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DESIGN OF 75KL ZINC ALUME (ZnAl)

ELEVATED WATER STORAGE TANK


with 10,12, 14, 16 & 18m RCC concrete staging

PROJECT : SWSM Project ( JJM )


PRATAPGARH, UTTAR PRADESH

UNDER JAL JEEVAN PROGRAMME (JJM)


MINISTRY OF JAL SHAKTI

GOYAL STEEL TANK


Tank Properties
Capacity of tank = 75.00 KL
Tank Diameter = 5.320 m
Tank Height = 4.030 m
Free Board = 0.300 m
Overflow Height = 3.568 m
Dead Storage = 0.162 m
Staging Height = 18.000 m

Wind Parameter
Wind Zone = IV
Basic Wind Speed = 47 m/s
Risk Cofficient (k 1) = 1.07
Terrain category for (k 2) factor = Category 2
Topograhy factor(k 3) = 1
Importance factor for cyclonic Region(k 4) = 1.2

Seismic Parameter
Seismic Zone = III
Zone factor = 0.16
Design horizontal seismic coefficient A h = [(Z/2)(I/R)/ (Sa/g)]
Response Reduction factor R = 4
Importance factor I = 1.5
Damping = 0.05
Soil Type = Medium

Material Properties
Wall Shell Material-G300 = Zincalume
Fu = 340.00 N/mm2
Fy = 300.00 N/mm2

Roof Sheet Material-G550 = Zincalume


Fu = 550.00 N/mm2
Fy = 550.00 N/mm2

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Bolts
M10 Dia_Grade 10.9 Fu = 1000.00 N/mm2
Fy = 900.00 N/mm2

Anchor Fastener
M16 Dia_Grade 5.8 Fu = 500.00 N/mm2
Fy = 400.00 N/mm2

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Wind load Calculation
Preliminary Data
Wind Zone = IV
Basic Wind Speed Considered , V b = 47.00 m/s
Terrain Category = Category 2
Staging Height = 18 m
Diameter of tank = 5.32 m
height of tank = 4.03 m

Design Factor
Risk Coefficient Factor, k 1 = 1.07
Terrain and Height Factor, k 2
For 0m to 10m = 1.00
For 10m to 15m = 1.05
For 15m to 20m = 1.07
For 20m to 30m = 1.12
Topography Factor, k 3 = 1.00
Importance Factor for Cyclonic Region, k 4 = 1.20

Design Wind Pressure


Design Wind Speed, V z = Vb xk1 xk2 xk3 xk4 = 60.35 x k 2 m/s
2
Wind Pressure, p z = 0.6 V z
Design Wind Pressure, p = Kd Kz Kc pz
Where, Wind directionality factor , K d = 1.00
Area averaging factor , K a = 1.00 ( Staging )
= 0.89 ( Tank )
Combination factor , K c = 1.00

Wind Load Calculation


Height From Pz Pd
K2 Vz (m/s) Remark
Ground,m (kN/m2) (KN/m2)

Up to 10m 1.00 60.35 2.19 2.185


2.464 For staging
18.00 1.06 64.09 2.46
2.205 For tank

22.03 1.08 65.18 2.55 2.281

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Wind Load on shell
F = ( Cpe - Cpi) x A x Pd = -49.14 kN
-29.49 kN
Where,
Cpe = External Pressure Co-efficient = -0.8
Cpi = Internal Presuure Co-efficient = 0.2
-0.2
A = Surface area of structural elements = 21.546 m2

Wind Load on Roof


P = 0.785 x D2 x ( Cpe - Cpi) x Pd = -48.14 kN
-27.87 kN
Where,
Cpe = External Pressure Co-efficient = -0.75
Cpi = Internal Presuure Co-efficient = 0.2
-0.2
D = Diameter of tank = 5.32 m

