NATIONAL CEMENT

COMPANY
AL-ANAD CEMENT PROJECT
YEMEN

DESIGN BRIEF
FOR
CIVIL AND STRUCTURAL WORK

FOR

CEMENT MILL-2 UPGRADATION

CEMENT PLANT
AT
AL-ANAD, YEMEN

Project 13187
REPORT NO. 13187-R-1-02

04th MARCH, 2014

Holtec Consulting Private

Limited
Holtec Centre, A Block, Sushant Lok, Gurgaon 122 001, Haryana, India
Phones : +91-124-26385095, 2385096 Fax: +091-124-2385114, 2385116
Email : info@[Link]
 DESIGN BRIEF
TABLE OF CONTENTS:
1. INTRODUCTION 1

2.1 GENERAL SITE CONDITIONS 1

2.2 Location 1

2.3 Topography 1

2.4 Climatological Data & other details 1

2.3.1 Temperature 1

[Link] Rainfall 1

[Link] Rainy season 1

2.3.3 Wind Velocity 1

2.3.4 Seismicity 1

2.3.5 Corrosion 2

2.3.6 Site Conditions 2

2.4 General Sub-surface Conditions 2

3.1 DESIGN LOADS 2

3.2 Dead Load 2

3.3 Live Loads 2

3.3.1 Table – 1 Design Live Loads 2

3.3.2 Imposed Load 3

3.3.3 Dust load 3

3.3.4 Factors of loading 3

3.3.5 Floor finishes 3

3.3.6 Table 2 – Parameters for structural design of storage structure 3

3.4 Wind Load 3

3.5 Seismic Loads 4

4.1 BUILDING MATERIALS 4

4.2 Cement 4

4.2.1 Ordinary Portland Cement 4

13187-R-1-01 TOC-i Mar’ 14

4.2.2 Sulphate Resisting Portland Cement 4

4.3 Reinforcement 4

4.3.1 Plain Mild Steel Reinforcement 4

4.3.2 High Yield Strength Deformed Bars 4

4.3.3 Concrete Cover 5

4.4 Structural Steel 5

4.5 Profiled Coated Steel Sheets for Rooting & Cladding 5

4.6 Aluminium Composite Panels 5

4.7 Precast Concrete Blocks 5

4.7.1 Precast Concrete Blocks 5

5.1 DESIGN PROCEDURES AND CODES 5

5.2 Concrete Structures 6

5.2.1 Limit State Method 6

5.2.2 Equipment foundation 6

5.2.3 Small equipment on fixing 6

5.3 Structural Steel 6

5.4 Design of Underground Basements Tunnels etc. 6

6.1 FINISHES & PROTECTION 6

6.2 RCC Work 7

6.2.1 Concrete surface protection 7

6.2.2 External waterproofing 7

6.3 Structural Steel Work 7

6.4 Precast Concrete Block for Building Walls – Table – 4 7

6.5 Side Cladding for Different Buildings

6.5.1 Process Building 8

6.5.2 Electrical Buildings 8

6.5.3 Single Storied Sheds like Workshops & Stores etc. 8

6.6 Floor Finishes 8

6.6.1 Process Buildings 8

6.6.2 Electrical Buildings 8

6.6.3 Material Stockpiles 8

13187-R-1-01 TOC-2 Mar’ 14

6.6 Roof Treatment 9

6.7 Plinth Protection 9

7.0 SPECIAL CONSIDERATIONS 9

8.0 LIST OF STANDARD DRAWINGS 9 & 10

ANNEXURE – 1 REINFORCED CEMENT CONCRETE

1.1 CONCRETE GRADE 11

1.2 REINFORCEMENT STEEL 11

1.3 SIZES OF RCC MEMBERS 11

1.3.1 Footings 11

1.3.2 Slabs 11

[Link] Maximum span of 150 mm thick slab 11

1.3.3 Beams 12

[Link] Width of Beams 12

[Link] Depth of beams 12& 13

1.3.4 Columns 13

[Link] Rectangular/Square Columns 13

[Link] Circular Columns

1.4 MAXIMUM PERCENTAGE OF MAIN

REINFORCEMENT STEEL 13

