Design Calculations
32 Meter, Self Supporting Chimney
The Chimney will be erected at Mysore
Design Data:
Total Height of Chimney 32 meters
Location Ankleshwar
Design Codes of Practice IS 6533 Part 1
IS 6533 Part 2
IS 875 Part 3
IS 800
IS 1893
Type of Chimney Self Supporting
Material of Construction Mild Steel for Chimney Shell
Inputs:
Description From To Unit
Height of Chimney 32.00 meters
Range of Zone 1 21.00 32.00 meters
Length of Zone 1 11.00 meters
Range of Zone 2 16.00 21.00 meters
Length of Zone 2 5.00 meters
Range of Zone 3 11.00 16.00 meters
Length of Zone 3 5.00 meters
Range of Zone 4 5.50 11.00 meters
Length of Zone 4 5.50 meters
Range of Zone 5 0.00 5.50 meters
Length of Zone 5 5.50 meters
Size Requirements:
As per Clause 7.2.4 of I.S. 6533 Part 2
Minimum height of Flared Portion 1/3 Total Height of Chimney
= 0.33 32 meters
= 10.667 meters
The provided height of Flared Portion is 11.000 meters
Hence, OK
Maximum Outside Diameter of Flared Portion at Bottom 1.6 Outside Diameter at Top
= 1.6 0.6 meters
= 0.96 meters
Whereas provided Inside Diameter of Flared Portion is 1.00 meters
Hence, OK
Wind Pressure Calculations:
Basic Wind Speed Vb 44.00 m/sec
Risk Co efficient K1 1.07
Risk Co efficient K2 1.13 Category 1, Class B
Topography Factor K3 1.00 Assumed Flat Ground
Calculations:
Vz (Design Wind Velocity) = Vb x K1 x K2 x K3
= 53.2004 m/sec
Design Wind Pressure = 0.6 x Vz x Vz
= 1698 KN/sq. m
= 170 Kg/sq. m
Safety Factor for Circular Exposed Surface 0.7
Calculations for Wind Moment and Checking for Stresses
As Per I.S 6533 (part-2 ) Cl 8.2.2 of I.S.6533-part2, to determine the wind
force acting at different heights of the chimney, the chimney shall be
divided in to five Zones.
Description From To Unit
Zone 1 21.00 32.00 meters
Zone 2 16.00 21.00 meters
Zone 3 11.00 16.00 meters
Zone 4 5.50 11.00 meters
Zone 5 0.00 5.50 meters
Calculations for Zone 1: 21.00 32.00 meters
Thickness of Shell 0.6 cm.
Outside Diameter of Shell (OD) 72.0 cm.
Inside Diameter of Shell (ID) 60.0 cm.
Pi 3.142
Moment of Inertia I = (3.142/64) x (OD4 – ID4)
= 0.0490875 13913856
= 682996 Cm4
Modulus of Section Z = I x (2/OD)
= 18972 Cm3
Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder 0.7 meters
[OD x Design wind pr. x safe factor x
(sq of height of zone) / 2] + [dia. of
Therefore, Wind Moment at 21 meters from Base, M =
ladder x Design wind pr. x 20% dia. of
ladder x (sq of height of zone) / 2]
= 11881 kg m
= 1188077 kg cm
Self Weight of Stack and Ladder P 1900 kg
Cross Sectional Area of Chimney A (3.142/4) x OD2
= 4072.032 sq. cm.
Stress at 21 meters from Base, (M/Z) + (P/A)
= 63.1 kg/sq. cm
6.2 N/mm2
Height to Diameter Ratio Height/Mean Diameter
= 16.67
= 7.31
Diameter to Thickness Ratio Mean Diameter/Shell Thickness
= 251
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel 1013 kg/sq. cm.
Therefore Section is Safe
Calculations for Zone 2: 16.00 21.00 meters
Thickness of Shell 0.8 cm.
Outside Diameter of Shell (OD) 151.6 cm.
Inside Diameter of Shell (ID) 150.0 cm.
