PETRONAS TECHNICAL STANDARDS

Blast Resistant Building Design

PTS 11.14.03
July 2017

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE ............................................................................................................................. 5
1.2 GLOSSARY OF TERM ....................................................................................................... 5
1.3 SUMMARY OF CHANGES ................................................................................................ 6
2.0 GENERAL CONSIDERATION .................................................................................... 7
2.1 OBJECTIVES ..................................................................................................................... 7
2.2 DESIGN PROCESS ............................................................................................................ 7
3.0 BASIC DESIGN CONSIDERATIONS ........................................................................... 9
3.1 sitting .............................................................................................................................. 9
3.2 blast assessment............................................................................................................. 9
3.3 BLAST RESISTANT BUILDING CLASSIFICATION.............................................................. 10
3.4 BUILDING STRUCTURAL ELEMENT/SYSTEM ................................................................. 10
3.5 OTHER CONSIDERATIONS OF BLAST RESISTANT BUILDING DESIGN ............................ 12
3.6 NOISE AND VIBRATION CONTROL ................................................................................ 12
4.0 BUILDING LAYOUT PLAN ...................................................................................... 13
4.1 GENERAL ....................................................................................................................... 13
5.0 DETAILED DESIGN CONSIDERATIONS FOR BLAST RESISTANT BUILDING ................ 16
5.1 GENERAL ....................................................................................................................... 16
5.2 DESIGN REQUIREMENTS............................................................................................... 16
5.3 CALCULATION DATA ..................................................................................................... 17
5.4 STRUCTURAL DESIGN ................................................................................................... 17
6.0 STRUCTURAL DESIGN ELEMENTS ......................................................................... 19
6.1 REINFORCED CONCRETE ............................................................................................... 19
6.2 STRUCTURAL STEEL ...................................................................................................... 19
7.0 FOUNDATION ...................................................................................................... 20
7.1 FOUNDATION DESIGN .................................................................................................. 20
7.2 STATIC ANALYSIS .......................................................................................................... 20
7.3 STATIC CAPACITY .......................................................................................................... 20
7.4 DYNAMIC ANALYSIS ...................................................................................................... 20
8.0 ARCHITECTURAL ELEMENTS ................................................................................. 21
8.1 DOORS .......................................................................................................................... 21
8.2 WINDOWS .................................................................................................................... 22
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8.3 OPENINGS ..................................................................................................................... 23

8.4 PENETRATIONS ............................................................................................................. 23
8.5 SUSPENDED ITEMS ....................................................................................................... 23
8.6 EXTERNALLY MOUNTED ITEMS AND AIR INTAKE STACK .............................................. 23
8.7 EQUIPMENT AND INTERNALLY MOUNTED ITEMS ....................................................... 24
8.8 FLOORS ......................................................................................................................... 24
8.9 WALLS AND CEILINGS ................................................................................................... 25
8.10 CABLE ENTRIES AND PASSAGES .................................................................................... 25
8.11 FINISHES ....................................................................................................................... 26
9.0 MECHANICAL AND ELECTRICAL FACILITIES ........................................................... 27
9.1 HEATING, VENTILATING AND AIR CONDITIONING (HVAC) SYSTEM ............................. 27
9.2 ELECTRICAL FITTING ..................................................................................................... 27
9.3 TELECOMMUNICATIONS .............................................................................................. 27
9.4 FIRE-FIGHTING FACILITIES ............................................................................................ 27
9.5 FIRE PROTECTION ......................................................................................................... 28
10.0 UPGRADE OF EXISTING BUILDINGS INTO BLAST RESISTANT BUILDING ............... 29
10.1 General ......................................................................................................................... 29
10.2 Evaluation & Upgrading Strategies............................................................................... 29
10.3 Retrofitting concepts .................................................................................................... 30
11.0 BIBLIOGRAPHY .................................................................................................... 31
APPENDIX 1 : TYPICAL CONTROL BUILDING LAYOUT PLAN AND SECTION .................... 33
APPENDIX 2 : CONCEPTS FOR BUILDING RETROFITTING .............................................. 34
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1.0 INTRODUCTION

This PTS provides the minimum requirements for the design, siting and construction of blast
resistant building in oil refineries, gas and chemical plants, power generation plants and
onshore utility plant facilities.

This PTS adopts various International Standards with additional requirements based on
PETRONAS lesson learnt and best practices.

1.1 SCOPE

The scope shall cover basic considerations, procedures and details involved in design and
evaluation of buildings for blast overpressure effects.

This PTS provides additional requirements, over and above the requirements for buildings as
stated in PTS 11.14.01 and supplementing the ASCE guidelines for Design of Blast Resistant
Buildings in Petrochemical Facilities.

