749500_a4-p________12.0_en

Structural design and erectionGeneral requirements

Approved date: 5-Mar-2008

Created by: OMa

Approved by: JaHo

Doc. No. 749500-12.0

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Structural design and erection

749500-12.0

List of contents:Page:

0. Revision historic..................................................................................................................3

1 General................................................................................................................................4

1.1 Purpose......................................................................................................................41.2 Standards...................................................................................................................41.3 General Arrangement drawings.................................................................................41.4 Sequential progression..............................................................................................41.5 Estimated information................................................................................................41.6 On hold......................................................................................................................41.7 Buyer supplied equipment.........................................................................................41.8 Release status...........................................................................................................51.9 Update of drawings....................................................................................................51.10 Overlapping plant departments.................................................................................5

2 Loads for calculation of civil structures.............................................................................6

2.1 General information...................................................................................................62.2 Units of measure........................................................................................................62.3 Natural loads..............................................................................................................62.4 Dynamic loads exerted by the equipment.................................................................72.5 Load categories.........................................................................................................7

2.5.1 Dead load (permanent loads).......................................................................72.5.2 Live loads, normal (variable loads)...............................................................72.5.3 Live loads, extraordinary..............................................................................82.5.4 Natural loads................................................................................................82.5.5 Special loads.................................................................................................8

2.6 Deck and roof............................................................................................................92.7 Special load requirements for roofs without access.................................................102.8 Stairs and landings..................................................................................................10

3 Execution of support structure.........................................................................................10

3.1 Settlements.............................................................................................................103.2 Concrete strength....................................................................................................103.3 Surface reinforcement.............................................................................................103.4 Alignment and grouting...........................................................................................113.5 Bolt holes.................................................................................................................133.6 Final grouting...........................................................................................................13

4 Various specifications.......................................................................................................13

4.1 Water seepage.........................................................................................................134.2 Covering and flashing..............................................................................................134.3 Drain........................................................................................................................144.4 Floors and walls.......................................................................................................144.5 Stairways and walkways..........................................................................................144.6 Exit doors.................................................................................................................144.7 Steel or concrete structures.....................................................................................144.8 Constructional elements (beams, columns, braces, etc.).........................................144.9 Tolerances...............................................................................................................15

5 Erection corrections..........................................................................................................15

The information transmitted by this document is the proprietary and confidential property of FLSmidthand may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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Structural design and erection749500-12.0

0 Revision historic

Version 12.0 5-Mar-08Section “0 Revision historic” addedSection “1.2 Standards” addedSection “1.7 Buyer supplied equipment” addedSection “1.8 Release status”. Editorial changesSection “1.9 Update of drawings”. Editorial changesSection “2.8 Stairs and landing” addedGeneral: “the equipment supplier” and “the supplier” have been substituted by “Seller”


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General

1.1 PurposeThis instruction manual is to provide the civil designer, the civil contractor and the erection contractor with general requirements regarding civil design and erection of the equipment. Specific requirements are stated in plant layout documentation and instruction manuals.

1.2 StandardsReference by Seller to any international or national Standard does not incur an obligation on Seller to provide any recipient, reader or user of the documentation with samples or copies of the said Standard(s).

Hence, any recipient, reader or user of the documentation is expected – at his own cost – to obtain necessary knowledge of the contents of any of the Standards referred to.

1.3 General Arrangement drawingsGeneral Arrangement drawings (GA drawings) serve to show the project arrangements with an indication of installation dimensions, conditions of space, access and loadings, etc. Loads and detailed dimensions are specified on GA drawings or Outline and Load drawings (OL drawings).

1.4 Sequential progressionThe GA drawings are developed through sequential progression and are issued in different stages of completion.

1.5 Estimated informationOn GA drawings some equipment measurements and loads may be estimated. This is indicated by a cloud marked with “E”. The cloud may cover the equipment or localised areas, where the detailed information is not available. Such drawings may still be used for the ongoing civil design work.

1.6 On holdSome information in the drawings may be “on hold”, which is indicated by a cloud marked with “H”. The cloud may cover some items of equipment or localised areas, where the detailed information is not available or needs verification by the Buyer or other parties. Such drawings may still be used for the ongoing civil design work with exception of the “on hold” areas.

