Design of steel chimneys using IS-6533

This study material is a compilation based on a term project carried out by Mr.Mithun Mohan, BTech(IITM),
MTech(IITM), Structural Engineer, Dubai while he was a student at IITM. Figures from open source literature are
acknowledged. This is for private circulation among Structures Research Forum (SRF) ,IITM members. Design
example is shown only for static forces. – Arul Jayachandran, IITM

Most of the industrial steel chimneys are tall behind a passing boat, and it is usually less sensitive
structures with circular cross-sections. Such slender, to Reynolds number than the frictional drag.
lightly damped structures are prone to wind-exited Formally, both types of drag are due to viscosity (if
the body was moving through an in-viscid fluid
vibration. Geometry of a self-supporting steel
there would be no drag at all), but the distinction is
chimney plays an important role in its structural useful because the two types of drag are due to
behavior under lateral dynamic loading. This is different flow phenomena. Frictional drag is
because geometry is primarily responsible for the important for attached flows (that is, there is no
stiffness parameters of the chimney. However, basic separation), and it is related to the surface area
dimensions of industrial self-supporting steel exposed to the flow. Pressure drag is important for
chimney, such as height, diameter at exit, etc., are separated flows, and it is related to the cross-
sectional area of the body.
generally derived from the associated
environmental conditions. To ensure a desired When the drag is dominated by viscous drag, we say
failure mode design code (IS-6533: 1989 Part 2) the body is stream-lined, and when it is dominated
imposes several criteria on the geometry (top-to- by pressure drag, we say the body is bluff. Whether
base diameter ratio and height-to base diameter the flow is viscous-drag dominated or pressure-drag
dominated depends
ratio) of steel chimneys.
entirely on the shape
of the body. A
THEORY streamlined body
looks like a fish, or an
Wind Effects: airfoil at small angles
of attack, whereas a
A body moving through a fluid experiences a drag bluff body looks like a
force, which is usually divided into two components: brick, a cylinder, or
frictional drag and pressure drag. Frictional drag airfoil at large angles
comes from friction between the fluid and the of attack. For
surfaces over which it is flowing. This friction is streamlined bodies,
associated with the development of boundary frictional drag is the dominant source of air
layers, and it scales with Reynolds number as we resistance.
have seen above. Pressure drag comes from the
eddying motions that are set up in the fluid by the Cylinders and spheres are considered bluff bodies
passage of the body. This drag is associated with the because at large Reynolds numbers the drag is
formation of a wake, which can be readily seen dominated by the pressure losses in the wake.

* The author can be reached at sumanmushace10b074@gmail.com

 Design of Steel Chimney using IS-6533

At a Reynolds number between 105 and 106, the
drag coefficient takes a sudden dip. The size of the
wake decreases, indicating that the boundary layer
separation on the cylinder or sphere occurs further
along the surface than before. The phenomenon is
related to the differences between laminar and
turbulent boundary layer. The boundary layer and
its interaction with the local pressure gradient play
a major role in affecting the flow over a cylinder. In
particular, near the shoulder, the pressure gradient
changes from being negative (decreasing pressure)
to positive (increasing pressure). The force due to
pressure differences changes sign from being an
accelerating force to being a retarding force. In
response, the flow slows down. However, the fluid
in the boundary layer has already given up some
momentum because of viscous losses and viscous
friction, and it does not have enough momentum to
overcome the retarding force. Some fluid near the
wall actually reverses direction, and the flow
separates
dynamic-load component. The static-load
component is that force which wind will exert if it
blows at a mean (time-average) steady speed and
which will tend to produce a steady displacement in
a structure. The dynamic component, which can
cause oscillations of a structure, is generated due to
the following reasons:
i) Gusts
ii) Vortex shedding
iii) Buffeting
Along Wind Effects: Along wind effects are
happened by the drag component of the wind force
on the chimney. When wind flows on the face of the
structure, a direct buffeting action is produced. To
estimate such type of loads it is required to model
the chimney as a cantilever, fixed to the ground.
The wind load acts on the exposed face of the
chimney to create predominant moments. But there
is a problem that wind does not blow at a fixed rate
always. So the corresponding loads should be
dynamic in nature. For evaluation of along wind
loads the chimney is modeled as bluff body with
turbulent wind flow. In many codes including IS:
6533:1989, equivalent static method is used for
estimating these loads. In this procedure the wind
pressure is determined which acts on the face of
the chimney as a static wind load. Then it is
amplified using gust factor to calculate the dynamic
effects.

