Bayer Crop science-Ankleshwar

Design Calculations
32 Meter, Self Supporting Chimney
The Chimney will be erected at Mysore
Design Data:
Total Height of Chimney
Location
Design Codes of Practice

32
Ankleshwar
IS 6533
IS 6533
IS 875
IS 800
IS 1893

meters

Type of Chimney
Material of Construction

Self Supporting
Mild Steel for Chimney Shell

Part 1
Part 2
Part 3

Inputs:
Description

From
32.00
21.00
11.00
16.00
5.00
11.00
5.00
5.50
5.50
0.00
5.50

Height of Chimney
Range of Zone 1
Length of Zone 1
Range of Zone 2
Length of Zone 2
Range of Zone 3
Length of Zone 3
Range of Zone 4
Length of Zone 4
Range of Zone 5
Length of Zone 5

To
32.00
21.00
16.00
11.00
5.50

Unit
meters
meters
meters
meters
meters
meters
meters
meters
meters
meters
meters

Size Requirements:
As per Clause 7.2.4 of I.S. 6533 Part 2
Minimum height of Flared Portion
=
=
The provided height of Flared Portion is
Hence, OK
Maximum Outside Diameter of Flared Portion at Botto
=
=
Whereas provided Inside Diameter of Flared Portion is
Hence, OK

1/3
0.33
10.667
11.000

Total Height of Chimney

32
meters
meters
meters

1.6
1.6
0.96
1.00

Outside Diameter at Top

0.6
meters
meters
meters

Wind Pressure Calculations:

Basic Wind Speed Vb
Risk Co efficient K1
Risk Co efficient K2
Topography Factor K3

44.00
1.07
1.13
1.00

m/sec
Category 1, Class B
Assumed Flat Ground

Calculations:
Vz (Design Wind Velocity) = Vb x K1 x K2 x K3
= 53.2004
m/sec
Design Wind Pressure = 0.6 x Vz x Vz
= 1698.16954
= 169.81695
Safety Factor for Circular Exposed Surface

KN/sq. m
Kg/sq. m

0.7

Calculations for Wind Moment and Checking for Stresses

As Per I.S 6533 (part-2 ) Cl 8.2.2 of I.S.6533-part2, to
determine the wind force acting at different heights of the
chimney, the chimney shall be divided in to five Zones.
Description
Zone
Zone
Zone
Zone
Zone

1
2
3
4
5

From
21.00
16.00
11.00
5.50
0.00

To
32.00
21.00
16.00
11.00
5.50

Unit
meters
meters
meters
meters
meters

Calculations for Zone 1:

Thickness of Shell
Outside Diameter of Shell (OD)
Inside Diameter of Shell (ID)
Pi

21.00

32.00

meters

0.6
cm.
72.0
cm.
60.0
cm.
3.142
Moment of Inertia I = (3.142/64) x (OD4 ID4)
= 0.0490875 13913856
= 682996.41
Cm4
Modulus of Section Z = I x (2/OD)
= 18972.1224

Cm3

Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder
0.7

meters

[OD x Design wind pr. x safe

factor x (sq of height of zone) /
Therefore, Wind Moment at 21 meters from Base, M = 2] + [dia. of ladder x Design
wind pr. x 20% dia. of ladder x
(sq of height of zone) / 2]
= 11880.7677
= 1188076.8

kg m
kg cm

Self Weight of Stack and Ladder P

1900

kg

Cross Sectional Area of Chimney A

(3.142/4) x OD2
= 4072.032

sq. cm.

Stress at 21 meters from Base,

Height to Diameter Ratio

(M/Z) + (P/A)
= 63.088836
Height/Mean Diameter
= 16.6666667
=
7.31

Diameter to Thickness Ratio

=
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel
Therefore Section is Safe

kg/sq. cm

Mean Diameter/Shell Thickness

251

1013

kg/sq. cm.

