DESIGN OF RCC CHIMNEY

PROJECT GUIDE
Dr.A.LEEMA ROSE M.E ,PhD

Project Members,
M.GOPI
B.KANDAVEL
R.MANI MARAN
 INTRODUCTION

A chimney is a structure for venting hot flue

gases or smoke from boiler, stove, furnace or 
fireplace to the outside atmosphere. Chimneys are
typically vertical, or as near as possible to vertical, to
ensure that the gases flow smoothly, drawing air into
the combustion in what is known as the stack, or
chimney effect. The space inside a chimney is called
a flue. Chimneys may be found in buildings, steam
locomotives, ships and industries.
TYPES OF CHIMNEYS

 Brick chimney

 RCC chimney

 Steel chimney
 BRICK CHIMNEY

Brick Chimneys are constructed with Brick &

Mortar, with some additive. Being the best in
the industry for long time, it has many
disadvantages over our pre-cast Chimneys.
STEEL CHIMNEY
SteelChimneys are constructed with steel plates
converted to Rolls or Pipes, with Stay wire, etc.
 RCC CHIMNEY

RCC Concrete Chimneys are constructed like a

Concrete building - Steel/Iron Rods & Cement
Mortar. Due to varying atmosphere and Air
Moisture, these chimneys get cracks and
damages very easily. Recovering these chimneys
is very expensive. Because of rich Iron rods
inside the wall (Condense Water formation
affected the Steel inside the wall).
 SPECIFICATIONS OF RCC
CHIMNEY
A reinforced concrete chimney is generally
circular in shape with a rigid concrete shell cast
with a rich concrete mix of M-20 to M-25 grade
and provided with longitudinal vertical
reinforcement and horizontal hoop
reinforcement. A fire brick lining 100 to 150mm
thick is provided inside the concrete shell with
an air gap of 80 to 150mm thick to reduce the
temperature gradient from the interior surface of
fire brick lining to the exterior surface of the
concrete shell.
 DESIGN FACTORS
Reinforced concrete chimneys are designed to
with stand the stresses developed due to
following factors,

 Self weight of chimney

 Wind pressure
 `Temperature stresses
 SHAPE FACTOR
Ratio of height to base 0-4 4-8 8 or over
width

Cross sectional shape of Shape factor

chimney

Circular 0.7 0.7 0.7

Octagonal 0.8 0.9 1.0

Square (wind perpendicular 0.8 0.9 1.0

to diagonal)

Square (wind perpendicular 1.0 1.15 1.3

to face)
 DESIGN OF RCC CHIMNEY
A concrete chimney of height 80m with external diameter of the shaft
being 4m at top and 5m at bottom is required in a place where the
wind intensity is 1.5KN/m2.Thickness of fire brick lining
=10cm.Temperature difference between the inside and outside of shaft
=750C.permissible bearing pressure on soil at site=150KN/m2.
Adopt M25grade concrete mix and steel Fe415 and design the following,
 Base section of chimney
 Foundation for the chimney

SOLUTION:
  PERMISSIBLE STRESSES:
σcbc=8.5N/mm2
σst =230N/mm2
m =11
 LOAD:

 
Weight of chimney= (π×4.2×0.3) ×80×24 =7600KN
Weight of fire brick lining (10cm thick) = (π×3.8×0.1)80×20
=1920KN
Total wind load above base = [(0.7×1.5×(4+5)/2×80)]
=375KN
Acting at a height of 40m above base,
Total dead load above base (W) = (7600+1920) =9520KN
Bending moment at base due to wind load,
(M) = (375×40) =15000KN.m
Eccentricity (e) = (M/W) = (15000/9520)
=1.575m.
REINFORCEMENTS:


Providing reinforcement of 1% of the cross sectional area,

Ast(r) =0.01(π×4600×400)
=57805mm2
Using 25mm diameter bars,
Ast(p) = (π×252/4) =491mm2
Number of bars = (57805/491)
=120
 
Provide 120 bars of 25mm diameter bars
Ast (p) = ((π×252/4)/120) ×1000
=58800mm2
ts =(Ast(p)/πdm)
= (58800/ (π×4600))
` =4mm
 ANALYSIS OF STRESSES AT BASE SECTION:

e=R× [(tc-ts) ((sin2α/4) + ((π-4)/2)) + (m×ts×π)/2]

[(tc-ts) {sinα+ (π-α) cosα} +π×m.ts.cosα]
Where,
e=1575mm,
ts=4mm,
tc=400mm,
R=2300mm,
α=angle subtended by the neutral axis at the centre.
Assumed until the value of calculated eccentricity coincides with actual
value e=1575mm.
TRIAL 1:

