foundation
iv) Hyperboloid foundation
The chimney foundation is usually designed as a circular slab and it is constructed
as the circumscribing octagon. In the design of foundation of the chimney, a
designer is to deal dith either the bearing condition of the soil is favourable and
economical where the chimney may be directly supported by the soil or the bearing
condition of the soil1 is poor where the chimney has to be placed on piles. The
foundation is designed to resist the stresses resulting from the following
combinations.
i) Dead load + Live load
ii Dead load + Wind or seismic forces
iii) Dead load + Live load + wind or seismic forces
The weight of chininey lining etc. are considered as live load.
The foundation of the form of the frustum of a cone or an eight sided pyramid
will be more econdmical. Therefore the shape of the foundation block is generally
in the form of a frustum of a cone or a frustum of a eight sided pyramid. The
square shaped foundations are not provided since the corners of square shaped
foundations are subjected to high pressure when the direction of the wind is
parallel to the diagonal. If the slope of the footing is 45" plain concrete foundation
can be used. If reibforced concrete foundation is used, it is not necessary to keep
the height 0.4b an4 a thinner foundation may be used.
The size and weight of the foundation should be such that the underside of the w
gn of Steel Chimneys
foundation is under compression only. In that case, the bottom of the foundation
block remains in contact with the soil. So the size of the foundation at the bottom
is kept sufficient to withstand the soil pressure and the bearing pressure in the soil
should be less than the allowable pressure in the soil. The weight of the foundation
is kept sufficient to prevent the overturning. In case the design of foundation is
such that the compressive stress at one edge of the foundation is zero, and it
increases to a maximum compressive stress at the other edge, under the extreme
conditions of loading then such design of foundation is most economical. In such
design of foundation, the unit stress due to the overturning moment of the wind is
just equal to the unit stress due to the weight of the foundation and steel chimney.
It should be noted that the weight of lining is omitted. However, the maximum
compressive stress on the leeward side due to wind, weight of foundation, steel
chimney and lining should not exceed the allowable unit pressure on soil.
For round foundation, the resultant thrust due to wind pressure, weight of steel
chimney, weight of lining, and weight of foundation should not lie outside the
middle quarter of the foundation. The foundation block is not subjected to tension
in such condition.
The maximum eccentricity is then limited to 118 of the width of foundation. The
maximum eccentricity
where, b = width of the circular or round foundation

Wf=weight of foundation block
As compared to the weight of foundation the weight of steel chimney W,, and the
weight of lining WL, are small. For preliminary design the weight of steel chimney
and the weight of lining are neglected. The weight of foundation
Then, the resisting moment due to weight of foundation is equal to the overturning
moment due to wind. Therefore
The width of foundation is then revised by considering the weight of steel chimney
and weight of lining.
The intensity of soil pressure is determind. It is given by
1
Steel Structures where, A and Z are the area and section modulus, respectively for the foundation
slab. If the radius of the circle of the circumscribing octagon is R, then the area of
foundation is 3.3 12 R and Z = 0.81 R~ as per (IS: 6533-197 1). The successive
trials are made for R to utilize fully. The soil pressure should not exceed the
allowable bearing capacity of the soil.
( a ) Foundation plan
L( b) Foundatron thickness
'I c ) Soil Dressure dragram
Figure 14.7
D = Diameter of footing = 2R
P = vertical load.
e = M/P
M = overturning moment
F = P/A
A = Area of circular footing
F,,, = Maximum unit bearing pressure including overturning moment.
The full utilisation of the bearing of soil may lead to situations where only the
part of foundation is in compression (Figure 14.7). In such a situation the footing
is designed as a circle, though it is constructed as octagonal.
Let f=[ W.S++: ...(14.26)
The maximum soil pressure is obtained from the following procedure.
The eccentricity e =
w,+ w,+W F
and thereby e/b valves are determined. The values of zero stress and the ratio Design of Steel Chimneys
f, lf are found from Figure 14.7 as per IS : (6533-1971) and thus the value of
f,,, is calculated. It is recommended in code IS : 6533-1971 that the elb valve
should not exceed 0.255 and K,lb not be less than 0.6.
14.14 LINING FOR CHIMNEY

In general practice, the self-supporting steel chimneys are all made with lining. The
steel chimneys are lined in order to protect the chimneys from heat, to act as a
protecting cover and thus reduce the corrosion on the steel plates and to maintain
the temperature of flue gases.
Figure 14.8 : Maximum Soil Pressure and Neutral Axis for Circular Footing
e,
The lining may be made of radial fire brick, common concrete brick, cement gunite
or vibrobestos acid resisting bricks etc. The materials used for lining should be
capable of withstanding high temperature up to 2000°F. The lining is required from
below the flue opening to the height, where the heat of gases does not damage the
chimney. The height of lining should not be less than.10 times the diameter or 113
of height above the flue opening. The self-supporting steel chimneys are usually
lined throughout the full height of chimney. The lined chimneys are inspeted every
alternate year. In addition to the checking of thickness of chimney plates, the
condition of lining and insulation is also checked.
The chimneys with riveted and bolted construction are checked near the flange
angles. The rivet heads on the interior surface are also checked. The interior surface
of lined chimney requires primary coat only. The exterior surfaces of the chimney is
painted as describer for unlined chimneys depending upon the service temperature.
- - - - --
14.15 STABILITY OF STEEL CHIMNEY

The steel chimney as a whole or any part of it is checked for stability. The
stability of the structure or any part of it should be ensured by providing
anchorages so that the least resisting moment including anchorages shall not be
less than the sum of 1.5 times the maximum overturning moment due to dead
loads and imposed loads with the seismiclwind loading considering as imposed
hads. The stability of steel chimney is ensured at all times during construction,
repair with probable variation in dead loads, or during such other temporary phase
of work is taken into account.
While the stability of steel chimney is checked, it is also seen that when the
resulting pressure and $hear forces are transferred to the supporting soil through the
foundation, the failure iof the foundation will not occur. The stability of the
chimney is investigated so that
where, ow= stress due to wind load

om= stress by any other load increasing the combined stress
q = stress due to dead load
oa= allowable load.
1 4 . 1 6 ~ PROBLEMS
~ ~ 1 ~ ~
Example 14.1
A self-supportingl steel chimney is 80 m high and its diameter at the top is
3 metres. ~ e s i g breech
n (flue) opening. Adopt the wind force as per IS : 875.
The location of the place is such that the intensity of wind pressure up to
30 m height is 1 3 0 k ~ / m ~ .
Solution
The steel chimney is shown in Figure 14.9. The height of the chimney is
80 m and its diaineter at the top is 3 m.
Figure 14.9 (a)
Step 1
Flared portion
A conical flared portion is provided in the lower portion of the steel chimney.
The recommended height of flared portion
Adopt the height of flared portion as 25 m. The diameter of conical flared

portion at its bottom
Adopt the diameter of flared portion as 4.5 m.

Step 2
Intensity of wind pressure.
The location of place is such that the intensity of wind pressure up to 30 m
height is 1.50 kN/m2. The intensities of wind pressure at higher heights as per
IS: 875 are as follows:
The above intensity of wind at the respective heights are shown in

Figure 14.9(b). The shape factor for steel chimney circular in plan 0.7.
Step 3
Overturning moment due to wind M,. Usually the intensity of wind pressure
is adopted as the average value of these at upper and lower section. However
for simplicity, the maximum intensity of wind pressure (i.e., at the top) has
been used in the calculations.
The overturning moments at respective sections are as under :
hl, h2, h3 ... etc. represent the height of respective forces pl, p,, p3 ... etc.
I , above the section considered in Figure 14.9 (b).
i) At section XI X1
p,. h, = 0.7 x 1.83 x 3 x 10 x 5 = 192.15kN-m
ii) At section X2 Xz
p,. hl = 0.7 x 1.83 x 3 x 10 x 10 = 384.30kN-m
Total = 430.76 kN-m

iii) At Section X5 X5
p5 .h5=0.7x1.72x3x5x2.5=45.15 kN-m
Total = 1698.90 kN-m
Steel Structures
I-w~nd pressure ( k ~ h n l l
- -80m
7 5m
---
--
hiyure 14.9 (b)
iv) At section X8X8

I
p, .h, = 0 . 7 x 1 . 8 3 ~ l3O~x 5 0 = 1921.50lcN-m

p2 . h2 = 0.7 x 1.77 x 3 x 5 x 42.5 = 789.86 kN-m
p3 . h3 = 0.7 x 1.77 x 3 x 5 x 37.5 = 696.64 kN-m
p, . h, = 0.7 x 1.72 x 3 x 5 x 32.5 = 586.95 kN-m
ps . h, = 0.7 x 1.72 x 3 x 5 x 27.5 = 496.65 kN-m
I
P6. h6 = 0.7 x 1.67 x 3 x 5 x 22.5 = 394.54 W - m

p7 .h7=0.7x 1 . 6 3 ~ 3 17.5=299.51kN-m
~ 5 ~
p 8 . h8 = 0.7 x 1.58 x 3 x 5 x 12.5 = 207.38 kN-m
p,. h9=0.7A 1 . 5 6 ~ x3 5 x7.5 = 122.85kN-m
plo . hlo = 0.7 x 1.50 x 3 x 5 x 1.5 = 39.38 kN-m
Step 4
Thickness of chimney plate.
It is assumed that the design life of the steel chimney shall be 20 years and
the coal is used as a fuel for the boiler. The chimney shall be lined and
insul2ted. The corrosion allowance is 4 mm for slight internal corrosion
At section X2 X2 (Height from top is 15 m). Design of Steel Chimneys
i)
Diameter of chimney = 3 m.
Assuming the thickness of steel plates as 3 mm without corrosion
3000
Radius of gyration, K = 0.7 x -= 1050 mm
2
Effective height for axial stress
hl = 2 x 15 x 1000=30000mm
Ratio -
h1 = [ -
k
1
3 ~ : = 28.57
For bending stress
~llowabfestress in axial compression

= 71.8 ~ / m m ~
Allowable stress in bending
= 78.7 ~ / m m ~
These stresses are increased by 25% for wind. The maximum tensile
stress on windward from Eq. 14.1
ii) At section X8X8(Height from top is 55 m), Diameter of chimney = 3 m

Assuming the thickness of steel plate as 7 mm without corrosion.
ratio = [ 3 x i 0 0 0 ) = 4 2 8

hl = 2 x 5 5 x l000= 110000mm
Radius of gyration,
X=(o.ixi]=3000 1050
Ratio (2) [= ' l o lo50 1

x loo0 = 194.76
For bending stress

Allowable stress in axial compression = 73.554N/mm2
Flowable stres!s in bending = 114.92 N/mrn2
The stresses ate increased by 25% for wind. The maximum tensile stress
on windward $ide from Eq. 41.1
The maximum compressive str#ss on the leeward side of the steel

chimney from Eq. 14.3
t = 0.01@3 m = 10.23 rnm

Therefore the total thickness with corrosion allowance is
11.44 + 4 = 15.44 mm
Adopt 16 rnrnr
Step 5
- Design of flue opeding
i) Portion of chidnney between sections X8 X8 and XIl XI,
Let there be two flue openings in the same direction.