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Abbreviations

No Term Definition

1 Blast load Load generated by an explosion

2 Blast Resilient Describes those structures or structural

components which have already a certain
elasticity/flexibility in their conventional design
to receive some low (limited) blast loads, or
those which are designed with an improved
conventional (enhanced resilient) design to
receive limited blast loads

3 Major Hazard Areas A major hazard area is an area that will be

affected by explosion and/or external
fire/thermal radiation or very toxic substances.
The severity will depend upon the distance
between the building's point of consideration
and the source of the major hazard(s)

4 Peak Side-on Over-Pressure Initial peak pressure rise, above ambient,

produced by a shock wave or a pressure wave
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as felt by a flat surface orientated parallel to

the direction of wave propagation

5 Shock Wave A blast wave that produced a near

instantaneous rise in pressure

6 Storey “Storey” for blast resistance building shall meet

both criteria:

i. Storey – That portion of a building

included between the upper surface of
a floor and the upper surface of the
floor or roof next above. A story is
measured as the vertical distance from
top to top of two successive tiers of
beams or finished floor surfaces and,
for the topmost story, from the top of
the floor finish to the top of the ceiling
joists or, where there is not a ceiling, to
the top of the roof rafters(IBC2015)

ii. Ceiling height – in accordance with PTS

11.14.01.
Table 1.2: Specific Abbreviations

1.2.3 Specific Abbreviations

No Abbreviation Description

1 DED Detailed Engineering Design

2 FEED Front End Engineering Design

3 SDOF Single Degree of Freedom

4 MDOF Multi Degree of Freedom

5 R.C. Reinforced Concrete

Table 1.3: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 11.14.03 (July 2017) replaces PTS 11.14.03 (July 2014).
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2.0 GENERAL CONSIDERATION

2.1 OBJECTIVES

The main objectives for providing blast resistant design for buildings are:

i. To provide a level of safety and minimise risk to personnel from the hazards of
accidental explosions in a plant.

ii. To provide sufficient protection for controlled shutdown equipment in the event
of a calamity.

The building shall retain its integrity and shall allow emergency actions to be taken by a
controlled shutdown in order to avoid loss of life, spread of danger and secondary damage to
the facilities.

The building is expected to perform at critical services. Critical service is where procedures
require that personnel remain inside during an accident to regain, or maintain control, or to
safely shut down operating units.

2.2 DESIGN PROCESS

The overall process involved in the evaluation and design of plant buildings for explosion
hazards is illustrated in Figure 2.1. This flowchart shows basic steps in the overall blast
assessment process, as follows:
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Project Design Basis / Specification S1

S3
S2
Building Risk Assessment
Building Requirements

S4
Desk Site Study /
Study Investigation
S5 S6 S7
Blast Loading Parameters Structural Material
System Propertie
(R.C. / Steel s
S8
Building Layout/
Plan
S9
Preliminary
Member Size

S1
0
Structural Analysis /
Calculation

NO
Deformation
Limit Satisfy

YES
S11 S12 S13
Foundation Design Detail Dwg. / Doc Architectural Design

Figure 2.1: Design Flowchart

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3.0 BASIC DESIGN CONSIDERATIONS

3.1 SITTING

3.1.1 Buildings shall preferably be situated in the main Administration area that are located in non-
major hazard areas as defined in PTS 11.14.01 and shall be located in an area classified as non-
hazardous, as described in PTS 13.00.01.

3.1.2 In hazard area or Plant Process Unit, preferable location shall be at the periphery of the
processing plant.

3.1.3 Building access road or parking area shall not be located facing the explosion source.

3.1.4 When siting the blast resistant building, the following factors shall be considered:

i. Buildings orientation such that the shorter side of the building faces the most
probable explosion source.

ii. Buildings sited away from areas of congestion and confinement as these
contribute to the severity of the explosion.

iii. Buildings shall not be sited downhill from potential release sources of heavier
than air materials.

iv. Buildings shall not be sited in prevailing downwind direction from potential
release sources.

v. Special attention shall be paid to the distance between bitumen blowing facilities
and the building to avoid any fouling due to spraying bitumen.

vi. The building shall not be located on a lower level than surrounding plants and
tank farms. It shall be located away from vibrating or noise-producing equipment,
e.g., controlled steam vents heavy-duty pumps and compressors; see PTS
11.14.01.

vii. For those plants where operating personnel also act as fire-fighting crew,
allocated parking spots next to the control building shall be provided.

3.1.5 Siting of building shall also be made reference to PTS 16.71.04.

3.2 BLAST ASSESSMENT

3.2.1 Plant or buildings risk assessment study shall (PSR) be undertaken to confirm the appropriate
selection of blast resistance building function based on appropriate risk level.

3.2.2 The risk assessment study report shall evaluate the explosion accident frequency,
consequences and addressing the following:

i. blast load impairment frequency criteria, consequences level by effect contour

and phase impulse or duration
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ii. blast peak overpressures

iii. fragment impact and thermal radiation load level and risk probability.

3.2.3 These parameters are required to classify building selection and blast load required for the
building structural design to withstand the peak blast overpressures and thermal radiation
generated.

3.3 BLAST RESISTANT BUILDING CLASSIFICATION

3.3.1 The design of the building shall depend on the blast load (peak side-on over-pressure) and
duration shall be classified as per Table 3.1, below:

Blast Loading (Peak Side-On Building Structural Loads

Over-Pressure) Classification

< 6.8 kPa (1.0 psi) or an Class I Those structural components are
impulse < 200 ms. designed only for conventional dead,
live, wind, and seismic loads. Normally
known as ordinary building.

6.8 - 21kPa (1.0 to 3.0 psi) Class II Those structural components which
with estimated duration have already a certain elasticity/
between 50 - 150 ms. flexibility in their conventional design
to receive to some low (limited) blast
loads.

21 - 48 kPa (3.0 to 7.0 psi) Class III Those structural components which are
with estimated duration designed with an improved
between 50 - 150 ms. conventional to receive limited blast
loads.

