ANNEXURE-B Design Basis Report Gandhidham

Grain Storage Silo Complex of 37500 MT @ FSD Gandhidham, Rev.No.
0
Gujarat, Food Corporation of India Date 10/08/2023
Authority Food Corporation of India
Concessionaire KCC Agri Logistics (Gandhidham) Pvt. Ltd. Page 1 of 16
Technical Support Lotus Harvestec Pvt Ltd , Gurugram
Design Basis Report
Of
Grain Storage Silo Complex of 37500 MT At
FSD Gandhidham, FCI Gujarat.
On
DBFOT mode under PPP Model

Grain Storage Silo Complex of 37500 MT @ FSD Gandhidham, Rev.No. 0
Concessionaire KCC Agri Logistics (Gandhidham) Pvt. Ltd.
Page 2 of 16
1 INTRODUCTION:
A concession agreement was signed between FCI and KCC Agri Logistics (Gandhidham) Pvt Ltd on
13rd Dec 2022. As per the provisions of Concessionaire agreement KCC Agri Logistics (Gandhidham)
Pvt Ltd (KCCALGPL) has proposed to develop Grain Storage Silo Complex of 37500 MT at FSD
GANDHIDHAM, Gujarat on Design basis.
This document is to briefly define the Engineering and Design methodology. All the system and project
components are to be designed as per applicable Indian and International Codes / standards.
The document includes the design philosophy of the facility.
Layout of Silo Complex 37500 MT Capacity (Long Term Storage Silos)
Based on the availability of land parcel available with the layout Drawing no.
LOTUS/FCI/KCC/GANDHIDHAM/FC2022/LAYOUT-01 to be incorporated of the 37500 MT Silo
complexes is finalized incorporating all the systems and the facilities to be developed as per the
Concessionaire agreement and in line with Concessionaire agreement requirement.
Fig.1 Layout of Silo Complex
The layout finalized has all the facilities as mentioned in the Concessionary Agreement. The details of the
provisions made in the silo complex is shared herein this document.
Page 3 of 16
2 SYSTEM AND FACILITIES PROPOSED AT THE SILO COMPLEX
2.1 Grain Storage and Handling system:
The silo complex is being designed and detailed our as per the Provisions of FCI Concessionaire
agreement for consuming area SPOKE location for Food Grain i.e. Wheat.
Following facilities, as per the Schedule B&C: Project Facilities, related to Silo and Material
handling system will be designed and implemented at the silo complex. All the project facilities
and associated infrastructure will be provide confirming to the specification & capacities
mentioned under respective heading in the concession agreement.
Silo Complex
Silo Complex 37500 MT @FSD Gandhidham by KCCALGPL
Configuration
Long Term Storage  3 numbers of flat bottom sheet metal silos, each of [12,500
Silos Metric Ton] built as per Standards and Specifications totaling
to a Capacity of 37500MT (Metric Ton)
 Each of the Long-Term Storage Silo shall be fitted with
stationary vents and mechanical ventilators, aeration fans, level
switches and aeration floors and temperature monitoring
system.
 The Long-Term Storage Silos are to be top loading and bottom
discharge.
 The intake capacity of the conveying system: 150 TPH being
consuming Area.
 The discharge / reclaim conveyors below of the long-term
storage silos including that of the sweep augur:100 Tons Per
Hour (TPH)
 The specifications of all the Silo components & material
handling systems etc. shall confirm to the concession
agreement.
Vehicle parking area Sufficient Area to allow for parking of