Pi 3.142
Moment of Inertia I = (3.142/64) x (OD4 – ID4)
= 0.0490875 21948064.2
= 1077375.599 Cm4
0.010773756 m4
Modulus of Section Z = I x (2/OD)
= 14213.39841 Cm3
Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder 0.7 meters
[OD x Design wind pr. x safe factor x
(sq of height of zone) / 2] + [dia. of
Therefore, Wind Moment at 16 meters from Base, M =
ladder x Design wind pr. x 20% dia. of
ladder x (sq of height of zone) / 2]
= 25197.03202 kg m
= 2519703.202 kg cm
Self Weight of Stack and Ladder P 3040 kg
Cross Sectional Area of Chimney A (3.142/4) x OD2
= 18052.80088 sq. cm.
Stress at 21 meters from Base, (M/Z) + (P/A)
= 177.4450131 kg/sq. cm
Height to Diameter Ratio Height/Mean Diameter
= 10.61007958
= 10.61
Diameter to Thickness Ratio Mean Diameter/Shell Thickness
= 188.5
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel 1187 kg/sq. cm.
Therefore Section is Safe
Calculations for Zone 3: 11.00 16.00 meters
Thickness of Shell 0.8 cm.
Outside Diameter of Shell (OD) 151.6 cm.
Inside Diameter of Shell (ID) 150.0 cm.
Pi 3.142
Moment of Inertia I = (3.142/64) x (OD4 – ID4)
= 0.0490875 21948064.2
= 1077375.599 Cm4
Modulus of Section Z = I x (2/OD)
= 14213.39841 Cm3
Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder 0.7 meters
[OD x Design wind pr. x safe factor x
(sq of height of zone) / 2] + [dia. of
Therefore, Wind Moment at 11 meters from Base, M =
ladder x Design wind pr. x 20% dia. of
ladder x (sq of height of zone) / 2]
= 43405.82468 kg m
= 4340582.468 kg cm
Self Weight of Stack and Ladder P 4000 kg
Cross Sectional Area of Chimney A (3.142/4) x OD2
= 18052.80088 sq. cm.
Stress at 21 meters from Base, (M/Z) + (P/A)
= 305.6082465 kg/sq. cm
Height to Diameter Ratio Height/Mean Diameter
= 13.92572944
= 13.92
Diameter to Thickness Ratio Mean Diameter/Shell Thickness
= 188.5
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel 1187 kg/sq. cm.
Therefore Section is Safe
Calculations for Zone 4: 5.50 11.00 meters
Thickness of Shell 1.0 cm.
Outside Diameter of Shell (OD) 197.0 cm.
Inside Diameter of Shell (ID) 195.0 cm.
Pi 3.142
Moment of Inertia I = (3.142/64) x (OD4 – ID4)
= 0.0490875 60237856
= 2956925.756 Cm4
Modulus of Section Z = I x (2/OD)
= 30019.55083 Cm3
Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder 0.7 meters
[OD x Design wind pr. x safe factor x
(sq of height of zone) / 2] + [dia. of
Therefore, Wind Moment at 5.5 meters from Base, M =
ladder x Design wind pr. x 20% dia. of
ladder x (sq of height of zone) / 2]
= 88069.04626 kg m
= 8806904.626 kg cm
Self Weight of Stack and Ladder P 6200 kg
Cross Sectional Area of Chimney A (3.142/4) x OD2
= 30484.4695 sq. cm.
Stress at 21 meters from Base, (M/Z) + (P/A)
= 293.5756808 kg/sq. cm
Height to Diameter Ratio Height/Mean Diameter
= 13.52040816
= 13.52
Diameter to Thickness Ratio Mean Diameter/Shell Thickness
= 196
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel 1187 kg/sq. cm.
Therefore Section is Safe
Calculations for Zone 5: 0.00 5.50 meters
Thickness of Shell 1.0 cm.
Outside Diameter of Shell (OD) 242.0 cm.
Inside Diameter of Shell (ID) 240.0 cm.