Size of the openings = 1.8 m x 20 m
Width of the openings, A1 = 1800 mm
Height of the Lentre line of openings above the base is 2 m. The

diameter of the chimney at this level is 4.36 m. The thickness of plates
less corrosion allowance is (16 - 4) = 12 mm
ii) Modulus of the chimney at the centre line of flue opening
Area of cross-beetion
= n x 4350 x 12 - 2 x 2000 x 12 (for opening)
= IT5908 mm2
iii) Weight of chidnney
Weight of chidnney above X8 X8
= 472.507 kN
It is obtained as follows.
.The thickness of lining increases from top to bottom. The weight of the
chimney may be assumed as 0.64, 0.80, 0.96 and 1.28 kN/m2 per .metre
height of the chimney at the sections X2X2, X5 X5,X8X8 and XI XI
respectively.
At section X2x X2
n x 3 x 15 x 0.64 = 90.432 kN
Add 10% for stiffeness
= 1 . 1 0 90.432=99.475
~ kN
Area of cross-section
At Section X5X5
n x 3 x 15 x 0.64 = 90.432 kN
7~~3~15~0.80=113.04kN
203.472 kN
Add 10% for cross-section
= 1.10~
203.472kN
= 223.82 kN
n x 3 lOOO(8 - 4) = 37680 mm.
At section X8X8
n x 3 x 15 x 0.64 = 90.432 kN
nx3x15x0.80=113.040kN
n x 3 x 25 x 0.96 = 226.080kN
= 429.552 kN
Add 10% for stiffeners
1.10x 429.552 = 472.507 kN
The maximum compressive stress on the leeward side of the steel
. t = 0.00103 m = 1.03 mm.

Therefore, the total thickness with corrosion allowance is
(1.03 + 4) mm = 5.03 mm
Adopt 6 mm.
Steel Structures At Seetion X5 XS (Height from top is 3 m), Diameter of Chimney = 3 m
ii)
Assuming the thickness of steel plates as 5 mm without corrosion.

h, = 2 x 30 x 1000 = 60,000 mrn
Radius of gyration
hi 60000
Ratio -= -- 57.14
k 1050
For bending stress
Allowable stress in axial compression
These stresses are increased by 25% for wind. The maximum tensile
stress on windward side from Eq. 14.1
The maximum compressive stress on the leeward side of the steel

Therefore the total thickness with corrosion allowance is (3.688 + 4) mm

= 7.68 mm
Adopt 8 mm
Weight of the opening X, X8 and X,,X1,

n x 3.75 x 25 x 1.28 = 376.80 kN Design of Steel Chimneys
Total = 849.307 1dV

Add 10% for overlap, rivets and stiffeners
Total weight = 1.10 x 849.307kN
= 934.238 kN
Actual stress =
i934.238 x id 11587.15x 106
+
115908 - 80790 x lo3
= (8.06 f 143.42) = 151.46N/mm2

1 N/md
iv) Allowable stress

h 1 = 2 x 8 0 x l000= 160000mm
Radius of gyration, k
ratio = [ )
4.5 x loo0 = 375
12
Ratio [2)=(x)= 160000

101.59
For bending stress,
Allowable stress in axial compression = 76.915 ~ / m m ~

Allowable stress in bending = 127.5 ~ / m m ~
These stresses are increased by 25% for wind. Therefore allowable stress
in bending is 159.375 N/mm2, which one is greater than 151.46 N/mm2
v) Check for interaction expression
It exceeds unity very slightly. Hence, the section is adequate.

Area of steel plates removed for flue openings = 2 x 2000 x 12
= 48000 mrn2
The vertical reinforcement provided is kept 20% larger than the area
removed.
:. Area of steel to be provided
Area of vertical reinforcement on each side of two flue openings
Provide 21SA 200 mm x 200 mm x 25 mm (one on outer side and one

Steel Structures on inner side of the opening).
Area provided = 2 x 9380 = 18760 mm2

The area of reinforcement provided on the top and the bottom of
opening are kept the same.
SAQ
1) Design a self-supporting steel chimney of 100 m height. The diameter of
the cylindrical shell is 4 m. The chimney has a 100 m thick brick lining
supported on the shell.
2) A self-supporting steel chimney is 60 m high and has a diameter of 3 m
at the top. Design the foundation and the riveted points. The hoizontal
pressure may be assumed as 1.50 k ~ l m The~ . bearing stress in cement
concrete is 4.0 ~ / m m ~ .
14.17 SUMMARY
. *-
Let us conclude this unit by summarising what we have covered in it. In this unit
we have
1) Defined steel chimneys.
2) Described factors for selecting type of steel chimneys.
3) Studied the design of thickness of steel plates, joints, flue openings and
foundation.
4) Derived expressions for bending moment, stresses, thickness of plates.
5) Introduced the concept of lining for chimney.
6) Described the stability of steel chimney.
I
4.18 ANSWERS TO SAQs
Refer Example given i n the text.
FURTHER READING
Design of Steel Structures - A.S. Arya & J. L. Ajmani
Steel Structures and Timber Structures, Vol. III - V.N. Vazirani & M.M. Ratwani
Design of Steel Structures - Vol. I & Vol. II - Dr. Ramchandia
Roofs and Bridges - M. Mprriman
Design of Steel Structures - M. Raghupati
Analysis, Design and DetaiYs of Structures- V. N . Vazirani & M.M. Ratvani
Design of Steel and Timber Structures - Ramamrutham
Structural Design in Steel - Sanvar Alum Raz
Desim o f Steel Structures 4Edwin H . Gaylord, Jr. & Charles N. Gavlard
CHAPTER
6
Design of Steel and Other Structures
6.1 INTRODUCTION
Steel chimneys are also known as steel stacks. The steel chimneys are made of
steel plates and supported on foundation. The steel chimneys are used to escape
and disperse the flue gases to such a height that the gases do not contaminate
surrounding atmosphere. The cross-sectional area of steel chimney is kept large
enough to allow the passage of burnt gases. The cross-sectional area of steel chimney
depends on the type and quantity of fuel to be used in a plant, available draft for
carrying the burnt gases. The cross-sectional area of steel chimney depends on the
type and quantity of fuel to be used in a plant, available draft for carrying the
burnt gases up the chimney and losses due to friction within the chimney. The
height of steel chimney is kept to provide the required draft. The draft is defined
as the difference between absolute gas pressure at any point in the duct or steel
chimney and the ambient atmospheric pressure. The draft depends on the height
of steel chimney above sea-level, the type of fuel to be burnt, the type of furnace
and the temperature of burnt gases. When the gases in a steel chimney are heated,
then the gases expand. The hot gases occupy larger volume than before. The weight
of gases per cubic metre becomes less. As a result of this, the unit pressure at the
bottom of chimney due to weight of hot gases also becomes less than the unit
pressure due to weight of cold air outside of chimney. The difference between two
pressures results in the flow of the burnt gases up the chimney. For the purpose of
the structural design of the steel chimney, the height and diameter of chimney at
the top are known data.
The steel chimney is made cylindrical in shape. The lower portion of steel
chimney is widened or flared, in order to provide a large base and greater stability.
The widened section of the chimney at the base reduces the unit stresses in the
steel at the base of the chimney. The loads acting on the steel chimney are
transferred to the foundation easily by the widened section. The base of the chimney
may be made bell-mouthed or conical. The fabrication of bell-mouthed base is
292 DESIGN OF STEEL STRUCTURES–VOL. II
costly. The bell-mouthed base does not have any advantage over the conical base.
Therefore, the conical base is provided generally. The recommended height of flared
portion of the chimney is equal to one-third the height of the chimney. The bottom
diameter of the flared portion shall not be less than one and a quarter times the
diameter of stack, (i.e., d1 = 5/4.d).
The steel chimneys are designed and constructed conforming to code of practice
for design and construction of steel chimneys, IS : 6533–1971.
6.2 TYPES OF STEEL CHIMNEYS

The steel chimneys are of two types :
1. Self-supporting steel chimneys 2. Guyed steel chimneys.
6.2.1 Self-Supporting Steel Chimneys

When the lateral forces (wind or seismic forces) are transmitted to the foundation
by the cantilever action of the chimney, then the chimney is known as chimney,
d
h C ylind rical
p ortion
X X
H = H eigh t o f
chim ne y
B re ech
o pe ning
Flare d
p ortion
C le a n o ut
d oo r
d1
Fig. 6.1 Self-supporting steel chimney

DESIGN OF STEEL AND OTHER STRUCTURES 293
self-supporting chimney. The self-supporting chimney together with the

foundation remains stable under all working conditions without any additional
support. A self-supporting chimney is shown in Fig. 6.1. The self-supporting
chimneys are made upto 10 m diameter and from 50 m to 100 m in height.

In high steel chimneys, the mild steel wire ropes or guys are attached to transmit
the lateral forces. Such steel chimneys are known as guyed steel chimneys. In
guyed steel chimneys, all the externally applied loads (wind, seismic force, etc.)
are not totally carried by the chimney shell. These attached guys or stays do share
these applied loads. These guys or stays ensure the stability of the guyed steel
chimney. These steel chimneys may be provided with one, two or three sets of
guys. In each set of guys, three or four or sometimes six wires are attached to the
collars. When one set of guy is used, then the guys are attached to a collar at one-
third or one-fourth of the height from the top. When more than one set of guys are
used, then these are used at various heights.
A particular type of steel chimney is selected depending on the advantage and
disadvantages with reference to economy. A choice between self-supporting and
guyed steel chimney is made by considering some of the important factors. Number
of units, type of equipment and the type of fuel to be used are considered. In case
the chimney is to be used for boilers, the surface area, output efficiency, draft
requirements etc. are taken into account. The mode of operation of the equipment
shall also be considered.
The temperature of the flue gases before entering the chimney and its likely
variation, are studied. The type of lining is decided knowing the composition of the
flue gases. The specific weight, the quantity of dust and data about the
aggressiveness of the flue gases must be known. The local statutory regulations,
relating to height, dispersion of ash, provision for earthing aviation warning lamp,
health etc. are the factors which should be considered for selecting a type of steel
chimney. The mode of erection is also considered.
The design of self-supporting chimney has been discussed in this chapter.
6.3 STEEL PLATES FOR CHIMNEY

The width of steel plates required for the steel chimney varies from 0.9 m to 2.5 m.
The steel plates of 1.50 m width are most commonly used. The thickness of steel
plates should not be less than 6 mm. The thickness of steel plates in the two upper
sections of the chimney should not be less than 8 mm to resist more corrosion
likely at the top of chimney. The thickness of steel plate in the flared portion
should not be less than the thickness at the lowest section of the cylindrical portion.
The steel plates are available in thickness of 5, 6, 8, 10, 12, 14, 16, 18, 20, 22, 25,
28, 32, 36, 40, 45, 50, 56 and 63 mm. For the ease in construction, the upper
diameter of plates forming the side of chimney is kept less than the lower diameter.
Each course fits telescopic over the lower course.
The steel plates are sheared or planed to proper bevel for caulking. The steel
plates of chimneys are caulked from the inner side of chimney. The caulking is
done with a round-nosed caulking tool.
The steel plates (or all steel work) are painted in order to avoid corrosion. One
coat of approved paint is applied before leaving the shop. Two coats of approved
paint are applied both inside and outside after the chimney is erected. The paint
applied should be heat-resistant. A graphite or carbon paint or other tried heat-
resistant paint may be applied. The painting should never be done in wet or freezing
weather. The thickness shall not be less than 6 mm. The corrosion resistant steel
plates may be used in the chimney. The steel having an admixture of 0.25 to 0.30
percent of copper is more resistant to corrosion than steel not containing copper.
Copper bearing steel plates may be used for self-supporting steel chimneys.
The thickness of steel chimney obtained from stress calculations and deflection
consideration shall be increased by permitting an allowance for corrosion determined
from the considerations of the design life of the chimney and aggressiveness of the
flue gases. The allowance for corrosion permitted is decided depending upon the
expected amount of internal corrosion of steel plates. For 10 years of design life,
the corrosion allowance for non-copper bearing quality of steel for slight, normal
and exceptional internal corrosion is 2 mm, 3 mm and 5 mm, respectively.
In case the design life for the steel chimney is 20 years, then this allowance for
said quality of steel and amount of internal corrosion is 4 mm, 5 mm and 8 mm,
respectively. Ths copper bearing quality of steel is used when it is essential. The
quality of steel needs less corrosion allowance as compared to that of non-copper
bearing quality of steel.
However, the minimum thickness of shell of a chimney shall not be less than 6 mm.
6.4 RIVETED JOINTS IN CHIMNEYS

