MACMET ENGINEERING LIMITED

JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE

Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

Design calculation of Trestle mkd TR-27 For

Pipe Conveyor SPC-1 & SPC-2
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC
1) DEAD LOAD REACTION FROM 26M & 38M GIRDER

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m
6 1 DEAD LOAD 0 18.1272 -0.3732 0 0 0
7 1 DEAD LOAD 0 18.127 0.3732 0 0 0
6 1 DEAD LOAD 0 18.1272 -0.3732 0 0 0
7 1 DEAD LOAD 0 18.127 0.3732 0 0 0
`

2) MECHANICAL DEAD LOAD REACTION FROM 26M & 38M GIRDER

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m
6 1 DEAD LOAD 0 7.6492 -0.0419 0 0 0
7 1 DEAD LOAD 0 7.6492 0.0419 0 0 0
6 1 DEAD LOAD 0 7.6492 -0.0419 0 0 0
7 1 DEAD LOAD 0 7.6492 0.0419 0 0 0

3) MECHANICAL LIVE LOAD REACTION FROM 26M & 38M GIRDER

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m
6 1 DEAD LOAD 0 20.2872 -0.533 0 0 0
7 1 DEAD LOAD 0 20.2859 0.533 0 0 0
6 1 DEAD LOAD 0 20.2872 -0.533 0 0 0
7 1 DEAD LOAD 0 20.2859 0.533 0 0 0
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

4) WIND LOAD(+Z) REACTION FROM 26M & 38M GIRDER

Horizontal Vertical Horizontal Moment
Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m
6 1 DEAD LOAD -0.8726 -16.1841 -4.65 0 0 0
7 1 DEAD LOAD 0.8726 -6.8224 -5.634 0 0 0
6 1 DEAD LOAD -0.8726 -16.1841 -4.65 0 0 0
7 1 DEAD LOAD 0.8726 -6.8224 -5.634 0 0 0

Member Wind for trestle from ( + Z) Direction.

basic wind speed (Vb) = 44 m/sec
probability factor (k1)= 1.07
terrain & height factor (k2)= 1.11 (upto 30 m ht) (category 2 & class B)
1.02 (From 10m to 15 m ht)

topography factor (k3)= 1.0

Design wind speed (Vz)=Vb x k1 x k2 X k3 = 52 m/sec (upto 15 m ht)
Design wind pressure (pz)= 0.6 x Vz² = 1639 N/m² = 1.64 kN/m²
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

Ae1= 0.2*35.1x2= 22.67 m² 2550

Ae2= 0.075*3.2x14= 11.66 m² 2550
Ae3= 0.1*14x2= 6.3 m²
2500
@
Ae= 40.63 m² 12 nos
Asolid= 158.7 m²
Solidity ratio, ɸ = 0.26 30000
Cf = 1.74 (from Table-28 of IS 875)

Wind load on near side frame

UDL on near side frame = F=Cf*As*f*pd =
1.74*3.5/2*0.26*1.28= 1.298 kN/m 0.130 T/m

Wind load on far side frame

Frame spacing ratio= 4.58
β = Effective solidity ratio, ɸ = for flat sided memb= 0.26
sheilding factor, η = 1.00 (from Table-29 of IS 875)
UDL on far side frame = 1.298*1= 1.3 Kn/m 0.130
T/m
Ht pz udl 3500
0 - 10 1.14 0.09
`10-15 1.23 0.1
15-20 1.31 0.1
20-30 1.44 0.11
30-40 1.5 0.12
5) WIND LOAD(-Z) REACTION FROM 26M & 38M GIRDER
Horizontal Vertical Horizontal Moment
Node L/C Fx Mton Fy Mton Fz Mton Mx kNm My kNm Mz kNm
29 1 DEAD LOAD 0.3467 -8.8528 5.5853 0 0 0
30 1 DEAD LOAD -0.3467 -14.4072 4.6 0 0 0
61 1 DEAD LOAD 0.3467 -8.8528 5.5853 0 0 0
62 1 DEAD LOAD -0.3467 -14.4072 4.6 0 0 0

Member Wind for trestle from ( - Z) Direction.

basic wind speed (Vb) = 44 m/sec

probability factor (k1)= 1.07
terrain & height factor (k2)= 1.11 (upto 30 m ht) (category 2 & class B)
1.11 (upto 30 m ht)

topography factor (k3)= 1.0

Design wind speed (Vz)=Vb x k1 x k2 X k3 = 52 m/sec (upto 15 m ht)
Design wind pressure (pz)= 0.6 x Vz² = 1639 N/m² = 1.64 kN/m²
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

Ae1= 0.2*35.1x2= 14.04 m² 2550

Ae2= 0.075*3.2x14= 3.36 m² 2550
Ae3= 0.1*14x2= 2.8 m²
2500
@
Ae= 20.20 m² 12 nos
Asolid= 122.9 m²
Solidity ratio, ɸ = 0.16 30000
Cf = 1.71 (from Table-28 of IS 875)

Wind load on near side frame

UDL on near side frame = F=Cf*As*f*pd =
1.71*3.5/2*0.16*1.28= 0.785 kN/m 0.079 T/m

Wind load on far side frame

Frame spacing ratio= 2.29
β = Effective solidity ratio, ɸ = for flat sided memb= 0.16
sheilding factor, η = 1.00 (from Table-29 of IS 875)
UDL on far side frame = 0.785*1= 0.79 Kn/m 0.079
T/m
3500
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

6) Wind Load from girder from ( + x ) direction.