For self-supporting steel chimney, wind is Across wind effects: Across wind effect is not
considered as major source of loads. This load can fully solved and it is required a considerable
be divided into two components respectively such research work on it. For design of self-supporting
as, steel chimney, Indian standard do not speak much
about it. But it is mentioned in IS 4998 (part 1):
i) Along-wind effect 1992 and ACI 307-95 which is applicable for
concrete chimney only. Also CICIND code does not
ii) Across -wind effect
mention this effects and depends on IS 4998 (part
The wind load exerted at any point on a chimney 1): 1992 and ACI 307-95. Generally chimney-like tall
can be considered as the sum of quasi-static and a structures are considered as bluff body and oppose
2 Structural Engineering Lab, Department of Civil Engineering, IIT Madras
 Design of Steel Chimney using IS-6533

to a streamlines one. When the streamlined body
causes the oncoming wind flow, the bluff body
causes the wind to separate from the body. Due to
this a negative regions are formed in the wake
region behind the chimney. This wake region
produces highly turbulent region and forms high
speed eddies called vortices. These vortices
alternatively forms lift forces and it acts in a
direction perpendicular to the incident wind
direction. Chimney oscillates in a direct ion
perpendicular to the wind flow due to this lift
forces.
Vortex shedding: It has been found that chimneys system which is very difficult to be monitored or
of circular cross section oscillate strongly across rectified. This may eventually lead to collapse of the
wind than along wind. It is, therefore, reasonable to system.
continue with the current practice which implies
that along wind, the oscillation will not cause
stresses greater than those calculated for the wind
velocities as specified in IS 875 (Part 3) : 1987 due to ##1. Dimensioning and section of the
static loading along with dynamic coefficient
proposed in IS 6533 (Part 2).
The regular fluctuating side force due to commonly
known as Von Karman vortex shedding, which may
be produced in a smooth air flow, will produce
strong oscillation at a velocity which gives
resonance with the natural frequency of the separately.
structure. This effect is resisted by high damping
and may be prevented by helical strakes or other
devices attached to a circular chimney. If the
tendency is strong, it is not effectively withstood by
increase of strength alone.
In a natural wind, the regular vortex shedding may
be interfered with by fluctuation of the wind so that
the build-up of amplitude is not continuous as in a
wind tunnel, and it may be more effectively resisted
by mass and stiffness. There are different views as
to how the vortex shedding should be allowed for in
practice but it is clear that low damping, low mass
and large flexibility must increase the probability
and the amount of the oscillation of chimneys. In
many cases, the behavior cannot be predicted with
certainty.
Even in the worst cases, a chimney can be made
safe by applying guys or strakes at any time after
construction if experience shows them to be
required, and provided that the chimney is made
strong enough in the first place to withstand the
additional load from guys or strakes applied later.
The across wind movement of the chimney is a vital
load component as the may lead to fatigue of the
PROCEDURE
chimney and Loads: The chimney is assumed as a
simple cantilever with varying thickness. The
chimney is divided into a number of section and
each section not less than 10m. After the sectioning
of the chimney the self-weight of the chimney with
refractory lining as well as without it is calculated
 Fully lined chimneys should have a
minimum clear diameter for 500mm.
 Chimneys of height greater than 40m
should be provided with a flare at the base up to
a height equal to one third height of the chimney.
 Minimum outside diameter of unlined
chimney shell at the top should be at least 1/20 th
the height of the cylindrical portion.
 Minimum outside diameter of a lined
chimney should be at least 1/25th of the height of
the cylindrical portion.