In the upper part of the steel chimney, lap joints are used in the vertical seams
and also for the horizontal seams. Lap joints are also used in the vertical seams of
the cylindrical portion and flared portion of the steel chimney. In the lower part of
the chimney, butt-joints are used in the horizontal seams with the heavy plates.
Butt joints are also used in the vertical seams in the bell-mouthed flare of large
chimney. The recommended types of riveted joints and diameter of rivets necessary
for different thickness of plates are given in Table 6.1.
Table 6.1
Thickness of steel Diameter of steel Type of riveted joint
plates (mm) (mm)
6 16 Single riveted lap joint
8–10 18 Double riveted lap joint
12–16 22 Triple riveted lap joint
Thicker than 16 24 Butt joint
The spacing of rivets along the caulked edges of plates shall not be greater than
10 times the thickness of plates. The spacing of rivets shall not be less than 2.5
times the diameter of rivet.
The steel plates more than 16 mm thick and not more than 22 mm thick are
sub-punched with a punch 5 mm smaller than the nominal diameter of rivet, and
reamed to a diameter of 1.5 mm larger than the rivet. The plates thicker than
22 mm are drilled.
6.5 LINING FOR CHIMNEY

The guyed steel chimneys are usually unlined. The self-supporting chimneys are
usually made with lining. Sometimes, the self-supporting chimneys are also left
unlined. The unlined chimneys have also given excellent service. In general practice,
the self-supporting chimneys are all made with lining. The steel chimneys are
lined in order to protect the chimneys from heat, to act as a protecting cover and
thus reduce the corrosion on the steel plates, and to maintain the temperature of
the flue gases.
The fire brick, common brick, solid grade diatomoceous (mole earth) bricks,
acid resisting bricks, moler concrete, refractory concrete, gunitings with sand and
cement mixtures, vitrobestos are the various materials used for lining. The material
used for lining should be capable of withstanding high temperature upto 2000°F.
The lining is required from below the breech opening to the height, where the heat
of gases does not damage the chimney. The height of lining should not be less than
10 times the diameter or one-third height above the breech opening. The lining
may be done from the base to the top of chimney. The self-supporting chimneys
are usually lined throughout the full height of the chimney.
Lining materials. The brief-description of lining made of different materials,
construction and maintenance of lining is as following.
6.5.1 Fire Bricks

In order to suit the dimensions of the steel chimneys, the fire bricks are made in
radial forms. The alumina content between 28 and 32 percent in fire bricks is
satisfactory for most of the application. These bricks are set in the mortar. The
mortar is made from ground clay or any other suitable heat resisting cement. The
fire brick lining acts as a protective lining. It reduces the corrosion. It also protects
the chimney upto a temperature of 1200°C. The fire bricks have high density. As
such this type of lining is not suitable in maintaining the temperature of flue
gases. Its strength and hard surface give necessary protection to the steel chimney
from abrasion. The fire bricks having thermal conductivity 1 to 1.25 kcal/mh °C,
bulk density 1820 kN/m–3, crushing strength 14 N/mm2 and the coefficient of
thermal expansion 11 × 10–5/°C are considered suitable. When the steel chimneys
are to discharge flue gases having a temperature higher than 1200°C, then the
special duty lining shall be used. The joints between the fire bricks shall be properly
filled and shall be as thin as possible. The mortar is not placed between steel
chimney and bricks.
6.5.2 Insulating Refractory Bricks

These bricks are used to achieve all the three functions of lining stated above.
Three different grades of these bricks are available to suit temperatures of 850°C,
1250°C and 1500°C, respectively.
6.5.3 Solid Grade Diatomaceous (moler earth) Bricks

These bricks are made to suit diameter of chimney and to suitable thickness as
needed by the designer. These bricks are set in mortar. The mortar is made from
the brick material ground to powder with the addition of portland or alumina
cement depending on the temperature of the flue gases. The lining provided with
these bricks gives the necessary protection from heat and also maintains the
temperature of the flue gases. These bricks provide protective cover depending
upon the nature of the flue gases. These bricks are used for temperature of 150–
800°C. The co-efficient of thermal expansion for this material is very low. Its
material has exceptional resistance to rapid temperature changes. These bricks
have thermal conductivity of 0.14 – 0.19 kcal/mh°C, bulk density of 6.90 – 7.05
kN/m2, crushing strength over 4.6 N/mm2 and co-efficient of linear expansion
2.1 × 10–6/ °C.
6.5.4 Acid Resisting

When the flue gases are highly acidic and have a temperature below 150 °C, then
the lining is made from the acid resisting bricks. These bricks are set in acid
resisting cement. This type of lining is not suitable to resist short fluctuations in
temperature.
The refractory and acid resisting lining are provided with the necessary expansion
joints. Horizontal joints are provided at every 6 m. Such section of lining shall be
supported by internal rings which are firmly fixed to the chimney shell. A gap is
left at the top of each of the sections to keep clear of the ring above to allow for
expansion. This expansion gap is filled with asbestos fibre, mineral wool or such
other pliable filling.
6.5.5 Moler Concrete

The aggregate for moler concrete is made from moler earth bricks in appropriate
gradings and mixed with alumina cement. The moler concrete may be precasted
to shapes needed, casted in situ or gunited. In no case, the thickness of monolithic
lining shall be less than 50 mm. A minimum cover of 25 mm shall be provided to
anchorage where the corrosive conditions exist. This lining protects the chimney
from heat and maintains the temperature of the gases. This lining provides
protective covering in temperature range of 150° to 980° C depending upon the
type of flue gases.
6.5.6 Refractory Concrete

This type of lining may be casted in situ or gunited. This lining is similar to fire
brick lining in its use and fulfils the similar requirements. The aggregate for this
type of concrete is made from fire bricks or insulating refractory bricks of appropriate
gradings. This lining is used to line the chimneys less than 1 m in diameter with
brick.
The moler bricks or refractory and insulating concrete lining do not need
expansion joints as these linings have low thermal expansion.
6.5.7 Sand and Cement Mixture

This is useful as lining by guniting for low temperature range, normally below
150°C.
6.5.8 Guniting
The guniting is done by commencing from the bottom and progressing upwards. It
is done in narrow strips. The height of each band depends on the diameter of the
chimney, the thickness of the insulation and materials used, so that the initial
setting starts after the strips are completed. All incomplete lining is removed at
the end of the day’s work. It is removed by trowel and left square to the chimney
and at the level where the full thickness of the insulation exists. Studs of 3.15 mm
diameter and length equal to half the thickness of guniting are spot welded to the
inside surface of the steel chimney at 500 mm distances. These studs are staggered
both ways, on to which welded wire fabric of mesh 150 mm square is welded. The
mesh acts as reinforcement for guniting.
6.5.8.1 For Lining Supporting Rings

In the upper part of the chimney, the lining is supported on steel angles riveted to
the inside of chimney. For steel chimneys upto about 50 m height 125 mm thick
fire brick lining is used. The fire brick lining consists of 100 mm of fire brick and
Top stiffe ne r
C h im ne y she ll
10 m m
M in era l
12 m m w o ol or
a sb esto s
ro pe
M in era l
w o ol or
a sb esto s
ro pe
C h im ne y
L in ing she ll
In su la tion In su la tion L in ing

(a ) D e tail of an gle iro n ring (b ) D e ta ils of lin in g ne ar
for su pp ortin g the lin in g ch im ney h ea d
Fig. 6.2
25 mm of backing. ISA 100 mm × 75 mm and 10 mm to 12 mm thick are used to

support 100 mm thick lining. The angle section is placed with 100 mm leg
horizontal. In case the height of steel chimney is more than 50 m, then 175 mm
lining consisting of 150 mm fire brick and 25 mm backing is used. ISA 150 mm ×
75 mm and 10 mm to 12 mm thick are used to support 15 mm lining. The angle
section is placed with 150 mm leg horizontal. The vertical leg is kept downward as
shown in Fig. 6.2. The angle sections are attached with every second horizontal
section. It is not necessary to attach these angles with the horizontal joints except
that a support is provided at joint connecting the conical base to the main body of
the chimney. These angles may then be placed 2 m to 5 m apart. These angles
support lining and also stiffen the chimney. For an independent lining, a 200 mm
thick wall is necessary for the lower half and 100 mm brick wall for the upper half
of the chimney. When the supporting rings are used, the first layer of the lining
shall extend beyond the edge of the ring by not less than 12 mm and not more than
one third of the thickness of lining. It is done to protect the lining and also to allow
the condensate to fall below clear off the lining. The method of providing angle
support and stiffeners is shown in Fig. 6.2 (a).
A cap ring is provided at the top of chimney as shown in Fig. 6.2 (b). The cap
ring prevents the upper part of chimney from collapse and protect the lining also.
The top cap is made about 25 mm thick and 300 mm wide. The top cap may be
made of cast-iron. It is bolted with the top with non-corrosive bolts.
6.6 BREECH OPENING

The breech opening is also known as flue opening. The flue opening is provided for
the entrance of flue gases. The flue gases come from furnaces of the boilers.
A breech opening is provided in the steel chimney as shown in Fig. 6.1. The
area of breech opening is kept about 20 percent larger than the internal cross-
sectional area of the chimney. The maximum width of the breech opening should
not be greater than two-thirds of the diameter. In order to compensate the removed
material, the reinforcement should be provided all around the breech opening. The
vertical reinforcement provided should be 20 percent larger than the material
removed in the ratio of diameter to the long chord perpendicular to the face of the
opening. The horizontal reinforcement provided at the top and bottom of the opening
is kept equal to the vertical reinforcement. The reinforcing material provides
sufficient vertical stiffness. In order to transfer and distribute the stress into the
steel of the chimney, the reinforcing material should be extended above and below
the opening. In the self-supporting steel chimney the breech opening is kept well
above the flared base, so that it does not extend into the flared base.
The steel chimneys may have one breech opening, two breech openings, in the
same direction, two breech openings at right angles and three breech openings as
shown in Fig. 6.3 (a), (b), (c) and (d), respectively.
The number of flue-openings may be one, two, three or four depending on the
requirement. It is suggested that a maximum of two flue-openings may be provided
at one level so that the chimney remains safe enough to resist the applied forces at
the plane of the openings. However, it is possible to provide three openings in one
plane. This is done only when the number of flue openings is three only. The width
of opening does not exceed one-third of the diameter of the chimney at that plane.
D D
A1
A1 A1
(a ) O n e b re ech op en in g (c) Tw o b ree ch o pe ning s
a t righ t a ngle s
A1 f = T hickn ess
of she ll plate
D D
A1 A1
A1 A1
(b ) Tw o bree ch o pe ning s (d ) T hre e bre e ch o pe ning s
Fig. 6.3
A cleanout door as shown by dotted lines in Fig. 6.1 is provided preferably on

the opposite side of the breech opening near the base. The minimum size of cleanout
door shall be 500 mm × 800 mm clear. The cleanout doors are also properly
reinforced. The cleanout door serves the purpose for removal of ash and inspection
of inside of the steel chimney.
6.7 LADDER
A permanent ladder as shown in Fig. 6.4 is provided outside of all large chimneys
for easy maintenance. The ladder may be provided from the base or 3 m above
2 50
3 35 m m 3 50 m m
mm Flat
50 m m x 6 m m
20 m m φ
C h im ne y L ad de r
she ll ru ng 3 0°
4 00 m m
3 0°
Flat
50 m m x 8 m m
Fig. 6.4 Detail for ladder connection

the base to the top of the chimney. The ladder is built of 60 mm × 20 mm bars with
18 mm round rings, 300 mm apart. In case the height of steel chimney is more
than 20 m, then, safety enclosure or cage is provided. The safety rings are made of
50 mm × 10 mm bars braced on the outside with one 50 mm × 8 mm vertical bar.
The inside clearance of these rings should not be less than 600 mm in width and
depth. The spacing between these rings shall not be more than 3 m.
6.8 MAINTENANCE AND PAINTING OF STEEL CHIMNEY