Wind Overturning Moment


Mw = Pd x cf x D x H2/2 = 68.98 kN-m

Wind Base shear


V = 34.23 kN

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Seismic Analysis

Preliminary Data

Geometry = Circular
Configuration = Elevated
Tank inner Diameter,D = 5.32 m
Tank Height = 4.03 m
Max. Depth of liquide, h = 3.57 m
h/D = 0.67
Seismic Zone = III
Zone factor = 0.16
Response Reduction factor R = 4
Importance factor I = 1.5
Soil Type = Medium
Number of sheet per ring = 6 Nos
Vetical overlap = 200 mm
Length of single sheet = 2.986 m
Height of ring = 1220 mm

Weight Calculations

Weight CG Weight x CG
Components Calculation
( kN ) (m) (kN-m )

4th Ring 6 x 0.0008 x 2.986 x 1.22 x 78.5 1.37 4.27 5.86


3rd Ring 6 x 0.0008 x 2.986 x 1.22 x 78.5 1.37 3.05 4.19
2nd Ring 6 x 0.0012 x 2.986 x 1.22 x 78.5 2.06 1.83 3.77
1st Ring 6 x 0.0016 x 2.986 x 1.22 x 78.5 2.75 0.61 1.67
Roof 1.62 4.18 6.79

Total 9.17 22.28

Total weight of Empty container = 9.17 kN


Height of CG of Empty container above top of circular ring Beam = 2.43 m

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Calculation for weight of staging :
Weight
Components Calculation
( kN )

Columns 𝜋 x 0.45 x 0.45 x 18 x 6 x 25/4 429.42


Braces 8 x 0.3 x 0.6 x 3 x 2.21 x 25 238.68
Ground Beam 8 x 0.3 x 0.6 x 2.21 x 25 79.56
Slab & balcony 𝜋 x 7.32 x 7.32 x 0.2 x 25/4 210.42
Stair Flight 1 to 9 3 x 0.150 x 1 x 25 X 9 101.25
Stair Flight 10 5.657 x 0.150 x 1 x 25 21.21
Total 1080.54

Parameters of Two Mass Idealization Model

Total weight of water = 778.05 kN = 778050 N


Volume of Water = 778.05 / 9.81 = 79.31 m3
Mass of water, m = 79311.927 kg
Inner Diameter of tank, D = 5.32 m
Max. Depth of liquid, h = 4.03 m

For h/D = 4.03 / 5.32 = 0.76 m


m i /m = 0.713 mi = 56549.40 kg
m c /m = 0.301 mc = 23872.89 kg
h i /h = 0.496 hi = 2.00 m
h i */h = 0.576 hi* = 2.33 m
h c /h = 0.683 hc = 2.75 m
h c */h = 0.73 hc* = 2.95 m

Mass of Empty Container + 1/3 of Staging ms = 37650.65 kg

Lateral Stiffness of Staging

Deflection of CG of tank due to an arbitrary 10 kN force is = 2.521E-03 m


Hence, Lateral Stiffness of one Frame Staging = 10/0.002521 = 3966.68 kN/m
Hence, Total Lateral Stiffness Ks = 3966.68 kN/m

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Time Period

Time Period of Impulsive Mode,

Ti = 2π mi +ms = 0.97 sec


Ks

Time Period of Convective Mode,

Tc = Cc D = 2.42 sec
g

Design Horizontal Seismic Coefficient

Design Seismic coefficient for impulsive mode,

𝑍𝐼 𝑆 𝑍= 0.16
𝐴 =
2𝑅 𝑔 𝐼= 1.50
𝑅= 4.00
𝑇𝑖 = 0.970 sec
= 0.059 𝑆𝑜𝑖𝑙 𝑡𝑦𝑝𝑒 = Medium
𝑆
= 1.96
𝑔

