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1.

GENERAL

1.1 Scope of Work

This calculation is prepared to explain the detail design of calculation for TCM New Crushing Plant
Conveyor 15 Structure & Foundation to be performed for Bunyut Coal Procesing
Stockpiles and Port Expansion (BCPSPE), Kalimantan Indonesia

1.2 References Document

- 2864-TCM-C-GL-001 General Layout Existing Condition


- 2864-TCM-M-CV15-001 Gonveyor CV15 General Arrangement
- 2864-TCM-M-CV15-002 Gonveyor CV15 Belt Profile

1.3 Design Criteria

(A) Applicable Codes and Standards


SNI-03-1726-2003 , "Tata Cara Perencanaan Gempa untuk Bangunan Gedung"
ASCE/SEI-7-2010, “American Society of Civil Engineers, Minimum Design Loads for
Building and Other Structures"
AISC, March 9, 2005 edition, " American Institute of Steel Construction, Specification
for Structural Steel Buildings"

(B) Project Specification


General Design and Spesification for Civil and Structure
Design Specification for Wind Load
Design Specification for Seismic Load

1.4 Major Material

(1) Concrete
Specified compressive strength of concrete
For general concrete foundation : fc' = 210 kg/cm 2
For levelling concrete : fc' = 140 kg/cm 2
Concrete density : γc = 2400 kg/m 3
Cement shall conform to ASTM C-150 or SNI 15-2049-2004
Cement type used Type I

(2) Reinforcing Steel Bar


For structural type shall use deformed rebar conform to SNI 07-2052-2002 BJTD 40 or
ASTM A615 Grade 60 or or JIS G3112
Yield strength for deform rebar : fy = 4000 kg/cm 2

For non structural type shall use plain rebar conform to SNI 07-2052-2002 BJTP 24 or
ASTM A615 Grade 40 or or equivalent
Yield strength for deform rebar : fy = 2400 kg/cm 2

Steel density : γc = 7850 kg/m 3


(3) Structural steel
E = 2.1 x 106 kg/cm 2
Density = 7850 kg/m3

ASTM A 36 or JIS G3101-SS400 or equivalent, for structural steel pipe shall use ASTM
A-53 Grade B ERW type or seamless pipe or JIS G 3444 STK400 or equivalent.

Minimum yield strength : Fy = 235 N/mm 2 (2400 kg/cm 2)

(4) Bolt Connection


High Strength Bolt (HSB) ASTM A 325 TIPE-I (AISC 9th, table 1A, 1D)
Allowable shear stress : Fvb = 21 ksi (1476 kg/cm 2)
Allowable tension stress : Ftb = 54 ksi (3796 kg/cm 2)

Ordinary Structural Bolt (OSB) ASTM A 307 Grade-A (AISC 9th, table 1A, 1D)
Allowable shear stress : Fvb = 10 ksi (700 kg/cm 2)
Allowable tension stress : Ftb = 20 ksi (1400 kg/cm 2)

(5) Weld Connection


Welding AWS A-5.1 for carbon steel, Electrode E70XX (grade 70)
Minimum tensile strength : Fu = 72 ksi (5062 kg/cm 2)
Minimum shear : Fvw = 0 3 Fu = 1518 kg/cm2
0.3

1.5 Basic Assumption

1.5.1 Structural Calculation Concept

> Structure system : structure to be designed as steel structure.


> Reinforced concrete will be designed as per ACI 318 code.
> Steel structure will be designed as per AISC ASD (Allowable Stress Design) code
> Supporting type of column steel structure is Fixed connection. Column to be
anchored to concrete structure. Supporting type of Gallery Structure is Pinned
connection.
> Structure will be analyzed as StaadPro space frame structure analysis.
> Foundation type is pile foundation, with pinned pile head treatment (free head).

1.5.2 Allowable Displacement

A. The limiting permessible vertical deflection for structural steel member


(beam) shall be as specified below :

Beam for Building and Structure :


Beam loaded with live load only
Beam loaded with live load plus dead loads

B. The limiting permissible horizontal displacement for multi storied steel


structure/building shall be Height/200.
C. Maximum permissible deflection for concrete structure, the requirement
shown in ACI 318 shall apply.
Minimum thickness of nonprestressed beams or one-way slabs unless
deflections are computed :

Notes :
1. Span length l is in inches
2. Values given shall be used directly for members with normalweight
concrete (wc = 145 lb/ft³) and grade 60 reinforcement
reinforcement. For other
conditions, the values shall be modified as follows
a. For Structural lightweight concrete having unit weight in the
range 90-120 lb/ft³, the values shall be multiplied by
(1.65 - 0.005wc) but not less than 1,09, where wc is the unit
weigt in lb/ft³
b. For fy other than 60000 psi, the values shall be multiplied by
(0.4+fy/100000)

B. Maximum permissible deflection of steel structrure beam shall be as spe-


cified in the following :

1 Beam for Building and Structure


Beam loaded with live load only L/360
Beam loaded with live load plus dead loads L/240

1.5.3 Unit of Measurement


Unit of measurement in design shall be in Metric system.
2. DESIGN LOADS

2.1 Dead Load (D)


a. Structure Selfweight
Dead Load of structure will be calculated automatically by STAAD Pro with
"Selfweight Y -1.2" command.