Design wind pressure 164 kg/m 2
Longitudinal wind on gallery
Ht (c/c of top & bot chords) of galle 2.50 m
c/c width of gallery = 6.5 m
Panel spacing = 3m

Ae1= 0.254*2.5*2 1.27 m² (Girder Verticals UB 254)

Ae2= 0.1*6.5= 0.65 m² (Top . Horizontals SHS 100x100x6)
Ae3= 0.254*6.5= 1.65 m² (cross beam UB 254)
Ae= 3.57 m²
Asolid= 16.3 m²
Solidity ratio, ɸ = 0.2 Gallery Girder Cross section
Cf = 1.6 (from Table-28 of IS 875)
Wind load on first frame
F = Cf*Ae*pd = 1.6*0.164*3.57= 0.94 T

Wind load on next & remaining frames

Frame spacing ratio= 2.17
β = Effective solidity ratio, ɸ = for flat sided memb= 0.2
sheilding factor, η = 0.40 (from Table-29 of IS 875)
Wind load on next frame= 0.94*0.4 = 0.38 T
Total no of frame = 12 nos

Load from 1st frame= 0.94 T

Load from next 11 frame= 4.136 T
5.08 T
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

Member Wind for trestle from (+) 'X' Direction.

basic wind speed (Vb) = 44 m/sec

probability factor (k1)= 1.01
terrain & height factor (k2)= 0.98 (upto 10 m ht) (category 2 & class B)
0.98 (upto 30 m ht)
topography factor (k3)= 1.0
Design wind speed (Vz)=Vb x k1 x k2 X k3 = 44 m/sec (upto 15 m ht)
Design wind pressure (pz)= 0.6 x Vz² = 1138 N/m² = 1.14 kN/m²
2000

4450

Ae1= 0.305*33.65x2= 27.28 m² 2000

Ae3= 0.09*38.28x2= 9.266 m²
Ae5= 0.05*36.64*4 = 4.329 m² 9000
Ae6= 0.1*16*8 = 8.415 m²
Ae= 49.29 m²
Asolid= 545.60 m²
Solidity ratio, ɸ = 0.09 2000
Cf = 1.83 (from Table-28 of IS 875)
7000
Wind load on near side frame
UDL on near side frame = F=Cf*As*f*pd = 2250
1.83*8*0.09*1.14= 1.502 kN/m 0.15 T/m
5000
Wind load on far side frame
Frame spacing ratio= 0.22
β = Effective solidity ratio, ɸ = for flat sided memb= 0.09
sheilding factor, η = 0.83 (from Table-29 of IS 875) 16000

UDL on far side frame = 1.502064*0.8 1.25 Kn/m 0.125 T/m

Ht pz udl udl far

0 - 10 1.14 0.15 0.1247
`10-15 1.23 0.16 0.1345
15-20 1.31 0.17 0.1433
20-30 1.44 0.19 0.1575
30-40 1.5 0.19 0.164
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

Wind load on each trestle leg Wind load on Girder

Ae1= 0.09*16x2= 2.88 m²
Ht pz Cf width udl (T/m) Ae3= 0.075*41.19= 3.0893 m²
0 - 10 1.14 2.05 0.6 0.140 Ae= 5.97 m²
`10-15 1.23 2.05 0.6 0.151 Asolid= 36.00 m²
15-20 1.31 2.05 0.6 0.161 Solidity ratio, ɸ = 0.17
20-30 1.44 2.05 0.6 0.177 Cf = 1.83 (from Table-28 of IS 875)
30-40 1.5 2.05 0.6 0.185
Wind load on top & bottom chord girder
UDL on near side frame = F=Cf*As*f*pd =
(0 -10m Ht) 1.83*1.125*0.17*1.14= 0.0399 T/m
(10 - 15m Ht) 1.83*1.125*0.17*0.1512 0.0529 T/m
(15-20m Ht) 1.83*1.125*0.17*0.1611 0.056 T/m
(20-30m Ht) 1.83*1.125*0.17*0.1771 0.062 T/m

7) Wind Load from girder from ( - x ) direction.

