CLIENT:

MANAGEMENT:

CONTRACTOR:

PROJECT:

OCP- EXTENSION FERTILIZER STORAGE HE1 to HE4 - JORF LASFAR - MOROCCO

03 29/11/2017 Revised Wind and Seismic load BOE BOE BOE

02 19/10/2017 Revised issue BOE BOE BOE
01 05/10/2017 Revised issue BOE BOE BOE
00 03/08/2017 First issue BOE BOE BOE

Rev. Date Notes Issued Checked Approved

ITEM: DOCUMENT DESCRIPTION: DOC. STATUS

General Structural design criteria for conveyors, towers FOR INFORMATION

FOR APPROVAL
and purchased equipment
PROJECT NUMBER: VALID FOR DESIGN/PURCH.

VALID FOR CONSTRUCTION

C17005
AS BUILT

CONTRACT NUMBER: DOCUMENT NUMBER: Rev. Pages

5622J/5624J/16 C17005-0000-MS-K-001 03 14

This document is property of BEDESCHI S.p.A. and cannot be copied, reproduced or divulgation, wholly or partially,
without written permission.
 Structural design criteria for conveyors, towers and Doc. No.
purchased equipment C17005-0000-MS-K-001

INDEX

1. SCOPE ............................................................................................................... 3
1.1 Site location .................................................................................................................... 3
1.2 Object ............................................................................................................................ 3
1.3 Materials to be conveyed ................................................................................................... 3
2. DESIGN CODES .................................................................................................. 4
3. LOADS DEFINITION........................................................................................... 4
3.1. Dead [D] Loads ................................................................................................................ 4
3.2. Product (operating) [O] Loads ............................................................................................ 4
3.3. Belt Tension [BT] Loads (for belt conveyorsystems)............................................................... 5
3.4. Live [L] Loads .................................................................................................................. 5
3.5. Temperature and Thermal [T] Effects .................................................................................. 5
3.6. Maintanance loads [ML] ..................................................................................................... 6
3.7. Wind [W] Loads ............................................................................................................... 6
3.8. Seismic [E] Loads ............................................................................................................. 8
3.8.1. General ...................................................................................................................... 8
3.8.2. Site classification & Seismic Factors ........................................................................... 8
3.8.2.1 Elastic Response Spectrum .................................................................................... 8
3.8.3. Associated Seismic masses ........................................................................................ 9
3.9. PARITIAL COEFFICIENT for Material .................................................................................... 9
3.10. PARTIAL COEFFICIENT for Loads .................................................................................. 9
3.11. Design Loads Combination .......................................................................................... 9
3.11.1. Loads Combination with Wind: .............................................................................. 10
3.11.2. Loads Combination with Earthquake: .................................................................... 10

4. ALLOWABLE STRUCTURAL DISPLACEMENTS.................................................... 10

4.1. Deformations and DISPLACEMENTS................................................................................... 10
5. EXPANSION JOINTS BETWEEN STRUCTURES ................................................... 11
5.1. JOINTS BETWEEN STRUCTURES ....................................................................................... 11
6. STEEL MATERIAL FOR STRUCTURAL DESIGN ................................................... 12
6.1. Structural steel: ............................................................................................................. 12
6.2. Bolts: ........................................................................................................................... 12
6.3. Flooring and Cladding: .................................................................................................... 12
6.4. Concrete: ...................................................................................................................... 13
6.5. Reinforcment Steel: ........................................................................................................ 13
6.6. Excavatiuon and Backfilling: ............................................................................................. 13
7. INTERFACE WITH EXISTING STRUCUTRES AND SOIL ...................................... 14

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1. SCOPE

The following DESIGN CRITERIA is relevant to the supporting structures of belt conveyors and towers
pertaining to the handling system, to be designed at MAROC PHOSPHORE III-IV at JORF LASFAR.

This document has been done in order to clarify any possible discrepancy and misunderstanding among the
Contract (Contract N°5622J/5624J/16 between OCP SA and Bedeschi Groupement) and the related Technical
Annexes mentioned in Item 1.2.5 of the Contract "Ordre de prioritè des documents du contract" and listed on
"REQUISITION" (document n°JEC-Q3221-04-III / M.02f / 00001) at ARTICLE 2 : "DEFINITION" , "ANNEXES
A : SPECIFICATIONS TECHNIQUES".