The designed lives of both lined and unlined chimneys are ensured by periodical
inspection and attending the necessary maintenance work.
6.8.1 Unlined Chimneys

The thickness of chimney plates are inspected and checked by ultrasonic test or by
any other suitable approved method. In case the thickness of plate is found
insufficient anywhere, it is compensated by patch work with new plates. Both the
exterior and interior surfaces are painted.
Before painting, the surfaces are prepared. The rust, loose particles, dirt etc.
are completely removed with wire brush, emery cloth etc. Wherever, the
temperature of the flue gases exceeds 150°C, the surfaces are cleaned by sand-
blasting or acid pickling.
The interior surface upto 150°C is painted with medium heat resisting and
anticorrosive paints either with brush or by spray over appropriate priming coat.
Such paints are to conform to IS : 161–1950. In case, the temperature of flue gases
is likely between 150°C and 300°C, the heat resisting and anticorrosive paints
conforming to IS : 158–1968 are applied. When the temperature of flue gases is
likely to exceed 300°C, spraying with zinc or aluminium dust is done. Black colour
paints are applied on the inner surface and aluminium paints are used for the
exterior surface. The painter’s trolley is used for painting the exterior and interior
surfaces of the chimney.
A Z-bar is provided near the top of chimney. The Z-bar acts as a track for the
painter’s trolley. The Z-bar also stiffens the top of the chimney. The section modulus
of Z-bar should not be less than 0.66 d2 × 103 mm3, where d is the diameter of the
chimney in metres. The painter’s trolley is suspended from this track. The trolley
can move around the chimney. The details of painter’s trolley are shown in Fig.
6.5. For chimneys of diameter exceeding 3 m at the top, two such painter’s trolleys
are used.
6.8.2 Lined Chimneys

The lined chimneys are inspected every alternate year. In addition to the checking
of thickness of chimney plates, the condition of lining and insulation is also checked.
The chimneys with riveted and bolted construction are checked near the flange
angles. An accumulated rust between the flange angles is removed. The rivet
heads on the interior surface are also checked.
3 50 m m
D 2 5 m m M in
Tro lley
w h ee l 1 25 m m
1 85 m m
B o lt
20 m m φ
B o lt 75 75
Tro lley 20 m m φ
tra ck 2 45 m m 1 45 m m
IS A 7 5 x 7 5 x 10
B ra cke t B ra cke t
sup po rting Tro lley S u pp ortin g IS A 1 00 x 1 00 x 10
w h ee l
Tro lley
tra ck IS A 1 00 m m th ick
1 00 x 10 0 x1 0 p la te gu id e
fo r trolley
B o lt 1 50 m m w h ee l
C h im ne y 40 40
20 m m φ
she ll
DESIGN OF STEEL AND OTHER STRUCTURES
1 0 m m th ick
75 m m p la te be nt
1 0 m m p la te 80 m m to sha pe
b en t to sha p e
Fig. 6.5
301
The interior surface of lined chimney requires priming coal only. The exterior
surfaces of the chimney is painted as described for unlined chimneys depending
upon the service temperature.
6.9 LIGHTENING CONDUCTOR

It is not necessary to provide a lightening conductor with the steel chimney under
ordinary circumstances. In case, the chimney is supported such that there is no
metal connection between the ground and chimney, then, a suitable form of metal
connection is provided. The metal in the chimney should be well grounded so that
the chimney is not damaged from lightening discharge. The lightening conductors
are provided to protect the steel chimneys against lightening in accordance with
IS : 2309–1963. The lightening conductors and earthing connections are inspected
and maintained in good conditions for efficient functioning.
6.10 FORCES ACTING ON STEEL CHIMNEY

The various forces acting on the self-supporting steel chimney are as follows :
1. Self-weight of the steel chimney
2. Weight of lining
3. Wind pressure
4. Seismic forces.
6.10.1 Self-Weight of the Chimney

The self-weight of steel chimney, W s acts vertically. Consider a horizontal section
XX as shown in Fig. 6.1. The thickness of steel plates of chimney above the section
XX, may be assumed constant. The self-weight of chimney is given by
Ws = ρ. (πd) . (t) . (h)
where
ρ = Unit weight of steel = 79 kN/m3
d = Diameter of chimney in metres
t = Thickness of steel plates in metres
h = Height of steel chimney above the section XX in metres
∴ Ws = 79 (π dt . h) kN ...(6.1)
The compressive stress in the steel plates at the section XX due to the self-
weight of chimney is given by
⎛ Ws ⎞ ⎛ 79π ⋅ d ⋅ t ⋅ h ⎞
fs1 = ⎜ πdt ⎟ = ⎜ π ⋅ d ⋅ t ⎟ kN/m
2
⎝ ⎠ ⎝ ⎠
= 0.079 h N/mm2 ...(6.2)
6.10.2 Weight of Lining

The weight of the lining in the steel chimney, WL, also acts vertically. The thickness
of brick lining may be assumed as 100 mm. The weight of lining
WL = ρl . π . d(0.1) . h
where ρl = Unit weight of brick lining
= 20 kN/m3
∴ WL = (2p . d . h) kN ...(6.3)
The compressive stress in the steel plates at the section XX, due to the weight of
lining
⎛ WL ⎞ ⎛ 2πd ⋅ h ⎞
fs2 = ⎜ ⎟=⎜ ⎟ N/mm
2
⎝ π ⋅ d ⋅t ⎠ ⎝ π ⋅ d ⋅t ⎠
⎛h⎞
= 0.002 ⎜ ⎟ N/mm2 ...(6.4)
⎝t⎠
6.10.3 Wind Pressure

The wind pressure acts horizontally. The wind pressure acting on a structure
depends on the shape of the structure, the width of the structure, the height of the
structure, the location of the structure, and the climatic condition. The wind pressure
per unit area increases with the height of the structure above the ground level. In
order to simplify the design, the steel chimney is divided into number of segments
of equal height. The height of each segment may be kept 10 m. The intensity of
wind pressure over each segment may be assumed as uniform. The intensity of
wind pressure corresponding to the mid-height of each segment may be noted from
IS : 875–1984. The wind pressure on the flared portion may be found by using
average diameter. The wind pressure is assumed to act at the mid-height of each
segment and as also in the flared portion. It has also been practice to take uniform
wind pressure over the full height of chimney. The wind pressure
P = k . p1 × (Projected area of chimney)
where, k = Shape factor. It accounts for the shape of the structure. The shape
factor for cylindrical portion is 0.7.
p1 = Intensity of wind pressure
∴ P = 0.7 × (p1 × d´ × h ) kN
where, d´ = Outer diameter of the chimney.
In addition to the overturning effect due to wind pressure, the wind has also
aerodynamic effect. The aerodynamic effect of wind has not been taken into
consideration for the design of steel chimney.
6.10.4 Seismic Forces

The seismic forces also act horizontally. The seismic forces act on a structure,
when the structures are located in the seismic areas.
The following load combinations for calculations of stress at any point of steel
chimney are considered:
(i) Dead load + Wind load + Temperature effect.
(ii) Dead load + Earthquake (seismic) load + Temperature effect.
The worst combination out of the effect due to seismic (earthquake) forces and
wind effect is only taken into consideration. Only one effect is considered for the
design of the structure out of these two forces.
6.11 BENDING MOMENT ON SELF-SUPPORTING STEEL

CHIMNEY
The wind force acts as uniformly distributed load on the self-supporting steel
chimney. For the purpose of determining bending moment at any section XX Fig.
6.1, the wind force is assumed to act at the middle height above the section. The
bending moment due to wind at section XX, h metres below the top.
⎛ h⎞
Mw = ⎜ P × ⎟ ...(i)
⎝ 2⎠
where P = Total wind force.
Substituting the value of from Eq. 6.5,
⎛ h⎞
Mw = 0.7 × ⎜ p1 × d´×h × ⎟ kN-m ...(ii)
⎝ 2⎠
Sometimes, the self-supporting steel chimney is erected between the constructed
buildings. A portion of the chimney extends over the roof of the building as shown
in Fig. 6.6. The remaining portion of the chimney remains protected from the
H2
R o of -le ve l
Ms Ms
(H 1 – x) ( H 1 – x)
Mx Mx
H1
Ms
x x
M s+ M s ( H 1 – x )
H /2
C a se (a ) C a se (b )
Fig. 6.6 Chimney Extending Over-roof
wind. The bending moment for the part of chimney above the roof is calculated in
accordance with the expression (ii) above, the bending moment of chimney below
the roof (protected from the wind) shall be determined as under:
When the chimney is not fixed at the roof
⎛ x1 ⎞
Mx = ⎜ H × Ms ⎟ ...(iii)
⎝ 1 ⎠
⎛ H2 ⎞
Ms = ⎜ P × 2 ⎟ ...(iv)
⎝ ⎠
When the chimney is fixed at the roof
⎛ H ⎞
Mx = Ms . ⎜1 + 1 ⎟ ...(v)
H1
⎜ ⎟
⎝ 2 ⎠
The maximum bending moment occurs at the base of the chimney
⎛ H ⎞
Mmax = Ms . ⎜1 + 1 ⎟ ...(vi)
H1
⎜ ⎟
⎝ 2 ⎠
This bending moment acts as over turning moment on the steel chimney. The
overturning moment Mw, due to the wind pressure causes compressive stress on
the leeward side of the steel chimney and the tensile stress on the windward side
of the steel chimney. The maximum compressive stress and tensile stress on the
extreme fibre of steel chimney due to wind are equal.
6.12 BENDING STRESS ON STEEL CHIMNEY DUE TO

WIND
The bending stress, fw at the extreme fibre of steel chimney due to overturning
moment, Mw (moment due to wind in kN-m) is given by
⎛M d⎞
fw = ⎜ w × ⎟ ...(i)
⎝ I 2⎠
where, I = Moment of inertia of circular ring section of the steel chimney
⎛ Mw ⎞
⎜ ⎟ ⎛ Mw ⎞
or fw = ⎜ I ⎟ = ⎜ ⎟ ...(ii)
⎜ (d / 2 ) ⎟ ⎝ Z ⎠
⎝ ⎠
where, Z = modulus of section of chimney ring section with no breech opening
t = thickness of steel plate (viz., without corrosion allowance)
I ⎛ π ⋅ d3 ⋅ t ⎞
Z = =⎜ ⎟
d ⎜ d ⎟
⎜ 8 × ⎟
2 ⎝ 2 ⎠
⎛π ⎞ ⎛ 3.14 ⎞
= ⎜ ⋅ d2 ⋅ t ⎟ = ⎜ × d2 × t ⎟
⎝4 ⎠ ⎝ 4 ⎠
= 0.785 (d2 × t)
⎛ Mw d ⎞
⋅ ⎛ 4Mw ⎞
∴ fw = ⎜ πd3t 2 ⎟ = ⎜ kN/m2
⎜⎜ ⎟⎟ ⎝ π ⋅ d2 ⋅ t ⎟⎠
⎝ 8 ⎠
⎛ Mw ⎞
or fw = ⎜ ⎟ N/mm
2 ...(6.6)
⎝ 250 d2 ⋅ t ⎠
IS : 6533–1971 ‘Code of Practice for Design and Construction of Steel Chimney’
recommends the value of section modulus of steel chimney ring with no breech
opening as below
Z = 0.77d2. t ...(iii)
The modulus of section of chimney-cross-section with breech openings as shown
in Figs. 6.3 (a), (b), (c) and (d) are given by the following expressions, respectively
⎛ A ⎞
Z1 = 0.77 d2 . t ⎜1 − 0.65 1 ⎟ ...(iv)
⎝ d ⎠
⎛ A ⎞
Z2 = 0.77 d2 . t ⎜1 − 0.30 1 ⎟ ...(v)
⎝ d ⎠
⎛ A1 ⎞
Z3 = 0.77 d2 . t ⎜1 − 0.70 ⎟ ...(vi)
⎝ d ⎠
⎛ A A3 ⎞
Z4 = 0.77 d2 . t ⎜1 − 1.30 1 − 0.216 13 ⎟ ...(vi)
⎝ d d ⎠
It is to note that these expressions are applicable for thickness of the plate less
than 0.015 d.
6.13 PERMISSIBLE STRESSES

