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STEEL CHIMNEY
Dr. Hassan Irtaza, Associate Professor
Department of Civil Engineering, A.M.U., Aligarh-202002, India.

Introduction:
 Steel chimneys are also known as steel stacks, is made
of steel plates and supported on foundation. It is made
cylindrical in shape. The lower portion of the steel
chimney is widened or flared, in order to provide large
base and greater stability.
 It is used to escape and disperse flue burnt gases
coming from furnaces of boiler to such a height that the
gases do not contaminate the surrounding atmosphere.
 The cross sectional area of chimney depends on the
type and quantity of fuel to be used in a plant, available
draft for carrying the burnt gases up the chimney and
losses due to friction within the chimney.

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 The height of steel chimney is kept to provide the

required draft.
 The draft is defined as the difference between absolute
gas pressures at any point in the duct or steel chimney
and the ambient atmospheric pressure.
 The draft depends on the height of steel chimney above
sea level, the type of fuel to be burnt, the type of
furnaces and the temperature of the burnt gases.
 Before structural designing the steel chimney, it is
necessary to decide the proper height and diameter of
the chimney at the top i.e. diameter and height are
known data before designing the various components
of the chimney.

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Types of Steel Chimney
1. Self-supporting Steel Chimney
When the wind or seismic
forces (lateral forces) are
transmitted to the foundation
by cantilever action of the
chimney, then the chimney
are known as self-supporting
chimney. It remains stable
under all working conditions
without any additional
support. It is made upto 10m
diameter and from 50m to
100m in height.
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Guyed Steel Chimney
If the high tension steel
ropes or guys are attached
to the chimney to transmit
the lateral forces (wind,
seismic force, etc.) are not
totally carried by chimney
shell, are known as guyed
chimney. These guys or
stays ensure the stability of
the guyed steel chimney.
Guyed Steel Chimney
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Certain Codal Provisions:

 The steel chimney are designed and constructed
conforming to code of practice for design and
construction of steel chimneys, IS:6533 – 1989.
 The base of the chimney may be made bell-mouthed or
conical. The fabrication of bell-mouthed base is costly
and does not have any advantage over conical base.
Therefore, the conical base is provided.
 The recommended height of flared portion of steel
chimney is equal to one-third the height of the chimney.
 The bottom diameter (d1)of the flared portion shall not be
less than one and a quarter times the diameter of stack.

 Steel chimney are kept atleast 5m taller in height than

the tallest building within an area of 150m radius.
 The thickness of the steel plate in the flared portion
should not be less than the thickness at the lowest
section of the cylindrical portion.
 For ease in construction, the upper diameter of plates
forming the side of chimney is kept less than the lower
diameter. Each course fits telescopic over the lower
course.
 Maximum deflection of steel chimney shall be limited
to 1/200 of the unsupported length.

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Steel Plates for Chimneys

 The width of the steel plates commercially available from
0.9m to 2.5m. The most commonly width is 1.5m
 The thickness of the steel plates should not be less than
6mm. The upper two sections of the chimney should not
be less than 8mm to resist corrosion.
 The steel plates of thickness available in the market are:
5, 6, 8, 10, 12, 14, 16, 18, 20, 22, 25, 28, 32, 36, 40, 45,
50, 56, 63 mm.
 A graphite or carbon paint or other dried heat-resistant
paint (approved) may be applied both inside and outside
after the chimney is erected.

Joints in Chimneys
1. Lap Joints: In the upper part of the chimney, lap joints are
used both in the vertical and horizontal seams.
2. Butt Joints: In the lower part of the chimney, butt-joints
are used in the horizontal seams with the heavy plates.
Thickness of Steel Diameter of Types of Joints
Plates in mm Rivets in mm
6 16 Single riveted lap-joint

8-10 18 Double riveted lap-joint

12-16 22 Triple riveted lap-joint

More than 16 25 Butt-joint

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The spacing of rivets along the caulked edges of plates

shall not be greater than 10 times the thickness of plates.
The spacing of rivets shall not be less than 2.5 times the
diameter of rivet.