 3-axle trucks of 20 (twenty) nos.
 10 (ten) cars &
 24 (twenty-four) two-wheelers.
Lorry Weigh bridge  16 m X 3 m – 60 MT Lorry Weighbridge – 1set or 2 nos.
Laboratory for quality  Laboratory equipped to test at least 30 samples per hour for
testing 150 TPH (intake system), as per the FAQs (Fair Average
Quality) parameters a standard mention in CA Schedule -E
page no.203 & 204.
 Testing facilities including, but not limited to, moisture meter,
Dockage testing, Sample divider, sensitive lab scale, sieve sets,
a foot long sample probes, four feet long sample probes and
oven for moisture calibration
 Adequate numbers of Hydraulic Truck Samplers
Page 4 of 16
Grain intake system  Grain intake system comprising of unloading station with dump
pits arrangement comprising of four (04) hopper bins covered
with MS grating suitably connected through a conveyor to Pre-
Storage Silos.
 Truck Unloading shed : Min 22 X 16 mtrs. Sufficient for
unloading of Trucks through 4 hoppers of minimum 2.7x2.7
mtrs.
 Hydraulic Tippler( 16 mtrs x 3 mtrs ) : 2 No
 Drag Chain Conveyor: 150 TPH
 Dust suppression system
Pre-storage silos  1 hopper bottom silos of 500 Metric Tons (MTs) with
Aeration fans, Sanitary vents & Fumigation provisions.
 Top chain conveyors to have access from ground by ladder
and be equipped with catwalk for facilitating
inspection.
Process Tower  Pre-Cleaner System: 150 TPH
 Online Weigher: 150 TPH
 Suitably designed Bag filter & Dust Collection system
Bulk Truck Loading  50 MT Hopper Bottom Silo :2 Nos
System  100 TPH Drag Chain Conveyor: 1 Set (as per actual
requirement)
 Provision for Container Tilter for future requirement (as
per specification shall be incorporated as mentioned in CA for
procuring region.)
Bagging system  Semiautomatic weigher and bagger mechanism –30 TPH: 2
Nos (Total storage Capacity 60 TPH)
 50 MT Hopper Bottom Silo: 2 Nos
Bag Storage  Covered Warehouse as per FCI / CWC Specifications / norms

Warehouse :800 MT Capacity with suitable place to store Empty Bags –
Approx Size of Covered Shed: 700 SQM
 The proposed warehouse will have good cross ventilation and
have the requisite plinth level and should be rodent
and fire proof.
Fumigation system  A closed loop fumigation system, either from the Silos’
aeration fans or separate centrifugal fan or a separate phosphine
generator
Silo Grain  Temperature monitoring system: Min 13 Temperature Cables
Temperature for 12500 MT Silos and Min 9 Temperature Cables for 4000
Monitoring and Silo MT Silos – Total Min 61 Temperature cables with centralized
Complex Automation temperature monitoring and control system
system  Motor Control Center (MCC)
 PLC Panel
 SCADA with required interface facility and display
 Weather station
Administration office  Admin office with required furniture and toilets – 100 SQM
Page 5 of 16
Electrical Substation  Meter Room: 10 SQM (at Suitable locations)

with Power Back-up (As  Compact Substation of required capacity – Open to sky *
per state electricity
norms & IS Standards)  Main DG Set :>180 KVA DG Set (as Power Back-up)*
 Stand-by DG Set :> 63 KVA DG Set (as stand by Power Back up)*
 UPS (for Critical Power) : 10 KVA * shall capable to provide
24*7 power supply to uninterrupted operation.
Pump house with Fire  75000 Ltrs UGT for Fire Hydrant System
Fighting Hydrant  Fire Hydrant System including suitably designed Main fire
System (Shall be Electrical Pump and Jockey Pump with Fire hydrant line and
comply with state fire hose pipes
department)  Diesel Engine Powered Fire Hydrant Pumps
 Pump House above Water Tank – 25 SQM
 Portable fire extinguishers like CO2, dry powder type etc.
 Smoke detector to be provide at appropriate location.
Rain water harvesting  Rain water harvesting recharge bores with collection tanks
 As per requirement & State Government norms (Shall be
proposed in low level area.)
Engineering Workshop  Engineering Office and Store – 20 SQM

and Store  Engineering Workshop - 35 SQM
Fumigation Store  Fumigation Store( fire proof) – 16 SQM
Internal Roads and  As per requirement