1.7 Buyer supplied equipmentBuyer supplied equipment (BSS), e.g. screw conveyors, secondary filters etc, is estimated in size, if the equipment is a natural part of the arrangement.Detailed information regarding hole sizes, platform sizes, loads, reference to Outline and Load Drawing etc., are not given by Seller.If water pipes, compressed air pipes, cables, etc. are Buyer supply, trenches and holes in floors are not shown by Seller.Buyer supplied equipment is usually shown as being Seller supply i.e. Seller equipment.In case the documentation shows equipment, lining, etc. supplied by Buyer the measurements and loads have to be informed by the Buyer.


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In case equipment or the operational conditions at a later stage is changed by Buyer the impact on the structure has to be considered by a civil designer.

1.8 Release statusThe release status of the GA drawings (e.g. Basic, Main, Detail) is not written on the drawing. The release status is only described in the release note.

1.9 Update of drawingsEvery time a GA drawing is updated, the revisions are shown encircled with clouds, and the drawing is given a new version number for example 2.0. Minor version numbers, for example 2.1, may be used for communication internally in Seller’s organisation. These minor versions numbers are not forwarded to the Buyer

1.10 Overlapping plant departmentsThe department numbering follows the equipment rather than the physical boundaries of the buildings. Therefore some GA drawings may show parts of other departments where the equipment overlaps. In such cases, the GA drawing will show the outline of the overlapping department(s) together with a reference to the relevant department(s). In such cases the civil designer must cross-reference between departments to find the required information and the civil designer must take due consideration of these loads and other influences and restrictions.


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2 Loads for calculation of civil structures

2.1 General informationThe drawings state loads originating from the equipment as well as live loads on decks, platforms, walkways, etc. For load categories, see sub-section 2.5.In some cases the actual load data may not be available in due time. A higher general floor replacement load might then be given for the area concerned (for example for electrical panels or minor equipment).Design the individual decks to withstand all the loads specified, i.e. loads from the equipment as well as the uniformly distributed loads.Apply load factors, safety system and partial coefficient according to applicable codes and design norms.The civil designer assumes full responsibility for compliance with all local regulations and codes of practice.

2.2 Units of measureThe units applied are SI-units.Elevations are in m, whereas other dimensions are in mm. Loads are in N (Newton) or kN (kiloNewton).

2.3 Natural loadsLoads originating from external forces, e.g. wind load, snow load and seismic loads, are not indicated on the drawings, but must be determined by the civil designer in accordance with local regulations codes of practice and conditions.When calculating of natural loads assume, that expansion joints on machines and ducts cannot transfer loads.When calculating seismic loads, the assumption is to safeguard against major structural failure and loss of life, but not to prevent damage nor to maintain function of the equipment.The civil designer is also required to evaluate and determine loads caused by settlement, temperature stresses, etc.Consult Seller, if deflections or settlements of the civil structure are greater than specified.Fixtures for the equipment are designed for loads caused by wind, snow and seismic loads.On certain drawings, e.g. for electrostatic precipitators, natural loads are stated. The purpose of this is solely to indicate the loads for which the equipment has been designed. Supports and foundations must be designed in accordance with local regulations codes of practice and conditions.


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2.4 Dynamic loads exerted by the equipment a) For equipment subject to comparatively small dynamic loads, the dynamic loads

are specified as an equivalent additional static load (See sub-section 2.5).b) For equipment subject to considerable dynamic loads (e.g. heavy-duty fans) the

individual load rates of the equipment are specified (dead load, live load and dynamic loads).

c) The load rate applying to certain equipment will be specified as the total load (P) of the equipment multiplied by factor (k). The specified factor (k) incorporates dynamic loads and load variations.Unless otherwise specified on the drawing, the load can be divided into a dead load (permanent load) of 1 x P and a normal live load (variable load) of (k - 1) x P.

Attention is drawn to the fact that in each individual case the civil designer assumes full responsibility in respect of ensuring that the individual constructions are so designed that vibrations and noise nuisances from the building structures are eliminated in accordance with the local codes and regulations.A minimum 20 % deviation from the dynamic frequency of the equipment and the natural frequency of the load-carrying structures (incl. the mass of the equipment and its foundation) is required.

2.5 Load categories2.5.1 Dead load (permanent loads)

Dead load of equipment, lining and other well-defined installations (in terms of both load and location).The dead load is sub-divided as follows:

DL1 Dead load from equipment, etc.DL2 Dead load from lining or insulation.