1.5 The reinforcement bars and its estimated quantity 13

ANNEXURE - 2 STRUCTURAL STEEL - STANDARD SECTIONS

1.1 STANDARD SECTIONS 14 & 15

ANNEXURE – 3 - STAIRS, HAND RAILS AND LADDERS

1.1 STAIRS 16

1.2 Structural Steel stair cases 16

1.3 Minimum width of stairs 16

1.4 Plant structures, stairs 16

13187-R-1-01 TOC-3 Mar’ 14

1.5 Slope of stair-ways 16

1.6 Recommended size of stringers 16

2.1 HAND RAILINGS 16

2.2 Hand rails 16

2.3 32 mm NB steel tube hand-rail 17

2.4 Hand rails 17

3.1 LADDERS 17

3.2 Ladders 17

ANNEXURE – 4 - ALLOWABLE DEFLECTION

1.0 Deflection of structural member 18

2.1 Structural Elements 18

2.2 Floor beams and girders 18

2.3 Roof and roofting beams 18

2.4 Vertical frame work elements 18

2.5 Beams supporting masonry walls 18

2.6 Crane Girders 18

2.7 Monorail tracked cranes 18

3.0 Buildings 18

4.0 Members subject to vibratory loads 18

ANNEXURE – 5 -GEOTECHNICAL PARAMETERS

SOIL PROFILE 19

SOIL PROFILE – BOREHOLE NO. CORRELATION 19

BUILDING – PROFILE CORRELATION 20

Bearing Capacity of a Circular Footing of a Diameter Ranging

Between 0.5 to 5.0 m 20

Bearing Capacity fo Wall Footing of a Width Ranging

Between 0.5 to 5.0 m 20

Bearing Capacity of a Circular Raft of a Diameter Ranging

Between 20.0 to 65.0 21

13187-R-1-01 TOC-4 Mar’ 14

 Bering Capacity of Circular Footing of 10 m2 Surface Area 22

ELASTIC AND DYNAMIC PARAMETERS 23

FOUNDATION RECOMMENDATIONS 23

Note 24

13187-R-1-01 TOC-5 Mar’ 14

 HOLTEC CONSULTING PRIVATE LIMITED

PROJECT 13187

DESIGN BRIEF

CIVIL AND STRUCTURAL WORK FOR CEMENT MILL -2 UPGRADATION WORK AT CEMENT
PLANT FOR NATIONAL CEMENT COMPANY, AL-ANAD, YEMEN

1.0 INTRODUCTION

National Cement Company, Yemen., have proposed to set up a 295 TPH Roller Press under
their expansion project of Al Anad Cement Project, Yemen.

2.1 GENERAL SITE CONDITIONS:

2.2 Location

This is an expansion project inside existing plant located at AL-Anad, 68 KM from Aden. It
is located at about 110 Km. from Taiz on Taiz-Aden highway.

2.3 Topography

The site is located in a valley with high hillock exists on all sides. The natural ground level
at main plant area is varying from 436 M to 446M.

2.4 Climatological Data & other details

2.4.1 Temperature:

- Maximum : 45o Celsius (approximately)

- Minimum : 15o Celsius

2.3.2.. 1 Rainfall:

- Average annual : 43 mm
- Maximum : 108 mm in 8 Hours

[Link] Rainy season:

- Start : April
- End : Mid June

2.3.3 Wind Velocity:

Wind speed shall be considered 120 Km per hour for design of structure. Most prevalent
wind direction is from South to Southwest.

2.3.4 Seismicity:

The proposed plant site falls in seismic zone 3 and the design co-efficient shall be 0.3
(basic horizontal seismic co-efficient) as per 1991 WBC (UNIFORM BLD. CODE).