Table‐1
Dead Loads of Major Materials
Material Dead Load
Reinforced Concrete 2.4 ton/m3
Plain Concrete 2.3 ton/m3
Structural Steel 7.85 ton/m3
Fireproof Concrete 2.4 ton/m3
Fireproof Concrete (in case of FENDOLITE MⅡ) 1.3 ton/m3
Soil 1.8 ton/m3

Y
X
Z Load 15

Load 15
2.2 Live Load (LL)

Live loads are all the moving loads including personnels, tools, miscellaneous equipment,
movable partitions, crane, hoist, and stores material.
a. Technological structure (open/enclosed structure)
‐ operating area : 500 kg/m2
‐ maintenance area : 750 kg/m2
b. Compressor House/Turbine Generator
‐ operating area : 750 kg/m2
‐ maintenance area : 750 kg/m2
c. Service Platform
‐ isolated platform/valve opert : 250 kg/m2
‐ acces way : 250 kg/m2
‐ cross over : 200 kg/m2
d. Staircase : 500 kg/m2

Using 500 kg/m2  
 with Area 0.8 m x 1.47 m / 4 point 0.1 ton

2.3 Empty Load

Empty Load similar with Dead Load with safety factor 1.2
2.4 Operating Load

Nominal Capacity (W) = 1700 ton / h


0.47 ton/ sec

Belt Speed (V) = 3.10 m/s


W/V
W / V = 0.15
0 15 ton/m

-0.320 MT
-0.320 MTon/
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m 51.60m
-0.320 MTon/m
-0.320MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320 MTon/m
-0.320MTon/m
-0.320 MTon/m

Y
X
Z Load 4
2.4 Test Load

Nominal Capacity (W) = 1700 ton / h


0.47 ton/ sec

Belt Speed (V) = 3.10 m/s


W/V
W / V = 0.15
0 15 ton/m

with SF = 1.2
W / V = 0.18 ton/m
-0.380MTo
-0.380 M
-0.380 MTon/
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m 51.60m
-0.380 MTon/m
-0.380MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380 MTon/m
-0.380MTon/m
-0.380 MTon/m

Y
X
Z Load 5
2.4 Impact Load

Nominal Capacity (W) = 1500 ton / h


0.42 ton/ sec

Belt Speed (V) = 1.32 m/s


W/V
W / V = 0.32
0 32 ton/m

with RF = 0.1
W / V = 0.032 ton/m

-0.0
-0.03
-0.032 M
-0.032 MTo
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
51.60m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032 MTon/m
-0.032MTon/m
-0.032 MTon/m
Y
X
Z Load 6
2.5 Wind Load
Wind load calculation refers to ASCE/SEI-7-10, American Society of Civil Engineers.
Calculate Wind pressure, P, on each structure surface :

p = q.G.Cp − qi.(GCpi) (lb/ft2) (N/m2)

Where:
q = qz for windward walls evaluated at height z above the ground
q = qh for leeward walls, side walls, and roofs, evaluated at height h
qi = qh for windward walls, side walls, leeward walls, and roofs of enclosed buildings
and for negative internal pressure evaluation in partially enclosed buildings
qi = qz for positive internal pressure evaluation in partially enclosed buildings where
height z is defined as the level of the highest opening in the building that could
affect the positive internal pressure. For buildings sited in wind-borne debris
regions,glazing that is not impact resistant or protected with an impact resistant
shall be treated as an opening in accordance with Section ASCE-7-10, 26.10.3.
For positive internal pressure evaluation, qi may conservatively be evaluated at
height h (qi = qh )
Cp = external pressure coefficient from ASCE-7-10 Fig. 27.4-1 or 27.4-2 and 27.4-3
(GCpi ) = internal pressure coefficient from ASCE-7-10 Fig. 26.11-1
2.5 Seismic Load

Seismic load for this structure is calculated based on UBC 1997


Total base shear force of structure, building, and equipments due to earthquake
load shall be calculated in accordance with formula below:

V = C1 . I/R x W t = Cd . W t
3. LOAD COMBINATION
LOAD COMB 100 (D + EE + PE) + WX+
LOAD COMB 101 (D + EE + PE) + WX‐
LOAD COMB 102 (D + EE + PE) + WZ+
LOAD COMB 103 (D + EE + PE) + WZ‐
LOAD COMB 104 (D + EE + PE) + 1/1.4EQX+
LOAD COMB 105 (D + EE + PE) + 1/1.4EQX‐
LOAD COMB 106 (D + EE + PE) + 1/1.4EQZ+
LOAD COMB 107 (D + EE + PE) + 1/1.4EQZ‐
LOAD COMB 108 (D + EO + PO + AF + FX+) + L
LOAD COMB 109 (D + EO + PO + AF + FX‐) + L
LOAD COMB 110 (D + EO + PO + AF + FZ+) + L
LOAD COMB 111 (D + EO + PO + AF + FZ‐) + L
LOAD COMB 112 (D + EO + PO + AF) + WX+
LOAD COMB 113 (D + EO + PO + AF) + WX‐
LOAD COMB 114 (D + EO + PO + AF) + WZ+
LOAD COMB 115 (D + EO + PO + AF) + WZ‐
LOAD COMB 116 0.9(D + EO + PO + AF) + WX+
LOAD COMB 117 0.9(D + EO + PO + AF) + WX‐
LOAD COMB 118 0.9(D + EO + PO + AF) + WZ+
LOAD COMB 119 0.9(D + EO + PO + AF) + WZ‐
LOAD COMB 120 (D + EO + PO + AF) + 0.75(L + WX+)
LOAD COMB 121 (D + EO + PO + AF) + 0.75(L + WX‐)
LOAD COMB 122 (D + EO + PO + AF) + 0 75(L + WZ+)
LOAD COMB 122 (D + EO + PO + AF) + 0.75(L + WZ+)
LOAD COMB 123 (D + EO + PO + AF) + 0.75(L + WZ‐)
LOAD COMB 124 (D + EO + PO + AF) + 1/1.4EQX+
LOAD COMB 125 (D + EO + PO + AF) + 1/1.4EQX‐
LOAD COMB 126 (D + EO + PO + AF) + 1/1.4EQZ+
LOAD COMB 127 (D + EO + PO + AF) + 1/1.4EQZ‐
LOAD COMB 128 0.9(D + EO + PO + AF) + 1/1.4EQX+
LOAD COMB 129 0.9(D + EO + PO + AF) + 1/1.4EQX‐
LOAD COMB 130 0.9(D + EO + PO + AF) + 1/1.4EQZ+
LOAD COMB 131 0.9(D + EO + PO + AF) + 1/1.4EQZ‐
LOAD COMB 132 (D + EO + PO + AF) + 0.75(L + 1/1.4EQX+)
LOAD COMB 133 (D + EO + PO + AF) + 0.75(L + 1/1.4EQX‐)
LOAD COMB 134 (D + EO + PO + AF) + 0.75(L + 1/1.4EQZ+)
LOAD COMB 135 (D + EO + PO + AF) + 0.75(L + 1/1.4EQZ‐)
LOAD COMB 136 (D + ET + PT) + L
LOAD COMB 137 (D + ET + PT) + 0.75(L + WX+)
LOAD COMB 138 (D + ET + PT) + 0.75(L + WX‐)
LOAD COMB 139 (D + ET + PT) + 0.75(L + WZ+)
LOAD COMB 140 (D + ET + PT) + 0.75(L + WZ‐)
*FACTORED LOAD COMBINATION FOR FOUNDATION DESIGN
LOAD COMB 200 0.9(D + EE + PE) + 1.6WX+
LOAD COMB 201 0.9(D + EE + PE) + 1.6WX‐
LOAD COMB 202 0.9(D + EE + PE) + 1.6WZ+
LOAD COMB 203 0.9(D + EE + PE) + 1.6WZ‐
LOAD COMB 204 0.9(D + EE + PE) + EQX+
LOAD COMB 205 0.9(D + EE + PE) + EQX‐
LOAD COMB 206 0.9(D + EE + PE) + EQZ+
LOAD COMB 207 0.9(D + EE + PE) + EQZ‐
LOAD COMB 208 1.2(D + EO + PO + AF + FX+) + 1.6L
LOAD COMB 209 1.2(D + EO + PO + AF + FX‐) + 1.6L
LOAD COMB 210 1.2(D + EO + PO + AF + FZ+) + 1.6L
LOAD COMB 211 1.2(D + EO + PO + AF + FZ‐) + 1.6L
LOAD COMB 212 1.4(D + EO + PO + AF + FX+)
LOAD COMB 213 1.4(D + EO + PO + AF + FX‐)
LOAD COMB 214 1.4(D + EO + PO + AF + FZ+)
LOAD COMB 215 1.4(D + EO + PO + AF + FZ‐)
LOAD COMB 216 0.9(D + EO + PO + AF) + 1.6WX+
LOAD COMB 217 0.9(D + EO + PO + AF) + 1.6WX‐
LOAD COMB 218 0.9(D + EO + PO + AF) + 1.6WZ+
LOAD COMB 219 0.9(D + EO + PO + AF) + 1.6WZ‐
LOAD COMB 220 1.2(D + EO + PO + AF) + L + 1.6WX+
LOAD COMB 221 1.2(D + EO + PO + AF) + L + 1.6WX‐
LOAD COMB 222 1.2(D + EO + PO + AF) + L + 1.6WZ+
LOAD COMB 223 1.2(D + EO + PO + AF) + L + 1.6WZ‐
LOAD COMB 224 0.9(D + EO + PO + AF) + EQX+
LOAD COMB 225 0.9(D + EO + PO + AF) + EQX‐
LOAD COMB 226 0.9(D + EO + PO + AF) + EQZ+
LOAD COMB 227 0.9(D + EO + PO + AF) + EQZ‐
LOAD COMB 228 1.2(D + EO + PO + AF) + L + EQX+
LOAD COMB 229 1 2(D + EO + PO + AF) + L + EQX
LOAD COMB 229 1.2(D + EO + PO + AF) + L + EQX‐
LOAD COMB 230 1.2(D + EO + PO + AF) + L + EQZ+
LOAD COMB 231 1.2(D + EO + PO + AF) + L + EQZ‐
LOAD COMB 232 1.4(D + ET + PT)
LOAD COMB 233 1.2(D + ET + PT) + 1.6WX+
LOAD COMB 234 1.2(D + ET + PT) + 1.6WX‐
LOAD COMB 235 1.2(D + ET + PT) + 1.6WZ+
LOAD COMB 236 1.2(D + ET + PT) + 1.6WZ‐
LOAD COMB 237 1.2(D + ET + PT) + L + 1.6WX+
LOAD COMB 238 1.2(D + ET + PT) + L + 1.6WX‐
LOAD COMB 239 1.2(D + ET + PT) + L + 1.6WZ+
LOAD COMB 240 1.2(D + ET + PT) + L + 1.6WZ‐
4. RESULT CALCULATION