Calculations for Zone 2:

Thickness of Shell
Outside Diameter of Shell (OD)
Inside Diameter of Shell (ID)
Pi

16.00

21.00

meters

0.8
cm.
151.6
cm.
150.0
cm.
3.142
Moment of Inertia I = (3.142/64) x (OD4 ID4)
= 0.0490875 21948064
Cm4
= 1077375.6
Modulus of Section Z = I x (2/OD)
= 14213.398

Cm3

Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder
0.7

meters

[OD x Design wind pr. x safe

factor x (sq of height of zone) /
Therefore, Wind Moment at 16 meters from Base, M = 2] + [dia. of ladder x Design
wind pr. x 20% dia. of ladder x
(sq of height of zone) / 2]
= 25197.032
= 2519703.2

kg m
kg cm

Self Weight of Stack and Ladder P

3040

kg

Cross Sectional Area of Chimney A

(3.142/4) x OD2
= 18052.801

sq. cm.

Stress at 21 meters from Base,

Height to Diameter Ratio

(M/Z) + (P/A)
= 177.44501
Height/Mean Diameter
= 10.6100796
=
10.61

Diameter to Thickness Ratio

=
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel
Therefore Section is Safe

kg/sq. cm

Mean Diameter/Shell Thickness

188.5

1187

kg/sq. cm.

Calculations for Zone 3:

Thickness of Shell
Outside Diameter of Shell (OD)
Inside Diameter of Shell (ID)
Pi

11.00

16.00

meters

0.8
cm.
151.6
cm.
150.0
cm.
3.142
Moment of Inertia I = (3.142/64) x (OD4 ID4)
= 0.0490875 21948064
Cm4
= 1077375.6
Modulus of Section Z = I x (2/OD)
= 14213.398

Cm3

Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder
0.7

meters

[OD x Design wind pr. x safe

factor x (sq of height of zone) /
Therefore, Wind Moment at 11 meters from Base, M = 2] + [dia. of ladder x Design
wind pr. x 20% dia. of ladder x
(sq of height of zone) / 2]
= 43405.8247
= 4340582.5

kg m
kg cm

Self Weight of Stack and Ladder P

4000

kg

Cross Sectional Area of Chimney A

(3.142/4) x OD2
= 18052.801

sq. cm.

Stress at 21 meters from Base,

Height to Diameter Ratio

(M/Z) + (P/A)
= 305.60825
Height/Mean Diameter
= 13.9257294
=
13.92

Diameter to Thickness Ratio

=
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel
Therefore Section is Safe

kg/sq. cm

Mean Diameter/Shell Thickness

188.5

1187

kg/sq. cm.

Calculations for Zone 4:

Thickness of Shell
Outside Diameter of Shell (OD)
Inside Diameter of Shell (ID)
Pi

5.50

11.00

meters

1.0
cm.
197.0
cm.
195.0
cm.
3.142
Moment of Inertia I = (3.142/64) x (OD4 ID4)
= 0.0490875 60237856
Cm4
= 2956925.8
Modulus of Section Z = I x (2/OD)
= 30019.551

Cm3

Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder
0.7

meters

[OD x Design wind pr. x safe

factor x (sq of height of zone) /
Therefore, Wind Moment at 5.5 meters from Base, M = 2] + [dia. of ladder x Design
wind pr. x 20% dia. of ladder x
(sq of height of zone) / 2]
= 88069.0463
= 8806904.6

kg m
kg cm

Self Weight of Stack and Ladder P

6200

kg

Cross Sectional Area of Chimney A

(3.142/4) x OD2
= 30484.4695

sq. cm.

Stress at 21 meters from Base,

Height to Diameter Ratio

(M/Z) + (P/A)
= 293.57568
Height/Mean Diameter
= 13.5204082
=
13.52

Diameter to Thickness Ratio

=
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel
Therefore Section is Safe

kg/sq. cm

Mean Diameter/Shell Thickness

196

1187

kg/sq. cm.