13187-R-1-01 1 Mar’ 14
2.3.5 Corrosion:

The site is located far away from coastal area. Hence, special corrosive protection
requirement is not envisaged. However, as per the Chemical analysis of soil & water
carried out to find super corrosive element in soil. The chloride content is reported higher
than allowable. Hence, protection of all foundation shall be carried out as recommended in
the geotechnical investigation report.

2.3.6 Site Conditions:

The area is presently being undeveloped comprising raised rocky hump on southern side.
Hillocks exists on all sides of proposed plant area, thus plant is proposed to be located in
valley. A river was passing through the area which was diverted. Numerous natural
nallahas from surrounding hill was passing through the plant area. Access to the site is
from eastern side through two hillocks

2.4 General Sub-surface Conditions:

Refer Geotechnical investigation report.

3.1 DESIGN LOADS

The various structures/buildings for the proposed Cement Plant shall be designed for
the following loads :-

3.2 Dead load

Self-weight of the structural members, weight of the floors, floor finishes, roofs, roof
treatment, walls etc. shall be assumed as per the Standard values available. The weight
and pressures due to soil shall be considered as per the recommendations of the Geo-
technical investigation report.

3.3 Live Loads

3.3.1 Live loads to be considered for design of various floors and roofs shall be as per Table - 1
below:
TABLE - 1

DESIGN LIVE LOADS

Sl. Location For Floor Slabs and Secondary

Beams in Kg/M2
01 Operating floors, Platforms, 500 *
Staircase and Landings
02 Burners Floor 1000/3000 Kg/M2 (for brick storage area)

03 Operators Rooms 300

04 Packer Floor and Bags Storage 800

05 Control Room & Sub-Station 250

06 Accessible roof 200

07 Inaccessible Roofs :

13187-R-1-01 2 Mar’ 14
 Sl. Location For Floor Slabs and Secondary
Beams in Kg/M2
- Flat 150**

- Sloping Roof Slope 00 50 100 150 200 250 230

Load Kg/M2 75 75 74 72 71 68 65
08
Typical floor (residential Table is valid for roof pitches upto 30slope
building) 200

** On special requirement of Plant operation.

For Design, relevant BS codes of practices to be followed

3.3.2 In addition to the live loads as specified in 3.2.1, loads imposed by machinery, including
the effect of dynamic characteristics shall be considered. The loads due to the machinery
and equipment shall be as specified by the manufacturer. Resonant conditions should be
avoided by suitably proportioning the supporting structural members.

3.3.3 Dust load of 50 Kg./M2 shall be considered in addition to live load on floor and roof of
process buildings and storage halls.

3.2.5 Floor finishes

Load for floor finishes shall be minimum 160 Kg/m2 for typical floor of electrical building
and screeding of roof of electrical building and all process building.

3.2.6 In the structural designs of storage structures like Silos, Hoppers etc. the following
parameters shall be considered:
TABLE 2

PARAMETERS FOR STRUCTURAL DESIGN OF STORAGE STRUCTURES

MATERIAL CIVIL DESIGN DENSITY ANGLE OF FRICTION

Kg./M3 (Degrees)
Cement Clinker 1520 30
Cement 1600 20
Gypsum 1600 35
Blast Furnace Slag 1440 35
Raw Meal 1440 20

3.3 Wind Load

Wind load on structure shall be as per IS: 875 (Part-3) – 1987 (Reaffirmed 2003), basic
wind speed (Vb ) for Surat is 44 m/s for design purpose. For calculation of design wind
speed, the following coefficients shall be adopted.

Probability factor for return period of 50 years.