Design wind pressure 164 kg/m 2
Longitudinal wind on gallery
Ht (c/c of top & bot chords) of galle 2.50 m
c/c width of gallery = 6.5 m
Panel spacing = 3m

Ae1= 0.254*2.5*2 1.27 m² (Girder Verticals UB 254)

Ae2= 0.1*6.5= 0.65 m² (Top . Horizontals SHS 100x100x6)
Ae3= 0.254*6.5= 1.65 m² (cross beam UB 254)
Ae= 3.57 m²
Asolid= 16.3 m²
Solidity ratio, ɸ = 0.2 Gallery Girder Cross section
Cf = 1.6 (from Table-28 of IS 875)
Wind load on first frame
F = Cf*Ae*pd = 1.6*0.164*3.57= 0.94 T

Wind load on next & remaining frames

Frame spacing ratio= 2.17
β = Effective solidity ratio, ɸ = for flat sided memb= 0.2
sheilding factor, η = 0.40 (from Table-29 of IS 875)
Wind load on next frame= 0.94*0.4 = 0.38 T
Total no of frame = 12 nos

Load from 1st frame= 0.94 T

Load from next 11 frame= 4.136 T
5.08 T
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC

Member Wind for trestle from (-) 'X' Direction.

basic wind speed (Vb) = 44 m/sec

probability factor (k1)= 1.07
terrain & height factor (k2)= 0.98 (upto 10 m ht) (category 2 & class B)
1.11 (upto 30 m ht)
topography factor (k3)= 1.0
Design wind speed (Vz)=Vb x k1 x k2 X k3 = 52 m/sec (upto 15 m ht)
Design wind pressure (pz)= 0.6 x Vz² = 1639 N/m² = 1.64 kN/m²

3071
2100

Ae1= 0.305*33.65x2= 20.53 m² 3425

Ae3= 0.09*38.28x2= 6.89 m²
Ae5= 0.05*36.64*4 = 7.328 m² 3500
Ae6= 0.1*16*8 = 12.8 m²
Ae= 47.54 m² 3500
Asolid= 538.40 m²
Solidity ratio, ɸ = 0.09 3500
Cf = 1.9 (from Table-28 of IS 875)
4000
Wind load on near side frame
UDL on near side frame = F=Cf*As*f*pd = 4000
1.9*16/2*0.09*1.64= 2.244 kN/m 0.22 T/m
4000
Wind load on far side frame
Frame spacing ratio= 0.19 4000
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC
β = Effective solidity ratio, ɸ = for flat sided memb= 0.09
sheilding factor, η = 0.90 (from Table-29 of IS 875) 16000

UDL on far side frame = 2.244*0.9= 2.02 kN/m 0.202 T/m

7) TEMPARATURE LOAD REACTION FROM 24M GIRDER

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m
29 1 DEAD LOAD 0 0 0.8283 0 0 0
30 1 DEAD LOAD 0 0 0.8325 0 0 0
61 1 DEAD LOAD 0 0 -0.8283 0 0 0
62 1 DEAD LOAD 0 0 -0.8325 0 0 0
 MACMET ENGINEERING LIMITED
JSW STEEL MHS-AREA- IV : INTERPLANT RMHS DOC. NO. DATE
Client: DOLVI PROJECT Project:
LIMITED FACILITIES JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
APS AP AC
`

8) TEMPARATURE LOAD REACTION FROM 24M GIRDER

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m
29 1 DEAD LOAD 0 0 -0.8283 0 0 0
30 1 DEAD LOAD 0 0 -0.8325 0 0 0
61 1 DEAD LOAD 0 0 0.8283 0 0 0
62 1 DEAD LOAD 0 0 0.8325 0 0 0
 MEL RVM PROJECTS JOINT VENTURE
RAW COAL TRANSPORTATION BY PIPE DOC. NO. DATE
CONVEYOR SYSTEM FROM HINGULA OCP
Client: MAHANADI COALFIELDS LIMITED Project: TO HINGULA WASHERY AND SILO JN2506-S-006_Rev 00 43628
CONSTRUCTION AT BALARAM SIDING

Designed Checked Appvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
SD AP AC

Consideration of Wind Loads during Trolley Movement

During extreme wind condition, the maintenance trolley will remain parked at Parking Bay. However, a remote possibility of the
maintenace trolley moving while there is a storm of 75% of extreme wind condition is considered and the girder is checked for
adequacy of members etc.

In order to carry out the above exercise, the following loads and its' combinations have been used in STAAD Pro:

1. Load Case - 750:

The loads due to Maintenance Trolley (1.56T per wheel) are applied on the girder considering one of the pairs of rear wheels at the
centre of Gallery. The other pair of same load are at a distance of 2.8m have been considered in STAAD model. This location of wheels
will impart highest loading on the girder members. (Refer next sheet for the explanatory diagram for the loadings considered)

2. Load Case -751:

Wind Loads on Girder and Maintenance Trolley have been calculated and applied on STAAD model as under: (Refer next sheet for the
explanatory diagram for the loadings considered)
Design Wind Pressure = 0.128 T/m2 (for extreme Wind condition)
So, for Wind Loading during Trolley movement = 0.75 x 0.128 = 0.096 T/m2

Area of obstruction due to

maintenance trolley = 3.5 m x 4.0m = 14 m2

Total Wind Load on Maintenance Trolley = 1.344 t

Hence, Loading at each wheel location of maintenance trolley = 0.340 T

Wind Load on Girder

UDL ON TOP CHORD NEAR SIDE FRAME = 0.75 x 0.12= 0.083 T/M
UDL ON BOTTOM CHORD NEAR SIDE FRAME = 0.083 T/M
UDL ON TOP CHORD FAR SIDE FRAME = 0.059x 0.75 = 0.044 T/M
UDL ON BOTTOM CHORD NEAR SIDE FRAME = 0.044 T/M