The aim of this document is also to provide the best reliable solutions after technical evaluations.

Upon approval of this document, the parties (OCP, Jacobs, Bedeschi) agreed to proceed following the present
document.

1.1 SITE LOCATION

The site is located El Jadida, Marocco at 33°06'53.7"N 8°36'45.1"W.

1.2 OBJECT

Structures involved are mainly of the following type:

- elevated belt conveyors structures (beam or truss beams types)
- intermediate vertical support (Pendulum bents) for belt conveyor structures
- transfer towers
- civil works (i.e. foundations)

1.3 MATERIALS TO BE CONVEYED

The materials handled in this plant are:

Material characteristics as per JEC-Q3221-04-III/M.02a/00007

Material Density Size Relative Repose
[t/mc] [mm] humidity [%] angle [°]
Solid fertilizer: DAP, MAP, TSP, 1.037-1.1 1-5 1-4.5 30-36
ASP

Equipment capacities

Equipment Material Density [t/mc] Maximum design

capacity [t/h]
Belt conveyor Solid Fertilizer 1.037-1.1 2400
or derivate
For SB Belt conveyor Solid Fertilizer 1.037-1.1 1200
or derivate

Further, details can be found in Mechanical Design Criteria document number C17005-0000-ME-K-001.

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2. DESIGN CODES

Indication regarding load and design on structures are taken from following codes, if not reported here
explicitly.

Loads: Eurocode 1, (EN1991)

Concrete design: Eurocode 2, (EN1992)
Steel design: Eurocode 3, (EN1993)
Geotechnical design: Eurocode 7, (EN1997)
Seismic design: Eurocode 8, (EN1998)

National Annexes for France will be considered.

3. LOADS DEFINITION

ACTING LOADS:

Following loads are to be considered in the structural design:

3.1. DEAD [D] LOADS

 [D0] – Dead load (self-weight) of the supporting structure

 [D1] – Permanent load of mechanical parts of belt conveyor as:
 Drive/Deviation/Tail heads including pulleys, Gears/Motors and relevant accessories
 Belting
 Carrying and return idlers including supports
 Hood cover (where required)
 Deck plates (if any)
 Lateral claddings (where required)
 Miscellaneous for services (i.e. air-water-power & instrument cables)
 Minor Miscellaneous

– Permanent load of mechanical parts for loading/unloading

and truck loading systems such as:
 Drive/Deviation/Tail heads including, Gears/Motors and relevant accessories
 Handling mechanical system
 Hood cover (where required)
 Miscellaneous for services (i.e. air-water-power & instrument cables)
 Minor Miscellaneous

3.2. PRODUCT (OPERATING) [O] LOADS

 [O] – Handled Product for structural design is considered as follows:

 Nominal capacity for belt conveyors and other conveying systems based on the maximum
design capacity
 Spillage under belt conveyors will be considered as a depth of 50 mm based on the maximum
unit weight (spillage will be considered on deck plates if any)

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 Encrustation load based on a 10% of the nominal capacity load as specified above for all bulk
product conveying systems.
 Bulk product inside chutes / hoppers are computed for structural purposed as completely full at
the specified bulk unit weight in exceptional load condition.

3.3. BELT TENSION [BT] LOADS (FOR BELT CONVEYORSYSTEMS)

Following Belt tension are recognized:

T1 = Maximum Belt Tension in operation at IN of Drive Pulleys
T1s = Maximum Belt tension at starting (short transitional period)
T2 = Intermediate Belt Tension in operation (where present)
T3 = Minimum Belt Tension in operation at OUT of Drive Pulleys
 [BT] – Belt tension is considered as follows:
 Combination of above tensions at actual and in accordance with the belt conveyor layout,
multiplied by a safety factor K=1.00
The factor K takes care of the tension based also on the maximum motor nameplate power.
The detail of tensions along conveyor belt is attached

3.4. LIVE [L] LOADS

Loads in accordance with JEC-Q3221-03-III/S.02a/00003 section 1.3.2.