Design Seismic coefficient for convective mode,

𝑍𝐼 𝑆 𝑍= 0.16
𝐴 =
2𝑅 𝑔 𝐼= 1.50
𝑅= 4.00
𝑇𝑐 = 2.42 sec
= 0.029 𝑆𝑜𝑖𝑙 𝑡𝑦𝑝𝑒 = Medium

𝑆
= 0.98
𝑔

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Base Shear

Base Shear for Impulsive Mode,

Vi = (A h ) i (m i +m s ) g
= 0.059 x (56549.4 + 37650.65) x 9.81
= 54.42 kN

Base Shear for Convective Mode,

Vc = (A h ) c m c g
= 0.029 x 23872.89 x 9.81
= 6.91 kN

Total Base Shear at Base,

V = Vi2 + Vc2

= 54.85 kN

Base Moment

Overturning Moment at Base of tank for Impulsive Mode,


Mi* = (A h ) i [ m i ( h i * +h s )+m s h cg ] g
= 0.059 x [56549.4 x (2.33+0)+37650.65 x 2.43] x 9.81
= 128.94 kN.m

Overturning Moment at Base of tank for Convective Mode,


Mc* = (A h ) c m c ( h c * +h s ) g
= 0.029 x 23872.89 x (2.95+0) x 9.81
= 20.37 kN.m

Total Overturning Moment at base of Staging,


M* = Mi*2 + Mc*2

= 130.54 kN.m

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Hydrodynamic Pressure

Impulsive Hydrodynamic Pressure :

Pressure on Wall,

P iw (y) = Q iw (y) (A h ) i ρ g h cos ф

Where,
Q iw (y) = 0.866 [1 -( y / h) 2 ] tanh (0.866* D / h)

Maximum Pressure will occure at φ = 0

At Base of Wall, y = 0
Q iw(y=0) = 0.866 x [1-(0/4.03)^2] x tanh(0.866 x 5.32/4.03)
= 0.706

P iw (y=0) = 0.706 x 0.059 x 1000 x 9.81 x 4.03 x cos(0)


= 1.644 kN/m2

Pressure on Base Slab (y = 0),


P ib = 0.866 (A h ) i p g h sinh(0.866 x/h)/cosh(0.866 l'/h)
= 0.866 x 0.059 x 1000 x 9.81 x 4.03 x {sinh(0.866 x 5.32/2 x 4.03)/cosh(0.866 x 5.32/2 x 4.03)}
= 1.041 kN/m2

Convective Hydrodynamic Pressure :

Pressure on Wall,

P cw (y) = Q cw (y) (A h ) c ρ g D [1- 1/3 cos2ф] cos ф


Where,
Q cw (y) = 0.5625 cosh (3.674 y/D)/cosh(3.674h /D)

Maximum Pressure will occure at φ = 0


At Base of Wall, y = 0
Q cw(y=0) = 0.5625*cosh(0)/cosh(3.674*4.03/5.32)
= 0.069
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At top of Water Height, y = h = 4.03 m
Q cw (y=h) = 0.563

P cw (y=0) = 0.069 x 0.029 x 1000 x 9.81 x 5.32 x 0.67 x 1


= 0.071 kN/m2
P cw (y=h) = 0.563 x 0.03 x 1000 x 9.81 x 5.32 x 0.67 x 1
= 0.580 kN/m2

Pressure on Slab,
P cb = Q cb (x) (A h ) c ρ g D
Where,
Q cb (x) = 1.125[x/D – 4/3 (x/D) 3] sech (3.674 h/D)
Consider x as D/2 = 2.66 m
Q cb (x) = 1.125 x [2.66/5.32-4/3 x (2.66/5.32)^3] x sech(3.674 x 4.03/5.32)
= 0.046

P cb = 0.046 x 0.03 x 1000 x 9.81 x 5.32


= 0.071 kN/m2

Pressure Due to Wall Inertia

P ww = (A h ) i t ρ m g
= 0.294 kN/m2

Pressure due to Vertical Excitation

Pv = (A v ) [ρ g h ( 1- y / h )]
Where, Consider Time Period as 0.3 sec
𝑍= 0.16
2 ZxIxSa 𝐼= 1.5
Av =
3 2xRxg 𝑅= 4

= 2.50
= 0.050

Pv = 0.05 x [1000 x 9.81 x 4.03*(1-0/4.03)]


= 1.977 kN/m2

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Maximum Hydrodynamic Pressure

P = (p iw +p ww ) 2 + p cw 2 + p v 2

= (1.644 + 0.294)^2 + 0.071^2 + 1.977^2

= 2.770 kN/m2 ( This Load apply on cylindical wall in STAAD )