2.5.2 Live loads, normal (variable loads)Normally occurring loads from e.g. plant operators, furniture and equipment, traffic, material (stored, transported, occasional accumulations, dust, fillings, etc.).When a dynamic load is approximated to an additional static load, this additional load, which stems from normally occurring conditions of impacts and vibrations, is included in this load category. (See sub-section 2.4.a).Normal live loads are sub-divided as follows:

LL1 Live load (per m, per m2 or as a point load) from plant operators, furniture and equipment, stored or transported goods and materials. (Normal operating conditions).

LL2 Material accumulations and similar conditions.LL3 Traffic load. (As e.g. loads originating from trucks operating in stores,

loads from rolling materials handling devices, etc.).LL4 Static additional load equivalent to a dynamic vibration or impact

load.LL5 Dynamic vibration or impact load.LL6 Explosion load and similar conditions.LL7 Friction load originating from thermal expansions and contractions.


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2.5.3 Live loads, extraordinaryThe loads only affect the construction transiently and only occur where extreme operating conditions for the equipment or plant department are encountered.Cases in point include explosions, falling objects or collisions.Extraordinary live loads are sub-divided as follows:

EL1 Falling objects, shock impacts, etc.EL2 Collision impacts, etc.EL3 Extraordinary material accumulations, etc.EL4 Explosion recoil loads, etc.

Additional information regarding explosion recoil load might be stated in the drawings:

tR The duration of the pulse of explosion recoil loads in seconds [s].IR The impulse transmitted by the explosion recoil load [kNs].

The assumption is that extraordinary live loads act simultaneously with the load types DL1, DL2, LL1, LL2 and LL3, but not simultaneously with neither LL4, LL5, LL6 nor LL7.

2.5.4 Natural loads Reference is made to sub-section 2.3.

2.5.5 Special loadsIn case of quite extraordinary load types, these will in each individual case be specified and described on drawings.


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2.6 Deck and roofLevels are given to top of concrete or top of steel structure. However, for secondary platform without equipment the level is to top of grating or embossed plate (chequered plate).The drawings specify the uniformly distributed live load as well as any live loads acting as line or point loads.If specific deck areas require designing for a higher live load than the remaining part of the deck (uniformly distributed loads or point loads), this area will be marked on the drawing, specifying the live load applying to that area.All concrete decks and roofs must be designed to withstand the below-mentioned single loads (P1 and P2) which are applied to the deck at random points. The single loads, which may be considered as normal live loads, are not assumed to act simultaneously nor coinciding with the live loads specified on the drawings for deck and roof constructions.

Specified uniformly distributed live load

kN/m2

Single load

P1

kN

Single load

P2

kN

Single load

P3

kN

25.0 18.0 - 7.0

20.0 15.0 - 6.0

10.0 12.0 - 5.0

7.5 11.0 - 4.5

5.0 10.0 - 4.0

2.5 5.0 1.5 3.0

2.0 4.0 1.5 2.5

1.5 - - 2.0

1.0 - - 1.0

P1 is assumed to act over an area of 0.75 m x 0.75 mP2 is assumed to act over an area of 0.2 m x 0.2 mP3 is assumed to act over an area of 0.1 m x 0.1 m


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2.7 Special load requirements for roofs without accessUnless otherwise specified, it must be assumed that light roofs without access are subjected to a uniformly distributed live load LL1 (dust) of 0.75 kN/m2 (horizontal projection), whereas concrete roofs without access are assumed to be subjected to a uniformly distributed live load LL1 (dust) of 1.0 kN/m2 (horizontal projection).In connection with pre-fabricated concrete roofs and light steel roofs, the purlins must as a minimum requirement be able to absorb a single load of 1 kN, applied at random points and act simultaneously with LL1. Rafter constructions in workshops, etc. must likewise be capable of absorbing a single load of 10 kN, applied at random points to the underside of rafter and simultaneously with LL1.

2.8 Stairs and landingsIf not otherwise stated the connecting stairs and landings have to be designed for the same load as the evenly distributed load for the deck or platform, where the stairway leads to. However max 5 kN/m2.

3 Execution of support structure

3.1 SettlementsIf the equipment is supported by several supports, the supports must be executed so that detrimental differential settlements are avoided.In general the GA- or OL-drawings are specifying the maximum acceptable settlement. If settlements, deflections or bendings of the structure due to poor soil conditions, wind, earthquake etc. exceed the given figures, the Seller must be contacted for his approval.Separate supports for gear units and motors must be executed to prevent differential settlements from occurring between the support of the machine and the support of the drive station.If a number of silos are erected next to one another or in connection with other buildings, the silo foundations must be executed so that following a maximum load condition (full silo) no settlements occur having detrimental effects on the connecting conveyors.