 [L1] – Live load on platforms, stairs and roof

In addition of permanent mechanical loads as defined at point 3.2. following loads are considered to act
on maintenance platform of transfer towers.
A global uniform load of 5.00 kN/m2 will be considered and apply for floor beams and grating or a local
concentrated load of 5 kN in the worse position. This will not apply to grating itself.

On accessible roofs a global uniform load of 2.00 kN/m2 and on non-accessible roofs a global
uniform load of 1.00 kN/m2 is applied.

 [L2] – Live load on belt conveyors walkways

A uniform distributed global uniform load of 3.50 kN/m2 on each walkway present along elevated belt
conveyor (on truss beams) will be considered
The above applies to truss beams, vertical columns and bents as well.

Each local member will be able to bear Concentrated local load of 5.0 kN in the worse position
whichever is worse. This will not apply to grating.

 [L3] – Local Live load on parapets and handrails

On parapet and handrail, a horizontal force on top handrail of ±0.60 kN/m must be applied.

3.5. TEMPERATURE AND THERMAL [T] EFFECTS

 [T] – Temperature effects will be based as follows:

For open structures
on a gradient of ± 30 °C.
For cladded close structures
on a gradient of ± 15 °C.

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Temperature at site are minimum 0 °C and maximum 48°C as stated in JEC-Q3221-03-III/S.02a/0001

section 1.1.

3.6. MAINTANANCE LOADS [ML]

Loads in accordance with JEC-Q3221-03-III/S.02a/00003 section 1.3.2.

Device Application of Load Dynamic Effect

Cranes Monorail I Vertical forces on supports 25% of the nominal load to be lifted.

Hoisted Bridges II Longitudinal forces on 10% of the maximum load to be applied to

supports the support.

III Lateral forces on supports
20% of the sum of the weights to be lifted
and the winch trolley to be applied to the
rail on each side, half shall be considered
as acting in either direction normal to the
support.

Columns I Vertical forces 25% of the nominal load to be lifted.

II Lateral forces 20% of the weight of equipment.

3.7. WIND [W] LOADS

 [W] – Base wind pressure is based in accordance to NV 65:2007 and Appendix.

The site is considered region 3 as stated in JEC-Q3221-03-III/S.02a/0001 section 1.5.

Dynamic normal pressure qb=0.875kN/m2 (vb=37.8m/s) value from NV65 Moroccan code Zone 1
Dynamic extreme pressure qb=1.310kN/m2 (vb=46.3m/s) Table 5 in NV 65:2007

Wind pressure p will be computes as following EN1991-1-4 with NA:2008 for France:
p = qb * ce(z) * cd * cp
where:
qb = base wind pressure
seasonal factor cseason and direction factor cdir both set to 1.0. (vb=vb,0)

ce(z) = exposure factor

in accordance EN1991-1-4 with NA:2008 for France
Figure of ce for category II terrain, states:
z0 = 0.05 [m]
z0,II = 0.05 [m]
zmin = 2.00 [m]

kr = 0.19*(z0/z0,II)^0.07 = 0.190
Iv(z) = 1/ln(z/z0)

Exposure factor:
ce(z) = [kr ln (z/z0)]^2 x [1+7/ln (z/z0)]

cd = dynamic factor

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In the present case, due to the typology of the structures, it will be

Considered on the safety side: cd = 1.00

cp = form factor
a) For belt conveyor truss beams, following average form coefficient cp will be considered
 Truss beams cross wind:
Handrail & walk way windward projected gross area : cp=1.00
Cladded Truss structure on projected gross area : cp =1.30
Not cladded Truss structure on projected gross area : cp =1.10
Handrail & walk way leeward on projected gross area : cp =0.50
Hood cover on projected gross area : cp =0.80
 Truss beams longitudinal wind:
Front average wind on total projected gross area : cp =1.30
Friction average wind on “conventional lateral surface” : cp =0.06
 Pendulum Supporting Bents:
Cross average wind on each single column gross area : cp =1.60
Front average wind on “conventional gross surface” : cp =0.70

b) For Transfer Towers and Solid structures in general, following average form coefficient cp will be
considered
cp =1.30 Cross average wind on gross area considering cp = cpW + cpL
where: cpW = 0.80 (windward coefficient)
cpL = 0.50 (leeward coefficient)