3. The above loads have been combined with DL, LL and Temp. Load under the following load cases to check for
displacements and design of members:
i. For Displacements: Load combinations 850 to 853 wherin unfactored loads have been applied

ii. For Member Design: Load combinations 854 to 861 wherin factored loads have been applied
 MEL RVM PROJECTS JOINT VENTURE
RAW COAL TRANSPORTATION BY PIPE DOC. NO. DATE
CONVEYOR SYSTEM FROM HINGULA OCP
Client: MAHANADI COALFIELDS LIMITED Project: TO HINGULA WASHERY AND SILO JN2506-S-006_Rev 00 43628
CONSTRUCTION AT BALARAM SIDING

Designed Checked Appvd

Title: Design calculation of Trestle mkd TR-27 For Pipe Conveyor SPC-1 & SPC-2
SD AP AC
 MACMET ENGINEERING LIMITED

Pipe Conveyor from Nandihalli to JSW DOC. NO. Date

Client: JSW Steel Limited Project: Plant JN2404-1106-Rev 0 6/12/2019
Designed Checked Appvd
Title: Design calculation of Trestle 33m height
APS AP AC

Details of Load Cases and Combinations – 24m Standard Gallery

While combining different load cases mentioned above, the following load factors have been
considered for Limit State of Strength and Limit State of Serviceability conforming to IS:800 –2007:

1. For Member Design (Limit State of Strength):

The moving load of maintenance trolley being an Accompanying Live Load, the load factor considered is 1.05
while in combination with DL+LL as per Table 4 of IS:800-2007. The same is 1.05 or 0.53 when the load factor for
Wind Load is considered as 0.6 or 1.2 respectively as per Table 4 of IS:800-2007.

LOAD COMB 201 DL + LL

1 1.5 2 1.5 3 1.5
LOAD COMB 202 DL + LL + WL(+Z)
1 1.5 2 1.5 3 1.5 4 1.2
LOAD COMB 203 DL + LL + WL(-Z)
1 1.5 2 1.5 3 1.5 5 1.2
LOAD COMB 204 DL + LL + WL(+X)
1 1.5 2 1.5 3 1.5 6 1.2
LOAD COMB 205 DL + LL + WL(-X)
1 1.5 2 1.5 3 1.5 7 1.5
LOAD COMB 206 DL + LL + TL(+)
1 1.5 2 1.5 3 1.5 8 1.5
LOAD COMB 207 DL + LL + TL(-)
1 1.5 2 1.5 3 1.5 9 1.5
LOAD COMB 208 DL + LL + WL(+Z) + TL(+)
1 1.2 2 1.2 3 1.2 4 1.2 8 1.2
LOAD COMB 209 DL + LL + WL(+Z) + TL(-)
1 1.2 2 1.2 3 1.2 4 1.2 9 1.2
LOAD COMB 210 DL + LL + WL(-Z) + TL(+)
1 1.2 2 1.2 3 1.2 5 1.2 8 1.2
LOAD COMB 211 DL + LL + WL(-Z) + TL(-)
1 1.2 2 1.2 3 1.2 5 1.2 9 1.2
LOAD COMB 212 DL + LL + WL(+X) + TL(+)
1 1.2 2 1.2 3 1.2 6 1.2 8 1.2
LOAD COMB 213 DL + LL + WL(+X) + TL(-)
1 1.2 2 1.2 3 1.2 6 1.2 9 1.2
LOAD COMB 214 DL + LL + WL(-X) + TL(+)
1 1.2 2 1.2 3 1.2 7 1.2 8 1.2
LOAD COMB 215 DL + LL + WL(-X) + TL(-)
1 1.2 2 1.2 3 1.2 7 1.2 9 1.2
LOAD COMB 216 DL + WL(+Z)
1 1.5 2 1.5 4 1.5
LOAD COMB 217 DL + WL(-Z)
1 1.5 2 1.5 5 1.5
LOAD COMB 218 DL + WL(+X)
1 1.5 2 1.5 6 1.5
LOAD COMB 219 DL + WL(-X)
1 1.5 2 1.5 7 1.5
LOAD COMB 220 DL + WL(+Z) + TL(+)
1 1.2 2 1.2 4 1.2 8 1.2
LOAD COMB 221 DL + WL(+Z) + TL(-)
1 1.2 2 1.2 4 1.2 9 1.2
LOAD COMB 222 DL + WL(-Z) + TL(+)
1 1.2 2 1.2 5 1.2 8 1.2
LOAD COMB 223 DL + WL(-Z) + TL(-)
1 1.2 2 1.2 5 1.2 9 1.2
LOAD COMB 224 DL + WL(+X) + TL(+)
1 1.2 2 1.2 8 1.2
LOAD COMB 225 DL + WL(+X) + TL(-)
1 1.2 2 1.2 9 1.2
LOAD COMB 226 DL + WL(-X) + TL(+)
1 1.2 2 1.2 8 1.2
LOAD COMB 227 DL + WL(-X) + TL(-)
1 1.2 2 1.2 9 1.2