K 1 = 1.00

13187-R-1-01 3 Mar’ 14
 K 2 = Terrain, height and structure rise factor to be determined from
Table – 2 of IS: 875 (Part-3)
Terrain classification = Category-3
Structure size factor = Class Ref. IS:875 (Part-3),1987
K3 = 1.0
Vz = Vb K1 K2 K3 and design wind for Pz = 0.6 Vz*Vz
Where Vz = Design wind speed in m/sec. at Height z
Pz = Design wind pressure in N/Sq.M. at Height z

3.4 Seismic Loads

The site is located in zone 3 of seismic zoning map of 1991 UNIFORM BLDG. CODE. The
design horizontal seismic co-efficient shall be taken as 0.3. The importance factor to be
considered for design of structures against seismic forces shall be 1.25. In case of tall
structure, response spectrum method shall be used.

4.1 BUILDING MATERIALS

The following major materials shall be used for construction of the buildings:

4.2 Cement

Ordinary Portland cement (OPC), type I or II according to ASTM or BS12 will be

used. Sulphate resisting Portland cement (SRC), Type V according to ASTM-C150 or BS
4027 will be used.

4.2.1 Ordinary Portland Cement

Conforming to BS 12 or ASTM C 150 Type 1, but containing not less than 7% by weight
of tricalcium aluminate and having strength class 42.5N shall be used.

4.2.2 Sulphate Resisting Portland Cement

Cement complying with either BS-4027 or ASTM-C150 type 5 in strength class 42.5N shall
be used for all the underground structures & foundations.

4.3 Reinforcement

4.3.1 Plain Mild Steel Reinforcement

Plain mild steel reinforcement rods shall conform to BS 4449. The minimum guaranteed
yield strength should be 250 N/[Link]. The dia of plain mild steel reinforcement rods to
be used shall be:
10 mm, 12 mm, 16 mm, 20 mm and 25 mm

4.3.2 High Yield Strength Deformed Bars

High Yield Strength Deformed Bars shall conform to BS-4449 ASTM 615 Grade 60. The
guaranteed yield strength shall be 460 N./[Link]. The diameter of high yield strength
reinforcement bars to be used shall be:
8mm, 10mm, 12mm, 16mm, 20mm, 25mm, 28mm , 32mm,36mm

4.3.3 The minimum cover to the reinforcing bars shall be as listed below or equal to the
diameter of the bar, whichever is greater:

13187-R-1-01 4 Mar’ 14
 TABLE - 3

Position Minimum Cover - mm

Main bars of columns and beams 40

Main bars in floor slabs and soffits of roof slabs 30
Main bars in top of roof slabs 30
Bars in walls 30
Bars in top of ground slabs 40
Bars near faces in contact with soil 70

4.4 Structural Steel

All structural steel sections shall conform to BS: 5950/BS: 4449. The structural sections to
be used shall be as per enclosed Annexure - 2.

The structural sections to be used shall be as per enclosed Annex - 2.

4.5 Profiled Coated Steel Sheets for Roofing & Cladding

Profiled Coated Steel Sheets shall be 0.50-mm thickness to ASTM 427, lock forming
quality. The profile shall be trapezoidal type. The galvanising shall not be less than 350
grammes per sqm.

4.6 Aluminium Composite Panels

Aluminium roofing sheets shall be of composite panel. Roof and wall cladding shall
comprise of profiled aluminium sheeting in composite insulated panel form. The panel
shall comprise of external fully protected aluminium weathering sheet, 48 mm of
polyurethane foam and an internal lining sheet with a finish to suit the final application. The
aluminium sheeting shall be of a quality not less than the requirement of BS 4300/6
conforming to alloy 3105 with H6 or H8 temper.

The aluminium sheeting shall further conform to the requirements for material and finishes
as laid down in BS 4868, 1972 - `Profiled Aluminium Sheet for Building’.

The aluminium sheeting available is in rolled form in width between 90cm to 100cm and in
any length. However, aluminium insulated sandwich sheet is of max. length of 12.0 m and
width of 0.9 m.

4.7 Precast Concrete Blocks

4.7.1 Precast Concrete Blocks

Precast concrete hollow blocks shall be used for masonry work in superstructure and solid
blocks shall be used for substructure. The size of solid/hollow blocks is 400x200x200.
Concrete block shall be as per BS 6073 Part-I & II.

