Structural Design of Steel Pipe Support Structures

By Kasi V. Bendapudi, P.E., S.E.

Structural steel pipe supports are extensively utilized in

industrial and manufacturing facilities. Lack of uniform
industry standards for this topic leads to each organization
adopting its own engineering standards, at times, without ®

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a clear understanding of the underlying theoretical concepts
and the cost implications. This is the first of a two-part series of
articles on the behavior and design of steel support structures

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for pipes. This article (Part 1) discusses the effects of ambient
temperature changes, expansion joint requirements, and an
introduction to design loads. Part 2 concludes with the continu-

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ation of design loads, structure stability concepts and detailing
for stability requirements. ht
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It is common to overemphasize the struc- Side view of 4 tier process pipe rack with longitudinal bracing. Courtesy of Midrex Corporation,

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tural design of pipe support structures, Inc., Charlotte, NC.
rather than focus on detailing for stability plant personnel due to pipe breakage or systems. The movements of the pipes
or economics and practical aspects of the

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leaks. The following discussion includes occur due to expansion, contraction, and

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steel structure and the foundations. This a review of the considerations involved transient loads. System shutdowns and re-
is sometimes referred to as “over-designing” in the design, detailing, and structural

i n starts could also cause movements in the

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and “under-detailing”. Sometimes the stability of pipe racks. Optimal solutions pipes. Transverse guides limit the lateral

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hanger-type pipe supports or the trapezes are still governed by the judgment of the displacements of the pipes.

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supported by another structure, such as design engineer.
the main building frame, are referred to
as “pipe support structures.” For the pur-

g a
Overview of piping design
Temperature effects

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poses of this discussion, the terms “pipe Ambient temperature differentials induce

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racks,” “pipe supports,” and “pipe support In general, pipes are designed to move forces in both pipes and pipe supports.
structures” are interchangeable. Essential freely on their supports in the longitudinal These forces are generally induced over a
direction (along the axis of the pipe), period of time if they are due to variations

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elements for limit states of pipe support
systems are often ignored, since these except at the anchor points. Pipe anchor- in the ambient temperature. However, the
ages are required to account for expansion forces occur more rapidly if the thermal
Structural Design

systems are comprised of secondary ele-

ments and rarely impact the structural
integrity of any industrial facility.
Structural failures of pipe supports are
neither documented nor disseminated to
the structural community. The structural
design of pipe racks varies widely depend-
ing upon the plant operations and the
associated plant standards. However, pipe
rack failures could cause serviceability
problems for plant operations. Failures
of pipe support systems could potentially
impact the health, welfare, and safety of
and contraction of pipes due to variations variations are affected by the contents in
in the ambient temperatures. The expan- the pipes. Particularly during the time
sion/contraction of pipes resulting from of plant startups and shutdowns, these
changes in temperature and pressure of forces can occur rapidly. A pipe rack or
the contents is taken into consideration by a pipe support is not typically subjected
the piping engineers during piping design. to noticeable punishment under seasonal
Anchor points will be required to maintain temperature differentials, because it re-
the pipes in a state of equilibrium. Expan- sponds like an “accordion”. Thermal
sion loops are also used to limit pipe stresses variations due to the contents of the pipe
and the associated failures in the piping result in anchor forces that are more severe
Y
130˚F
DESIGN RANGE USED IN EXAMPLE

SYMM ABOUT CL
design issues for structural engineers

+ t
MEAN TEMP. OF ERECTED (EXPANSION DOMAIN)
STRUCTURE (ASSUMED)

60˚F

TYPICAL “LOCK-IN” BRACE 50˚F

SYMM ABOUT CL STRUCTURE

30˚F ERECTION – t
(CONTRACTION DOMAIN)

ASSUMED CYCLICAL ANNUAL VARIATIONS

IN ATMOSPHERIC TEMPERATURES

PREFERRED BRACE – 30˚F

Figure 1: Vertical bracing arrangements. Figure 2: Thermal variations of structure.

STRUCTURE magazine 6 February 2010

and should be considered in the design of the SYMM ABOUT CL OF BRACING
AND THERMAL STIFFNESS
supporting structure.
The effects of temperature change (expansion 1 2 3 4 5 6 7 8 9 10 11 12 13 14
or contraction) occur with respect to the 
center of thermal stiffness of the structure. As

(~ 16 m)
H=50’ – 0
A
a matter of good practice, “lock-in” bracing
(Figure 1) should be avoided. Such vertical
bracing provided at the ends of the pipe rack ®
structure, in any given straight segment of the

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COMPRESSION BRACE
structure, tends to restrain the thermal forces.
On the other hand, if the vertical bracing is DISPLACEMENT 
1  H / 480 10 BAYS @ 20’ = 200’ 10 BAYS @ 20’ = 200’

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AT POINT “A” @ COL. LINE
provided at the center or close to the center
of the pipe rack structure, the “accordion” Figure 3: Partial elevation of pipe rack with no expansion joints.
effect can be achieved in the structural system.