2. For Checking Deflections (Limit State of Serviceability):

LOAD COMB 101 DL + LL

1 1.0 2 1.0 3 1.0
LOAD COMB 102 DL + LL + TL(+)
1 1.0 2 1.0 3 1.0 8 1.0
LOAD COMB 103 DL + LL + TL(-)
1 1.0 2 1.0 3 1.0 9 1.0
LOAD COMB 104 DL + LL + WL(+Z)
1 1.0 2 1.0 3 1.0 4 1.0
LOAD COMB 105 DL + LL + WL(-Z)
1 1.0 2 1.0 3 1.0 5 1.0
LOAD COMB 106 DL + LL + WL(+X)
1 1.0 2 1.0 3 1.0 6 1.0
LOAD COMB 107 DL + LL + WL(-X)
1 1.0 2 1.0 3 1.0 7 1.0
LOAD COMB 108 DL + LL + WL(+Z) + TL(+)
1 1.0 2 1.0 3 1.0 4 1.0 8 1.0
LOAD COMB 109 DL + LL + WL(+Z) + TL(-)
1 1.0 2 1.0 3 1.0 4 1.0 9 1.0
LOAD COMB 110 DL + LL + WL(-Z) + TL(+)
1 1.0 2 1.0 3 1.0 5 1.0 8 1.0
LOAD COMB 111 DL + LL + WL(-Z) + TL(-)
1 1.0 2 1.0 3 1.0 5 1.0 9 1.0
LOAD COMB 112 DL + LL + WL(+X) + TL(+)
1 1.0 2 1.0 3 1.0 6 1.0 8 1.0
LOAD COMB 113 DL + LL + WL(+X) + TL(-)
1 1.0 2 1.0 3 1.0 6 1.0 9 1.0
LOAD COMB 114 DL + LL + WL(-X) + TL(+)
1 1.0 2 1.0 3 1.0 7 1.0 8 1.0
LOAD COMB 115 DL + LL + WL(-X) + TL(-)
1 1.0 2 1.0 3 1.0 7 1.0 9 1.0
LOAD COMB 116 DL + WL(+
1 1.0 2 1.0 4 1.0
LOAD COMB 117 DL + WL(-Z)
1 1.0 2 1.0 5 1.0
LOAD COMB 118 DL + WL(+X)
1 1.0 2 1.0 6 1.0
LOAD COMB 119 DL + WL(-X)
1 1.0 2 1.0 7 1.0
LOAD COMB 120 DL + WL(+Z) + TL(+)
1 1.0 2 1.0 4 1.0 8 1.0
LOAD COMB 121 DL + WL(+Z) + TL(-)
1 1.0 2 1.0 4 1.0 9 1.0
LOAD COMB 122 DL + WL(-Z) + TL(+)
1 1.0 2 1.0 5 1.0 8 1.0
LOAD COMB 123 DL + WL(-Z) + TL(-)
1 1.0 2 1.0 5 1.0 9 1.0
LOAD COMB 124 DL + WL(+X) + TL(+)
1 1.0 2 1.0 6 1.0 8 1.0
LOAD COMB 125 DL + WL(+X) + TL(-)
1 1.0 2 1.0 6 1.0 9 1.0
LOAD COMB 126 DL + WL(-X) + TL(+)
1 1.0 2 1.0 7 1.0 8 1.0
LOAD COMB 127 DL + WL(-X) + TL(-)
1 1.0 2 1.0 7 1.0 9 1.0
 Date
6/12/2019
Appvd
AC
 MACMET ENGINEERING LIMITED
THE SANDUR Downhill Pipe Conveyor System from DOC. NO. DATE
Client: MANGANESE AND IRON Project:
ORES LIMITED KTIO Mines to PMBR (BMM) Siding. JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of TR-27 For conveyor DCS-1
APS AP AC
Design of Base plate (gussetted base)
Summary of Support Reaction
Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon-m My MTon-m Mz MTon-m

Max Fx 1 205 DL + LL + WL(-Z) 13.17 212.64 13.22 0.00 0.00 0.00

Min Fx 2 205 DL + LL + WL(-Z) -14.83 139.25 11.45 0.00 0.00 0.00

Max Fy 1 205 DL + LL + WL(-Z) 13.17 212.64 13.22 0.00 0.00 0.00

Min Fy 2 206 DL + WL(+Z) 5.70 -92.92 -14.01 0.00 0.00 0.00

Max Fz 1 207 DL + WL(-Z) 10.95 174.32 16.68 0.00 0.00 0.00

Min Fz 26 206 DL + WL(+Z) 10.80 173.80 -16.91 0.00 0.00 0.00

Max Mx 1 201 DL + LL 7.57 128.64 -0.21 0.00 0.00 0.00
Min Mx 1 201 DL + LL 7.57 128.64 -0.21 0.00 0.00 0.00
Max My 1 201 DL + LL 7.57 128.64 -0.21 0.00 0.00 0.00