Lining for Chimneys

 In general practice, the guyed steel chimneys are unlined,
while the self supporting chimneys are lined up to the
top. Chimneys are made with lining in order to protect it
from heat, to act as protecting cover and thus reduce the
corrosion of the steel plates and to maintain the
temperature of the flue gas.
 Fire brick, common brick, solid grade diatomaceous
(mole earth) brick, acid resistant brick, molar concrete,
refractory concrete, guniting with sand and cement
mixtures, vitrobestos, etc. are the materials used for
lining chimney. The materials used for lining should be
capable of withstanding high temperature up to 2000 F.

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Breech (Flue) Opening

The breech opening is also known as flue opening, the flue
opening is provided for the entrance of flue gases. The flue
gases come from furnaces of the boilers.
Breech opening provided in the steel chimney as shown in
Fig.

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 The area of breech opening is kept about 20 percent

larger than the internal cross-sectional area of the
chimney. The maximum width of the breech opening
should not be greater than two-thirds of the diameter. In,
order to compensate the removed material. The
reinforcement should be provided all around the breech
opening. The vertical reinforcement provided should be
20 percent larger than the material removed in the ratio of
diameter to the long chord perpendicular to the face of
the opening.

 The horizontal reinforcement provided at the top and

bottom of the opening is kept equal to the vertical
reinforcement. The reinforcing material provides
sufficient vertical stiffness. In order to transfer and
distribute the stress into the steel of the chimney, the
reinforcing material should be extended above and below
the opening. In the self-supporting steel chimney the
breech opening is kept well above the flared base, so that
it does not extend into the flared base.

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The steel chimneys may have one breech opening, two

breech openings in the same direction two breech
openings at right angles and three breech openings as
shown in Fig. The number of flue-openings maybe one,
two, three or four depending on the requirement. It is
suggested that a maximum of two flue-openings may be
provided at one level so that the chimney remains enough
to resist the applied forces at the plane of the openings.
However, it is possible to provide three openings in one
plane. This is done only when the number of flue
openings is three only. The width of opening does not
exceed one third of the diameter of the chimney at that
plane.

Cleanout Door
A clear out door as
shown by dotted lines
in the figure is provided
preferably on the
opposite side of the
breech opening near the
base. The minimum
size of cleanout door
shall be 500 mm x 800
mm clear. The cleanout
doors are also properly
reinforced.

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Forces Acting on Steel Chimney

The various forces acting on the self-supporting steel
chimney are as follows:
1. Self-weight of the steel chimney

2. Weight of the lining

3. Wind pressure

4. Seismic forces

Self-weight of the steel chimney

Consider a section X-X as shown in the figure . The thickness of
the plates of the chimney above the section X-X may be assumed to
be constant. The self-weight of the chimney Ws is given by
Ws   .  d  .t.h where,
ρ = unit weight of steel = 79 kN/m3
d = diameter of chimney in meter
t = thickness of steel plates in meter
h = height of steel chimney above the section X-X in meter
 Ws  79  dt.h  kN
The compressive stress in the steel plates at the section due to the
self-weight of chimney is given by
 W   79 .d .t.h 
f s1   s     kN m  0.079h N mm
2 2

  .d .t    .d .t 

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Weight of Lining
The weight of the lining in the steel chimney, also acts in the
vertically downward direction. Assuming the thickness of the lining
as 100 mm. The weight of lining
Wl   1 . .d .  0.1 .h
where,  1  unit weight of brick lining = 20 kN/m3
Wl   2 .d .h  kN

The compressive stress in the steel plates at the section X-X, due to
weight of lining
 W   2 d .h  h
fs2   l     kN m 2  0.002   N mm 2
  .d .t    .d .t  t

Wind Pressure
The wind pressure acts horizontally and depend on the shape
of the structure i.e. width and height, location of the structure
and climatic condition.
The wind pressure increases with height above the ground
level and in order to simplify the design, the steel chimney is
divided into number of segments of equal height.
The intensity of wind pressure corresponding to the mid-
height of each segment may be obtained from IS:875-1984. It
is assumed that the wind pressure act at the mid-height of
each segment and also in the flared portion.

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The wind pressure P  k  p1  projected area

where, k= shape factor. The shape factor for cylindrical portion
is 0.7, p1 = intensity of wind pressure
P  0.7   p1  d ' h  kN
where d' = outer diameter of the chimney

In addition to the overturning effect due to wind pressure, the

wind has also aerodynamics effect.