3.2 Concrete strengthConcrete used for the execution of support structures must have a 28-day cube strength σT 30 MN/m2, corresponding to a 28-day cylinder strength of σC 25 MN/m2.

3.3 Surface reinforcementConcrete support structure for kilns, mills, main gear units, crushers and other heavy machinery must be executed with an appropriate surface reinforcement, however, as a minimum 7 kg/m2.When determining the reinforcement, account must be taken of the influences from the equipment, including temperature loads.Concrete supports for small-size equipment must be executed with appropriate surface reinforcement, however, as a minimum 3.5 kg/m2.The lateral face reinforcement of the concrete support must be carried to level where it covers the construction joint between the first pour and grouting which is executed after the equipment has been mounted. See Figs. 3.4a and 3.4b and sub-sections 3.4, 3.5 and 3.6.


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3.4 Alignment and groutingThe support heights are stated on the drawings with a level corresponding to the underside of the equipment supporting surface.Normal mounting means that the equipment must be aligned. Unless otherwise specified, the equipment must be supported on the entire supporting face.When equipment has small supporting faces, alignment plates must be used, if required directly on to steel or concrete bases. Gear unit and motor must always be supported by minimum 10 mm alignment irons, taking account possible future replacement of gear unit and motor, which may have minor dimensional deviations when supplied. Place the alignment irons between the foundation blocks or the rails, if any, according to the instruction manuals.When aligning equipment having large supporting faces, subsequently involving grouting with concrete or mortar, the support must not be carried to the full height during the initial pouring operation.To ensure proper grouting under the entire supporting face, usually 100 mm are required for large supporting faces, whereas small supporting faces require 50 mm.In special cases is required non-shrinking mortar. The use of non-shrinking mortar is specified in the applicable instruction manuals.The grout thickness must be determined by the consulting civil engineering company.The contractor must consider to use templates in order to keep the tolerances between multiple bolt for fixing the bolts during grouting.The construction joint between first pour and the grout must be executed so that an effective connection is established.


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Figs. 3.4a and 3.4b.

1. Grout the holding down bolts here after coarse alignment of the equipment.

2. Do not forget wedges or shims on either side of the bolt.

3. Bend down the side face reinforcement.

4. Spot welding, if required.

5. Support height specified on drawings.

6. Grout (50-100 mm) after fine alignment of the equipment.

7. Support height without grout.

8. In some cases it is required to embed the support frames. See specifications on drawings.

When the equipment is attached to embedded plates, the plates must be inserted in the formwork and support must be carried up to full height.Supports for equipment requiring fastening with expansion bolts, stud anchors or similar must be carried to the full height.

Some heavy equipment, e.g. preheater cyclones, is supported directly on the first concrete pour. Grouting below the supporting surface can not be used due to friction loads from heat expansions and extractions from the equipment. Tolerances of the first pour are stated on the GA- or OL-drawings.


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3.5 Bolt holesAfter the equipment has been mounted and aligned, grout the holding down bolts freely suspended from the equipment. Use mortar or concrete having a minimum strength as specified in sub-section 3.2.Holding down bolt holes indicated on drawings by e.g. ø100/M24 may be made round having a diameter of 100 mm, or square with a side of 100 mm. M24 indicates that a 24 mm bolt must be grouted.The hole must be made using corrugated steel or plastic moulds ensuring an effective connection with the grout.When the holding down bolts are to be grouted, the bolts must be degreased and be absolutely free from oil. Remove water and impurities at the bottom of the holding down bolt holes before grouting.

3.6 Final groutingHaving finally aligned the equipment and tightened up the holding down bolts, grout or embed the equipment.Use mortar or concrete having strength as specified in sub-section 3.2. When proportioning mortar and concrete, use correctly graduated additives having an adequate maximum stone size to ensure good placement properties. It may be required to use special grouting mortars for particular applications.For heavy equipment the sequence and number of groutings as well as the use of non-shrinking mortar are described in the mechanical instruction manuals. These manuals must be handed over to the contractor before the work commence.Prior to grouting or embedment of the equipment, the parts to be grouted and embedded must be degreased and cleaned.Remove (chip off) any oil spillage, grease stains and impurities on the concrete in the construction joint. Embed the support flange only if it is shown on the drawings or required in the instruction manuals.