Min My 1 201 DL + LL 7.57 128.64 -0.21 0.00 0.00 0.00

Max Mz 1 201 DL + LL 7.57 128.64 -0.21 0.00 0.00 0.00
Min Mz 1 201 DL + LL 7.57 128.64 -0.21 0.00 0.00 0.00

The Base Plate is designed for maximum loads out of Case-1 and Case-2:

Pu = Max Factored load on col.= 212.64 T

Bearing strength of conc.= 0.45*fck (as per clause 34.4 of IS:456-2000)

For M 25 grade of conc. bearing strength = 0.45*25= 11.25 N/mm²

Provide Base plate size= 800 mm x 450 mm Area provided= 360000 mm²

So, intensity of base pressure, w =212.64*10^4/(800*450)= 5.91 N/mm² < 6.25 N/mm² ok
 MACMET ENGINEERING LIMITED
THE SANDUR Downhill Pipe Conveyor System from DOC. NO. DATE
Client: MANGANESE AND IRON Project:
ORES LIMITED KTIO Mines to PMBR (BMM) Siding. JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of TR-27 For conveyor DCS-1
APS AP AC
For 4.6 Grade bolts:
Yield stress of bolt, fy= 240 N/mm² fy = 250 N/mm²
Ultimate stress of bolt, fub= fu = 1 mm strip
400 N/mm² 410 N/mm²
partial safety factor for material ,γmo = 1.10 12 12 188
partial safety factor for material of bolt ,γmb = 1.25 400.0 mm
partial safety factor for shop welding ,γmw = 1.25

450

250
partial safety factor for site welding ,γmw = 1.50
X
360
a a

100.0

100
Column properties
Ax= 75.6 cm² Tf= 20.0 mm 800
Tw= Z
D= 400.0 mm 16.0 mm
Bf= 250.0 mm

Assume thickness of Gusset plate = 12 mm

Check for local buckling
Length of gusset ,D= 250.0 mm 100 250 100

ɛ =√(250/fyg)= √(250/250)= 1
200

D/ɛt = 250/(1*12)= 20.83 < 29.3 ok

(Table 2 of IS 800-2007)
12 mm th
200

gusset plate

Gusset outstand, s ≤ 13.6*ɛ*t 250

Max allowable outstand, s =13.6*1*12= 163.2 mm > 100 mm ok

Check for Shear capacity

Shear on each gusset plate,V = 5.91*400*100/10³ = 236.4 kN
Shear capacity of gusset ,Vn=Vp=Av*fyg/(√3*γmo) = 400*12*250/(√3*1.1*1000)= 629.8 kN > 236.4 kN
V= 236.4 kN < 0.6*629.8= 378 kN ok

Check for Moment capacity

Moment at section a-a = 5.91*400*100*100/(2*10^6)= 11.8kN-m
Moment capacity of gusset ,Mg =Ze*fyg/γmo = (12*400^2*250)/(1.1*10^6*6)= 72.73 kN-m >> 11.8 kN-m
Gusset plate to column weld
Total vertical load= 2126.4 kN
Load per weld= 1063.2 kN
Length of weld (col to gusset & base plate) = 400*2+250*1= 1050 mm
Load per unit length of weld = 1063.2/1050= 1.013 kN/mm
Provide 10 mm thk weld
Effective throat thickness,tt= K*S = 0.7*10= 7 mm
Design strength of weld, Pdw = Lw*tt*fu/√3*γmw = (1*7*410)/(√3*1.5*10^3)= 1.105 kN
> 1.013 kN ok
 MACMET ENGINEERING LIMITED
THE SANDUR Downhill Pipe Conveyor System from DOC. NO. DATE
Client: MANGANESE AND IRON Project:
ORES LIMITED KTIO Mines to PMBR (BMM) Siding. JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of TR-27 For conveyor DCS-1
APS AP AC
Thickness of base plate
Considering 1 mm strip of the edge of base plate
5.91 N/mm

A B
C D Reaction,RC=RD = 2364.0 N
194 412 194
RC RD

Moment at C, MC = 5.91*194^2/2= 111214.38 N-mm

The moment developped in the plate supported on three sides (By Mukhanov), M 3=α3qd1²
a1= 225 a1/d1= 0.546
d1= 412 α3= 0.060 (Ref-Table-8-11, Design of Metal Structures by Mukhanov)
Moment, M3 = 0.06*5.91*412^2= 60191.22 N-mm

Max moment= 111214.38 N-mm

Moment capacity of gusset ,Mg =1.2*fy*Ze/γmo = (1.2*250*t²)/(6*1.1) Ze=t²/6

t= √(111214.38*6*1.1)/(1.2*250)= 49.46 mm
Provide 50 mm thk base plate ok

Design of Anchor Bolts

Max total uplift force= 929.2 kN

Let us provide 4 nos 42 dia bolt

Tension per bolt = 929.22/4= 232.3 kN
dia of hole,dh= 45 mm
Net area, Anb = 1121 mm²
Shank area, Asb = 1385 mm²