2
Hydrostatic pressure acting on wall Pst = 39.54 kN/m
Hydrodynamic pressure acting on wall P = 2.77 kN/m2

Hydrodynamic check at evry mt depth

p st p dyn
y from top Q iw p iw Q cw p cw pv 2 % Ratio
(kN/m ) (kN/m 2 )

0.000 0.000 0.000 0.563 0.580 0.000 0.000 0.650


0.955 0.295 0.687 0.294 0.303 0.468 9.369 1.129 12.049
1.930 0.514 1.198 0.156 0.161 0.947 18.933 1.774 9.372
2.905 0.651 1.516 0.091 0.094 1.425 28.498 2.306 8.091
4.030 0.706 1.644 0.069 0.071 1.977 39.534 2.770 7.005

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Analysis for Tank Empty Condition

For empty condition, tank will be considered as single degree of freedom system.

Mass of Empty Container + 1/3 of Staging ms = 37650.65 kg


Lateral Stiffness Ks = 3966.68 kN/m

Time Period

T= Ti = 2π ms = 0.612 sec
Ks

Empty tank will not have convective mode of vibration.

Design Horizontal Seismic Coefficient

ZxIxSa 𝑍= 0.16
Ah =
2xRxg 𝐼= 1.50
𝑅= 4.00

= 2.222
Ah = 0.067

Base Shear

Total base shear,


V = Ah ms g
= 24.747 kN

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Truss Design

FEM Results from Tank Roof Truss STAAD model

Geometry of roof truss

3D View

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Member Properties

Member Properties assiged in STAAD


R1 = ISA 40x40x4 as Vertical Braces and Purlin Members
R2 = TUBE 40 X 40 X 2.5 as Bottom Chord Members
R3 = TUBE 40 X 25 X 2.5 as Top Chord Members
R4 = Plate 40x5 as Diagonal Braces Members

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Loading

Utilization Ratio

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Shell Design
Thickness Calculation

Hw Hydro Hydro
Impulsive Convective Vertical Total
From static Dyanamic
Ring Pressure Pressure Pressure Pressure
Top Pressure Prssure

(m) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2) (kN/m2)

R4 0.955 9.55 0.69 0.30 1.42 1.61 11.16


R3 1.930 19.30 1.20 0.16 0.95 1.54 20.84
R2 2.905 29.05 1.52 0.09 0.47 1.59 30.64
R1_Bottom 4.030 40.30 1.64 0.07 0.00 1.65 41.95

Shell Thickness Calculation ( Sample )

Total Pressure, P = 41.95 kN/m2


Tensile strenght of corrugated shell material = 0.6 x fy
σa = 180.00 N/mm2

= 1.80E+05 kN/m2

𝑃𝐷
Thickness Required 𝑡𝑟𝑒𝑞 = = 0.62 mm
2𝜎𝑎

Thick. Thick.
Ring Reqd Prod

(mm) (mm)

R4 0.16 0.80
R3 0.31 0.80
R2 0.45 1.20
R1_Bottom 0.62 1.60

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STAAD FEM MODEL

3D View

Shell Properties
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Shell Properties

Plate stress due to Horizonatal pressure ( Water )

Check for plate stress due to water pressure


Hw THK Allowable
Height of Sy
From of stress
Ring Ring (From STAAD) Check
Top Ring 0.6Fy

(m) (mm) (mm) (N/mm2) (N/mm2)

R4 Fourth Ring 0.955 0.800 955.00 24.65 180.00 OK


R3 Third Ring 1.930 0.800 975.00 53.37 180.00 OK
R2 Second Ring 2.905 1.200 975.00 69.73 180.00 OK
R1_Bottom First Ring 4.030 1.600 1125.00 42.88 180.00 OK

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Plate stress due to Wind Pressure
Check for plate stress due to wind pressure
Hw THK Allowable
Height of Sx
From of stress
Ring Ring (From STAAD) Check
Top Ring 0.6Fy

(m) (mm) (mm) (N/mm2) (N/mm2)