 Assume α=700
e= [(400-4) ((sin1400/4) + (π-700)/2) + (11×4×π)/2]
[(400-4) ((sin600+ (π-700) ×cos700) +π×11×4×cos700]
e=1742mm>1575mm.
Hence reduce the value of α.  
TRIAL 2:
 Assume α=600
e= [(400-4) ((sin1200/4)+(π-1.047)/2)+(11×4×π)/2]
[(400-4) ((sin600+(π-1.047)cos600)+π×11×4×cos600]
e=1586mm=1575mm.
Hence the value of angle α=600
Using the value of α in load equation,
W= [2Rσc/ (1+cosα)] [(ts-tc) {sinα+ (π-α) cosα} +πm×ts×cosα]
9520×103= [2×2300σc/ (1+cos600]
[(400-4) {sin60+ (π-1.047) ×cos600}
+π×11×4×cos600]
Stresses in concrete,
σc=3.75N/mm2<8.5N/mm2
Stresses in steel,
σs=m.σc×[R (1-cosα)/R (1+cosα)]
=11×3.75× [(1-cos600)/ (1+cos600)]
=13.75N/mm2<230N/mm2
The stresses in concrete and steel are within safe permissible limits.
 DESIGN OF HOOP REINFORCEMENT:
Shear at the base of chimney =375KN
Mean diameter at base =4600mm
Using 10mm diameter hoops at 200mm centers
At= ((π×102/4)/200) ×1000=79mm2
 
Stresses in steel (σs) = (H×S/ (1.6×At×d)
= (375×103×200/ (1.6×79×4600))
=129N/mm2<230N/mm2
Hence stresses are within permissible limits.
 TEMPERATURE STRESSES (COMBINED EFFECT OF
WIND LOADS, SELF WEIGHT &TEMPERATURE):
 compression zone (leeward side):
Providing an effective cover of 50mm to steel
tc=400mm
ts=4mm
atc=350mm
a=0.875
p= (ts//tc) = (4/400)
=0.01
T=750
α=11×10-6/0C
m=11
Ec= (Es/m)
= (210×103/11)
σc =3.75N/mm2
 
σc[1+(m-1)p] = Ec×a×T×α
[(k'/2)-mp ((a-k')/k')] (1+ ((a-k')/k'))
 
(210×103×0.875×75×11
3.75× (1+10×0.01) = ×10-6/11)
0.5k'-(11×0.01(0.875-k')/k') [1+ ((0.875-k')/k'))]
 
k' =0.70
 
σc'= [Ec×a×T×π]
[1+ (a-k')/k']
= (210×103×0.875×75×11×10-6/11)
(1+ (0.875-0.70)/0.7)
=11N/mm2
 
The permissible compressive stress for M25 grade concrete when wind
loads also considered is (1.33×8.5)=11.33N/mm2.
 
Stresses in steel (σs) = mσc'(a-k')/k'
= (11×11(0.875-0.7)/0.7)
=30.25N/mm2<230N/mm2
 Tension zone (wind ward side):
  p×σs = α×T×Ec×k'
[pm ((a-k')/k')-0.5k']

0.01×13.73 = [11×10-6×75×210×103×k'/11]
[0.01×11× ((0.875-k')/k')-0.5k']
 
k' =0.55
 
σc=α×T×Ec×k'
 
σc=(11×10-6×75×210×103×0.55/11)
 
=8.66N/mm2<11.33N/mm2
Stresses in steel (σs) =m×σc'(a-k')/k'
=11×8.66 (0.875-0.55)/0.55
=56.28N/mm2<230N/mm2
 Stresses at neutral axis:
 
k=-mp+√ (2mpa+p2 m2)
p=0.01
m=11
a=0.875
k= -11×0.01×√ (2×11×0.01×0.875+0.012×112) =0.342
Stresses in concrete, σct =Ec×α×k×T
σct =(210×103×11×10-6×0.342×75)
=5.386n/mm2<11.33N/mm2
 Stresses in steel=Es×α×T× (a-k)
= (210×103×11×10-6×75)(0.875-0.342)
=92.34N/mm2<230N/mm2
Hence stresses are within permissible limits.
STRESSES IN HOOP STEEL DUE TO TEMPERATURE :
 

Hoop steel of 10mm diameter at 200mm centers provided at base section.