If structures are not cladded (free area 60% of gross area) following average form coefficient cp will
be considered.
cp =1.00 Cross average wind on gross area considering cp = cpW + cpL
where: cpW = 0.65 (windward coefficient)
cpL = 0.35 (leeward coefficient)

For lower supporting structure, average wind on gross projected area:

cp =1.30 for cladded structures considering: cp = cpW + cpL
where : cpW = 0.80 (windward coefficient)
cpL = 0.50 (leeward coefficient)
cp =1.00 for not cladded structures considering: cp = cpW + cpL
where : cpW = 0.65 (windward coefficient)
cpL = 0.35 (leeward coefficient)

Extreme wind pressure is applied locally on small elements and on cladding edges.

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3.8. SEISMIC [E] LOADS

3.8.1. General

 [E] – Seismic design will be based in accordance to Eurocode 8 (EN1998).

 Seismic load spectrum as per Reglement de Construction Parsismique (R.P.S 2011)

3.8.2. Site classification & Seismic Factors

As indicated in R.P.S 2011, El Jadida, is located in Seismic Zone 2, see Figure 5.2 and table in appendix.
This is in accordance with the statement in JEC-Q3221-03-III/S.02a/0001 section 1.6.

R.P.S 2011 gives:

- Construction Class I (Section 3.2.2.1)
- I=1.3 Construction Coefficient (Table 3.1)
- ND1 Ductility (Table 3.2)
- K=2 Behaviour factor (Table 3.3)
- ζ=0.03 for steel structures
- Seismic Zone 2 (Figure 5.2)
- Zv=0.10 ground velocity parameter v/(m/s) (Table 5.1)
- Za=0.10 ground acceleration parameter Amax/g (Figure 5.3)
- S1 type of site (Table 5.2)
- S=1.0 Site coefficient (Table 5.2)

Dynamic amplification factor D as function of period T

R.P.S 2011 Table 5.3 Za/Zv =1.0
- D(T)= 2.5 for T<=0.25
- D(T)= -2.4T+3.1 for 0.25<T<0.50
- D(T)= 1.20/T^(2/3) for 0.50<=T

The vertical acceleration spectrum is the horizontal spectrum multiplied by the factor of 2/3, see R.P.S 2011
section 5.2.1.

3.8.2.1 Elastic Response Spectrum

The horizontal and vertical elastic response spectrum calculates as, in accordance with R.P.S 2011 Eq.
(6.1).

SH(T)= Zv *S*D(T)*I*m/K

SV(T)=2/3 SV(T)

m = associate seismic mass, see section 3.8.3.

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3.8.3. Associated Seismic masses

For the determination of the masses to be taken into consideration during the event that a design
earthquake will occur, following percentage will be used based on load type:

Type of Vertical Load %

[D0] – Dead load (self-weight) of the supporting structure ....... 100
[D1] – Permanent load of mechanical parts of belt conveyor ... 100
[O1] – Handled Product Nominal capacity ............................... 70
Spillage and encrustation ……………………................. 70
Spillage Bulk product inside chutes/transfer items ........ 30
Hoist pay-loads (where provided) .................................. 0
[L1] – Reduced Global Live load on platforms and stairs ......... 50
[L2] – Global Live load on belt conveyors walkways ................ 50

3.9. PARITIAL COEFFICIENT FOR MATERIAL

Unless otherwise required following partial coefficients for material will be used:
M0 = 1.05
M1 = 1.05
M2 = 1.25

3.10. PARTIAL COEFFICIENT FOR LOADS

Unless otherwise required, following partial coefficients for loads will be used:
Own weight and dead loads [D] G = 1.35
Operating loads [O]: O = 1.50
Belt Tension [BT]: BT = 1.40
Live Loads [L]: L = 1.50
Temperature effect [T]: T = 1.50
Wind Loads [W]: W = 1.50
Seismic Loads [E]: E = 1.00

Loads from non-contemporary events are considered in the design load combination with a reduction
coefficient =0,70.