Calculations for Zone 5:

Thickness of Shell
Outside Diameter of Shell (OD)
Inside Diameter of Shell (ID)
Pi

0.00

5.50

meters

1.0
cm.
242.0
cm.
240.0
cm.
3.142
Moment of Inertia I = (3.142/64) x (OD4 ID4)
= 0.0490875 111982096
Cm4
= 5496921.1
Modulus of Section Z = I x (2/OD)
= 45429.1

Cm3

Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder
0.7

meters

[OD x Design wind pr. x safe

factor x (sq of height of zone) /
Therefore, Wind Moment at 5.5 meters from Base, M = 2] + [dia. of ladder x Design
wind pr. x 20% dia. of ladder x
(sq of height of zone) / 2]
= 155807.734
= 15580773

kg m
kg cm

Self Weight of Stack and Ladder P

8400

kg

Cross Sectional Area of Chimney A

(3.142/4) x OD2
= 46002.022

sq. cm.

Stress at 21 meters from Base,

Height to Diameter Ratio

(M/Z) + (P/A)
= 343.15161
Height/Mean Diameter
= 13.2780083
=
13.52

Diameter to Thickness Ratio

=
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel
Therefore Section is Safe

kg/sq. cm

Mean Diameter/Shell Thickness

241

1147

kg/sq. cm.

[OD at Bottom+OD of Zone 4]/[2 x Designed

Wind Pressure x Factor of Safety x Ht. of
Zone 1]+[OD at Top x Designed Wind
Pressure x Factor of Safety x Ht. of Zone 2]+
[Factor of Safety x Designed Wind Pressure x
20 % of Total Height]

Total Horizontal Force at Base Plate Level

= 5131.4608

kg.

Check for Combined Stresses and Stability

As per I.S. 6533 - part-2 CL. 9.1.1, the chimney is 1.6(s + s ) 0.9s < 1.8 s
w
m
e
a
stable provided the following is satisfied.
Where,
sw = Stress produced by Wind load

M/Z
= 342.96901

sm = Stress produced by any other load which acts at all

times & will reduce the combined stress

se = Stress due to Dead load

Therefore, 1.8 sa
Final Calculations

kg/sq. cm.

0
P/A

= 0.1826007

kg/sq. cm.

617.67289

kg/sq. cm.

1.6(sw + sm) 0.9se < 1.8 sa

548.58607
<
1111.81

Therefore Structure is Safe.

Design of Foundation Bolts
Maximum Bending Moment M
Maximum Shear Q
Weight of Chimney

###
5131.46
13050.00

Maximum Force on one Anchor Bolt T = (4M / n D) W / n

Where, n = number of bolts used
24
D = PCD of Bolts
275
8899.14298
Tensile Capacity of each M36 Bolt
Maximum Shear Capacity

nos.
cm
kg.

10.178cm2 x 1300Kgs/cm213232.4
10.178 x 1100
11195.8

kgs.
kgs.

Check for Combined Stress for Shear and tension

(Max. Tensile
Force/Tensile Cap. Of
each Bolt)+(Total
Horizontal Force on
Base/Max. shear Cap.)
1.1308653

<

1.4

Hence Design is Safe

T / Pi x d x tbd

Bolt Embedment Length in concrete = l =

tbd = Permissible stress in bond
Diameter of the Bolt, d

8
Kgs/Cm2 (for M20 Concrete)
3.6
cms
81.581143
cms

Whereas Provided Length is more than

100

cms.

Hence OK
Design of Baseplate
Maximum Bending Moment M
###
Diameter of Chimney at Base d=
242.00
cms.
Weight of Chimney W =
13050.00 kgs.
Maximum compressive force / unit length of circumference = 4M/ Pi D2 + W / PiD
354.7
kg/cm
Provided Baseplate Thickness T
25
cms.
Fbe = Bearing Pressure
Fc/T
14.188
kg/sq. cm.
Which is less than 40 Kg/sq. cm. (For Concrete)
Thickness of Base plate T = Nb x (3 x Fbe / sb)0.5
Where Nb = Maximum projection =
15
cms.
Fbe =
14.188
kg/sq. cm.
sb =Permissible Bending Stress
1650
kg/sq. cm.
Therefore T=

Whereas provided thickness is 2.5 cms.

Hence, OK.

2.4

cms