Pi 3.142
Moment of Inertia I = (3.142/64) x (OD4 – ID4)
= 0.0490875 111982096
= 5496921.137 Cm4
Modulus of Section Z = I x (2/OD)
= 45429.10031 Cm3
Note: For wind force on Ladder etc. 20% of Ladder Dia is considered for calculation
Diameter of Ladder 0.7 meters
[OD x Design wind pr. x safe factor x
(sq of height of zone) / 2] + [dia. of
Therefore, Wind Moment at 5.5 meters from Base, M =
ladder x Design wind pr. x 20% dia. of
ladder x (sq of height of zone) / 2]
= 155807.7342 kg m
= 15580773.42 kg cm
Self Weight of Stack and Ladder P 8400 kg
Cross Sectional Area of Chimney A (3.142/4) x OD2
= 46002.022 sq. cm.
Stress at 21 meters from Base, (M/Z) + (P/A)
= 343.1516076 kg/sq. cm
Height to Diameter Ratio Height/Mean Diameter
= 13.2780083
= 13.52
Diameter to Thickness Ratio Mean Diameter/Shell Thickness
= 241
Refer to table -3 of I.S 6533 (part-2 ).
Maximum Permissible Stress for mild steel 1147 kg/sq. cm.
Therefore Section is Safe
[OD at Bottom+OD of Zone 4]/[2 x Designed Wind
Pressure x Factor of Safety x Ht. of Zone 1]+[OD at Top
Total Horizontal Force at Base Plate Level x Designed Wind Pressure x Factor of Safety x Ht. of
Zone 2]+[Factor of Safety x Designed Wind Pressure x
20 % of Total Height]
= 5131.460777 kg.
Check for Combined Stresses and Stability
As per I.S. 6533 - part-2 CL. 9.1.1, the chimney is stable provided the
1.6(sw + sm) – 0.9se < 1.8 sa
following is satisfied.
Where,
sw = Stress produced by Wind load M/Z
= 342.969007 kg/sq. cm.
sm = Stress produced by any other load which acts at all times & will
0
reduce the combined stress
se = Stress due to Dead load P/A
= 0.182600669 kg/sq. cm.
Therefore, 1.8 sa 617.6728937 kg/sq. cm.
Final Calculations 1.6(sw + sm) – 0.9se < 1.8 sa
548.5860705 < 1111.8112
Therefore Structure is Safe.
Design of Foundation Bolts
Maximum Bending Moment M 15580773.42
Maximum Shear Q 5131.46
Weight of Chimney 13050.00
Maximum Force on one Anchor Bolt T = (4M / n D) – W / n
Where, n = number of bolts used 24 nos.
D = PCD of Bolts 275 cm
8899.142982 kg.
Tensile Capacity of each M36 Bolt 10.178cm2 x 1300Kgs/cm2 13232.39 kgs.
Maximum Shear Capacity 10.178 x 1100 11195.8 kgs.
(Max. Tensile Force/Tensile
Cap. Of each Bolt)+(Total
Check for Combined Stress for Shear and tension
Horizontal Force on Base/Max.
shear Cap.)
1.130865277 < 1.4
Hence Design is Safe
Bolt Embedment Length in concrete = l = T / Pi x d x tbd
tbd = Permissible stress in bond 8 Kgs/Cm2 (for M20 Concrete)
Diameter of the Bolt, d 3.6 cms
81.58114269 cms
Whereas Provided Length is more than 100 cms.
Hence OK
Design of Baseplate
Maximum Bending Moment M 15580773.42
Diameter of Chimney at Base d= 242.00 cms.
Weight of Chimney W = 13050.00 kgs.
Maximum compressive force / unit length of circumference =Fc 4M/ Pi D2 + W / PiD
354.7 kg/cm
Provided Baseplate Thickness T 25 cms.
Fbe = Bearing Pressure Fc/T
14.188 kg/sq. cm.
Which is less than 40 Kg/sq. cm. (For Concrete)
Thickness of Base plate T = Nb x (3 x Fbe / sb)0.5
Where Nb = Maximum projection = 15 cms.
Fbe = 14.188 kg/sq. cm.
sb =Permissible Bending Stress 1650 kg/sq. cm.
Therefore T= 2.4 cms
24.1 mm
Whereas provided thickness is 2.5 cms.
Hence, OK.