3.11. DESIGN LOADS COMBINATION

The Ultimate Limit State [ULS] design is subject to the following Load Combinations [L.C], which are in general
specific for this kind of structures for belt conveyor handling system. For service limit state design [SLS] all
partial factors are set to 1.0.

Symbols interpretation:
(±) means that the combination must maximise the compression and/or the tension
(+/¬) means that the combination must maximise the compression and/or the tension either with or without
the load.

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3.11.1. Loads Combination with Wind:

Following combination must be considered:

L.C. 1: +G [D] +O [O] +/¬ BT [BT] + L [L] ± 0.7 T [T] ± 0.7 W [W x or y]
L.C. 2: +G [D] +O [O] +/¬ BT [BT] +0.7 L [L] ± T [T] ± 0.7 W [W x or y]
L.C. 3: +G [D] +O [O] +/¬ BT [BT] +0.7 L [L] ± 0.7 T [T] ± W [W x or y]
L.C. 4: +1.0 [D] +O [O] +/¬ 0.7 BT [BT] 0.0 ± 0.7 T [T] ± W [W x or y]
[W] in X (longitudinal to extension) direction and Y (transversal to extension) direction are alternative.

For handling system transfer towers, which have in general two similar dimensions in plan, diagonal wind
should also be considered as stated below:

L.C. 5: +G [D] +O [O] +/¬ BT [BT] + L [L] ± 0.7 T [T] ± 0.5 W [W x + y]
L.C. 6: +G [D] +O [O] +/¬ BT [BT] +0.7 L [L] ± T [T] ± 0.5 W [W x + y]
L.C. 7: +G [D] +O [O] +/¬ BT [BT] +0.7 L [L] ± 0.7 T [T] ±0.7 W [W x + y]
L.C. 8: +1.0 [D] +O [O]+/¬ 0.7 BT [BT] 0.0 ± 0.7 T [T] ±0.7 W [W x + y]

3.11.2. Loads Combination with Earthquake:

Following combination must be considered:

L.C. 9: + [D] + [O] +/¬ 0.8 [BT] +0.5 [L] ± 0.8 [T] ± 1.0 [Ev] ± 0.3 [Ex] ± 0.3 [EY]
L.C. 10: + [D] + [O] +/¬ 0.8 [BT] +0.5 [L] ±  [T] ± 0.3 [Ev] ± 1.0 [Ex] ± 0.3 [EY]
L.C. 11: + [D] + [O] +/¬ 0.8 [BT] +0.5 [L] ± 0.8 [T] ± 0.3 [Ev] ± 0.3 [Ex] ± 1.0 [EY]

4. ALLOWABLE STRUCTURAL DISPLACEMENTS

4.1. DEFORMATIONS AND DISPLACEMENTS

For service limit state (SLS) design, deformation values as presented below should be considered. The SLS
must be verified in permanent loading condition (i.e. Dead Load, Belt Tensioning, Live Load normal condition,
Temperature and Wind Load in normal condition). See section 1.4 in JEC-Q3221-03-III/S.02a/00003.

1) Girders and beams supporting the equipment

Less than 1/400 of the span

2) Other girders and beams, including pipe-racks and stand, consoles

Less than 1/250 of the span

3) Roof cladding
Less than 1/200 of the span

4) Horizontal displacement of the structure (seen in elevation (total))

Less than 1/200 of the height

5) Crane girders, crane carriage rails and trolley console (manual control)
Less than 1/500 of span

6) Floor joists and uprights

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Less than 1/250 of the span

7) Floors supporting machines

Less than 1/300 of span

5. EXPANSION JOINTS BETWEEN STRUCTURES

5.1. JOINTS BETWEEN STRUCTURES

Minimum distance between two independent structures Δ ≥ HMAX / 500 where: HMAX is the total height of the
higher structure

For steel structures:

- Expansion joints will be provided each L ≤ 60 m within on structure unit.
- However, in case of belt conveyors supporting structure joints will be provided each L ≤ 200 m

For concert structures:

- Dilatation joints should be foreseen every 10 to 15m. Surfaces should be limited to 200m2.

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6. STEEL MATERIAL FOR STRUCTURAL DESIGN

6.1. STRUCTURAL STEEL:

As per JEC-Q3221-03-III/S.02a/00002 section 3.1, the characteristics of the basic steels must comply with the
values set by the:
EN10020;
EN10025 for non-alloy steels;
EN10164, for all grades contained in these standards.