The windward side of steel chimney is subjected to tensile stress due to the combined
effect of the wind and weight of steel chimney. The leeward side of steel chimney is
subjected to compressive stress due to the combined effect of the wind, weight of
steel chimney and the weight of lining. On the compressive side the efficiency of
the joint depends on the strength of rivet in shear and in bearing and does not
depend on the tensile strength of plate. The efficiency of joint on compression side
is 100 percent. The efficiency of joint on the tension side is 70 percent.
In order to prevent the flattening of the steel plates on the tension or windward
side, and buckling of the steel plates on compression or leeward side, the permissible
stress in compression on gross-sectional area is adopted less than the permissible
stress in tension on the net sectional area. The permissible stresses in steel chimney
in axial tension, shear and bearing shall be adopted as specified in IS : 800–1984.
The allowable stresses in axial compression and in bending for circular chimneys
depend upon the effective height of the steel chimney h1, the-radius of gyration,
k(0.707 × radius) the diameter and the thickness t of the chimney to be considered
for different types of steel chimneys is given in Fig. 6.7.
C C
b b
B B
a a
A A
S e lf G uye d G uye d
sup po rting w ith fixed b ase w ith pin n ed ba se
S tress BC AB BC AB
a xial
h 1 = 2L h1 = 2 b h 1 = 0 .85 a h1 = 2 b h1 = a
b en ding
h1 = L h1 = b h 1 = 0 .8 5a h1 = b h1 = a
h = E ffe ctive h e ig ht of ch im n ey
Fig. 6.7
The allowable stress in axial compression and in bending for circular steel
chimney have been given in Tables 6.2 and 6.3 as per IS : 6533–1971 (‘Code of
Practice for Design and Construction of Steel Chimneys’).
The combined stress shall comply with the requirements of IS : 800–1984.
The member or part of the steel chimney reasonably exposed to adverse
temperature shall be considered. The allowable stresses are obtained by multiplying
the basic stresses specified in Tables 6.2 and 6.3 by the appropriate temperature
coefficient, kt. The value of kt may be noted from Table 6.4 as specified in IS: 6533–
1971.
⎡ Mw h⎤
⎢ 2
=+ 0.079h + 0.002 ⎥ kN/m2
⎣ 250πd t t⎦
< η2 . σ2 ...(6.9)
where, σc = Permissible stress in compression in steel plates
η2 = Efficiency of the joint on the compression side
= 1 (∴ η2 = 100 percent)
Thus, the thickness of steel plates from compression side
⎡ 4Mw ⎤
⎢ d + Ws + WL ⎥
t2 = ...(6.10)
⎢ ⎥
⎣ π ⋅ d ⋅ σ c ⎦
The thickness of steel plates at the various horizontal sections are found. The
thickness of steel plates at the junction of cylindrical and flared portions, and the
base of flared portion are also found. The thickness of steel plates of flared portion
should not be less than the thickness of steel plates in the cylindrical portion. The
thickness of steel plates of chimney is kept in excess than what is necessary (in
order to protect them from corrosion) by allowance for corrosion, which depends
upon design life of the steel chimney.
6.15 DESIGN OF BASE-PLATE

Cast iron, cast steel or structural steel circular base plates are provided for the
self-supporting steel chimney. It is preferable to use cast steel base plates as
L ug
C /L of x A n ch o r
a ncho r b olt
b olts
B a se
p la te
l x
b = W idth of ba se b = W idth of ba se
p la te p la te
(a ) (b )
Fig. 6.8
compared to the cast iron base plates. The structural steel base plates are even
better than cast steel base plates for high steel chimneys. The width of base plate
should be sufficient to transmit the compressive stresses to the foundation. The
allowable bearing pressure on a good cement concrete foundation is 4 N/mm2.
Thickness of base plate should be such that the bending stress and shearing stress
in the base plate do not exceed the allowable bending and shearing stresses. There
are two methods of connecting the flared portion of the steel chimney with the base
plates. These methods are as shown in Fig. 6.8.
The maximum compressive stress at the base plate on the leeward side of the
chimney
σbc = ⎡ 4 M w Ws + WL ⎤
⎥ kN/m
2 ...(6.11)
⎢ 2 + 2
π
⎣ 1 d t π d1 t ⎦
where, d1 = Diameter of the steel chimney at the base of the flared portion.
The maximum compressive stress per unit circumferential length at the base
plate on the leeward side of the chimney.
F1 = σbc × (t × 1) kN/m ...(6.12)
⎛ 4 M w Ws + WL ⎞
∴ F1 = ⎜ + × (t × 1) kN/m
⎝ πd12t πd1t ⎟⎠
⎛ 4 M w Ws + WL ⎞
or F1 = ⎜ + kN-m
⎝ πd12t πd1 ⎟⎠
The width of the base plate
⎛ F1 ⎞
b = ⎜ ...(6.13)
⎝ σbcr ⎟⎠
where, σbcr = Permissible bearing stress on the foundations.
In case the anchor bolts are provided on inside and outside of the steel chimney,
then the base plate may be kept symmetrical with chimney, as shown in Fig. 6.8
(a). The unsupported length of base plate l, measured from the extreme edge upto
the critical section XX, as shown in Fig. 6.8 (a) are equal. In case the anchor bolts
are provided on the outside only, then the unsupported length l, would be kept
more than the inner unsupported length l, would be kept more than the inner
unsupported length. The critical section is marked upto the root of angle section.
The thickness of base plate is found as under:
The maximum bending moment at the critical section XX
1
M =
2
(
⋅ σbcr ⋅ l2 ) ...(i)
The moment of resistance of unit length of base plate at the critical section
1
MR =
6
(
⋅ 1 ⋅ a2 ⋅ σbs ) ...(ii)
where, a = thickness of the base plate at the critical section. It is to note that
this includes the thickness of the angle section used for the
connection
σbs = Permissible bending stress in the base plate (0’75fy, where, fy is
the yield stress for steel).
Equating (i) and (ii)
M = MR
⎛1 2⎞ ⎛ 2⎞
∴ ⎜⎝ ⋅ 1 ⋅ a ⎟⎠ ⋅ σbs = ⎜ σbs ⋅ l ⎟
6 ⎝ 2 ⎠
1/2
⎛ 3σ ⎞
a = l . ⎜ bs ⎟ ...(6.14)
⎝ σbs ⎠
The thickness of base plate may be found by deducting the thickness of the
angle section from the total thickness obtained as per Eq. 6.14. The critical section
may be checked for shear stress. It is to note that the total thickness of base plate
a, has been found by using permissible bearing stress on the foundation instead of
actual bearing stress. This provides comparatively more thickness. In case the
unforeseen wind pressure increases such that the bearing pressure on the foundation
may reach the permissible bearing stress, even then, the base plate would be safe.
6.16 DESIGN OF ANCHOR BOLTS

The windward side of the steel chimney is subjected to the uplift pressure due to
the overturning effect of wind. The anchor bolts (holding down bolts) are provided
to resist this uplift pressure. The uplift pressure is found by considering the
combined effect of wind pressure and the weight of chimney only. The weight of
A n ch o r
b olt
D irectio n of
w in d d2
9 = S pa cing o f
a ncho r
b olts
Fig. 6.9
lining is omitted as discussed in Sec. 6.14. It is assumed that all the anchor bolts
are drawn up tight. Further it is assumed that the line of rotation is perpendicular
to the direction of wind and passes through the centre of the horizontal base section
of the steel chimney as shown in Fig. 6.9. The initial tension in the anchor bolt, if
any, is neglected.
The maximum tensile stress at the base plate on the windward side of the
chimney
⎛ 4Mw Ws ⎞
σt = ⎜ − kN/m2 ...(6.15)
⎝ π ⋅ d1 ⋅ t π ⋅ d1 ⋅ t ⎟⎠
2
The maximum tensile stress per unit circumferential length at the base plate
on the windward side of the chimney
F2 = σ1 × (t × 1) kN/m ...(6.16)
The maximum uplift force in one anchor bolt
= F2 . g = σt × (t × 1) × g kN
⎡ 4Mw Ws ⎤
= ⎢ 2
− ⎥ × g kN ...(6.17)
⎣ π ⋅ d1 π ⋅ d1 ⎦
where, g = spacing of the anchor bolts in metres.
The number of anchor bolts may be found by dividing the circumference of
anchor bolt ring by the spacing of anchor bolts. The permissible stress in axial
tension at the root of threads of anchor bolt is adopted from IS: 833–1994.
6.17 DESIGN OF FOUNDATION

A plain cement concrete or reinforced cement concrete foundation is used for self
supporting steel chimney. The chimney foundation is usually designed as a circular
slab and it is constructed as the circumscribing octagon. In the design of the
foundation of the chimney, a designer is to deal with either the bearing condition
of the soil is favourable and economical where the chimney may be directly supported
by the soil or the bearing condition of the soil is poor where the chimney has to be
placed on piles. The foundation is designed to resist the stresses resulting from the
following combinations.
(i) Dead load + Live load
(ii) Dead load + Wind or seismic forces, and
(iii) Dead load + Live load + Wind or seismic forces.
The weight of chimney lining etc. are considered as live load.
The weight of foundation is kept sufficient to prevent the overturning. The size
of foundation at the bottom is kept sufficient so that the bearing pressure in the
soil remains less than the allowable pressure in the soil. It is economical to use the
round or eight-sided foundations. Therefore, the shape of foundation block is
generally in the form of a frustum of a cone or a frustum of an eight-sided pyramid.
The square shaped foundations are not provided since the corners of square shaped
foundations are subjected to high pressure when the direction of wind is parallel to
the diagonal. The plain cement concrete is used so long as the slope of side of the
foundation with the vertical is less than 45 degrees. In case the slope of side of
foundation with the vertical is greater than 45 degrees then, the reinforced cement
concrete foundation is used.
The size and weight of foundation should be such that the underside of foundation
is under compression only. In that case, the bottom of foundation block remains in
contact with the soil. In case, the design of foundation is such that the compressive
stress at one edge of the foundation is zero, and it increases to maximum compressive
stress at the other edge, under the extreme conditions of loading, then, such design
of foundation is most economical. In such design of foundation, the unit stress due
to the overturning moment of the wind is just equal to the unit stress due to the
weight of the foundation and steel chimney. It is to note that the weight of lining
is omitted as discussed in Sec. 6.14. However the maximum compressive stress on
the leeward side due to wind, weight of foundation, steel chimney and lining should
not exceed the allowable unit pressure on soil.
In case the plain cement concrete foundation is provided, then, it is assumed
that the depth of foundation h1, is kept equal to 0.4 times the width of foundation.
For round foundation, the resultant thrust due to wind pressure, weight of steel
chimney, weight of lining and weight of foundation should not lie outside the
middle quarter of the foundation. The foundation block is not subjected to tension
in such condition. The maximum eccentricity is then limited to one-eighth the
width of foundation. The maximum eccentricity
⎛ Mw ⎞ b
e = ⎜ =
⎝ Ws + WL + WF ⎟⎠ 8
⎛ 8 Mw ⎞
∴ b = ⎜ ...(6.18)
⎝ Ws + WL + WF ⎟⎠
where, b = Width of the round foundation
WF = Weight of the foundation block
As compared to the weight of foundation, the weight of steel chimney Ws, and
the weight of lining W L, are small. For preliminary design the weight of steel
chimney and the weight lining are neglected. The weight of foundation
⎛π ⎞
WF = ⎜ b2 × 0.4b × 24⎟ kN
⎝4 ⎠
Then, the resisting moment due to weight of foundation is equal to the overturning
moment due to wind. Therefore,
1
WF . b = Mw
8
⎛π 2 ⎞ 1
or ⎜⎝ b × 0.4b × 24⎟⎠ × b = Mw
4 8
3
or π × b4 = Mw
10
∴ b = 1.015 (Mw)1/4 ...(6.19)
The width of foundation is then, revised by considering the weight of steel chimney
and weight of lining.
The intensity of soil pressure is determined. It is given by