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Seismic forces
The seismic forces also act horizontally and should be taken into
consideration when the structure is located in the seismic areas.
The following load combinations are considered for calculations
of stresses
1. D.L. + W.L. + Temperature effect
2. D.L. + Seismic load due to earthquake + temperature effect.

The worst combination out of these two forces is taken into

consideration for the design of the structure.

Bending moment at any cross-section of self-

supporting steel chimney

The wind forces acts as uniformly distributed and assumed to

act at the middle height above the section. The bending
moment due to wind at section X-X, h meters below the top
is: h
M w  P  , where, P = total wind force
2
h
M w  0.7   p1  d ' h   kNm
2

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The bending stress fw at the extreme fibre of steel chimney due to

overturning moment is given by
M d M 
fw   w     w 
 I 2  Z 
where, Z = section modulus of chimney (ring section) with no
breech opening and t = thickness of steel plate without corrosion
allowance.  
 4M w    kN
f w   3w .   
M d Mw

2    2
d t 2    .d .t   0.785  d  t  m
2
 8 
 Mw  N
or, f w    2
 250d  t  mm
2

IS:6533-1989, ‘Code of practice for design and construction of

steel chimney’ recommends the value of section modulus of steel
chimney ring with no breech opening as:
Z  0.77  d 2  t
The modulus of section of chimney cross section with breech
openings as shown in Fig. A, B, C, and D are given by following
expressions: Z1  0.77  d 2  t 1  0.65 A1 d 
Z 2  0.77  d 2  t 1  1.3 A1 d 
Z 3  0.77  d 2  t 1  0.7 A1 d 


Z 4  0.77  d 2  t 1  1.3 A1 d  0.216 A13 d 3 
The above expression is applicable for thickness of the plate less
than 0.015d.

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Permissible Stresses
 The windward side of steel chimney is subjected to tensile
stress due to combined effect of wind and weight of steel
chimney. The efficiency of the joint on tension side is
70%.
 The leeward side of the steel chimney is subjected to
compressive stress due to combined effect of the wind,
weight of steel chimney and the weight of lining. On the
compression side the efficiency of the joint depends on
the strength of the rivets in shear and in bearing and is
taken as 100%.
 The permissible stresses in steel chimney in axial tension,
shear and bending shall be adopted as specified in IS:800-
2004.

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 The allowable stress in axial compression and in bending

for circular steel chimney have been given in IS:6533-
1989, ‘Code of Practice for Design and Construction of
Steel Chimneys’.
 The combined stress shall comply with the requirements
of IS:800-2007.

Temperature Coefficient
The member or part of the steel chimney reasonably
exposed to adverse temperature should be considered. The
allowable stresses are obtained by multiplying the basic
stresses by the appropriate temperature coefficient as
specified in IS:6533-1971.
Values of Temperature Coefficient, Kt
Temper- 0-20 250 300 350 400
ature
Kt 1.00 0.75 0.67 0.60 0.50

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 In case, the increase in stresses is solely due to wind

forces, the allowable stresses may be exceeded by 25%.
However, the thickness of steel plates shall not be less than
that needed if the wind forces were neglected.
Similarly, when the effect of seismic load is considered,
the allowable stresses may be exceeded by 25%. The
thickness of the steel plate shall not be less than that
required if the seismic forces were not taken into account.
The permissible stresses in rivets are adopted as per

IS:800 – 2007.

Calculation of Thickness of Steel Plates for Self-

supporting Chimney

 The wind-ward side of steel chimney is subjected to

tensile stress due to combined effect of the wind and
weight of steel chimney. The weight of lining is omitted
in calculating the maximum tension, since the maximum
wind pressure may act on steel chimney before the lining
is done.
 The maximum total tensile stress on windward side =
 4 M w Ws   M w 
 t1      0.079h  N 2  1   t
  d t  dt   250 d t  mm
2 2

where, σt = permissible stress in tension in steel plates,

η1=efficiency of the joint on the tension side.