45 - 65 kPa (7.0 to 10.0 psi) Class IV Those structural components which are
with estimated duration designed to receive total blast loads.
between 50 - 150 ms.
Table 1.1: Building Classification
NOTE(S): If the blast overpressure is more than 65 kPa (10.0 psi), Owner shall be consulted as the building is no more
economically to be constructed, new siting for the building is preferable.

3.4 BUILDING STRUCTURAL ELEMENT/SYSTEM

3.4.1 The following structural elements design requirements shall be taken into consideration.

Building Class Structural Elements

Class I  Unreinforced masonry walls, and weak structural connections, could

make these buildings vulnerable to even low-level blast effects.

 Conventional steel framing with metal cladding, and steel framing.

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Class II  Reinforced masonry clad or wall constructed to resist conventional

and blast loading.

 Pre-engineered metal buildings are comprised of steel frames with

cold formed steel panels supported on cold-formed steel girts and
purlins.

Design improvements to enhance the structure strength can be

achieved by:

i. Provide closer spacing of steel frames

ii. Using symmetric sections (back-to-back C-shapes) for girts and
purlins and reducing their spacing.
iii. Increasing size of anchor bolts and strengthening wall panel
connections at the foundation and at the roof.
iv. Increasing the number of cladding fasteners and using oversized
washers to reduce tear-out of siding material.
v. Fixed base of columns

Class III  Structural elements and connections shall be able to resists all
vertical and lateral loads. Enhancement elements for design
consideration includes;

i. Closer oversized spaced of steel/ reinforced concrete frames

frame resists all vertical and lateral loads
ii. Increased size of anchor bolts or reinforcement,
iii. Increased cladding or reinforced wall profile,
iv. Oversized washers to reduce tear-out of siding material.

Class IV  Provided with a reinforced monolithic or prefabricated concrete

structure.

 The structure depends on a structural concrete frame to support

vertical loads. Thickness of the concrete walls, and size and
placement of the reinforcing steel, can be chosen to provide
resistance to any anticipated design blast loads.
Table 3.2: Building Structural Element/System
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3.5 OTHER CONSIDERATIONS OF BLAST RESISTANT BUILDING DESIGN

3.5.1 The building shall be built as a single storey building unless approved otherwise by Owner and
shall be as compact as possible.

3.5.2 The air-conditioning unit shall be located on the ground elevation.

3.5.3 All related components, such as windows, panes, doors, etc. shall also withstand the blast
loads.

3.5.4 If there is a possibility that gas, smoke, fire, heat, etc., can enter the manned building through
damaged windows after an explosion, no windows shall be provided in the outer walls of the
buildings.

3.6 NOISE AND VIBRATION CONTROL

3.6.1 The level of reflected noise shall be reduced by installing an acoustic ceiling and acoustic
material on the upper part of the walls. If noise-generating equipment is installed in the
control building, PTS 12.01.02 shall be followed. For noise limits reference is made to PTS
11.14.01.

3.6.2 Vibrations in the control room shall be limited in order to ensure continuously reliable
operation of the (process) computer equipment.

3.6.3 The maximum allowable vibration intensities as applied to the equipment are:

i. Sustained vibration (5 s or longer) at frequencies less than 14 Hz: 0.25 mm peak

to peak;

ii. Sustained vibration at frequencies of 14 Hz or higher: 0.07 GRMS;

iii. Intermittent vibration (less than 5 s) at frequencies less than 7 Hz: 2.5 mm peak
to peak;

iv. Intermittent vibration of 7 Hz and higher: 0.18 GRMS.

3.6.4 Any control room and instrument room in the blast resistant building shall be completed with
operating air conditioning system, prior to the installation of its associated computer
equipment. In particular, no concrete work shall be done after the installation of this
equipment, and pile driving operations shall not take place in the vicinity of the room after
the installation of the computer.
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4.0 BUILDING LAYOUT PLAN

4.3 GENERAL

4.1.1 The building will normally comprise of:

i. Control room;

ii. Computer room;

iii. Training/conference room;

iv. A supervisory area adjacent to the control room;

v. Instrument rack room, electrical equipment, UPS and battery room;

vi. HVAC machine room;

vii. The first-aid compartment;

viii. The plant laboratory, if necessary;

ix. Offices, including prayer room, pantry/mess room, washroom, locker and toilet
rooms.

For typical layout, see Appendix 1.0 (Figure 1.0 and 2.0).

4.1.2 Control Room and Rack Room

i. The control room is that section of the control building in which the instrument
consoles and the operator computer facilities are accommodated.

ii. The control room shall be designed so that sufficient space for installation of
equipment for future extensions.

4.1.3 Computer Room

i. A room to accommodate digital process computers etc. This computer room

shall be in such a location that the risk of exposure to fire, water, smoke and
dust from adjoining areas and activities is kept to a minimum.

ii. The computer room shall not be located adjacent to rooms with equipment
which could cause electrical interference, such as rotating electrical
machinery, transformers or electrical switchgear, unless special precautions
have been taken to safeguard the proper functioning of the computer
equipment.