Drain
RCC Pre Cast  1.8-meter-high boundary wall made of bricks/stone and
Boundary Wal mortar/Pre stressed Pre-Cast having 0.75-meter concertina wire
coils protected from outside intrusion
 MS Gate with separate entry and exit
Drivers’ Rest Room &  Integrated facility for Drivers and Working staff: 75 SQM
Cafeteria Approx
Page 6 of 16
3 DESIGN METHODOLOGY, CODES & REFERENCE
3.1 Design Methodology & sequence:
 Land Demarcation
 Contour Surveying & area surveying
 Silo Complex facility Layout incorporating all facilities as per the
requirement.
 Finalization of process Flow
 Finalization of Elevation of Silos and Material Handling systems and
facilities
• Silo Finished Level to kept at Min + 750 mm above High
flood Level (HFL) RECORDED
• Roads Level within the complex + 300 mm HFL
• Truck Unloading hopper Top Level + 500 mm HFL
• Process Tower and Other Elevator Pits Wall + 500 mm HFL
• All the buildings and transformer CSS, DG Sets etc. to be kept
at +500mm above HFL.
 Finalization of Silo and Material Handling system reaction loads
 Civil Structure Design of Silos, Material Handling system and Process
Tower.
 Finalization of Roads & Railway Siding design and per relevant Codes and
practices.
 Finalization of Electrical Load Data Sheets.
 Designing of Electrical Substation and Power Backup System.
 Structure Designing and material selection for all ancillary buildings.
3.2 Major Design Codes and Standards to be followed:
 Civil and Structure Design
Code/StandardTitle
IS: 875 (PART-III) Wind Load Design

IS: 875 (PART-II) Live Load Design
IS: 875 (PART -I) Dead Load Design
IS: 456-2000 Code of Practice for Plain and Reinforced Concrete IS:
10262:2009 Mix Design of Concrete
IS1904-1986 Code of practice for design & construction of foundations in soil general
requirements
IS2950, Part1-1981 Code of practice for design & construction of raft Foundations, Part I-
Design
IS: 269-2015 Ordinary Portland cement, 33 Grade-
Specification
IS: 455-1989 Portland slag cement- specification
IS: 1489(PartI)-1991 Portland Pozzolana cement-specification (Fly-ash based)
Page 7 of 16
IS: 1786-2008 Specification for high strength deformed steel bars and wire for
concrete reinforcement
IS:800-2007 Steel Design
IS: 383-2016 Specification for coarse and fine aggregates from natural
sources for concrete
IS:9103-1999 Concrete admixtures–Specification
IS: 1905-1987 Code of Practice for Structural use of unreinforced Masonry IS:
816 – 1969 Welding code
IS: 11089-1984 Code of Practice for Design & Construction of Ring Foundation
 Material Specifications
MaterialsUnit Weight(kN/m3)
Steel 78.50
Plain Cement Concrete (PCC) 24.00
Reinforced Cement Concrete (RCC) 25.00
Soil 18.00
Water 10.00
 Electrical System
Code/StandardTitle
 National Building Code of India – 2016

 Energy Conservation Building Codes
 Relevant codes of National fire Codes
 Relevant codes of Bureau of Indian Standards
 NEC – NFPA 70, National Electric Code
 NFPA 101, Life safety code
 NEC, National Electric Code of India.
 Fire Hydrant System
Code/StandardTitle
 National Building Code - 2016: Part IV, Fire and Life Safety.
 BIS and IS Codes; IS: 3044, IS: 5290, IS: 5312, IS: 908, IS: 2190, IS: 3844 etc.
 Local Bye – Laws and Guidelines of Local Fire Authority.
 NFPA & TAC Manual (for reference and guideline).
 Consultation with local (CFO) Chief Fire Officer.
Page 8 of 16
 General System Design

Code/StandardTitle
 The silo complex will be designed in accordance with the prevailing standards as applicable to the job.
 FCI (Food Corporation of India) Norms defined n Concessionaire agreement
 Indian Electricity Rules
 State Electricity Board (SEB) regulations West Bengal
 Chief Electrical Inspectorate requirements of State of West Bengal
 Indian Factory Act
 Indian Weights & Measures Act
 Any other applicable Indian Act
3.3 Major Design Codes and Standards to be followed:
 MATERIAL SPECIFICATIONS AND GENERAL ASSUMPTIONS FOR CEMENT

