4.

5 Bunkers & silos: These are large size containers used to store dry materials like cement, coal,
food grains, flours of food grains, etc. They have vertical portions at top and hopper conical portion
at bottom. The cross section of vertical top portion may be square/rectangular / hexagonal / circular
in shape and the hopper conical portion has a door opening at bottom to draw the material out.
Usually, a free board of 150mm to 300mm is provided at the top. The walls of top & bottom portions
are built with steel plates. The inner surfaces of walls are given suitable linings in case powdery
materials are stored. The opening at the bottom is large enough to allow easy flow of material
during emptying process. The conical walls of the hopper bottom are given inclinations larger than
the angle of repose.

4.5.1 Difference between Bunkers & Silos: Bunkers are shallow containers, for which the plane of
rupture drawn from the bottom level of vertical portion meets the top surface of the material stored
before meeting the opposite wall. Silos are deep containers, in which the plane of rupture drawn
from bottom level intersects the opposite wall before reaching the top free surface of material. The
material in silo develops horizontal pressure on large portion of vertical cylindrical wall. And the wall
portion in turn, offers frictional resistance for the free movement of material. This resistance induces
large amount of compressive force in the silo wall. Such compressive forces set up in bunkers are
small and are neglected in design procedure.

Free surface of material

Plane of
rupture Plane of
rupture

Fig (a) bunker and silo

Storage capacity = (vol. of top portion +vol. of conical bottom portion) x density of material.

4.6 silos:

4.6.1 Constructional features: The cylindrical vertical walls are made of plates bent to arc shapes,
which are connected together along the overlapping portions at edges. The circular wall plate is
strengthened with hoop rings and vertical stiffeners made of flats / angles. The wall of conical
hopper portion is made of steel plate, which is stiffened with horizontal and meridional elements.
Both vertical and hopper portions are supported by a ring girder provided at the junction of the two
portions. This ring girder in turn is supported an a No. of columns ( 4 / 6 / 8 No.s). The columns are
provided with horizontal and diagonal bracings.
Loads: The loads acting on the components of a silo include self-weights of components, vertical &
horizontal (or, normal / tangential) forces due to material stored, skin friction forces on the wall
while filling / emptying operations, fabrication & assembling forces, etc.

Design procedure for silos:

Step 1. Vertical cylindrical portion: Calculation for loads acting on cylindrical wall:

For the maximum depth of material stored in the vertical portion, the design values of horizontal
pressure ‘ph’ and vertical pressure ‘pv’ are estimated as under-
pi

pi  pi ,max 1  e     (1)

h
z0
 , where, ‘i’
 
h emptying
stands for v, h or w, corresponding to the
pressure being calculated;
R
Z0     ( 2) , here,
k
R is the wetted perimeter =
(area of cross section/perimeter)
R= (0.283 a) for a square cross section; filling
 2ab  a 2 
 0.283  for pressure on longer
 b  Fig(b)
sides of rectangular cross section;
=0.283a for pressure on shorter side of Item filling emptying
rectangular cross section;  𝜑 𝜑
 𝜇 𝜇
Calculations for Z & (h/Z): Since the
pressure offered by the material is different k kf ke
𝑅 𝑅 𝑅
for filling & emptying operations, we find 𝑍 = 𝑍 = 𝑍 =
𝑘𝜇 𝑘 𝜇 𝑘 𝜇
their absolute max values as indicated in the
h
ℎ ℎ ℎ
table. i.e., we select larger value of 1  e z0 𝑍 𝑍 𝑍
and calculate the magnitudes of pressures. 1−𝑒 1−𝑒
1−𝑒
---------------------- (2)

Step 2. Hoop tension in cylindrical wall at a depth ‘h’ from top: T = ph.D/2 -------------(3)

where, D is the dia of section. Provide sufficient thickness as t  T/(1000 mm x f t,all ) and round off to
6,8,10,…such that hoop stress induced is smaller than f t,all = 0.6Fy 1. Here 1 is the efficiency of
joints in tension. -----(4)

Find pv at that section using pv = (ph / k) -------(5)

Then weight of material supported by skin friction alone of walls is given by ( . ph ) per m length.
----------------(6a)