R4 Fourth Ring 0.955 0.800 955.00 7.61 180.00 OK


R3 Third Ring 1.930 0.800 975.00 36.71 180.00 OK
R2 Second Ring 2.905 1.200 975.00 58.08 180.00 OK
R1_Bottom First Ring 4.030 1.600 1125.00 19.68 180.00 OK

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Plate stress due to Seismic pressure

Check for plate stress due to Seismic pressure


Hw THK Allowable
Height of Sy
From of stress
Ring Ring (From STAAD) Check
Top Ring 0.6Fy

(m) (mm) (mm) (N/mm2) (N/mm2)

R4 Fourth Ring 0.955 0.800 955.00 37.88 180.00 OK


R3 Third Ring 1.930 0.800 975.00 63.11 180.00 OK
R2 Second Ring 2.905 1.200 975.00 77.59 180.00 OK
R1_Bottom First Ring 4.030 1.600 1125.00 46.59 180.00 OK

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Wall Buckling due to wind

As per Code AS 2304 -2011 Sec 5.2.2 tank with liners,the minimum base metal thickness for profiled wall bolted
steel tank wall plates shall be 0.8 mm.

Buckling Pressure shall be determined from the following eq. 5.3.2.3

FOR NON UNIFORM ORTHOTROPIC TANK (i.e.profiled differ thick for the height of the tank),
Ring Thickness
R1 1.60 mm
R2 1.20 mm
R3 0.80 mm
R4 0.80 mm

b = 75 mm
d = 17 mm

𝜋𝑅
𝐸𝐼 𝜋𝑅 𝑚𝑙 𝐼 𝐼 𝜋𝑅 𝐸 𝐼 𝑚𝑙
𝑃 = + + +
𝑅 𝑙 𝜋𝑅 𝐼 𝐼 𝑚𝑙 𝑅 𝜋𝑅 𝑚𝑙 𝑡 𝑡 𝜋𝑅
𝑡 +2 +
𝜋𝑅 𝑡 𝑡 𝑚𝑙
Where
R = Tank radius
E = Young's modulus
l = Height of buckle, in meter
m = Number of buckling wavelenght around the tank circumference
t = Base metal thickness of the wall sheet joined at a vertical seam
𝑡 ,𝑡 ,𝑡 = Equivalent membrane properties per unit projected width
𝐼 ,𝐼 ,𝐼 = Equivalent flexure properties per unit projected width

The Equivalent membrane properties shall be determined by the following equations :


2𝑡
𝑡 =
3𝑑

𝜋 𝑑
𝑡 =𝑡 1+
4𝑏

𝑡
𝑡 =
𝜋 𝑑
1+
4𝑏

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The Equivalent flexural properties shall be determined by the following equations :
𝑑 𝑡 𝜋 𝑑
𝐼 = 1+
8 8𝑏
𝑡
12
𝐼 =
𝜋 𝑑
1+
4𝑏

𝑡 𝜋 𝑑
𝐼 = 1+
3 4𝑏

Thickness 𝑡 𝑡 𝑡 𝐼 𝐼 𝐼
Ring
(mm) (mm) (mm) (mm) (mm) (mm) (mm)

R4 0.80 0.0012 0.8646 0.7403 30.73 0.0379 0.1923


R3 0.80 0.0012 0.8646 0.7403 30.73 0.0379 0.1923
R2 1.20 0.0040 1.2968 1.1104 46.10 0.1278 0.6490
R1 ( Bottom ) 1.60 0.0094 1.7291 1.4805 61.46 0.3029 1.5384

Shell ht m Pc Pf Pw
Ring Check
( mm ) ( Nos ) (kPa) (kPa) (kPa)

R4 955 7 24.60 15.99 2.28 OK


R3 1930 5 9.11 5.92 2.28 OK
R2 2905 5 8.42 5.47 2.28 OK
R1 ( Bottom ) 4030 5 7.68 4.99 2.28 OK

As limit state of Buckling pressure ( Pf ) , is greater than wind action on each ring, there is no need of
horizonatal stiffeners in any ring.