4.1.4 Electrical Equipment and Battery Room

Batteries for emergency power supply shall be located in separate rooms at floor level with
separate exhaust facilities.
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4.1.5 Heating, Ventilating and Air-Conditioning (HVAC) Room

i. The HVAC room shall be located in the basement (if provided) or on the ground
floor.

ii. This machine room shall be at least 2m from the computer room and from
electronic instrumentation located in the control room and control room
basement, or shall be separated by a 300-mm thick reinforced concrete wall, to
reduce mechanical and electrical interference from power cables/switchgear to
control and computer cables/equipment.

iii. No windows shall be installed in this machine room.

iv. The entrance to the machine room shall be located in such a way that the HVAC
maintenance personnel can reach the machine room without having to pass
through the instrument, computer or electrical area.

4.1.6 First-Aid Compartment

i. A closed compartment shall be provided in the control building for first aid
equipment. The facilities will also depend on the location of the control building
(local or remote from the process plant), and on the existence of other medical
facilities (medical centre and/or manning).

ii. As a minimum, the compartment shall include spare safety equipment such as
helmets, gloves and spectacles, and a collapsible stretcher for the transport of
injured personnel.

4.1.7 Supervisor Room/Area

i. The shift supervisor shall have a view from his office into the control room and
equally the operators shall be able to see the control room from the mess room,
thus affording quick visual communication, whenever necessary.

ii. All other rooms shall be connected with the control room via air locks or
corridors (with at least 2 doors to pass).

4.1.8 Laboratory

i. Number of people shall be minimized near potential hazards, and to reduce the
size of control buildings, a general site laboratory shall not be part of the control
building. The general site laboratory shall be located, if possible, near the
administration area and in a non-major hazard area. This laboratory can be built
in accordance with PTS 11.14.01.

ii. If provided, shall have no direct communication with the rest of the building
through doors, movable windows or hatches, to prevent gases from entering the
control room. The laboratory shall have two doors: one entrance door to a
corridor or air lock of the building, and one emergency exit door direct to the
outside.
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iii. Gas cylinders that may be required for the laboratory and shall be kept outside
the building.
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5.0 DETAILED DESIGN CONSIDERATIONS FOR BLAST RESISTANT BUILDING

5.1 GENERAL

The buildings shall be designed in accordance with the requirements of this PTS, PTS
11.14.01 and local building regulations.

5.2 DESIGN REQUIREMENTS

5.2.1 Shape and Height of Buildings

The building shall be designed as a single storey building with a rectangular shape. The building
shall be without protruding canopies, equipment on the roof except for the air intake and
exhaust facilities (penthouse), and no re-entrant angles.

5.2.2 Flying Glass Fragments

Flying glass fragments are one of the greatest dangers to occupants of buildings during an
explosion, windows shall be restricted to offices, mess room and the shift supervisory room
only.

5.2.3 Brittle Behaviour

Materials with a brittle behaviour, such as masonry, shall not be used in such a way that they
are required to have a structural or resistive function during blast loading.

5.2.4 Roof

The roof shall be well insulated, but shall not be covered with gravel or loose concrete tiles
as these will fly in the event of an explosion. On the roof, only the air intake and exhaust
facilities (penthouse) of maximum height 1.8 m, fresh air intake stack, aerials, TV cameras
and similar equipment are permitted.

5.2.5 Fragment Impact

The possible consequences of an explosion are flying fragments, e.g., valves, which can
penetrate the building. The thickness of the walls shall therefore be sufficient to withstand
these fragment impacts.

5.2.6 Gas Tightness of Buildings

Buildings located in major hazard areas and which are subjected to gas cloud (toxic or
explosive) exposure shall be gastight (gas proof). The selection of construction and
materials shall be based on this requirement.

5.2.7 Construction and Materials

The structural system and materials shall be selected to provide the most economical
design. All performance requirements as mentioned in this specification and as indicated by
local requirements shall be met.
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Brittle constructions, such as unreinforced concrete, pre-stressed concrete, unreinforced

masonry (bricks or blocks) and cement based panels, shall not be used for load carrying
components of blast resilient or resistant buildings.

5.3 CALCULATION DATA

5.3.1 Building Blast Loading Parameters

The input of the dynamic calculations for the structure and structural elements of a building
subject to blast loads shall be based on the following blast wave parameters:

i. Shock or pressure wave

ii. Peak side-on positive (or negative) over-pressure

iii. Positive (or negative) phase duration

iv. Positive (or negative) impulse

v. Peak reflected pressure

vi. Dynamic (blast wind) pressure

vii. Shock front velocity

viii. Blast wavelength

ix. Material Properties

Method to determine the above parameters may be referred in the ASCE "Design of Blast
Resistant Buildings in Petrochemical Facilities”.

5.4 STRUCTURAL DESIGN

5.4.1 Design Methods and Procedures

All blast resistant buildings and their structural components may be designed using the
methods provided in the ASCE "Design of Blast Resistant Buildings in Petrochemical
Facilities". Other design methods may also be used as long all the methods meet the
requirements of this PTS.

5.4.2 Load Combinations

In addition to the load combinations as prescribed in PTS 11.14.01, a blast resistant

structure shall be designed for the blast load condition as follows:

U(t) = D + (A x L) + B(t)

Where:
U(t) = total applied time dependent load or its effect
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D = static dead load

B(t) = time dependent blast load or its effect (horizontal & vertical)

L = conventional static live load

A = reduction factor (normally zero) applied to conventional live loads

to reflect the portion of live load expected to occur
simultaneously with the blast load.