Design tension capacity of bolt, Tdb =Tnb /γm1

Tension capacity of bolt, Tnb =0.9*fub*Anb or fyb*Asb*γmb /γm0 Whichever is less

0.9*fub*Anb = 0.9*400*1121= 403560 N= 404 kN
fyb*Asb*γmb /γm0 = 240*1385*(1.25/1.1)= 377727.27 N= 378 kN
So, Design tension capacity of bolt = 377.73/1.25= 302.2 kN > 232 kN ok

[Tensile capacity based on concrete breakout failure, Nu=k*√fck* (hef 1.5)]

For 42 dia bolt with embeded length= 250 mm & M 25 conc

k= 15.5 for cast-in-situ inserted bolts
Nu= 15.5*√25*250^1.5/1000= 306.3 kN > 232 kN ok
 MACMET ENGINEERING LIMITED
THE SANDUR Downhill Pipe Conveyor System from DOC. NO. DATE
Client: MANGANESE AND IRON Project:
ORES LIMITED KTIO Mines to PMBR (BMM) Siding. JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of TR-27 For conveyor DCS-1
APS AP AC
Check for shear capacity
Vnsb=(fub/√3)(nu*Anb+ns*Asb)βlj*βlg*βpkg

fub= 400 N/mm²

nu= 1
βlj= 1.0 As the distribution of shear force is uniform over the base plate
βlg= 1.0 As total thk of connecting plates = 50 mm < 5*42= 210 mm
βpkg= 1.0 As no packing plates are required

Vnsb= ((400/√3)*(1*1121)*1*1*1)/1000= 258.9 kN per bolt

Total factored shear in X-direction= 131.72 kN
Total factored shear in Z-direction= 169.08 kN
Hence resultant shear= √(131.72^2+169.08^2)= 214.3 kN
Hence shear per bolt= 214.3/4= 53.6 kN << 258.9 kN ok
No shear key is reqd.

Check for combined tension & shear = 232.3/302.2+53.6/258.9= 0.976 ok

Hence Shear key to be provided
Design of shear Key

Maximum shear= = 214.3 kN = 21430 kg

Let's provide a shear key
of width= = 45.00 cm
depth= = 15.00 cm
(0.5xwx45x15)= = 21430.00 kg
Hence w=(21430x2/(45x15)= = 63.5 kg/cm2
Maximum Moment=(21430x10/3)= = 71433 kg-cm
Maximum moment/cm=(71433.3/45)= = 1587 kg-cm/cm
Thickness required=(6x1587.40666666667/1650)^0.5= = 2.40 cm provide = 25 mm ok

Hence provide 450width x150 deep and 25 thick shear key

 MACMET ENGINEERING LIMITED
THE SANDUR Downhill Pipe Conveyor System from DOC. NO. DATE
Client: MANGANESE AND IRON Project:
ORES LIMITED KTIO Mines to PMBR (BMM) Siding. JN2506-S-006_Rev 00 6/12/2019

Designed Checked Apvvd

Title: Design calculation of 24 m Staright Standard Girder For conveyor DCS-1
APS AP AC
Node Displacement Summary

Rotational
Horizontal Vertical Horizontal Resultant
rX rad rY rad rZ rad
Node L/C X mm Y mm Z mm mm

Max X 84 112 DL + LL + WL(+X) + TL(+) 69.126 -3.698 -0.102 69.225 0 0 -0.002

Min X 82 127 DL + WL(-X) + TL(-) -66.226 -1.346 0.009 66.24 0 0 0.002

Max Y 13 124 DL + WL(+X) + TL(+) 64.852 5.654 -0.217 65.098 0 0 -0.002

Min Y 78 111 DL + LL + WL(-Z) + TL(-) 2.703 -11.386 -43.39 44.94 -0.002 0 0

Max Z 14 121 DL + WL(+Z) + TL(-) 1.324 -2.05 44.66 44.726 0.002 0 0

Min Z 14 110 DL + LL + WL(-Z) + TL(+) 2.135 -2.212 -44.761 44.867 -0.002 0 0

Max rX 85 108 DL + LL + WL(+Z) + TL(+) 4.13 -1.735 43.362 43.593 0.003 0 0

Min rX 87 111 DL + LL + WL(-Z) + TL(-) 4.128 -8.482 -43.6 44.609 -0.003 0 0

Max rY 83 117 DL + WL(-Z) 1.517 -3.173 -43.551 43.693 -0.002 0.001 0

Min rY 83 104 DL + LL + WL(+Z) 3.73 -6.775 43.461 44.144 0.002 -0.001 0

Max rZ 80 114 DL + LL + WL(-X) + TL(+) -62.895 -0.558 -0.248 62.898 0 0 0.003

Min rZ 10 112 DL + LL + WL(+X) + TL(+) 61.266 -3.015 -0.289 61.341 0 0 -0.003

Max Rst 84 113 DL + LL + WL(+X) + TL(-) 69.056 -10.488 -0.015 69.848 0 0 -0.002

Check for Deflection of Trestle :