5.1 DESIGN PROCEDURES AND CODES

All designs shall be as per the relevant IScodes.

13187-R-1-01 5 Mar’ 14
 Plant structures have to primarily meet the functional requirements and the load data
conditions stipulated by the process and the machinery suppliers. In general, all buildings
shall be in Reinforced cement concrete construction with suitable cladding wherever
necessary. Structural steel construction shall be adopted in the following cases where
flexibility of future changes is possible.

- Secondary floors/platforms for maintenance and for supporting light equipments.

- Material conveyor galleries and trestles.
- Staircases in Process Buildings.
- Supports for ducting etc.

Platforms/floors with heavy vibratory equipment will be in RCC. Staircase in various

buildings shall be as per the Annex - 3.

Limiting deflections of various structural members shall be according to the Annex - 4.

5.2 Concrete Structures

5.1.1 Limit State Method, as per IS latest code IS 456 shall be adopted for all RCC designs.

The basic mix of concrete to be used for reinforced concrete work for substructure works
shall be of not less than grade C40 with Sulphate Resisting Portland Cement i.e. concrete
having a characteristic compressive strength of not less than 40N/mm2 at 28 days with a
minimum cement content of 400 kg per cubic meter as per recommendations of the Soil
Investigation Report.

For superstructure work concrete grade shall be not less than C25 with O.P.C. i.e.
concrete having a characteristic compressive strength of not less than 25N/mm2 at 28
days.

Reinforcement shall be of steel confirming to BS 4449/ASTM 615 Grade 60. Basic

parameters for design shall be as per the Annex - 1.

5.1.2 All equipment foundation resting on floor shall be fixed on antivibration mountings.

5.1.3 Small equipment like air slide blowers, fans, small ducts/chutes on columns, cable trays
with column/beam shall be tied with expansion bolts.

5.2 Structural Steel

Design shall be as per IS800

5.3 Design of Underground Basements Tunnels etc.

Construction of all basements and Tunnel etc. shall be made watertight and tanking water
proofing system shall be adopted.

However, suitable drains and sumps shall be provided to pump out any water that may
seep through.

6.1 FINISHES & PROTECTION

The following finishes and protection shall be used for different types of structures:

6.2 RCC Work

13187-R-1-01 6 Mar’ 14
 RCC work shall be provided with trowel finish.

6.2.1 Surfaces of concrete shall be protected as per standard drawing no.A2-05170-STD-01-15.

6.2.2 External waterproofing course for floors and walls shall protected as per standard drawing
no.A2-05170-STD-01-15.

6.3 Structural Steel Work

Following paint system shall be used for painting of all steel work:

For General Steel work

1st coat - 40 micron thick red oxide Zinc chromate

2nd coat - 40 micron thick finished paint
3rd coat - 40 micron thick finished paint

6.4 Precast Concrete Block for Building Walls

All walls & panels in block work shall be of sufficient strength & thickness to withstand live
loads, dead loads & wind pressure without distortion & cracking. Block work thickness less
than 10 CM will not be accepted.

Every joint shall be thoroughly filled with Mortar & shall be 10 to 12 mm thick. For wall
heights of 4.5 M & over the block work has to be subdivided by RCC framing into panel of
not more than 20 m2 in [Link] joint should be properly raked & cleaned.
TABLE - 4

Area Maintenance Cafeteria Toilets, Stores, All other

Steps/Lobby Kitchen, Electrical Room &
Laboratory, Room General
Pantry Corridors
Wall Heavy Tex Two coats of 20x20 cms of Two coats of Two coats of
Finishes Paint on S/C Plastic emuls- glazed alkyl based alkyl based
render ion paint on patterned gloss finish gloss finish
S/C render ceramic tiles on paints on S/C paints on
S/C screed render S/C render

6.5 Side Cladding for Different Buildings

The following side claddings for different types of buildings shall be used.