The blast load combination may consider either the direct loads or their effects. In
combining blast load effects with those from static dead and live loads, the time
dependence of the blast loading shall be taken into consideration.

i. Wind and seismic loads shall not be combined with blast loading.

5.4.3 Analysis Methods

The selected analysis methods shall adequately model the dynamic response of the
structure to the applied blast loads and the structural component interaction. The
ASCE "Design of Blast Resistant Buildings in Petrochemical Facilities" guideline may be
used.

Static analysis shall not be used for the design of blast resistant buildings.
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6.0 STRUCTURAL DESIGN ELEMENTS

6.1 REINFORCED CONCRETE

6.1.1 Reinforced concrete components shall be designed in accordance with the provisions of PTS
11.14.01. For additional information, the "Design of Blast Resistant Buildings in Petrochemical
Facilities" may be used.

6.1.2 The ultimate strength methods shall be used and the following specific requirements shall
apply:

i. Deformation limits as noted for shear shall be used where the member's shear
capacity is not at least 120 % of the flexural capacity.

ii. The concrete shall be at least grade 30.

iii. Reinforcement bars shall have yield strength (fy) of 460 N/mm2.

6.2 STRUCTURAL STEEL

6.2.1 Structural steel components shall be designed in accordance with the provisions of PTS
11.15.02, supplemented by the following requirements:

i. High tensile bolt connections shall not be used. Steel bolts of grade 8.8
conforming to ISO 898-1 and ISO 7411 shall be used for bolted connections.

ii. Oversize holes shall not use in connections that are part of the lateral force
resisting system.

iii. Flexural members shall be laterally braced on both faces to provide consistent
moment capacity in both positive and rebound response.

6.2.2 Cold Formed Steel

Cold formed steel, such as cladding and decking roof/wall panels, may be used for blast
resilient (< 20 kPa) applications. The yield strengths may vary from 220 N/mm2 to 450
N/mm2. If fragment hazards may arise, cold formed steel shall not be used.

6.2.3 Reinforced Masonry

Design of reinforced masonry may be used for blast resilient and shall be in accordance
with BS 5628, supplemented by the following specific requirements:

i. Strength reduction factors shall not be applied;

ii. Hollow sections shall be fully grouted;

iii. Reinforcement shall be in accordance with the requirements of Section 6.1.2 of

this PTS. Connections to roof and floor slabs or grade beams shall develop the
full flexural capacity of the wall.
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7.0 FOUNDATION

7.1 FOUNDATION DESIGN

7.1.1 Foundation design shall be based on geotechnical requirements, as per PTS 11.13.01.

7.1.2 The structure shall be firmly embedded in the ground, i.e., the vertical walls extending to at
least 1.5 m below high point of paving and having the same strength as the wall's above-
ground level. Relative displacements between columns and walls shall be minimised in order
to maintain structural integrity, e.g. by using grade beams to tie together spread footings or
pile caps, or by using combined mat foundation.

7.2 STATIC ANALYSIS

Static application of the peak dynamic reactions from the wall and roof components may be
used to design supporting members and compute overturning and sliding effects. For blast
load combinations, factors of safety for overturning shall be 1.2, and 1.0 for sliding.

7.3 STATIC CAPACITY

7.1.3 Foundations shall be designed as per PTS 11.15.03.

Where only passive resistance, frictional resistance, vertical piles, or battered piles are used
to support the lateral blast loading, the resistance shall be taken as 80 % of the ultimate static
value. However, if two or more of these resistances are used to support the lateral blast loads,
the lateral capacity shall be limited to 67 % of the combined ultimate static resistance.

7.4 DYNAMIC ANALYSIS

i. To optimise the foundation design, its components shall be analysed

dynamically for the calculated reaction-time history of the supported
components.

ii. The required dynamic material properties of the foundation soils, including
resistance and stiffness, shall be based on an appropriate geotechnical
investigation.

iii. No deformation limits are specified for dynamic response of foundations. The
Contractor shall determine whether the predicted maximum response is
acceptable for the permissible damage level of the building.
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8.0 ARCHITECTURAL ELEMENTS

8.1 DOORS

8.1.1 Blast resistant doors shall be provided according to the following requirements:

Category 1: The door shall be operable after the loading event. This category shall be
specified if the door should be required to withstand repeated blasts.

Category II: Non-catastrophic failure is permitted. The door assembly remains in the
opening. No major structural failure occurs in the panel structure, the
restraining hardware system, the frame or the frame anchorage

Category Ill: Non-catastrophic failure is permitted. The door assembly remains in the
opening. No major structural failure occurs in the panel structure, the
restraining hardware system, the frame or the frame anchorage; however, the
door will be rendered inoperable. This category should only be specified if
entrapment of personnel is not a possibility.

Category IV: Outward rebound force and resulting hardware failure is acceptable.

The response limits and other requirements shall be as given in Table 8.1.

Edge
Door Ductility Ratio
Category Panels Rotation Door Function
Condition Limit
(Degrees)
After Blast

I Operable Elastic 1.0 1.2 Primary exit or

repeated blast

II Operable Significant 3.0 2 Prevent

Damage entrapment

III Inoperable Substantial 10 8 Prevent blast

Damage from entering
building

IV Inoperable Failure in 20 12 Prevent door

Rebound from becoming
debris hazards
Table 8.1: Response Limit

*NOTE(S): The following categories shall be used to determine the requirements for blast resistant or resilient doors.
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8.1.2 In buildings large enough to require more than one exit door according to the requirements
in local building codes, at least two doors shall be designated as exit doors for the purpose of
limiting the damage to these doors when subjected to blast loads.