⎛ W + WL + WF ⎞ ⎛ M w ⎞
p = ⎜ s ⎟⎠ ± ⎜⎝ ⎟ ...(i)
⎝ A Z ⎠
where, A and Z are the area and section modulus, respectively for the foundation
slab. If the radius of the circle of the circumscribing octagon is R, then the area of
foundation is 3.312 R2 and Z = 0.81 R2 as per (IS : 6533–1971).
In case, the entire footing is in compression, then
⎛ Ws + WL + WF ⎞ ⎛ Mw ⎞
⎜⎝ ⎟⎠ is greater than ⎜⎝ ⎟.
A Z ⎠
The successive trials are made for R to utilize fully. The soil pressure should
not exceed the allowable bearing capacity of the soil.
(a ) Fo u nd ation p la n
( W S + W L + W F)
e fm ax
k5
b
(b ) Fo u nd ation th ickne ss (c) S o il p ressure d ia gra m
Fig. 6.10 Soil pressure diagram
The full utilisation of the bearing of soil may lead to situations where only the
part of foundation is in compression, Fig. 6.10. In such a situation, the footing is
designed as a circle, though it is constructed as octagonal.
⎛ W + WL + WF ⎞
Let f = ⎜ s ⎟ ...(ii)
⎝ A ⎠
The maximum soil pressure is obtained from the following procedure :
The eccentricity
⎛ Mw ⎞
e = ⎜ ⎟
W
⎝ s + WL + WF ⎠
e f
and thereby values are determined. The values of zero stress and ratio max
b f
are found from Fig. 6.11 as per (IS : 6533–1971) and thus, the value of fmax is
e
calculated. It is recommended in code IS : 6533-–1971 that the value should not
b
k5
exceed 0.255 and be not less than 0.6.
b
1 .0
0 .9
0 .8
0 .7
0 .6
Va lu es o f k 5 / D
Valu e s o f f m ax / F
0 .5
0 .4
0 .3
0 .2
0 .1
0 0 .20 0 .30 0 .40 0 .50

( e / D ) va lues
M axim u m so il pressu re an d ne utral axis for
circular footing
Fig. 6 .11
6.18 STABILITY OF STEEL CHIMNEY

The steel chimney as a whole or any part of it is checked for stability. The weight
or anchorages shall be so proportioned that the least resisting moment including
anchorage shall not be less than the sum of 1.5 times the maximum over-turning
moment due to dead loads and imposed loads with the wind/seismic loading
considered as imposed loads.
The probable variation in dead load during construction, repair or during such
other temporary phase of work is taken into account, so that the stability of steel
chimney is ensured at all times.
While the stability of steel chimney is checked, it is also seen that when the
resulting pressure and shear forces are transferred to the supporting soil through
the foundation, the failure of the foundation will not occur.
Example 6.1 A self-supporting steel stack is 80 metres high and its diameter
at the top is 3 metres. Design the plates for the stack. Also design the base plate,
lugs and anchor bolts. The foundation and riveted joints need not be designed.
Adopt the wind force as per IS : 875. The location of place is such that the intensity
of wind pressure upto 30 m height is 1.50 kN/m2.
Solution
Design : The steel chimney is shown in Fig. 6.12(a). The height of steel chimney
is 80 m and its diameter at the top is 3 m.
3m
10 m
X1 X1
5 m
X2 X2
5 m
X3 X3
5 m
X4 X4
5 m
X5 X5
5 m
X6 X6
80 m
10 m
X7 X7
10 m
X8 X8
5 m
X9 X9
10 m
X10 X 10
10 m
X 11 X 11
4 .5 m
Fig. 6.12 (a)
Step 1: Flared portion

A conical flared portion is provided in the lower portion of the steel chimney. The
recommended height of flared portion
H 80
= = = 26.67 m.
3 3
Adopt the height of flared portion as 25 m. The diameter of conical flared portion at
its bottom,
5 5
d1 = × d = × 3 = 3.75 m.
4 4
Adopt the diameter of flared portion as 4.5 m.
Step 2 : Intensity of wind pressure
The location of place is such that the intensity of wind pressure upto 30 m height
is l.50 kN/m2. The intensities of wind pressure at higher heights as per IS : 875
are as follows :
0 to 30 m = 1.50 kN/m2, at 50 m = 1.67 kN/m2

at 35 m = 1.56 kN/m2, at 60 m = 1.72 kN/m2
at 40 m = 1.58 kN/m2, at 70 m = 1.77 kN/m2
at 45 m = 1.63 kN/m2, at 80 m = 1.83 kN/m2
The above intensities of wind at the respective heights are shown in Fig. 6.12 (b).
The shape factor for steel chimney circular in plan is 0.7.
Step 3. Over-turning moment due to wind, Mw
Usually, the intensity of wind pressure is adopted as the average value of those at
upper and lower section. However, for simplicity, the maximum intensity of wind
pressure (i.e., at the top) has been used in calculations.
W ind p ressure
(kN /m 2 )
80 m
P1 1 .83
10 m 10 m
7 .5 m
X1 X1 70 m
1 .77
5m P2
X2 5m X2 10 m
5m 1 .77
P3
X3 5m X3 60 m
1 .72
5m P4
X4 5m X4 10 m
P5 1 .72
5m
X5 5m X5 50 m
1 .67
5m P6 5m
X6 5m X6 45 m
P7 1 .63
5m
10 m 5m 40 m
P8 1 .58 5m
X7 5m X7 35 m
P9 1 .56 5m
10 m 5m 30 m
1 .50
P10
X8 5m X8
1 .50
5m P 11
X9 X9
7 .5 m
1 .50
10 m P12 30 m
X10 10 m X10
1 .50
10 m
5m
X 11 X 11 0m
Fig. 6.12 (b)
The over-turning moment about the respective sections are as under :

h1, h2, h3...etc. represent the heights of respective forces P1, P2, P3...etc. above
the section considered, Fig. 6.12 (b).
(i) At section X1X1
P1.h1 = 0.7× 1.83 × 3 × 10 × 5 = 192.15 kN-m
(ii) At section X2X2
P1 . h1 = 0.7× 1.83 × 3 × 10 ×10 = 384.30 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 2.5 = 46.46 kN-m
Total = 430.76 kN-m
(iii) At section X3X3
P1 . h1 = 0.7 × 1.83 × 3 × 10 × 15 = 576.45 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 7.5 = 139.39 kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 2.5 = 46.46 kN-m
Total = 762.30 kN-m
(iv) At section X4X4
P1 . h1 = 0.7× 1.83 × 3 ×10 × 20 = 768.60 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 12.5 = 232.31kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 7.5 = 139.39 kN-m
P4 . h4 = 0.7 × 1.72 × 5 × 5 × 2.5 = 45.15 kN-m
(v) At section X5X5
P1 . h1 = 0.7 × 1.83 × 3 ×10 × 25 = 960.75 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 17.5 = 325.24kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 12.5 = 232.31 kN-m
P4 . h4 = 0.7 × 1.72 × 3 × 5 × 7.5 = 135.45 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 × 2.5 = 45.15 kN-m
(vi) At section X6X6
P1 . h1 = 0.7 × 1.83 × 3 × 10 × 30 = 1152.90 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 22.5 = 418.16 kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 17.5 = 325.24 kN-m
P4 . h4 = 0.7 × 1.73 × 2 × 5 × 12.5 = 225.75 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 × 7.5 = 135.45 kN-m
P6 . h6 = 0.7 × 1.67 × 3 × 5 × 2.5 = 43.84 kN-m
(vii) At section X7X7
P1 . h1 = 0.7 × 1.83 × 3 ×10 × 40 = 1537.20 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 32.5 = 604.01 kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 27.5 = 511.09 kN-m
P4 . h4 = 0.7 × 1.72 × 3 × 5 × 22.5 = 406.35 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 ×17.5 = 316.05 kN-m
P6 . h6 = 0.7 × 1.67 × 3 × 5 × 12.5 = 219.19 kN-m

P7 . h7 = 0.7 × 1.63 × 3 × 5 × 7.5 = 128.36 kN-m
P8 . h8 = 0.7 × 1.58 × 3 × 5 × 2.5 = 41.48 kN-m
(viii) At section X8X8
P1 . h1 = 0.7 × 1.83 × 3 ×10 × 50 = 1921.50 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 42.5 = 789.86 kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 37.5 = 696.64 kN-m
P4 . h4 = 0.7 × 1.72 × 3 × 5 × 32.5 = 586.95 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 × 27.5 = 496.65 kN-m
P6 . h6 = 0.7 × 1.67 × 3 × 5 × 22.5 = 394.54 kN-m
P7. h7 = 0.7 × 1.63 × 3 × 5 × 17.5 = 299.51 kN-m
P8 . h8 = 0.7 × 1.58 × 3 × 5 × 12.5 = 207.38kN-m
P9 . h9 = 0.7 × 1.56 × 3 × 5 × 7.5 = 122.85 kN-m
P10 . h10 = 0.7 × 1.50 × 3 × 5 × 1.5 = 39.38 kN-m
(ix) At section X9X9
P1 . h1 = 0.7 × 1.83 × 3 × 10 × 56 = 2113.65 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 47.5 = 882.79 kN-m
P3 . h3 = 0.7 5 × 1.77 × 3 × 5 × 42.5 = 789.86 kN-m
P4 . h4 = 0.7 × 1.72 × 3 × 5 × 37.5 = 677.25 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 × 32.5 = 586.95 kN-m
P6 . h6 = 0.7 × 1.67 × 3 × 5 × 27.5 = 482.21 kN-m
P7 . h7 = 0.7 × 1.63 × 3 × 5 × 22.5 = 385.09 kN-m
P8 . h8 = 0.7 × 1.58 × 3 × 5 × 17.5 = 290.33 kN-m
P9 . h9 = 0.7 × 1.56 × 3 × 5 × 12.5 = 204.75 kN-m
P10 . h10 = 0.7 × 1.50 × 3 × 5 × 7.5 = 118.13 kN-m
P11 . h11 = 0.7 × 1.50 × 3.15 × 5 × 2.5 = 41.34 kN-m
Total = 6572.35kN-m
(x) At section X10X10
P1 . h1 = 0.7 × 1.83 × 3 ×10 × 65 = 2497.95 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 57.5 = 1068.64 kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 52.5 = 957.71 kN-m
P4 . h4 = 0.7 × 1.72 × 3 × 5 × 47.5 = 857.85 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 × 42.5 = 767.55 kN-m
P6 . h6 = 0.7 × 1.67 × 3 × 5 × 37.5 = 657.56 kN-m
P7. h7 = 0.7 × 1.63 × 3 × 5 × 32.5 = 556.24 kN-m
P8 . h8 = 0.7 × 1.58 × 3 × 5 × 27.5 = 456.25 kN-m
P9 . h9 = 0.7 × 1.56 × 3 × 5 × 22.5 = 368.55 kN-m
P10 . h10 = 0.7 × 1.50 × 3 × 5 × 17.5 = 275.63 kN-m
P11 . h11 = 0.7 × 1.50 × 3.15 × 5 × 12.5 = 206.72 kN-m
P12 . h12 = 0.7 × 1.50 × 3.60 × 10 × 5 = 189.00 kN-m
(xi) At section X11X11