CONCRETE
 Portland Pozzolana cement shall be used for concrete works above ground.
 Portland fly ash cement to be used for concrete works below ground.
 Strength of concrete shall be tested by cube test .Size of cube shall
be150mmX150mmX150mm.
 Primary testing of concrete shall be done with at least 3 no’s of
cubes, prepared from each batch of fresh concrete.
 Cube test shall be done as per the table below
First Cube Second Cube Third Cube
After 7 days After 28 days curing As per site Engineer’s choice
curing
 Concrete mix shall be M30 with minimum cement content of 360
Kg/m3 for columns.
Mix Characteristic Maximum Free
Provision
Designation Strength N/mm2 water/Cement ratio
Annular
M30 30 0.4 Foundation,
Silo Ring Walls
RCC
Structural
components
M25 25 0.5
for General
Building
Construction
 Minimum slump for concrete shall be 75mm.
 Maximum drop height or free fall height of concrete shall be 1.5 meters.
 All Plain Cement Concrete (PCC) works shall be in mix proportion 1:3:6. (1
cement:3 Fine Aggregate : 6 Coarse aggregate ).
 Maximum water-cement ratio in lean concrete/PCC shall be 0.60.
 Minimum thickness of lean concrete/PCC shall be 75mm
Page 9 of 16
 MATERIAL SPECIFICATIONS AND GENERAL ASSUMPTIONS FOR

REINFORCEMENT
 All reinforcing bars having diameter greater than 10mm shall be HYSD
bars/TMT bars conforming to grade Fe500.
 Minimum diameter of main reinforcement in structures shall be 12mm HYSD
bars/TMT bars conforming to grade Fe500.
 Minimum diameter of stirrup reinforcement shall be 8mm HYSD bars/TMT bars
conforming to grade Fe500.
 Lap length for Tension and compression reinforcement shall be 45 times bar
Diameter.
 Minimum Lap length shall be 300mm.
 The binding wire shall be black annealed wire of 16 gauge. Care should be taken to
ensure that the projecting ends of the binding wire do not encroach into the
concrete cover. This is best achieved by turning the projecting ends in wards by
lying.
 Yield strength and tensile strength of reinforcement shall conform to the
following table
Grade of Steel Yield Strength Ultimate Strength

Fe 500 500 MPa 640 MPa
 Material Specifications: (Structural Steel)
 The following is the list of the material standards & specifications for which the
Structure components have been designed.
No. Structural Components Specifications Yield Strength

(Mpa)
1 Built-up sections Made from steel conforming to IS 2062 Fy = 345
2 Cold formed secondary members Fy = 345
Made from steel conforming to IS 2062
3 Anchor Bolts Hot Rolled bar per Grade 4.6 IS 2062 Fy = 345
Hot Dip Galvanized to A153, class C or
equivalent
4 High Strength Bolts ASTM A 325M = Bolts Ft = 303
ASTM A 563M = Nuts
ASTM F 436M = Washer
 Fy = Yield Strength
 Fu = Ultimate Tensile strength
Concessionaire KCC Agri Logistics (Gandhidham) Pvt. Ltd. Page 10 of 16
4 LOADING DATA:
4.1 GRAVITATIONAL LOAD:

 Silos: Loading has been taken from data provided by the vendor.
 Admin Building & other facilities: Loading data has been acquired from IS875
(Part1&2).
THICKNESS 175 mm
DEAD LOAD OF SLAB
DENSITY 25 kn/m3
FLOORFINISH 75 mm
DENSITY 24 kn/m3
Load of 175mm slab 4.375 kn/m2
Load of floor finish 1.8 kn/m2
Total dead load 6.175 kn/m2
SUNKEN LOAD
THICKNESS 300 mm
DENSITY 18 kn/m3
Dead Load Due
5.4 kn/m2
To Sunken
GROSS DEAD LOAD
DUE TO SUNKEN 11.575 kn/m2
AND
SLAB
DEAD LOAD OF AAC BLOCK
DENSITY 7.5 kn/m3
Height 3.2 m
Beam depth 550 mm
Net height for wall 2.65 Mtrs
Thickness of wall 200 mm
Thickness of wall 100 mm
For 200mm AAC block 3.975 kn/m
For 150mm AAC block 1.9875 kn/m
30mm plaster load 50 mm
Density of plaster 24 kn/m3
Dead load of plaster 3.18 kn/m
TOTAL DEAD LOAD
7.155 kn/m
OF 200mm WALL
TOTAL DEAD LOAD
5.1675 kn/m
OF 100mm WALL
Page 11 of 16
4.2 General Load Cases & Load Combinations:

Basic Wind Seismic
Site Location Coordinates Capacity
Speed Zone
FSD, Gadhidham, 23 Deg 2 Min 15 Sec N
70 Deg 8 Min 38 Sec E 37500 MT 180 kmPH Zone –IV
GUJARAT
DEAD LOAD LIVE LOAD SEISMIC-H EQXSEISMIC-H EQZ
1.5 DEAD + 1.5 LIVE

1.2 DEAD + 1.2 LIVE
1.2 DEAD + 1.2 LIVE + 0.6 SEISMIC-HEQX
1.2 DEAD + 1.2 LIVE + 0.6 SEISMIC-HEQZ
1.2 DEAD + 1.2 LIVE + -0.6 SEISMIC-HEQX
1.2 DEAD + 1.2 LIVE + -0.6 SEISMIC-HEQZ
1.2 DEAD + 1.2 LIVE + 1.2 SEISMIC-HEQX
1.2 DEAD + 1.2 LIVE + 1.2 SEISMIC-HEQZ
1.2 DEAD + 1.2 LIVE + -1.2 SEISMIC-HEQX
1.2 DEAD + 1.2 LIVE + -1.2 SEISMIC-HEQZ
1.5 DEAD
1.5 DEAD + 1.5 SEISMIC-HEQX
1.5 DEAD + 1.5 SEISMIC-HEQZ
1.5 DEAD + -1.5 SEISMIC-HEQX
1.5DEAD+-1.5SEISMIC-HEQZ
0.9 DEAD
0.9 DEAD + 1.5 SEISMIC-HEQX
0.9 DEAD + 1.5 SEISMIC-HEQZ
0.9 DEAD + -1.5 SEISMIC-HEQX
0.9 DEAD + -1.5 SEISMIC-HEQZ
1 DEAD + 0.35 LIVE

1 DEAD + 1 LIVE
1 DEAD + 0.8 LIVE
1 DEAD + 0.8 LIVE + 0.8 SEISMIC-HEQX

1 DEAD + 0.8 LIVE + 0.8 SEISMIC-HEQZ
1 DEAD + 0.8 LIVE + -0.8 SEISMIC-HEQX
1 DEAD + 0.8 LIVE + -0.8 SEISMIC-HEQZ
1 DEAD
1 DEAD + 1 SEISMIC-HEQX
1 DEAD + 1SEISMIC-HEQZ
Page 12 of 16
1 DEAD + -1SEISMIC-HEQX
1 DEAD + -1 SEISMIC-HEQZ
4.3 List of Drawing to be submitted
4.3.1 Silo Complex: Grain Handling and Storage system
 Design basis for all Silo Complex system

 Process Flow Diagram
 Silo Complex layout
 Silo Complex Equipment and system Elevation Drawing
 GA Drawings Silos
 Silo Base GA Drawing
 GA Drawings Conveyors and Elevators
 GA Drawings Truck Unloading Hoppers
 GA Drawings Cleaning system
 GA Drawings Dust Suppressions and Collection system
 GA Drawings Aeration system
4.3.2 Silo Civil Structure Drawings – Architectural, Structure and GA

Drawings
 Structure Design basis report

 Time & Security office
 Pile drawing
 Metering & PCC room
 Electrical Panel room
 Weighing office
 Warehouse
 Road - Internal
 Approach Road
 Main Silos
 Bagging Silo
 Water tank & Pump room including Shed
 Truck Intake Pit
 Process Tower with connecting tunnel
 Bulk loading Silo with ramp
 Receiving Silo
 Elevator Pit
 Dust collector support structure
 Impurity Bin Plinth
 Wagon Unloading Pit
 Rest room/ Toilet Block
 Septic tank & Soak Pit
 Catwalk support structure foundation
 Aeration fan foundation
 Weigh Bridge foundation
 Transformer Plinth
 DG Plinth
 Street light foundation
 High mast light foundation
 Truck &2/4 wheeler Parking
 Cable Chambers
 Rain water harvesting Pit
Page 13 of 16
 Admin Building
 Warehouse Structural
 Truck intake pit shed
 Main entry & Exit gate
 Watch Tower
4.3.3 Electrical system & Automation / Control System
 Design Basis report including Electrical Load Data