8.1.3 Outward opening doors shall be provided at two sides of the building for ease of access to
process areas and shall seat against the frame under the positive phase blast wave.

8.1.4 Air locks shall be installed to maintain the required over-pressure inside the building. All outer
doors shall be provided with automatic door closers.

8.1.5 Means of escape, including emergency exit(s), shall be provided from at least three sides of
the building. If only to be used for emergencies, the exit door does not need an air lock.

8.1.6 No windows shall be provided in the outer doors; only small peepholes shall be provided to
check, in the event of fire, that the area outside the door is safe to permit evacuation of the
building.

8.1.7 The outer and inner doors shall have a good seal between doors and frame to maintain the
different pressures between the various rooms and the outside of the building.

8.1.8 Equipment (Double) access doors shall be designed so that instrumentation, computer
equipment and air-conditioning equipment etc. can be transported into the control room
basement. The size of these equipment doors will depend on the dimensions of the
equipment but they shall be at least 1.8 m x 2.5 m. When not in use, equipment doors shall
be bolted to the steel doorframe and the seal shall be air-tight. If the doorway is also to be
used as a passageway, a single door shall be installed in the equipment door, and the seal shall
be airtight when the door is closed.

8.2 WINDOWS

No windows shall be provided in the outer wall. If required, the design of window frames
and anchorage shall be included to resist the blast pressure effect. The following
requirements shall be applied:

8.2.1 Rooms without Windows

The rooms include;

i. the instrument and computer room

ii. the electrical equipment and battery room

iii. the heating, ventilating and air-conditioning machine room

iv. the air locks.

8.2.2 Windows in internal partition walls

Shall have fixed windows to allow uninterrupted vision between rooms. These windows
2
shall have a maximum clear pane area of 1 m .
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8.2.3 Type of glass for internal windows

i. Transparent, laminated Georgian polished wired glass with fire- and explosion-
resisting properties shall be used for the internal windows.

ii. The glass panes shall be fixed in steel frames with screwed metal beads. The
laminated glass panes shall consist of one layer of float glass at least 3 mm thick
and one layer of wired glass, with a polyvinyl butyral (PVB) interlayer at least 1.9
mm thick.

8.3 OPENINGS

Large openings in the building envelope, such as intake ducts, shall be designed to prevent
entry of excessive blast pressures. The following shall be taken into account:

i. Blast valves, blast attenuators, or other devices shall be used to limit excessive
blast pressure entry into the structure. Test data and calculation shall
substantiate performance of the blast valve or attenuator.

ii. Blast valves shall be provided for openings greater than 0.1 m2 in any surface in
which the peak applied pressure is greater than 0.07 MPa. Blast dampers may be
used for these openings if the peak applied pressure is greater than 0.035 MPa.

8.4 PENETRATIONS

8.4.1 Wall and roof penetrations in reinforced concrete and masonry shall be sleeved and shall be
anchored.

8.4.2 Penetrations in metal clad structures shall be anchored with substantial framing attached to
structural steel members.

8.5 SUSPENDED ITEMS

Equipment and furnishings such as ceilings, HVAC ductwork, and light fixtures suspended
from the roof inside the building shall be secured to structural framing members.

8.6 EXTERNALLY MOUNTED ITEMS AND AIR INTAKE STACK

8.6.1 To avoid the potential for hazardous debris, large non-structural features such as signs on the
building exterior shall be minimised. However, small items such as instruments, fire alarms,
lights, strobes and beacons may be mounted on the exterior walls.

8.6.2 The stack for fresh air intake on the penthouse shall be designed for wind loading only. The
height of the stack (level of air intake) shall be 12 m above plant level. Blast valves/dampers
shall not be installed in this air intake, but shall be installed in the reinforced concrete roof
floor.
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8.7 EQUIPMENT AND INTERNALLY MOUNTED ITEMS

8.7.1 Instrumentation or electrical equipment shall not be mounted on the interior face of walls
subjected to blast loads without the written approval of the Owner.

8.7.2 All fixed floor supported items, such as lockers, electrical cabinets, racks, etc. shall have a
minimum clearance from exterior walls equal to the maximum calculated lateral blast load
deflection.

8.8 FLOORS

8.8.1 Cavity floors

i. The control room, computer room (including storage area), the computer
basement, the instrument basement and the electrical equipment room in the
building shall have a cavity floor supported by a recessed reinforced concrete
floor.

ii. If the above equipment areas are located on the ground floor level as in a one-
storey building, they shall also have a cavity floor.

iii. For all other areas, the floor construction and finish shall be in accordance with
PTS 11.14.01. The removable panels shall be 600 mm x 600 mm and 40 mm
thick, constructed of a non-combustible material, finished with 2 mm thick,
factory-applied, anti-static, wearing surface at the top and aluminium foil at the
bottom. The material shall not emit very toxic gas under high temperatures or in
the event of fire.

iv. The floor panels shall rest on adjustable pedestals manufactured of mild steel
with mild steel foot and top plates. The pedestals shall be glued to the concrete
floor, adjustable in height, providing a distance between the top of the cavity
floor and the top of the concrete floor of at least 600 mm.

v. The adjustable part shall have automatic positive locking.

vi. Bracings shall be installed to prevent lateral movement of the flooring system.

vii. Separate steel structures to be provided to support electrical equipment and

battery benches.

viii. Each floor panel shall be capable of supporting a concentrated toad of 4450 N,
applied on an area of 650 mm2 at any point, or 15 kN/m2 with a maximum
deflection of 1 mm.