P1 . h1 = 0.7 × 1.83 × 3 ×10 × 75 = 2882.25 kN-m
P2 . h2 = 0.7 × 1.77 × 3 × 5 × 67.5 = 1254.49 kN-m
P3 . h3 = 0.7 × 1.77 × 3 × 5 × 62.5 = 1161.56 kN-m
P4 . h4 = 0.7 × 1.72 × 3 × 5 × 57.5 = 1038.45 kN-m
P5 . h5 = 0.7 × 1.72 × 3 × 5 × 52.5 = 948.15 kN-m
P6 . h6 = 0.7 × 1.67 × 3 × 5 × 47.5 = 832.91 kN-m
P7. h7 = 0.7 × 1.63 × 3 × 5 × 42.5 = 727.39 kN-m
P8 . h8 = 0.7 × 1.58 × 3 × 5 × 37.5 = 622.13 kN-m
P9 . h9 = 0.7 × 1.56 × 3 × 5 × 32.5 = 532.35 kN-m
P10 . h10 = 0.7 × 1.50 × 3 × 5 × 27.5 = 433.13 kN-m
P11 . h11 = 0.7 × 1.50 × 3.15 × 5 × 22.5 = 372.09 kN-m
P12 . h12 = 0.7 × 1.50 × 3.60 × 10 ×1 5 = 567.00 kN-m
P13 . h13 = 0.7 × 1.50 × 4.10 × 10 × 5 = 215.25 kN-m
Total = 11587.15 kN-m
Step 4. Thickness of chimney plate
It is assumed that the design life of the steel chimney shall be 20 years and coal
is used as a fuel for the boiler. The chimney shall be lined and insulated. The
corrosion alowance is 4 mm for slight internal corrosion.
(i) At section X2X2 (Height from top is 15 m)
Diameter of chimney = 3 m
D ⎛ 3 × 1000 ⎞
ratio = ⎜ ⎟ = 1000
t ⎝ 3 ⎠
3000
Radius of gyration, k = 0.7 × = 1050 mm
2
h1 = 2 × 15 × 1000 = 30000 mm
h1 ⎛ 30000 ⎞
Ratio = ⎜ ⎟ = 28.57
k ⎝ 1050 ⎠
For bending stress,
1
h1
2 1
= × 28.57 = 14.28
k 2
= 71.8 N/mm2
= 78.7 N/mm2
These stresses are increased by 25 percent for wind. The maximum tensile
stress on windward from Eq. 6.7
⎛ Mw ⎞
⎜ 2
− 0.079 ⎟ < n1. ft
⎝ 250 πd t ⎠
⎛ 430.76 ⎞
0.7 ×1.25 × 71.8 = ⎜ 2
− 0.079 × 15 ⎟
⎝ 250 × π × 3 × t ⎠
t = 0.00095 m = 0.95 mm
The maximum compressive stress on the leeward side of the steel chimney
from Eq. 6.9
⎛ Mw h⎞
⎜ 2
+ 0.079h + 0.002 ⎟ < n2 × fc
⎝ 250πd t t⎠
⎛ 430.76 15 ⎞
(1.00 × 1.25 × 71.8) = ⎜ 2
+ 0.079 × 15 + 0.002 ⎟
⎝ 250 × π × 3 × t t ⎠
∴ t = 0.00103 m = 1.03 mm.
Therefore, total thickness with corrosion allowance is (1.03 + 4) mm = 5.03.
Adopt 6 mm.
(ii) At section X5X5 (Height from top is 30 m)
D ⎛ 3 ×1000 ⎞
ratio = ⎜ ⎟ = 600
t ⎝ 5 ⎠
h1 = 2 × 30 × 1000 = 60,000 mm
Radius of gyration,
3000
k = 0.7 × = 1050 mm
2
h1 60000
Ratio = = 57.14
k 1050
For bending stress,
1
h1
2 1
= × 57.14 = 28.57
k 2
= 71.8 N/mm2
= 78.7 N/mm2
⎛ Mw ⎞
⎜ − 0.079 ⎟ < n × f
⎝ 250πd2t ⎠ 1 t
⎛ 1698.90 ⎞
(0.7 ×1.25 × 71.8) = ⎜ 2
− 0.079 × 30 ⎟
⎝ 250 × π × 3 × t ⎠
∴ t = 0.003688 m = 3.688 mm
from Eq. 6.9
⎛ Mw h⎞
⎜ 2
+ 0.079h + 0.002 ⎟ < n2 × f c
⎝ 250 × πd t t⎠
⎛ 1698.90 30 ⎞
(1.00 × 1.25 × 71.8) = ⎜ 2
+ 0.079 × 30 + 0.002 × ⎟
⎝ 250 × π × 3 × t t ⎠
∴ t = 0.00344 m = 3.44 mm
Therefore, total thickness with corrosion allowance is (3.688 + 4) mm = 7.688.
Adopt 8 mm.
(iii) At section X8X8 (Height from top is 55 m)
Assuming the thickness of steel plate as 7 mm without corrosion
⎛D⎞ ⎛ 3 ×1000 ⎞
⎜ ⎟ ratio = ⎜ ⎟ = 428
⎝ t ⎠ ⎝ 2 ⎠
h1 = 2 × 55 × 1000 = 110000 mm
⎛ 3000 ⎞
Radius of gyration, k = ⎜ 0.7 × ⎟ = 1050 mm
⎝ 2 ⎠
Ratio of gyration,
⎛ h1 ⎞ ⎛ 110 × 1000 ⎞
⎜ ⎟ = ⎜ ⎟ = 144.76
⎝k⎠ ⎝ 1050 ⎠
For bending stress,
⎛1 ⎞
⎜ 2 h1 ⎟ ⎛1 ⎞
= ⎜ × 104.76 ⎟ = 52.38
⎜ ⎟ ⎝2 ⎠
⎝ k ⎠
= 73.554 N/mm2
= 114.92 N/mm2
⎛ Mw ⎞
⎜ 2
− 0.079h ⎟ < n1 . ft
⎝ 250 × πd t ⎠
⎛ 5555.57 ⎞
(0.7 ×1.25 × 73.554) = ⎜ − 0.079 × 55 ⎟
⎝ 250 × π × 32 × t ⎠
t = 0.01144 m = 11.44 mm
from Eq. 6.9
⎛ Mw 0.002 ⎞
⎜ 2
+ 0.079h + × h⎟ < n2 × fc
⎝ 250 × πd t t ⎠
⎛ 5555.57 55 ⎞
(1.00 ×1.25 × 73.554) = ⎜ 2
+ 0.079 × 55 + 0.002 × ⎟
⎝ 250 × π × 3 × t t ⎠
∴ t = 0.01023 m = 10.23 mm
Therefore, total thickness with corrosion allowance is
(11.44 + 4 mm) = 15.44. Adopt 16 mm.
(iv) At section X11X11 (Height from top is 80 m)
Diameter of chimney = 4.5 m
Assuming the thickness of steel plate as 11 mm without corrosion
⎛D⎞ ⎛ 4.5 × 1000 ⎞
⎜ ⎟ ratio = ⎜ ⎟ = 409
⎝ t ⎠ ⎝ 11 ⎠
Effective height for axial stress,
h1 = 2 × 80 × 1000 = 160,000 mm
Radius of gyration,
1
k = 0.7 × × 4.5 × l000 = 1575 mm
2
⎛ h1 ⎞ ⎛ 160000 ⎞
Ratio ⎜ ⎟ = ⎜ ⎟ = 101.59
⎝k⎠ ⎝ 1575 ⎠
For bending stress,
⎛1 ⎞
⎜ 2 h1 ⎟ = 50.79
⎜ ⎟
⎝ k ⎠
= 76.915 N/mm2
= 115.21N/mm2
stress on windward side from Eq. 6.7,
⎛ Mw ⎞
⎜ + 0.079h ⎟ < n1. ft
⎝ 250 × πd2t ⎠
⎛ 11587.15 ⎞
(0.7 × 1.25 × 76.915) = ⎜ 2
− 0.079 × 80 ⎟
⎝ 250 × π × 4.5 × t ⎠
t = 0.0099 m = 9.9 mm
from Eq. 6.9,
⎛ Mw 0.002h ⎞
⎜ 2
+ 0.079h + ⎟ < n2 × fc
⎝ 250 × πd t t ⎠
⎛ 11587.15 0.002 × 80 ⎞
(1.00 × 1.25× 76.915) = ⎜ 2
+ 0.079 × 80 + ⎟
⎝ 250 × π × 4.5 × t t ⎠
∴ t = 0.009896 m = 9.896 mm
Therefore, total thickness with corrosion allowance is (9.9 + 4) mm = 13.9 mm.
Adopt 18 mm.
Step 5. Modulus of section of steel chimney at the various sections
For 20 year design life of steel chimney, the value of slight corrosion allowance
(assumed) is 4 mm.
The modulus of section of steel chimney (without breech opening) is calculated
with t as the thickness of steel plate without allowance for corrosion
Z1_2 = 0.77 d2 . t
Z1_2 = 0.77 × 30002 × (6–4) = 13860 × 103 mm3
Z3_5 = 0.77 × 30002 × (8–4) = 27720 × 103 mm3
Z6–8 = 0.77 × 30002 × (16–4) = 83160 × 103 mm3
The diameter of steel chimney varies from section X8X8 to X11X11.
Step 6. Self-weight of steel chimney and lining
The thickness of lining increases from top to bottom. The weight of chimney
may be assumed as 0.64, 0.80, 0.96 and 1.28 kN/m2 per metre height of the chimney
at the sections X2X2, X5X5, X8X8 and X11X11, respectively.
At section X2X2
π × 3 × 15 × 0.64 = 90.432 kN
Add 10 percent for stiffeners
= 1.10 × 90.423 = 99.475 kN
Area of cross-section π × 3 × 1000 × (6–4) = 18840 mm2
At section X5X5
π × 3 × 15 × 0.64 = 90.432 kN
π × 3 × 15 × 0.80 = 113.04 kN
= 203.472 kN
= 1.10 × 203.472 kN
= 223.82 kN
π × 3 × 1000 × (8–4) = 37680 mm
At section X8X8
π × 3 × 15 × 0.64 = 90.432 kN
π × 3 × 15 × 0.80 = 11.3040 kN
π × 3 × 25 × 0.96 = 226.080 kN
= 429.552 kN
= 1.10 × 429.552 = 472.507 kN
π × 3 × 1000 × (16–4) = 113040 mm2
Step 7: Check for stresses
Actual stresses at section X2X2
⎛ 99.475 × 103 430.76 × 106 ⎞

= ⎜ ± ⎟ N/mm2
⎝ 18840 138.60 × 103 ⎠
= (5.28 ± 31.08) N/mm2
⎛ 223.82 × 103 1698.90 × 106 ⎞

= ⎜ ± ⎟ N/mm2
⎝ 37680 27720 × 103 ⎠
= (5.94 ± 61.28) N/mm2
⎛ 472.507 × 103 5555.57 × 106 ⎞