3 Structural Engineering Lab, Department of Civil Engineering, IIT Madras

 Design of Steel Chimney using IS-6533

 Minimum outside diameter of flared

𝑓𝑎 = allowable stress for steel in compression obtained form table 3 of IS
6533(Part II)
chimney shell at the base should be at least 1.6
times the outside diameter of the chimney shell ##2. Calculation of the deflection co-efficient:
at top. Using flexibility method we estimate the
 Minimum thickness of the chimney shell displacement of each section for a unit load.
should not be less than 6mm or 1/500th of the
outside diameter of the section under We assume a simple cantilever system with lumped
consideration whichever is Larger load at mid-points of each section, where, a unit
virtual load is applied and using flexibility matrix the
Dead and Imposed Dead loads should be calculated force vector is transformed to the displacement
taking into account the unit weight of materials as vector. From the matrix we get the displacement as
per IS 875(Part I):1987. well as the natural frequency of the system for the
first mode of oscillation.
Stress caused due the loads can be calculated using
the following expression ##3. Wind Load Calculation:

𝑊𝑠 Along the wind direction

𝜎=
𝜋𝑑𝑡
Static wind load
Where,

𝑊𝑠 = Weight of the material above the section under

Basic wind speed can be calculated as:
consideration
𝑑 = Diameter of the section Vz=VbK1 K2 K3 ---- ----(IS 875-part-2, 5.3)
𝑡 = Thickness of the section
Earthquake loads are estimated based on the where,
procedure laid out in IS1893 Vz= design wind speed at any height z m/s
K1= probability factor (risk coefficient)
K2= terrain, height and structure size factor
The most critical load combinations from the K3= topography factor

following should be used in the design Due to this a circumferential bending occurs and it
is more significant for larger diameter chimney. Also
drag force creates along-wind shear forces and
 𝐷𝐿 + 𝑊𝐿
bending moments.
 𝐷𝐿 + 𝐸𝑄
 𝐷𝐿 + 𝐷𝐿𝑑𝑢𝑒 𝑡𝑜 𝑙𝑖𝑛𝑖𝑛𝑔 + 𝐼𝐿 + 𝑊𝐿 Drag force:
 𝐷𝐿 + 𝐷𝐿𝑑𝑢𝑒 𝑡𝑜 𝑙𝑖𝑛𝑖𝑛𝑔 + 𝐼𝐿 + 𝐸𝑄
The drag force on a single stationary bluff body is,
The maximum tensile stress obtained from the
above expressions should be less than 0.6𝑓𝑦 and the Fd=0.5 Cd *A*ρa*U2
maximum compressive stress should be less than 𝑓𝑎 . where,
Fd= drag force, N
Cd= Drag coefficient
Where ,
A = area of section normal to wind direction, sq. m
𝑓𝑦 = yield stress of steel

4 Structural Engineering Lab, Department of Civil Engineering, IIT Madras

 Design of Steel Chimney using IS-6533
The value of drag coefficient depends on Reynolds
number, shape and aspect ratio of a structure.
Dynamic wind Load:
The first mode natural frequency is computed using
the equation below:
1 𝑔 ∑(𝑚𝑥) .5
𝑓 = 2𝜋 [∑〖(𝑚𝑥 2 〗)] ---- ----(IS 6533-part-2, 8.3.1)
Where,
m = mass of the zone including the lining or covering, in kg;
x = deflection of the same zone due to the force equal to gravity acting
on its mass normally at the mass center with the base fixed and top
free, in meters; and
g = rate of gravitational acceleration = 9.8 m/s2
If the natural frequency exceeds 0.25 seconds, the
wind load calculation will take the dynamic effects
due to pulsation of thrust due to the wind velocity,
into consideration.
The dynamic force is calculated using:
𝑃𝑑𝑦𝑛,𝑖𝑗 = 𝑀𝑗 ∗ 𝜉𝑖 ∗ 𝜂𝑖𝑗 ∗ 𝜈---- ----(IS 6533-part-2,
8.3.2)
Where,
𝑀𝑗 =mass of the jth section in kg concentrated at the center,
ξi= dynamic co-efficient based on time-period of the ith section and the
basic wind speed
ηij= deduced acceleration in m/s2 of the center of the jth section.
ν= co-efficient which takes care of the space correlation of wind
pulsation speed according to height and vicinity of building structures
The dynamic wind load calculation can also be done
using IS 875-part-3, wherein the Gust factor is
considered.
𝐹𝑧 = 𝐶𝑡 ∗ 𝐴𝑒 ∗ 𝑝𝑥 ∗ 𝐺---- ----(IS 875-part-3,
8.3)
where
Fz=along wind load on the structure at the height z corresponding to
strip area Ae
Ct=force co-ef of the building,
Ae=effective frontal area considered for the structure at height z,
5 Structural Engineering Lab, Department of Civil Engineering, IIT Madras
𝑝𝑒𝑎𝑘𝑙𝑜𝑎𝑑
G=gust factor[=
𝑚𝑒𝑎𝑛𝑙𝑜𝑎𝑑
],
The across wind direction: Due to the
differential air pressure in the along wind direction
there will be a component in the across wind
direction that will give rise to vortex shedding
causing the structure to move in the lateral
direction. The Strouhal critical velocity for vortex
shedding is calculated as:
𝑉𝑐𝑟 = 5 ∗ 𝐷𝑡 ∗ 𝑓---- ----(IS 6533-part-2, A-3)
where,
f=natural frequency of the chimney, in sec
Dt= diameter of the chimney at the top, in m
and the aerodynamic force is calculated:
𝐹𝑖 (𝑧) = 𝐹𝑒𝑖 (𝑧) ∗ 𝑦𝑖 (𝑧)---- ----(IS 6533-part-2,
A-4)
where
yi( z ) = relative ordinate at level z in the ith mode
oscillation;
Fei(z)= amplitude of force intensity at the free end of the
self-supporting chimney or at the center of the span of
guyed chimney and is equal to Cy* qcr* dz*hz;
Cy= coefficient of transverse force taken equal to 0.25;
qcr= speed thrust corresponding to critical velocity Vcr and
is equal to Vcr/16;
dz= diameter of the chimney at level z and z is in meters;
and
hz= height of the zone at level z.
##4.Stability Check: In addition to the previous
requirements any section of the should also
satisfy the following condition
1.6(𝜎𝑤 + 𝜎𝑚 ) − 0.9𝜎𝑒 < 1.8 𝜎𝑎
Where,
𝜎𝑤 = stress due to wind loads
 Design of Steel Chimney using IS-6533