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Anchor Bolt Design

Wind
Shear = 34.23 kN
Moment = 68.98 kN-m
Seismic
Shear = 54.85 kN
Moment = 130.54 kN-m

PDC of anchor bolt, D = 5.43 m


Max. Moment, M = 130.54 kN-m
Nos. of Anchor Bolts, N = 24 Nos.
Uplift per Bolts ( Ps = 4M/ND) = 4.01 kN

Dia of anchor bolt = 16 mm


ϒmo = 1.1
ϒmb = 1.25
Tension Capcity of single Bolts Tdb = 73.11 kN
For M-25 Grade of concrete Ʈbd = 1.4 N/mm2

1.5 X Tension in single bolt


Length of Bolts = = 85.40 mm
𝜋 x do x bond stress

Provide Embedment Length = 175.00 mm

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Bolt Design

Bolt Properties

Size = 10.00 mm
Material Grade = Grade 10.9
Fub = 1000.00 N/mm2
Fyb = 900.00 N/mm2
Shear Capacity of bolt
𝑉 =𝑉 /𝛾
𝑉 = 𝑓 /√3 × 𝑛 𝐴 +𝑛 𝐴
Bearing Capacity of bolt
𝑉 =𝑉 /𝛾
𝑉 = 2.5 𝑘 𝑑 𝑡 𝐹

Where,
Fub =Ultimate tensile strength of a bolt, in Mpa = 1000.00 N/mm2
Fu =Ultimate tensile strength of a plate, in Mpa = 340.00 N/mm2
d =Nominal diameter of the bolt, in mm = 10.00 mm
d0 =Nominal diameter of the holes, in mm = 12.00 mm
t =Thickness of the thinner connected part or sheet, in mm
nn =No of shear planes with threads intercepting shear plane, = 1.00
ns =No of shear planes without threads intercepting shear plane = 0.00
2
Asb =Nominal plane shank area of the bolt, in mm = 78.54 mm2
Anb =Net shear area of the bolt at threads, in mm 2 = 52.30 mm2
kb =Smaller of e/3d o , p/3d o - 0.25 , f ub /f u , 1.0
e =End distance of the fastener along bearing direction, in mm. = 37.50 mm
p =Pitch distance of the fastener along bearing direction, in mm. = 75.00 mm
ϒmb =Partial safety factor for bolted conn. with bearing type bolts = 1.25

Shear Capacity of bolt


𝑉 = 𝑓 /√3 × 𝑛 𝐴 +𝑛 𝐴 = 30.19 kN
𝑉 =𝑉 /𝛾 = 24.15 kN

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Bearing Capacity of bolt
𝑉 = 2.5 𝑘 𝑑 𝑡 𝐹 ( for 1.6mm THK) = 13.60 kN
𝑉 =𝑉 /𝛾 = 10.88 kN
𝑉 = 2.5 𝑘 𝑑 𝑡 𝐹 ( for 1.2mm THK) = 10.20 kN
𝑉 =𝑉 /𝛾 = 8.16 kN
𝑉 = 2.5 𝑘 𝑑 𝑡 𝐹 ( for 0.8mm THK) = 6.80 kN
𝑉 =𝑉 /𝛾 = 5.44 kN

Vertical Lapping

P Area Load Pbolt


Ring Total Bolts Load/Bolt Pbolts<Vdsb Pbolts<Vdpb
kN/m2 m2 kN

R4 11.16 22.23 248.08 180.00 1.38 OK OK


R3 20.84 22.23 463.14 180.00 2.57 OK OK
R2 30.64 22.23 681.07 180.00 3.78 OK OK
R1 ( Bottom ) 41.95 22.23 932.40 180.00 5.18 OK OK

Horizontal Lapping

Maximum force will be between RING1 & RING2

Maximum Pressure = 30.64 kN/m2


Area = 2.51 m2
Total Force = 76.81 kN
Total Number of Bolts = 108.00 Nos
Bolt Force = 0.71 kN OK

Bolt force is less than the capacity of M10 bolts in shear & Bearing.

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