Expansion joints are not necessary for pipe
rack structures less than approximately 400 to
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would be 116 kips (Equation 4). Design con- expansion is H/480 for a column height of 50
siderations should be segregated between the feet. Typically, longitudinal drift will not cause
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righ for its own movements

500 feet (125m to 155m) in length, if lock-in
bracing is avoided. Failures of pipe rack struc-
tures due to lack of expansion joints are rare,
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design of theypiping serviceability problems. There are no codes or
p
Co of pipe rack steel for the effects
and the design industry standards that prescribe limits on lon-
of variations in the ambient conditions. The gitudinal drift. For long stretches of pipe racks,

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and no recorded evidence is readily available. movements of pipes during the operating the pipe stress engineer should be consulted
The coefficient of linear expansion (€) is the conditions, or at the time of startups and for any special requirements for longitudinal
change in the length, per unit length, for a shutdowns, could either happen in the ex- drift control. As a matter of interest, Process In-

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change of one degree of temperature. The thir- pansion domain or the contraction domain dustry Practice (PIP) Structural Design Criteria

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teenth edition of the AISC Steel Construction (Figure 2). Any attempt to establish a design 2007 (STC 01015) limits transverse drift of

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Manual recommends a value of 0.0000065 basis for the pipe rack steel to combine both the pipe rack bents to H/100, which is very

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for each degree Fahrenheit (F) as a reasonable of these effects occurring concurrently is very lenient. Therefore, the column displacement
approximation of the coefficient of thermal cumbersome and impractical. at the top is not significant, and the structure

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expansion for temperatures less than 100 Any attempt to restrain such forces at each should be allowed to expand and contract due
degrees F. to the variations of the ambient temperatures.

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frame of the pipe rack would also be imprac-

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The change in length tical and uneconomical. Therefore, lock-in The total column displacements would be re-

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bracing as shown in Figure 1 should be avoided. duced along the longitudinal direction (see ∆
∆l = €tl Equation 1
For example, in a 440-foot-long stretch of pipe in Figure 3) if the column bases are fixed in the
Where l is the original length of the

m
member and t is the change in temperature.
The force imparted (P) due to restraint
of free thermal expansion (∆l)
P = AE (∆l)/l Equation 2
Substituting €tl for ∆l in Equation 2 the
change in stress  (psi) is expressed as
 = E € t Equation 3
rack with frames spaced 20 feet apart, the middle longitudinal direction; however, this is neither
two frames should be braced in accordance a common practice nor necessary. No expan-
with the preferred method as shown in Figure sion joints in the pipe racks are necessary for
1. In this arrangement, the extreme column rack lengths less than 500 feet (approximately
would be displaced approximately 1.25 inches 155m). Under such provisions (Figure 3), the
(0.125 x 10 bays) at the top in the longitu- structure is considered stable and serviceable.
dinal direction. Column slope caused by this continued on next page

P = A  = A E t €, Equation 4
where A is the cross-sectional area of
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STRUCTURE magazine 7 February 2010