8.8.2 Plinth for instrument panels

The instrument panels in the control room shall be placed on a concrete plinth except where
the control room has a cavity floor.
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8.8.3 HVAC room

HVAC machine room the floor shall be constructed with door thresholds of 100 mm minimum
height, to prevent condensate and other leakages from entering other parts of the building.
Drain facilities shall be installed in the room.

8.8.4 Floor level

i. The top of the finished floor of the building shall be at least 600 mm above the
surrounding ground level.

ii. Underground cables entering the building shall be covered with a layer of sand
of 600 mm minimum thickness.

iii. Approaches to the main entrances shall be ramps with a slope of 1 in 8 with a
non-slip finish of the top surface.

8.9 WALLS AND CEILINGS

8.9.1 Wall tiles

Wall tiles shall be avoided or glued firmly to the wall with special tile adhesive, to prevent
them from coming loose in the event of an explosion.

8.9.2 Ceilings

The aluminium grid ceiling in the control room shall be constructed in such a way that the
panels are secured in position and cannot fall down during an explosion.

This applies also to the lighting fixtures etc.

8.9.3 Wall and ceiling finishes

All surface finishing materials for walls and ceilings in the control room, the computer room,
and the instrument auxiliary/computer room etc. shall be fire-resistant or non-combustible
and shall have no loose fibres.

In these spaces, the surface of all walls, ceilings and floors, including the space under the cavity
floor, where dust is liable to accumulate shall be sealed with epoxy paint or PVC coating.

8.10 CABLE ENTRIES AND PASSAGES

8.10.1 Level of entries

Entries into the building shall be made below ground level and above ground water level at
such a level as to exclude any chance of rainwater, fire-fighting water, oil, liquefied gas or
other liquids finding their way into the building.
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8.10.2 Sealing of entries

The holes for cable entries shall be sealed gas-/watertight, preferably Multi Cable Transit
(MCT) blocks shall be used. Unused cable entries shall be closed with spare solid blocks.

All other service entries shall be sealed gas-/water tight. Unused entries shall be closed with
watertight brickwork.

8.10.3 Cable passages through floors

i. The holes shall have chamfered edges to prevent damaging of the cables during
cable pulling.

ii. Holes shall also be provided for possible future computer consoles. These holes
shall be positioned so as to clear the reinforcement bars in the floor.

8.11 FINISHES
The building exterior and interior finishes shall be provided as specified in PTS 11.14.01.
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9.0 MECHANICAL AND ELECTRICAL FACILITIES

9.1 HEATING, VENTILATING AND AIR CONDITIONING (HVAC) SYSTEM

9.1.1 General

The building shall be provided with a system for heating, ventilating and air conditioning, as
specified in PTS 12.24.01.

9.1.2 Others

i. Explosion protection (blast-resistance) valves, mounted in a concrete box on top

of the building (penthouse), shall be designed and installed to protect the air
intake and the air exhaust openings during an explosion.

ii. The blast- resistant valves shall close automatically and protect the building
against over-pressure or suction through the ventilation ducting. These valves
shall open automatically when the pressure is back to normal.

iii. Air-cooled condensers shall be located next to the building at grade level and
not on top of the building

9.2 ELECTRICAL FITTING

9.2.1 General

The electrical installation for power and lighting, etc., shall be in accordance with PTS
13.00.01.

9.2.2 Others

Illumination/lighting shall be designed in such a way as to avoid reflection/glaring on

computer screens.

9.3 TELECOMMUNICATIONS

9.3.1 General

Telecommunication (radio, telephone, paging and CCTV) system shall be in accordance with
PTS 14.40.01.

9.4 FIRE-FIGHTING FACILITIES

9.4.1 General

The fire-fighting systems shall be in accordance with PTS 16.73.01 and the requirements
specified below.

9.4.2 Fire and Gas Detection

The building shall be provided with smoke detection system; see PTS 14.12.07.
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9.5 FIRE PROTECTION

i. Terms used and tests mentioned in this PTS, see BS 476 Fire Tests on Building
Materials and Structures.

ii. Other minimum requirement includes;

a) Ducts or piping/cabling pass through roofs, walls or floors, the surrounding

gaps shall be closed air and water- tight by non-combustible materials and
constructed in such a way as to allow essential thermal movements.

b) Maximum travel distance from any point of a floor in the building to the
nearest exit of that floor is 25m.