𝜎𝑚 = stress due to any other destabilizing loads API-STD 560-2007 gives us procedural exposure of
𝜎𝑒 = stress produced by dead load and any other stabilizing loads
how the vortex shedding should be taken care of
for any given critical velocity:
##5.Calculation for resonance check: The
Speed, Vcr in Comments
design force and bending moment is estimated: m/s
0-15.6 Acceptable. If critical wind velocity occur in this
range, consideration should be given to fatigue
2
𝐹𝑑 = √[𝐹𝑟𝑒𝑠,𝑧 2 + (𝐹𝑠𝑡,𝑧 + 𝐹𝑑𝑦,𝑧 ) ]---- ----(IS 6533- failure.
15.6-31.25 Acceptable, if provided with strakes or vibration
dampers
part-2, 8.4.2) 31.25-62.25 Not acceptable unless the manufacturer can
demonstrated to the satisfaction of the client – the
validity of the stack design in this range
2
𝑀𝑑 = √[𝑀𝑟𝑒𝑠,𝑧 2 + (𝑀𝑠𝑡,𝑧 + 𝑀𝑑𝑦,𝑧 ) ]---- ----(IS >62.5 Acceptable
References:
6533-part-2, 8.4.2)
1. Kirtikanta Sahoo: “Analysis of Self Supported
The resultant force should be check whether they steel chimney as per Indian Standard”, M.Tech
are within the maximum permissible stress of the thesis, NIT Rourkela
chimney. 2. Mithun Mohan M: “Static Design of Self
Supported Steel Chimneys as per IS6533” , Term
The across wind effect is minimized to a great project for CE5600, IIT Madras
extend if helical strakes are added to the chimney
so, the across wind calculation can be neglected if
strakes are added.

Annex A
Procedure for Static Design using IS6533

Topic Description

Basic dimensions The basic dimensions should be decided after referring IS 6533(I) for
taking into account the requirements for pollution control,
composition of flue gases, presence of adjacent structures etc.

The basic dimensions should also meet the following minimum

requirements given in IS 6533(II)


Fully lined chimneys should have a minimum clear diameter for
500mm.
6 Structural Engineering Lab, Department of Civil Engineering, IIT Madras
 Design of Steel Chimney using IS-6533

 Chimneys of height greater than 40m should be provided with a

flare at the base up to a height equal to one third height of the
chimney.
 Minimum outside diameter of unlined chimney shell at the top
should be at least 1/20th the height of the cylindrical portion.
 Minimum outside diameter of a lined chimney should be at least
1/25th of the height of the cylindrical portion.
 Minimum outside diameter of flared chimney shell at the base
should be at least 1.6 times the outside diameter of the chimney
shell at top.
 Minimum thickness of the chimney shell should not be less than
6mm or 1/500th of the outside diameter of the section under
consideration whichever is larger.