Height of trestle= 35100 mm

1 Longitudinal direction (X) 35100/69.126= 507.76842 > 500 ok

2 Transverse direction (Z) 35100/44.761= 784.16479 > 325 ok

Check for Deflection of beam :

length of beam = 3300 mm

1 Vertical direction (Y) 3300/11.386= 347.8 > 325 ok

 Horizontal Vertical Horizontal Moment
Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 1 DEAD LO 0.437 6.089 0.337 0 0 0
2 1 DEAD LO -0.437 6.452 0.356 0 0 0
3 1 DEAD LO 0.434 6.029 -0.337 0 0 0
4 1 DEAD LO -0.434 6.392 -0.356 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 2 MECH.D 0.117 1.485 0.078 0 0 0
2 2 MECH.D -0.117 1.804 0.095 0 0 0
3 2 MECH.D 0.117 1.478 -0.079 0 0 0
4 2 MECH.D -0.117 1.796 -0.096 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 3 MECH. L 0.407 5.178 0.273 0 0 0
2 3 MECH. L -0.407 6.254 0.33 0 0 0
3 3 MECH. L 0.406 5.16 -0.274 0 0 0
4 3 MECH. L -0.406 6.235 -0.331 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 4 WIND LO -2.479 -35.811 -4.074 0 0 0
2 4 WIND LO 2.201 -35.318 -4.313 0 0 0
3 4 WIND LO 2.479 35.811 -4.074 0 0 0
4 4 WIND LO -2.201 35.318 -4.313 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 5 WIND LOA 2.479 35.811 4.074 0 0 0
2 5 WIND LOA -2.201 35.318 4.313 0 0 0
3 5 WIND LOA -2.479 -35.811 4.074 0 0 0
4 5 WIND LOA 2.201 -35.318 4.313 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 6 WIND LO -3.384 -42.174 -2.223 0 0 0
2 6 WIND LO -3.373 42.174 2.223 0 0 0
3 6 WIND LO -3.384 -42.174 2.223 0 0 0
4 6 WIND LO -3.373 42.174 -2.223 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 7 WIND LOA 3.383 42.433 2.237 0 0 0
 2 7 WIND LOA 3.394 -42.433 -2.237 0 0 0
3 7 WIND LOA 3.383 42.433 -2.237 0 0 0
4 7 WIND LOA 3.394 -42.433 2.237 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 8 TEMP (+) 0.328 0 -0.017 0 0 0
2 8 TEMP (+) -0.328 0 -0.017 0 0 0
3 8 TEMP (+) 0.344 0 0.017 0 0 0
4 8 TEMP (+) -0.344 0 0.017 0 0 0

Horizontal Vertical Horizontal Moment

Node L/C Fx Mton Fy Mton Fz Mton Mx MTon- My MTon- Mz MTon- Mz MTon-m
1 9 TEMP (-) -0.328 0 0.017 0 0 0
2 9 TEMP (-) 0.328 0 0.017 0 0 0
3 9 TEMP (-) -0.344 0 -0.017 0 0 0
4 9 TEMP (-) 0.344 0 -0.017 0 0 0
1 FX -0.437 FY -6.089 FZ -0.337
2 FX 0.437 FY -6.452 FZ -0.356
3 FX -0.434 FY -6.029 FZ 0.337
4 FX 0.434 FY -6.392 FZ 0.356

1 FX -0.117 FY -1.485 FZ -0.078

2 FX 0.117 FY -1.804 FZ -0.095
3 FX -0.117 FY -1.478 FZ 0.079
4 FX 0.117 FY -1.796 FZ 0.096

1 FX -0.407 FY -5.178 FZ -0.273

2 FX 0.407 FY -6.254 FZ -0.33
3 FX -0.406 FY -5.16 FZ 0.274
4 FX 0.406 FY -6.235 FZ 0.331

1 FX 2.479 FY 35.811 FZ 4.074

2 FX -2.201 FY 35.318 FZ 4.313
3 FX -2.479 FY -35.811 FZ 4.074
4 FX 2.201 FY -35.318 FZ 4.313

1 FX -2.479 FY -35.811 FZ -4.074

2 FX 2.201 FY -35.318 FZ -4.313
3 FX 2.479 FY 35.811 FZ -4.074
4 FX -2.201 FY 35.318 FZ -4.313

1 FX 3.384 FY 42.174 FZ 2.223

2 FX 3.373 FY -42.174 FZ -2.223
3 FX 3.384 FY 42.174 FZ -2.223
4 FX 3.373 FY -42.174 FZ 2.223

1 FX -3.383 FY -42.433 FZ -2.237

2 FX -3.394 FY 42.433 FZ 2.237
3 FX -3.383 FY -42.433 FZ 2.237
4 FX -3.394 FY 42.433 FZ -2.237

1 FX -0.328 FY 0 FZ 0.017
2 FX 0.328 FY 0 FZ 0.017
3 FX -0.344 FY 0 FZ -0.017
4 FX 0.344 FY 0 FZ -0.017

1 FX 0.328 FY 0 FZ -0.017
2 FX -0.328 FY 0 FZ -0.017
3 FX 0.344 FY 0 FZ 0.017
4 FX -0.344 FY 0 FZ 0.017