Welding filler products must comply with current standards EN757, EN760 and give a deposited metal with
mechanical properties at least equal to those of the base metal.

Profiles and plates dimensions as per:

EN10055, EN10055, EN10055, EN10055, EN10059, EN10210, EN10219, EN10279;

Preferred steel quality for pins is EN 10025 S355JR.

General indications based on JEC-Q3221-03-III/M.02a/00003 section 1.6 for primary structure elements:

Minimal element thickness for supporting structure is 5mm.

The minimal width (flange) members shall be at least 50 mm.
Beam elements minimum height is 65mm.
Gusset plate minimum thickness is 6mm.
Bracing should always be made as crosses.

6.2. BOLTS:

Bolts must comply with:

EN24016, EN24017, EN24018, EN20898-1 and 2, EN24033, EN ISO 10684, EN ISO 4014, EN ISO 4017, EN
ISO 4032, EN ISO 3506-1, EN ISO 3506-2

Preferred bolt quality is EN 20898 Bolt Resistance Class 8.8.

Requested bolt quality for friction type connection is NF EN 25-812 Bolt Resistance Class 10.9.
Maximum fiction coefficient μ=0.20.

General indications based on JEC-Q3221-03-III/M.02a/00003 section 1.10:

M16 is the preferred bolt diameter and minimum number of bolts per connections is 2.

6.3. FLOORING AND CLADDING:

As per JEC-Q3221-03-III/S.02a/00003 section 1.11:

Accessible floor stairs and walkways will use non-slip grating with maximal span of 1200mm.

Galvanized grating type 30x30x3mm is requested.

The cover plates and the cladding will be made of corrugated steel sheet min height 40mm.

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Cover plates and cladding will be supplied and assembled with all the sealing accessories (e.g. corner
bands, ridges, hooks, etc.). Natural lighting of the buildings will be ensured by translucent plates of the same
profile as the cover plates and cladding.

Use of chequered plate is normally excluded unless otherwise required by the project. Minimum thickness of
chequered is 6/8mm.

6.4. CONCRETE:

Concrete quality:

Concrete mixtures are defined in JEC-Q3221-04-III/M.02a/00002 section 1.5.1.a and JEC-Q3221-03-

III/S.02a/00006 section 3.2.2

Due to chemical aggressiveness of bulk-material: Phosphor, the concrete quality was increased to C25/30
with W/C Ratio=0.45.

Concert cover must be 5.0cm.

All concrete parts in contact with soil must be protected by a water base Bituminous coating. Except for bottom
surface which must be separated by a lean concrete layer C12/15, minimal thickness. 8cm.

6.5. REINFORCMENT STEEL:

Reinforcement steels are defined in JEC-Q3221-04-III/M.02a/00002 section 1.5.2.b.1

FeE 40 primary reinforcement steel

FeE 22 for secondary reinforcement steel

For both FeE 40 and FeE 22 steel, steel of equivalent characteristics or higher may be used.

Preferred steel grate is EN 10080 Gr. B500 A or B.

6.6. EXCAVATIUON AND BACKFILLING:

Excavation to level +0.08cm below foundation level. Ground must satisfy a compact level of 95% of MDD
based on ASTM D 1556 / ASTM D 6938.

Backfilling will be made with excavated material. Backfill will be compacted to the level found before
excavation. However a maximum of 95% of MDD based on ASTM D 1556 / ASTM D 6938.

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7. INTERFACE WITH EXISTING STRUCUTRES AND SOIL

Existing Structure:

Maximum loads for SB1, SB2, SB3 and SB4 supports on arches as indication below.
Embedded steel plates are made of non-alloy steel type EN10025 S235JR. This information was provided
through RFI005 and RFI013. This information is shown as Admissible Design Loads in the drawing.

On existing arches supports will be fixed with mechanical anchors. Loads remain the same.

Soil:

The geotechnical interpretation report,

Etude geotechnique pour le project extension de 04 Hangars de stockage d’engrais HE1 a HE4 a Jorf Lasfar
documents and interprets geotechnical conditions at site.

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