Dead and Imposed Dead and Imposed Dead loads should be calculated taking into
Dead Loads account the unit weight of materials as per IS 875(Part I):1987.
Stress caused due these loads can be calculated using the following
expression

𝑊𝑠
𝜎=
𝜋𝑑𝑡

Where,
𝑊𝑠 = Weight of the material above the section under consideration
𝑑 = diameter of the section
𝑡 = thickness of the section

Wind Loads To estimate the wind force acting at different heights of the chimney,
the latter should be divided into a number of convenient zones such
that the number of zones is not less than three and the zone height is
not more than 10m.

After dividing the chimney into a number of zones as described

above the wind loads can be estimated using the following
expressions.

𝑃𝑠𝑡,𝑘 = 𝐶𝑞𝑘 ℎ𝑘 𝑑𝑘

7 Structural Engineering Lab, Department of Civil Engineering, IIT Madras

 Design of Steel Chimney using IS-6533

Where,
𝑞𝑘 = static wind pressure at the midpoint of the kth zone obtained
from IS 875(Part III)
ℎ𝑘 =height of the kth zone
𝑑𝑘 =diameter of the kth zone

The total bending moment at the base cause due to wind loads is
given by
𝑀𝑏 = ∑ 𝐻𝑘 𝑃𝑠𝑡,𝑘
Where,
𝐻𝑘 =height of the midpoint of the kth zone form the base of the
chimney

Earthquake Loads Earthquake loads are estimated based on the procedure laid out in
IS1893(Part III)

Load Combinations The most critical load combinations from the following should be
used in the design

 𝐷𝐿 + 𝑊𝐿
 𝐷𝐿 + 𝐸𝑄
 𝐷𝐿 + 𝐷𝐿𝑑𝑢𝑒 𝑡𝑜 𝑙𝑖𝑛𝑖𝑛𝑔 + 𝐼𝐿 + 𝑊𝐿
 𝐷𝐿 + 𝐷𝐿𝑑𝑢𝑒 𝑡𝑜 𝑙𝑖𝑛𝑖𝑛𝑔 + 𝐼𝐿 + 𝐸𝑄
The maximum tensile stress obtained from the above expressions
should be less than 0.6𝑓𝑦 and the maximum compressive stress
should be less than 𝑓𝑎 .

Where ,
𝑓𝑦 = yield stress of steel
𝑓𝑎 = allowable stress for steel in compression obtained form table 3 of
IS 6533(Part II)

Stability In addition to the previous requirements any section of the should

also satisfy the following condition
1.6(𝜎𝑤 + 𝜎𝑚 ) − 0.9𝜎𝑒 < 1.8 𝜎𝑎

8 Structural Engineering Lab, Department of Civil Engineering, IIT Madras

 Design of Steel Chimney using IS-6533

Where,
𝜎𝑤 = stress due to wind loads
𝜎𝑚 = stress due to any other destabilizing loads
𝜎𝑒 = stress produced by dead load and any other stabilizing loads

Design of base plate The base plate should be designed to safely transfer all the loads to
the foundation. It is designed as per IS 800.

Load per unit width acting on the base plate is given by

(𝐷𝐿 + 𝐼𝐿 + 𝐷𝐿𝑙𝑖𝑛𝑖𝑛𝑔 ) 4𝑀
𝐹= +
𝜋𝑑 𝜋𝑑1 2
Where ,
𝑑1 = diameter of the bolt circle
If 𝑓 is the allowable bearing stress on the foundation then the width,
𝑤, of the base plate is obtained from

𝐹
𝑤=
𝑓

Base plate thickness Total moment acting at section 𝑋𝑋 =

𝑤 𝑤 𝑓𝑤 2
×𝑓× =
2 4 8
Section capacity
𝜎𝐼
=
𝑦
𝑓𝑐 × 𝑏𝑡 × 2 𝑓𝑐 𝑡 2
3
= =
12 × 𝑡 6
So, 𝑡 can be obtained from
𝑓𝑐 𝑡 2 𝑓𝑤
=
6 8

9 Structural Engineering Lab, Department of Civil Engineering, IIT Madras