Weight of wall portion above the section = (Ws ) per m length; ---(6b)
Total vertical load borne by the wall cross section per m length = (Ws )+ ( . ph ) ---(6c)
Adopting the thickness computed in (4), find the direct compression developed in wall as
(Ws +  . ph ) / (1000mm x t ) 2 . fc,all , here, 2 (eetah) is efficiency of joints in compression. ---(7)
Step 3. For the wall plate which is in compression, provide adequate buckling stiffeners in the form of
angles in vertical direction on outer face at a horizontal circumferential spacing of 1m / 1.5m / 2m.
Provide horizontal bracings between the vertical stiffeners at a vertical spacing of 1m /1.5m / 2m. ---
--(8)
Step 4. Design for hopper bottom: For the static condition/filling/emptying of the powdery/granular
material, calculate max vertical pressure developed at the top of conical wall. This pressure X c/s area
+ weight of material in conical portion + self-weight of conical portion develops a vertical load, which
is resisted by the axial tension set up in conical wall. Analyze for this tension using conical tank theory.
Assume suitable thickness for the wall plate and calculate axial tensile stress to verify if it is less than
0.6 fy. As the radius becomes smaller with depth, hoop tension becomes smaller. Hence provide
nominal stiffener angles/flats in meridional and horizontal directions.

Cylindrical wall plate

Horizontal
stiffener

Hopper bottom wall plate

Vertical
stiffener

Inclined stiffener

Horizontal
column
stiffener

Fig (a) Joints at ring girder

Step 5. Design for the ring girder: Let total weight of silo be W1. Take self-weight of girder as W2. Then
total weight = W = W1 + W2. Adopting ‘N’ number of columns and plan radius ‘R’ of the girder, calculate
for the critical magnitudes of +BMmax, -BMmax, Torsional moment & shear force V, as per table (3) of
IS:4995(part 2). -------------------(9)

Then, propose a built-up ‘I’ section and check for following stresses-

i. Weight on girder per m run along circumference = w= (W/2R);

 Then, direct compression stress in web = w/ (1000mm x t)  comp,all

ii. Design bending moment = (larger magnitudes among +BMmax , -BMmax ) + (Equivalent BM for
replacing Torsion); Then, calculate for bending comp/ten stresses as given by M/Z of the
section. These stresses should be within permissible limits;
iii. Combined effect of bending and compression: + ≤ 1.0
, ,

iv. Check for torsion    BMmax.

Step 6. Present the details of design in the form of drawings as shown in Fig( ) below.

Vertical
stiffener

‘h’ for
Horizontal Cylindrical
portion
stiffener

h1
Ver. & hor.
stiffeners
Fig (b) elevation of silo

Num(1) {from page 438 of Ramachandra} Design a circular steel silo of 12m height and 4m internal
dia to store cement of bulk density 15.5 kN/m3 & angle of internal friction 25 . The depth of hopper
bottom is 3m and the door opening is 0.6m in dia.
Solution:
Step 1. Given quantities are as under-
Dimensions: For cylindrical portion, internal dia = d=4m & vertical height = h = 12m; for hopper
bottom, depth = h1=3m, dia of door opening = d1 = 0.6m; Material stored is cement with bulk density
=  = 15.5 kN/m3 & angle of internal friction =  = 25 . And, its particle size = 32 which is  0.06mm.
Material is powdery type and hence from table (3) clause 5.4 of IS 9178-part (1), we have,

Pressure ratio during Angle of friction with wall during

filling emptying filling emptying
Kf = 0.5 Ke=0.7 𝜑 = 1.0𝜑 = 25∘ 𝜑 = 1.0𝜑 = 25∘
𝜇 = 𝑡𝑎𝑛 𝜑 = 0.4663 𝜇 = 𝑡𝑎𝑛 𝜑 = 0.4663

Assumption: The silo is designed for symmetrical discharge. ---------------------(1)

Components to be designed are:
i. vertical cylindrical wall plate, vertical & horizontal stiffeners;
ii. Hopper bottom wall plate and its stiffeners;
iii. Ring girder. ----------------------------------------------------------(2)

Step 2. Design for cylindrical portion:

i. Design for wall plate thickness: We design wall thickness for Hoop stress first, then verify
the strength for vertical compressive stress and then check for resultant stress as under-
a. Hoop stress: The magnitudes of pressures ‘ph’ & ‘pv’ acting on the wall increase with
the depth ‘h’ of the section from the top, but their magnitudes are different for
filling & emptying operations. Hence, we write the expressions for the magnitudes
of ‘ph’ during each operation and select the larger value as under-
The maximum depth of h = 12m. The hydraulic mean radius is given by,
𝑐/𝑠. . 𝑎𝑟𝑒𝑎 𝜋𝑑 /4 𝑑 4𝑚
𝑅= = = = = 1𝑚 − − − (3)
𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟 𝜋𝑑 4 4