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 Thus the thickness of the steel plate from tension side =

 1   1   4M w 
t1    .  .  Ws 
 1 t    d   d 

The leeward side of steel chimney is subjected to

maximum compressive stress due to combined effect of
wind, weight of steel chimney and weight of lining.
Thus the maximum compressive stress on leeward side is

 4 M w Ws Wl  kN
 c2     
  d t  dt  dt  m
2 2

 Mw h
  0.079h  0.002  N 2   2 . c
 250 d t t  mm
2

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 Thus the thickness of the steel plates from compression

side
 1   4M w 
t2   .  W  Wl
  d c
s
  d 

 The thickness of the steel plates at various horizontal

sections and at the junction of cylindrical and flared
portions, and at the base of the flared portions are found.
 The thickness of the flared portion should not less than
the thickness of steel plates in the cylindrical portion.
 The thickness of steel plates of chimney is kept in excess
than that necessary by allowance for corrosion, which
depends upon design life of the steel chimney.

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Design of Base Plate

 Structural steel circular base plates are provided for the
self-supporting steel chimney. The width of base plate
should be sufficient to transmit the compressive stresses
to the foundation.
 The allowable bearing pressure on a good cement
concrete foundation is 4 N/mm2.
 Thickness of the base plate should be such that the
bending stress and shearing stress in the base plate do
not exceed the allowable bending and shearing stresses.

 There are two ways of connecting the flared portion of

the steel chimney with the base plates. These methods are
shown below:

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 The maximum compressive stress at the base plate on the

leeward side of the chimney
 4 M w Ws  Wl 
 bc     kN m
2
  d 2t  d1t
 1 
where, (d1)=diameter of the steel chimney at the base of the
flared portion
 The maximum compressive force per unit circumferential

length at the base plate on the leeward side of the

chimney
 4 M w Ws  Wl 
F1   bc   t  1       t  1
  d 2t  d t
 1 1 

The width of the base plate, b   F1  bcr 

where, (σbcr)=Permissible bearing stress on the foundation
THICKNESS OF THE BASE PLATE
The maximum bending moment at the critical section X-X

M  1 .  bcr .l 2
2 
The moment of resistance of unit length of base plate at the
critical section
MR  1
6 1.a .l  where,
2 2

a = thickness of the base plate at critical section including

the thickness of the angle section used for the connection.

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σ = Permissible bending stress in the base plate (0.75 fy,

 bs
where, fy is the yield stress for steel).
Equating the above two equations

M  MR
1 . .l 2  1 .1.a 2
2 bcr 6
3
Hence, a  l.  bcr 

  bs 

Design of Anchor Bolt

 The windward side of the steel chimney is subjected to the
uplift pressure due to the overturning effect of the wind.
The anchor bolts (holding down bolts) are provided to resist
this uplift pressure. The uplift pressure is found by
considering the combined effect of wind pressure and the
weight of chimney only. It is assumed that all the anchor
bolts are drawn up tight. Further, it is assumed that the line
of rotation is perpendicular to the direction of wind and
passes through the centre of the horizontal base section of
the steel chimney as shown in the Fig. below. The initial
tension in the anchor bolt, if any, is neglected.

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The maximum tensile stress at the base plate on the windward

side of the chimney  4M w Ws 
1    2
  .d 2 .t  .d .t 
kN m
 1 1 
The maximum tensile stress per unit circumferential length at the
base plate on the windward side of the chimney
F2   1   t  1 kN m
The maximum uplift force in one anchor bolt

 4 M w Ws 
F2 .g   1   t  1  g     g kN
  .d 2  .d 
 1 1
where, g = spacing of the anchor bolts in meters.

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 The number of anchor bolts may be found by dividing

the circumference of the anchor bolt ring by the spacing
of anchor bolts. The permissible stress in axial tension
at the root of threads of anchor bolt is adopted from
IS:800-2007.

Design of Foundation
 Not part of syllabus
 The students have to design

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Stability of Steel Chimney

 The steel chimney as a whole or any part of it is checked for
stability. The weight or anchorages shall be so proportioned
that the least resisting moment including anchorage shall not
be less than the sum of 1.5 times the maximum overturning
moment due to dead loads and imposed loads with the
wind/seismic loading considered as imposed loads.
The probable variation in dead load during construction,
repair or during such other temporary phase of work is taken
into account, so that the stability of steel chimney is ensured
at all times.
Maximum deflection of the steel chimney shall be limited to
1/200 of the unsupported length.

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