4.1 Check Stress Ratio (R < 1)

4.2 Check Deflection (Def < 25 mm)


4.3 Check Support Reaction

4.4 Check Design Foundation

‐ Steel Pipe Pile φ  300mm, t9mm =
‐ Allowable Pile Capacity (axial) = 25.13 ton
‐ Allowable Pile Capacity (pull out)
Allowable Pile Capacity (pull out) = 12 08
12.08 ton
‐ Lateral = 1.65 ton
‐ Soil Capacity = 7.5 ton/m2
‐Footing  (F) 3(L) x 2 (B) x 0.9(H) x 2.4 ton/m3 = 51.84 ton
‐Pedestal(P) 1.5(L)x1.5(B) x 2(H) x 2.4 ton/m3 = 10.8 ton
‐Support Reaction ('R) = 10.96 ton

‐ P = F + P + R = 73.60 ton


‐ Area = 3m x 2m = 6 m2
2
‐ P / Area = 12.27 ton/m

2
On Soil Foundation Actual = 12.27 ton/m
(no recommended)

On Pile Foundation Actual with 1.5 = 110.40 ton


4.39 pcs pile
6.00 pcs pile provide
(recommended)
5. Detail Member Conveyor 13

B1 B2
BR

Plan View (Bottom Elevation)

Longitudinal Beam SH 200 x100 x 5.5 (B1)


Transversal Beam SH 250 x 125 x 6 (B2)
Bracing Beam L 100 x 100 x 7 (BR)

BR B2

Plan View (Top Elevation)
B1

Longitudinal Beam
Longitudinal Beam SH 200 x100 x 5.5
SH 200 x100 x 5 5 (B1)
Transversal Beam SH 250 x 125 x 6 (B2)
Bracing Beam L 100 x 100 x 7 (BR)

B1
B1

BR

02 01

Y
Z X
Load 6
Side View 

Longitudinal Beam SH 200 x100 x 5.5 (B1)


Transversal Beam SH 250 x 125 x 6 (B2)
Bracing Beam L 100 x 100 x 7 (BR)
Front View (01)

Column Foundation PIPE 355.6 x 7.9 (Col‐1)


Column H‐Beam SH 200 x 200 x 8 (Col‐2)
Beam SH 250 x 125 x 6 (B2)

Front View (02)

Column Foundation PIPE 216.3 x 8 (Col‐1)


Column H‐Beam SH 200 x 200 x 8 (Col‐2)
Beam SH 250 x 125 x 6 (B2)