Parameter filling emptying

𝑅 𝑅 1 𝑅 1
𝑍 = 𝑍 = = 𝑍 = =
𝑘𝜇 𝑘 𝜇 0.4663 × 0.5 𝑘 𝜇 0.4663 × 0.7
= 4.289 = 3.064
ℎ ℎ 12 ℎ 12
= = 2.8 = = 3.916
𝑍 𝑍 4.289 𝑍 3.064
.
1−𝑒 1−𝑒 = 1 − 2.7183 . 1−𝑒 = 1 − 2.7183
= 0.939 = 0.98
𝑝 15.5 × 1 15.5 × 1
𝜔𝑅 𝑝 = × 0.939 𝑝 = × 0.98
= 1−𝑒 / 0.4663 0.4663
𝜇 = 31.213𝑘𝑁/𝑚 = 32.578𝑘𝑁/𝑚

The ph value is larger in emptying operation. Hence, we take that value for
calculating Hoop tension as
Hoop tension at h=12m is,
𝑝 × 𝑑 32.578 × 4
𝐻= = = 65.14𝑘𝑁/𝑚. . ℎ𝑒𝑖𝑔ℎ𝑡
2 2
= 65.14𝑁/𝑚𝑚. . ℎ𝑒𝑖𝑔ℎ𝑡 − − − − − (4)

Considering 1 mm high strip and adopting thickness ‘t’ = 8 mm, hoop stress
. . .
induced in the wall is given by, 𝜎 = = = =
. . / × ×
8.143𝑁/𝑚𝑚 − −(5)
 This tensile stress 8.143 N/mm2  (0.6 fy = 150 N/mm2) okay. ---------(6)

b. Design for vertical compressive loads: The material stored presses against wall and some
portion ‘Wf’ of material load is resisted by the skin friction offered by the wall. Such a load is
indirectly calculated as,

Wf = (static vertical pressure – active vertical pressure) x (cross sectional area)

⇒ 𝑊 = (𝛾. ℎ − 𝑝 ) − − − −(7)

Here, pv has different magnitudes for emptying & filling operations and is given
by the relation k = ph / pv. Or, pv = ph / k.

Then, for emptying process, pv,e = ph,e / ke  pv,e = 32.578/0.7 = 46.54 kN/m2

And, for filling process, pv,f = ph,f / kf  pv,f = 31.213/0.5 = 62.426 kN/m2

Then, we take smaller pv and substitute in (7) to get larger Wf as under-

𝑊 = (𝛾. ℎ − 𝑝 ) = (15.5 × 12 − 46.54) = 1752.51𝑘𝑁 − −(8)

We assume the self-weights of different components of cylindrical portion as,

component Weight / unit area Area Weight in kN

wall including stiffeners 0.8 kN/m2 x4x12 120.64
Lining on inside 1.2 kN/m2 x4x12 180.864
Top cover plate 4 kN/m2 x42/4 50.24
Total wt of components Wc 351.744

----------------(9)

Then total vertical load on wall plate is,

W = Wf + Wc = 1752.51 + 351.744 = 2104.254 kN. -----(10)

Then, Vertical load per mm length along the perimeter is,

‘w’ per mm = (2104.254 x 1000 N) / ( x 4000 mm) = 167.451 N/mm.

With ‘t’ = 8mm, direct compressive stress is

 comp =167.451 / 8 = 20.931 N/mm2   comp. strength okay ---(11)

c. Effective stresses: Taking Poisson’s ratio  = 0.3, we have,

Effective compressive stress in vertical direction

= 20.931 + 0.3 x 8.143 = 23.373 N/mm2  comp. strength okay ---(12)

Effective tensile stress in circumferential direction

=8.143 + 0.3 x 20 931 = 14.422 n/mm2   tensile strength okay ---(13)
 d. Design for stiffeners: Since the stresses in wall plate are very very small, provide only
nominal stiffeners in the form of –
 horizontal rings of ISA 65x65x6 on the outer face at a vertical spacing of 1.5m c/c;
 six numbers of ISA 65x65x6 vertical stiffeners on outside at a circumferential spacing of
x4m/6 = 2.09m c/c.