= ⎜ ± ⎟ N/mm2
⎝ 113040 83160 × 103 ⎠
= (4.18 ± 66.81) N/mm2
(It is also assumed that the chimney shall not be exposed to temperature more
than 200°C, in which case, the appropriate temperature coefficient, k t remains to
be unity).
Step 8: Design of Breech (flue) opening
(i) Portion of chimney between sections X8X8 and X11X11
Let there be two flue (breech) openings in the same direction.
Size of the openings = 1.8 m × 2.0 m
Width of the openings, A1 = 1800 mm

Height of centre line of openings above the base is 2 m. The diameter of the
chimney at this level is 4.35 m. The thickness of plate less corrosion allowance is
(16–4) = 12 mm.
(ii) Modulus of the chimney at the centre line of flue opening
⎛ A ⎞
Z = 0.77d2t ⎜1 − 1.3 1 ⎟
⎝ d ⎠
⎛ 1800 ⎞
= 0.77 × 43502 × 12 × ⎜1 − 1.3 ⎟ mm
⎝ 4350 ⎠
= 80790 × 103 mm3
= π × 4350 × 12 – 2 × 2000 × 12 (for opening)
= 115908 mm2
(iii ) Weight of chimney
Weight of the chimney above X8X8
= 472.507 kN
Weight of the opening X8X8 and X11X11
π × 3.75 × 25 × 1.28 = 376.80 kN
Total = 849.307 kN
Add 10 percent for overlap, rivets and stiffeners.
Total weight = 1.10 × 849.307 kN = 934.238 kN
⎛ 934.238 × 103 11587.15 × 106 ⎞

Actual stress = ⎜ ± 3 ⎟
N/mm2
⎝ 115908 80790 × 10 ⎠
= (8.06 ± 143.42) = 151.46 N/mm2.
(iv) Allowable stress
h1 = 2 × 80 × 1000 = 160000 mm
Radius of gyration, k
1
= 0.7 × × 4.5 × 1000 = 1575 mm
2
⎛D⎞ ⎛ 4.5 × 1000 ⎞

⎜ ⎟ Ratio = ⎜ ⎟ = 375
⎝t ⎠ ⎝ 12 ⎠
⎛ h1 ⎞ ⎛ 160000 ⎞
Ratio ⎜ ⎟ = ⎜ ⎟ = 101.59
⎝k⎠ ⎝ 1575 ⎠
For bending stress,
⎛1 ⎞
⎜ 2 h1 ⎟
⎜ ⎟ = 50.79
⎝ k ⎠
= 76.915 N/mm2
= 127.5 N/mm2
These stresses are increased by 25 percent for wind. Therefore allowable stress
in bending is 159.375 N/mm2, which one is greater than 151.46 N/mm2.
(v) Check for interaction expression
⎛ 8.06 143.42 ⎞
= ⎜ + ⎟
⎝ 76.915 159.375 ⎠
= 0.105 + 0.899 = 1.044
It exceeds unity very slightly. Hence, the section is adequate.
Area of steel plates removed for flue openings
= 2 × 2000 × 12 = 48000 mm2
The vertical reinforcement provided is kept 20 percent larger than the area
removed.
∴ Area of steel to be provided
= 1.20 × 48000 = 57600 mm2
Area of vertical reinforcement on each side of two flue openings
1
=× 57600= 14400 mm2
4
Provide 2 ISA 200 mm × 200 mm × 25 mm (one on outer side and one on the
inner side of the opening).
Area provide = 2 × 9380 = 18760 mm2
The area of reinforcement provided on the top and the bottom of openings are
kept the same.
Step 9 : Design of Base Plate
The maximum compressive force per unit circumferential length
⎛ M w Ws + WL ⎞
F1 = ⎜ 2 + ⎟ × (t ×1) kN/mm
⎝ πd1 t πd1t ⎠
1 ⎛ M w Ws + WL ⎞
= ⎜ + × 1000 N/mm
1000 ⎝ πd12 πd1 ⎠⎟
⎛ 4 × (11587.15) 934.238 ⎞
= ⎜ + ⎟ N/mm
2
⎝ 3.14 × 4.52 3.14 × 4.5 ⎠
= 795.04 N/mm
Allowable bearing stress for M 15 grade of concrete is 40 N/mm2.
Width of the base plate required
⎛ 795.04 ⎞
= ⎜ ⎟ = 159 mm
⎝ 1.25 × 4.0 ⎠
Provide 300 mm wide plate. Two angle sections (2 ISA 130 mm × 130 mm × 10
mm) are used to transmit the pressure at the bottom of the flared portion of the
steel chimney. The length of projection of the base plate beyond angle section
1
= (300 – 2 × 130 – 18) = 11 mm
2
Length of cantilever portion of the base plate upto the critical section XX as
shown in Fig. 6.13
= (11 + 130 –10) = 131 mm
The thickness is designed for allowable pressure instead of actual bearing
pressure. Total thickness at the critical section XX, from Eq. 6.14
1/2
⎛ 3σc ⎞
a = l. ⎜ ⎟
⎝ σbc ⎠
1
⎛ 4 ⎞2
= 131 ⎜ 3 × 1.25 × × 1.85 ⎟ = 32.345 mm
⎝ 1.33 ⎠
Thickness of base plate
= (323.45 – 10) = 22.345 mm
Provide 24 mm thick base plate as shown in Fig. 6.13.
S tack
p la te
6 mm
th ick 12 m m
1 20 m m
d B a se p la te
th ick
3 00 m m
4 N /m m 2
Fig. 6.13
Step 10 : Design of Anchor bolts (Holding down bolts)

The maximum tensile force per unit length of circumference
⎛ 4 M w Ws ⎞
F2 = ⎜ 2
− ⎟ × (t × 1 ) kN/m
⎝ πd1 t πd1t ⎠
1 ⎛ 4 M w Ws ⎞
= ⎜ − × 1000 N/mm
1000 ⎝ πd12 πd1 ⎟⎠
⎛ 4 × 11587.15 Ws ⎞
= ⎜ −
⎝ 3.14 × 4.6
2 πd1 ⎟⎠
(neglecting even second term)
= 728.92 N/mm
Provide 37 mm diameter anchor bolts
Area at the root of threads
= 840 mm2
Strength of anchor bolts
(840 × 120 × 1.25 )
= = 126 kN
1000
Spacing of the anchor bolts
⎛ 126 × 1000 ⎞
= ⎜ ⎟ = 172.86 mm
⎝ 728.92 ⎠
Provide anchor bolts at 160 mm spacing.
Step 11 : Design of Lug
The lugs are provided for greater stability. The lug or a bracket for each anchor
bolt is built up of 2 ISA 200 mm × 100 mm × 15 mm with a clear space of 45 mm
in between them for the bolts. The angles are kept about 750 mm long as shown in
Fig. 6.14. A filler plate is provided between the lug angle and the stack plate. The
filler plate is also kept 750 mm long and 450 mm wide and 22 mm thick. An ISA
200 mm × 100 mm × 15 mm and 250 mm long is placed on the top of the two
vertical angles.
Strength of 22 mm diameter rivet in single shear
⎛ 2 ⎞
= ⎜1.25 × π × 23.5 × 100 ⎟ kN
⎝ 4 1000 ⎠
= 54.19 kN
Maximum pull which can be transmitted by one anchor bolt
= 126 kN
Number of rivets required
⎛ 126 ⎞
= ⎜ ⎟ = 2.325
⎝ 54.19 ⎠
IS A 2 00 m m x 10 0 m m
x x 15 m m 2 R ivets
22 m m φ
C e ntre lin e o f
a ncho r b olt
1 6 R ive ts
L ug (B ra cke t)
2 IS A 2 00 m m x 10 0 m m 22 m m φ
x 15 m m
Filler
p late
22 m m
Fig. 6.14
Provide 4 rivets, (2 rivets in each vertical leg), 2 separate rivets are provided to
connect the horizontal angle at the top. The rivets may be checked for eccentric
riveted bracket connection in which the c.g. of rivets is out of plane of force
transmitted.
Problems
6.1 Design a self-supporting chimney of 100 m height. The diameter of
cylindrical shell is 4 m. The chimney has a 100 m thick brick lining
supported on the shell.
6.2 Design the lug for the steel stack in Problem 6.1.
6.3 A self-supporting steel chimney is 60 m high and has a diameter 3 m at
the top. Design the plate of the chimney. Also design the base plate and
the anchor bolts. The foundation and the riveted joints need not be designed.
The horizontal pressure may be assumed as l.50 kN/m2. The bearing
stress in cement concrete is 40 N/mm2.

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UNIT 14 DESIGN OF STEEL CHIMNEYS

14.2 TYPES OF STEEL CHIMNEY

14.2.1 Self-supporting Steel Chimneys

14.2.2 Guyed Steel Chimneys

liigure 14.l(a) : Self-supporting Steel Chimney

Figure 14.l(b) : Guyed Steel Chimneys

14.4 DESIGN OF' STEEL PLATES FOR SELF-

where, o,= permissible stress in tension in steel plates

1 where, oc= permissible stress in compression in steel plates

14.5 DESIGN OF JOINTS FOR SELF-SUPPORTING STEEL

12-16 22 Triple riveted lap joint

Thicker than 16 24 Butt joint

( a) One bndch opening ( b) Two bkecn openings

[c Two breech openings (d 1 Three breech openings

14.7 FORCES ACTING ON STEEL CHIMNEY

p = unit weight of steel = 79 k ~ / r n ~

h = height of steel chimney above the section XX in metres

= 0.079 h N/mm2 ...( 14.6)

where, K = shape factor

where, dl = outer diameter of chimney.

ii) Dead load + Earthquake load

Design of Steel Chimneys

where, p = total wind force

When the chimney is fixed at the roof

Case(A) Case (El I

The maximum bending moment occurs at the base of the chimney

14.9 BENDING STRESS ON STEEL CHIMNEY DUE TO

I = Moment of inertia of circular ring section of the steel chimney

Z = Modulus section OF chimney ring section with no flue opening

IS : 6533-1971 'Code of practice for design and construction of steel chimney

The modulus of section of chimney cross-section with flue opening as shown in

14.10 PERMISSIBLE STRESSES

Temperature 0.20 250 300 350 40O0C

kt 1.OO 0.75 0.67 0.60 0.50

for Circular Steel Chimneys

60 125.0 125.0 125.0 125.0 125.0 124.0

70 116.0 116.0 107.0

hlflr Allowable Stress in k ~ / m m ~

Note : For Tables 14.3 and 14.4

14.11 DESIGN OF BASE PLATE

The width of the base plate

M k = -1( 1 . a 2 .ob,) ...(ii)

where, g = spacing of the anchor bolts in metres.

14.13 DESIGN OF FOUNDATION

A plain cement concrdte or reinforced cement concrete foundation is used for

a) full raft (circular slab)

where, b = width of the circular or round foundation

'I c ) Soil Dressure dragram

Let f=[ W.S++: ...(14.26)

The maximum soil pressure is obtained from the following procedure.

14.14 LINING FOR CHIMNEY

14.15 STABILITY OF STEEL CHIMNEY

where, ow= stress due to wind load

Figure 14.9 (a)

Adopt the height of flared portion as 25 m. The diameter of conical flared

Adopt the diameter of flared portion as 4.5 m.

The above intensity of wind at the respective heights are shown in

Total = 430.76 kN-m

iv) At section X8X8

p, .h, = 0 . 7 x 1 . 8 3 ~ l3O~x 5 0 = 1921.50lcN-m

P6. h6 = 0.7 x 1.67 x 3 x 5 x 22.5 = 394.54 W - m

For bending stress

~llowabfestress in axial compression