 Design loads
Pipe racks should be designed for all gravity
and natural hazards such as wind and seismic
loads, internal forces induced by restraint of
free thermal expansion, and the pipe anchor
and guide support loads. Gravity loads are the
largest of the operating loads during normal
plant operations or under the hydro-test con-
dition. The primary anchor forces consist of
longitudinal and transverse forces. Calculated
and identifiable load paths for strength and
stability should be provided. The longitudinal
anchor forces are typically resisted by the ver-
tical bracing of the pipe rack (Figure 3, page 7).
If adequate stiffness for the bracing is provided,
it will function as a “lean-on” brace. Pipe
anchor supports should be stabilized in both
orthogonal planes. Bracing in the longitudinal
direction for long stretches (greater than 500
feet) are typically located at or near the center
of thermal stiffness. The transverse bracing, or
bracing perpendicular to the length of the pipe
rack, does not provide restraint to the longitu-
dinal thermal movements of the pipe rack.
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Designing pipe supports for seismic conditions
consists of two parts: 1) design of connections
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(anchorage or fastening) of the pipes to the
supporting structure for the seismic loads;
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and, 2) design of the pipe support structure
for the seismic forces. These two cases are
independently investigated and should not be
combined. The controlling combinations for
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loads are specified in the governing codes and
standards. The base shears at the pipe support
structure must be transferred to the founda-
tions by means of appropriate anchorage.
The guidance given by the building codes is
minimal in this regard, since pipe racks are not
considered to be buildings and must be treated
as “Other Structures.”
Design of the pipe support structure, including
the lateral-load-resisting elements, should
typically be on the basis of the “equivalent
lateral force procedure.” ASCE 7 and the
International Building Code (IBC) also permit
the “modal analysis procedure” and “linear
response history analysis” for non-building
structures. Dynamic analysis may not be nec-
essary unless the contents of the pipes are
hazardous to the environment and there is a
concern for public safety. Pipe support struc-
tures should maintain symmetry and uniformity.
Irregularities should be eliminated as much
as possible.
Proper fastening of the pipes to the supporting
structure is essential in the seismic design
of pipe racks. The design of connections be-
tween the pipes and the supporting structure
should be based on the seismic base shear
attributable to the dead weight of the pipes
and their contents. Such seismic force should
be applied at the centroid of the pipe, and the
STRUCTURE magazine
ELEVATION AT COL. LINE -A
SHEAR TRANSFER
2 3
@ COL 28 & 38
(~4.5m)
15’ – 0 (TYP)
PIPE RACK – II
®
ELEVATION AT COL. LINES -3 & 4
E
DIRECT CONNECTION TO
PLAN BRACING INTERSECTING PIPE RACK
COLUMN
B
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A
15’ – 0 (TYP)
(~4.5m)
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PIPE RACK – I SEPARATE FRAME
AT INTERSECTION
NOTE: – VERTICAL BRACING FOR
h t
PIPE RACKS II & III NOT SHOWN PIPE RACK – III
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PLAN N (~6.0m)
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20’ – 0 (TYP)
1 4
Figure 4: Intersecting pipe racks.
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associated eccentricity should be considered REFERENCES
in the design of the fastening system between
i n
the pipe and the supporting structure. All pipe 1. American Institute of Steel
z
support structures should be provided with Construction, Specification for
Structural Steel Buildings, Chicago, IL ,
a
adequate bracing required for frame stability
as discussed in this article. Horizontal bracing March 9, 2005.
g
(plan bracing) underneath the pipes may be 2. American Institute of Steel
required to transmit the horizontal seismic Construction, Steel Construction
a
loads applied at the centroids of the pipes
(Figure 4). The plan bracing would function
Manual, Thirteenth Edition, Chicago,
IL, April 2007.
as a collector element (diaphragm) in order 3. Yura, J.A., and Helwig, T.A., “Bracing
to transmit the seismic loads to the vertical for Stability,” Structural Stability
bracing. The transverse force component of Research Council, May 1995.
anchor loads should be assumed to be shared 4. Perry, D.C., “Lecture #1: The Concept
by the adjoining two frames on either side of the of Stability,” Georgia Institute of
anchor point. This load-sharing concept assumes Technology (unpublished), 1973.
decay of this force beyond these five frames. This 5. Levy M., and Salvadori M., Why
is only possible when the plan bracing is pro- Buildings Fall Down, W.W. Norton &
vided. Therefore, it is imperative that the anchor Company, New York, NY, 1992.
points be located with at least two frames before 6. Bendapudi, K.V. “Structural Design
the end of the pipe support segment. of Industrial Facilities”, seminar notes,
presented September 21-22, 2006,
Manchester, NH. Sponsored by
Summary American Society of Civil Engineers
Part 1 of this two-part series discussed tem- (ASCE), Reston, VA.
perature effects on pipe racks, including the 7. Bjorhovde, R., “Columns: From
forces imparted, recommended bracing arrange- Theory to Practice,” AISC Engineering
ments, drift control requirements, and an Journal, 1st Qtr. 1988, Chicago, IL (pp
introduction to design loads. The upcoming 21-34).
Part 2 will discuss the interaction between the 8. Bendapudi, K.V., “Practical
pipe support structure and the pipes, stability Approaches in the Design of Mill
requirements, and detailing for the stability of Building Columns Subjected to Heavy
pipe racks.▪ Crane Loads,” AISC Engineering
Journal, 4th Qtr., 1994, Chicago, IL,
Vol. 31, No. 4, pp.125-140.
Kasi V. Bendapudi, P.E., S.E. is the Chief 9. International Code Council, Inc.,
Civil, Structural, and Architectural Engineer International Building Code, Country
with BE&K Inc., at Houston, Texas. He can Club Hills, IL.
be reached at kasib46@yahoo.com. 10. Construction Industry Institute, Process
Industry Practices (PIP), Austin, TX,
September 2007.
8 February 2010