Step 3. Design of hopper portion: The vertical forces acting on the trough portion are-

i. At 12m depth from top, total vertical pressure due to material is calculated with larger
magnitude of pv as (ph/k) = (31.213/0.5) = 62.426kN/m2. Then load due to pv is,
𝜋𝑑 𝜋4
𝑝 × = 62.426 × = 784.07𝑘𝑁
4 4
ii. Weight of cement in hopper portion
𝜋𝑑 ℎ 𝜋×4 3
≈ × ×𝛾 = × × 15.5 = 194.68𝑘𝑁
4 3 4 3
iii. Self wt of hopper components (assumed) = 40 kN

Then total vertical load = Whop = 784.07 + 194.68 + 40 = 1018.75 kN ------(14)

Tension Tension
T/m run T/m run
pv=62.426 kN/m2
3m
W


Wt. of
cement 1.7m
in hopper
Self wt of Fig(b)
Fig( a)vertical
hopper
loads of hopper
Let ‘T’ be the meridional tension induced in the conical wall per meter run as shown
in Fig(b). Then, 𝑡𝑎𝑛 𝜃 = ⇒ 𝜃 = 50.46∘ ; 𝑇 =
.
.
= ( ∘) = 93.18𝑘𝑁/𝑚 − − − − − − − −(15)
× × .
i.e., tension per mm length along the perimeter of conical cross section is,
T1 = T x1000 N/ (1000mm) = 93.18 N/mm.

With 8mm thick wall plates, tensile stress in plate = mer = 93.18/8 = 11.647 N/mm2.

And, hoop stress at top of conical portion is same as hoop stress at bottom of
cylindrical portion = 8.143 N/[Link] resultant of the two stresses is small when
compared to 0.6 Fy.  Okay.--------------------------(16)

Stiffeners for hopper bottom: Provide nominal stiffeners in the form of ISA 65x65x6
horizontal rings spaced vertically at 1.5m c/c, and similar sections in vertical
direction at convenient converging spacing. ----------------------(17)
Step 4. Design for ring girder: A ring girder provided at the junction of cylindrical & conical portions
is assumed to be supported on 8 columns along its centre line.
4.1 UDL acting on the girder: Loads acting on girder are-
i. Material stored = Wt. of cement in (cylindrical + conical portions)
=( ×ℎ×𝛾 + 194.68) = 2337.3 + 194.68 = 2531.98𝑘𝑁.
ii. Self wt of cylindrical portion = wall & stiffeners +lining + top cover plate
= 120.64 + 180.864 + 50.24 =351.744 kN.
iii. Self wt of conical portion = 40 kN.
iv. Wt. of platform (assumed) = 50 kN.
v. Self wt. of girder (assumed) = 50 kN.
Then, total weight = 2531.98 + 351.744 + 40 + 50 + 50 = 3023.724  3025 kN (say)----(18)

Hence, UDL on girder = 3025 / ( x 4) =240.72 kN/m ------------------(19)

240.72kN/m Design forces: The ring girder
behaves like a beam curved in
plan. Here, angle subtended at
centre by each span is 45 and
the design forces are calculated
using the coefficients given in
table (3) Appendix A-1.4 of
45 IS:9178(part2) as under-

W= total wt. = 3025 kN;

R= radius of centre line = 2m;

Max. BM developed at supports

= -0.00827 WR
=-0.00827 x 3025 x 2
=50.03 kN-m ------(20)
Fig (e) centre line of ring girder

Torsion developed in beam = T = 0.00063 WR = 0.00063 x 3025 x 2 = 3.812 kN-m----(21)

Max. axial compression induced in ring girder due to pull offered by conical wall is,

. . × ×
𝐶 = = . = 2669.12𝑘𝑁 − − − (22)

Design for built-up section: Try a section as shown in Fig(f). 350

Here, section properties are as under-

c/s area A= 300x25x2 + 950x12=26400mm2

300  10003  288  9503 950
I xx   4423  106 mm 4
12
4423  106
Z xx   8846  106 mm 3
500

Fig(f)
 25 × 300 950 × 12
𝐼 =2× + = 112.64 × 10 𝑚𝑚
12 12
112.64 × 10
𝑍 = = 750912𝑚𝑚
150
𝐼 4423 × 10
𝑟 = 𝐴= 26400 = 409.31𝑚𝑚
𝐼 112.64 × 10
𝑟 = 𝐴= 26400 = 65.32𝑚𝑚

Length of chord between two columns  curved length of beam between two columns

= (x4)/8 = 1.571m = 1571mm.

Slenderness ratio for the chord length = (L /rmin) = (1571 / 65.32) = 19.24. Then, permissible
compressive stress is c,all = 0.6 Fy = 150 N/mm2 .

Hoop compression if no columns were there = Caxial = 2669.12 kN.

Since, the circumference is divided into 8 individual arc segments. Hence, compression developed in

each segment = Caxial / 8 = 2669.12 / 8 = 333.64 kN.

Then, compressive stress induced in c/s of girder is

act = 333.64 x1000/26400 = 12.64N/mm2 . This is   comp. strength.  okay.