 
%p= (As/ (s.tc)) = (79/ (200×400))
=0.00098
a=0.875
m=11
 
k'=√(2×p×m×a+p2m2)-p×m
=√ (2×0.00098×11×0.875+0.000982×112)-(0.00098×11)
=0.127
 
σs'=m×σc'(a-k')/k'
=11× σc'× (0.875-0.127)/0.127
=60.45× σc'
 
(σs'+m σc')= (EsαT.a)
(60.45σc'+11σc')= (210×103×11×10-6×75×0.875)
σc'=2.12N/mm2
σs'=128.25N/mm2
Total stress in hoop steel= (stress due to shear) + (stress due to
Temperature difference)
= (129+128.15)
=257.25N/mm2>230N/mm2
Hence the spacing of the hoop reinforcement can be reduced to 150mm instead of
200mm centers.
 
DESIGN OF FOUNDATION:
 
A circular R.C slab foundation is designed for the chimney.
Total vertical load on base =9520KN
Bending moment =15000KN.m
Allowable bearing pressure = 150KN/m 2
Self weight of footing (assumed at 10%) =950KN
Total load on soil= (9520+950) =10470KN
 
If D-diameter of the circular footing for tension to develop,

`  (W/A) = (M/Z)
10470/ (π×D2/4)) = (15000/ (π×D3/32))
D =11.4m
 
The loading on the base is taken as annular loading on the mean diameter. The
bending moments in the base obtained by superimposing the two types of
loading as shown in fig.

Intensity of soil pressure (w) = (10470/ (π×11.42/4))

=103KN/m2
 
2a=11.4m
2b=4.6m
 
Maximum bending moment in the section is governed by the radial moment.
 
 Mt=bending moment at center of footing
 
= (W/8π) [2loge (a/b) +1-(b/a) 2] - (3×w×a2/16)
= (10470/8π) [2loge(5.7/2.3)+1-(2.3/5.7)2]- (3×103×5.72)
=476.28KN.m/m
 
Mr(max) = moment at junction of footing and chimney walls at a
Radius of 2.3m

= (W/8π)[2loge(a/b)+1-(b/a)2]-(3×103×(5.72-2.32)
= (10470/8π) [2loge(5.7/2.3)+1-(2.3/5.4)2]
- (3×103× (5.72-2.32)
=578.38KN.m/m
 
Design ultimate moment (Mu) = (1.5×578.38)
=868KN.m
 Using M-20 grade concrete and Fe-415 HYSD bars,
 
Effective depth (d) = √ (Mu/ (0.138×fck×b))
=√ (868×106/ (0.138×20×1000))
=561mm
 

 
 
Since moment is large, adopt larger depth of footing to reduce the quantity
of reinforcements.
 
Adopt,
Effective depth (d) =700mm
Overall depth (D) =800mm
 Using design chart of SP: 16,
 (Mu/bd2) = (868×106) / (1000×7002)
=1.77
Refer table-2 SP: 16 and find out the percentage of reinforcements as,
 %p= (100Ast/b×d) =0.555
Ast(r) = (0.555×1000×700/100)
=3885mm2
 Provide 28mm diameter at 150mm c/c,
Ast (p) = ((π×282/4)/150) ×1000
=4105mm2
Providing area of steel reinforcement is 4105mm2 in perpendicular
directions both ways as shown in fig. Also provide 12mm diameter bars
both ways at top of the footing.
CHECK FOR SHEAR:
 
Intensity of soil pressure (p) =103KN/m 2
Ultimate soil pressure (pu) = (1.5×103)
=154.5KN/m2
Cantilever projection = [(0.5×11.4)-2.5]
=3.2m
 Maximum shear force at a distance‘d’ from the support is given by,
 Vu= [154.5× (3.2-0.7)]
=386.25KN
 τv= (Vu/b×d)
= (386.25×103/(1000×700)
=0.5N/mm2
 
 %p=(100Ast/b×d) = (100×4105/ (1000×700))
=0.586
Refer table 19 of IS: 456-2000 and find out the permissible shear stress,
 
k×τc= (1×0.52) =0.52N/mm2
 
Hence τv<k.τc the slab is safe against shear failure.
 CONCLUSION

 Some very high chimneys are used for carrying antennas of mobile
phone services and low power FM/TV-transmitters.
 Special attention must be paid to possible corrosion problems if these
antennas are near the exhaust of the chimney.
  So that the design of R.C.C chimneys is stable when compared to other
type of chimneys.
 REFERENCE

 Advanced Reinforced Concrete Design

by N. Krishnaraju,
CBS Publishers and Distributors – 1988