4 Various specifications

4.1 Water seepageRoofs must be constructed so as to avoid water accumulations and water seepage.Holes in roofs for lead-in of machines and pipes to be made with a raised edge of minimum 100 mm in order to prevent rainwater seepage. On completion of mounting, the equipment must be provided with a cap, which is extended beyond the raised edge.Storey partitions, which also are roofs in a closed room, must be constructed so that no water seeps into the room.

4.2 Covering and flashingCoverings and flashings must be made to the extent shown on the GA drawings. Coverings and flashings must be constructed to avoid water ingress and water seepage. Openings in building fronts for ventilation or pressure relief from explosion flaps must likewise be made as shown on the GA drawings.Any deviations will be accepted only subject to prior arrangement with Seller.


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4.3 DrainPits, basements, inspection trenches, etc. placed below ground level must be made watertight and must be provided with pump sumps or water drainpipes discharging into a permanent drainage system.When carrying out the design and execution of drainpipes and drainage systems, spillage of raw meal, clinker, cement, oil, petrol, etc. entering the drainage system must be avoided.Drains are required at water drain-off points.Where equipment is placed at ground level, it must be inclined to ensure that surface water is diverted.Rain water must be drained away from the foundations and supports.

4.4 Floors and wallsDue consideration must be taken to the finish of surfaces of floors and walls in rooms for oil, water, electrical equipment, etc. Tiles and painting to be considered due to house keeping and resistance for water and oil.

4.5 Stairways and walkwaysSafety guards to stairways, walkway, platforms, etc. to be made in compliance with local safety and health regulations.Openings in floors to be provided with toe plates or raised edges with a minimum upstand of 100 mm and placed maximum 10 mm from the finished floor level.The locations given for main stairways and stair flights are for guidance only. However, the location of stairways and ladders for access platforms and equipment is final and binding.If not otherwise stated in the contract permanent stairs and guardrails have to conform to EN ISO 14122-3. Example: The minimum headroom (vertical distance) for working platforms and walkway, etc. is 2100 mm. The minimum headroom for stairs is 2300 mm. The minimum clearance (perpendicular distance) is 1900 mm.Guardrails must be provided if the vertical distance between two levels exceeds 500 mm.

4.6 Exit doorsExit doors must be equipped with anti-panic bar opening system.

4.7 Steel or concrete structuresIndications of building construction for steel or concrete are for guidance only.

4.8 Constructional elements (beams, columns, braces, etc.)The dimensions of constructional elements (beams, columns, etc.) are approximate. It is the obligation of the civil designer to assess the indicated location of columns and beams, choice of materials and enclosures, and in consultation with Seller to establish the most suitable structural system from a material optimisation point of view but still ensuring a robust and flexible structural system which is easy to manufacture and construct and which can be adjusted to the possible changes which may be introduced by the Buyer and/or the authorities during the approval process. Consult Seller, if the final dimensions result in reduced space around the equipment.GA drawings do not specify stiffening braces in steel constructions. These must be determined taking account of equipment, pipes, access conditions, maintenance and service, etc.Special requirements apply for buildings where inflammable dust can occur.

4.9 TolerancesIf GA or OL drawings does not specify any special tolerance requirements, the civil contractor must ensure that the geometry of the finished buildings meets the following requirements concerning maximum permissible tolerances:


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General:

Plotting of main axes relative to established superior plotting system 25 mm

Concrete constructions:

Position of construction elements relative to plotted line system 15 mm

Cross sectional dimensions of construction elements

- 5 mm

+ 15 mm

Dimensions and position of holes and recesses 10 mm

Position of grouted components 10 mm

Straightness of decks measured with 3-metre straight edge + 5 mm

Steel constructions:

Distance between columns 3 mm

Deck elevations 5 mm

Dimensions and location of holes, etc. 5 mm

5 Erection correctionsNormal erection operations include the correction of minor misfits by moderate amounts of straightening, shimming, reaming, chipping, cutting or grinding and the drawing of elements into line using drift pins. Misfits which cannot be corrected by the foregoing means or which require major changes in equipment configuration are to be reported immediately to Seller by the erection contractor, to enable Seller either to correct the misfit or to approve the most efficient and economic method of correction to be implemented.

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749500_a4-p________12.0_en

Documents

load drawings ol drawings

erection general requirements

general information62

civil contractor

live loads

erection contractor

equipment supplier

general arrangement