9.5.1 Fire Resistance

The minimum fire rating values of the elements of the building shall be as follows:

Elements Fire Rated (minimum)

Roof and outside walls, (including doors but not windows) 2 hrs

Mechanical and Electrical Room doors 2 hrs

Doors of air locks 1 hr

Internal walls of control/computer/instrument 1 hr

aux./UPS/electrical/ battery rooms and plant laboratory

Walls of offices and social amenities None

Raised floors (computer floors) 0.5 hrs

Table 9.1: Minimum Fire Rating Values

NOTE(S): All materials for walls and ceilings shall be of non-combustible type materials with a resistance to surface spread of flame
corresponding to BS 476-7, Class 1.
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10.0 UPGRADE OF EXISTING BUILDINGS INTO BLAST RESISTANT BUILDING

10.1 GENERAL

Upgrading or retrofitting of existing buildings can be range from minimal such as window and
door replacement, to a very significant such as providing a concrete shell. It is important to
remember that costs involve are not only for the construction but also the downtime due to
the interruption of operations which may be necessary to implement the upgrading works.

10.9.1 A common understanding prior to upgrading work is to ensure that existing structures can
absorb blast load through inelastic response near incipient hazard source, if the personnel
could be protected and the dynamic response of the building structure is acceptable then the
upgrading may not be required.

10.9.2 Blast protection study for an existing building should involve the following steps:

Step 1: Determine the source location, size, distance and impulse duration of potential
explosion and establish the blast loads and parameters.

Step 2: Establish the appropriate level of blast protection based on building strength

Step 3: Inspect the existing building and evaluate the structural components for blast
resistance.

Step 4: Determine whether the structural deficiencies exist on the existing structural
building frame to meet the blast resistant requirements.

Step 5: Identify different upgrade options and select based on technical feasibilities and
cost effectiveness.

10.2 EVALUATION & UPGRADING STRATEGIES

10.2.1 The primary objectives are:

i. To ensure personnel (personnel safety) be protected

ii. To protect critical equipment for safe shutdown

iii. To ensure that the dynamic response received shall be acceptable for the
building.

10.2.2 Upgrading Strategies shall cover the following:

i. Minimum downtime due to interruption of operations which may be necessary

to implement the upgrading works

ii. Cost optimization options.

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10.2.3 Upgrade of existing facility depends on the increase in blast capacity required. Level of blast
protection is generally based on building category, function, risk level and blast loads.
Structural assessment and cost evaluation are then made to determine the best alternative.

10.3 RETROFITTING CONCEPTS

10.3.1 Possible retrofitting concepts are as follows:

i. Shield Structure System

ii. Interior Catch System

iii. Strong-back System

iv. Shield Panels/Fibre Reinforced Polymers System

Illustrations and description of concepts above are shown in Appendix 2.

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11.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each Standards/Publications shall be used, together
with any supplements/revisions there to:

PTS STANDARDS

Index to PTS PTS 00.01.01

PTS Requirements, General Definition Of Terms, Abbreviations & PTS 00.01.03

Reading Guide

Geotechnical Engineering for Onshore Facilities PTS 11.13.01

Design and Engineering of Buildings PTS 11.14.01

Steel Structures PTS 11.15.02

Design and Construction of Reinforced Concrete Foundations and PTS 11.15.03

Structures

Noise Control PTS 12.01.02

Heating, Ventilation and Air Conditioning (HVAC) System for PTS 12.24.01
Onshore Application

Electrical Engineering General Specifications PTS 13.00.01

Design, Installation, Maintenance of Fire and Gas Detection System PTS 14.12.07

Plant Telecommunication PTS 14.40.01

Quantitative Risk Assessment (QRA) PTS 16.71.04

Fire Safety For Onshore Facilities PTS 16.73.01

INTERNATIONAL STANDARDS

Management of Hazards Associated with Location of Process Plant

API RP 752
Building, American Petroleum Institute

Design of Blast Resistant Buildings in Petrochemical Facilities ASCE 40265

Thermal insulation of pipework and equipment in the temperature

BS 4449
range – 100 Degrees C to + 870 Degrees C)

Fire tests on building materials and structures BS 476

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Part 3: External fire exposure roof test BS 476-3

Part 7: Method of test to determine the classification of the

BS 476-7
surface spread of flame of products

Code of practice for the use of masonry BS 5628

Carbon steel bars for the reinforcement of concrete BS 5970

An Approach to The Categorization of Process Plant Hazard and

CIA 1992
Control Building Designs, Chemical Industries Association

International Building Code 2015 IBC 2015

Siting and Construction of New Control Houses for Chemical

SG22, CMA
Manufacturing Plants, Chemical Manufacturing Association

Unified Facilities Criteria Structures to Resist The Effects of

UFC 3-340-02
Accidental Explosions
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APPENDIX 1 : TYPICAL CONTROL BUILDING LAYOUT PLAN AND SECTION

Figure 1: Typical Layout Plan for Blast Resistant Building Layout

Figure 1: Typical Cross Section of Blast Resistance Building

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APPENDIX 2 : CONCEPTS FOR BUILDING RETROFITTING

System Concept Illustration Concept Description

Shield Reinforced shotcrete wall

Structure with foundation attached to
System building exterior.

Shield Precast concrete wall and

Structure foundation attached to
System building exterior
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System Concept Illustration Concept Description

Shield Cast-In-Place reinforced

Structure concrete wall and foundation
System attached to building exterior

Interior Steel structure constructed

Catch on the interior of the building
System

Strong- Steel strong-back attached to

back the exterior masonry walls to
System reduce wall span
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System Concept Illustration Concept Description

Shield Proprietary catch

Panels/ material/panels attached to
the interior, exterior, or both
Fiber
Reinforced
Polymers
System