 Single Line Diagram
 Compact Substation sizing (CSS)
 DG Set Sizing
 Ups Sizing
 Cable Tray - Route layout
 Temperature Monitoring, Automation and Grain Management
Software Architecture
4.3.4 Fire Hydrant System
 Fire Hydrant Line with complete mountings, Pipes and Fittings

 Pump Room Drawings – Mechanical
4.3.5 Drains and Rain Water Harvesting system
 Design basis for Rain Water Harvesting system

 Slope Calculations and sizing of Storm Water Drains
4.3.6 Key Plans
 Complete Silo Complex with levels / elevation

 Connectivity – Road and Railway
 Land Utilization
Page 14 of 16
5 Analysis Of Structure:
The analysis and design of the silo foundation. System shall be done manually using MS excel.
The design procedure of the same has been given in Annex-A.
5.1 Silo Foundation and Tunnel Foundation

The base slab shall be designed based on vendor provided load coming on it.
Below is a typical sketch of Silo Foundation and Tunnel Foundation Section.
The base ring shall be designed considering the hoop stress generated on the ring wall due to the
surcharge value, direct pressure from the confined earth and forces coming from silo due to wind load
and seismic load. The hoop tension is used to calculate the total requirement of the reinforcement
on the wall.
The foundation shall be designed using Code IS 11089-1980. The foundation design is performed in
accordance with loading data provided by vendor.
Annular foundation with service tunnel having separate raft foundation to be done for 12500 Ton Silos.
Fig. 4 Ring RCC beams & Annular Foundation Section
6 Engineering Timelines with execution schedule

Page 15 of 16
Page 16 of 16

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Grain Storage Silo Complex of 37500 MT @ FSD Gandhidham, Rev.No.

Design Basis Report

Grain Storage Silo Complex of 37500 MT At

FSD Gandhidham, FCI Gujarat.

DBFOT mode under PPP Model

Layout of Silo Complex 37500 MT Capacity (Long Term Storage Silos)

Fig.1 Layout of Silo Complex

2 SYSTEM AND FACILITIES PROPOSED AT THE SILO COMPLEX

2.1 Grain Storage and Handling system:

Vehicle parking area Sufficient Area to allow for parking of

Bag Storage  Covered Warehouse as per FCI / CWC Specifications / norms

Electrical Substation  Meter Room: 10 SQM (at Suitable locations)

Engineering Workshop  Engineering Office and Store – 20 SQM

Fumigation Store  Fumigation Store( fire proof) – 16 SQM

Internal Roads and  As per requirement

3 DESIGN METHODOLOGY, CODES & REFERENCE

3.1 Design Methodology & sequence:

3.2 Major Design Codes and Standards to be followed:

 Civil and Structure Design

IS: 875 (PART-III) Wind Load Design

 National Building Code of India – 2016

 General System Design

3.3 Major Design Codes and Standards to be followed:

 MATERIAL SPECIFICATIONS AND GENERAL ASSUMPTIONS FOR CEMENT

 MATERIAL SPECIFICATIONS AND GENERAL ASSUMPTIONS FOR

Grade of Steel Yield Strength Ultimate Strength

 Material Specifications: (Structural Steel)

No. Structural Components Specifications Yield Strength

4.1 GRAVITATIONAL LOAD:

4.2 General Load Cases & Load Combinations:

1.5 DEAD + 1.5 LIVE

1 DEAD + 0.35 LIVE

1 DEAD + 0.8 LIVE + 0.8 SEISMIC-HEQX

4.3.1 Silo Complex: Grain Handling and Storage system

 Design basis for all Silo Complex system

4.3.2 Silo Civil Structure Drawings – Architectural, Structure and GA

 Structure Design basis report

4.3.3 Electrical system & Automation / Control System

 Design Basis report including Electrical Load Data

4.3.4 Fire Hydrant System

 Fire Hydrant Line with complete mountings, Pipes and Fittings

4.3.5 Drains and Rain Water Harvesting system

 Design basis for Rain Water Harvesting system

4.3.6 Key Plans

 Complete Silo Complex with levels / elevation

5.1 Silo Foundation and Tunnel Foundation

Fig. 4 Ring RCC beams & Annular Foundation Section

6 Engineering Timelines with execution schedule

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