6.5.1 Process Buildings

The side cladding for process buildings for the ground storey or internal partition walls
shall be in Precast concrete blocks, plastered on the inside surface and pointed on the
outside face. Doors, windows and rolling shutters shall be provided as necessary.

Above the ground storey, all side cladding shall be in profiled pre-painted steel/ Aluminium
Sheets louvers, all around, fixed on structural steel runners and louvers brackets. Internal
walls, if any shall be in precast block masonry.

6.5.2 Electrical Buildings

13187-R-1-01 7 Mar’ 14
 The side walls for all electrical buildings like MCC Rooms, load centres, etc. shall be in
precast block masonry for all floors. Suitable doors, windows, ventilators etc. shall be
provided for access and ventilation. Roofs shall be provided with waterproofing treatment.

6.5.3 Single Storied Sheds like Workshops & Stores etc.

The side cladding for single storied sheds likes workshop and stores etc. shall be in
Precast block masonry. Internal partition walls shall also be in precast block masonry.

6.6 Floor Finishes

The floor finishes for the different types of buildings shall be as follows:

6.6.1 Process Buildings

a/ Ground Floor : As per standard drawing no.A2-05170-STD-01-06. As per

standard detail (Ref drawing no. ).

b/ Upper Floors : As per standard drawing no.A2-05170-STD-01-06.

6.6.2 Electrical Buildings

a/ Ground Floors: The finish for ground floors for all electrical buildings shall be
similar to that of the process buildings except that the top 40
mm thick finishing layer shall be of cast-in-situ terrazzo flooring
laid over RCC floor slab. Terrazzo tiles also can be used.

b/ Upper floors : The floor finishing for upper floors for electrical buildings shall
comprise of 40 mm thick terrazzo tile flooring laid over RCC floor
slab.
6.6.3 Material Stockpiles

For all Stockpiles, the following flooring shall be provided.

The bottom shall be dressed and well compacted to the required grade.

Suitable drainage system shall be provided to avoid accumulation of water.

6.7 Roof Treatment

For water proofing of roofs, following arrangement shall be adopted:

a/ The roof slab shall be cast in slope (1 in 200) .

b/ Bitumen Fillet

c/ 4mm thick torch welded polymer bitumen elasto plastomeric waterproof membrane
with continuously extruded non-woven spun bond plastic fabric

d/ 50 mm thick extruded polystyrene insulation

e/ Filter layer (coarse sand, however, it depends upon the manufacturer’s specification)

f/ 50mm thick sand cement mortar

13187-R-1-01 8 Mar’ 14
 g/ 300x300x25mm white cement tiles, laid in panels

h/ Mastic sealant

6.8 Plinth Protection

In order to prevent scouring of the soil around the building, owing to the splash of
rainwater, PCC plinth protection shall be provided around all the buildings. For details
refer standard drawing No. A2-05170-STD-01-06.

7.0 SPECIAL CONSIDERATIONS

All Silos shall be in R.C.C. constructed by slipform technology.

8.0 LIST OF STANDARD DRAWINGS

01 A1-05170-STD-1-101 : General Notes & Abbreviations

02 A1-05170- STD -1-102 : Typical Flooring & Plinth protection details

03 A1-05170- STD -1-103 : Typical details of Mild Steel insert plates

04 A1-05170- STD -1-104 : Typical details of louvers & Side cladding

(Sheet 1 of 2)

05 A1-05170- STD -1-105 : Typical details of louvers, Side cladding & Tie Bands
(Sheet 2 of 2)

06 A1-05170- STD -1-106 : Standard Splice for steel sections and equal angles

07 A1-05170- STD -1-107 : Construction Joint details

08 A1-05170- STD -1-108 : Cable Tunnel & Trenches Details (Sheet 1 of 2)

09 A1-05170- STD -1-109 : Cable Tunnel & Trenches Details (Sheet 2 of 2)

10 A1-05170- STD -1-110 : Standard Lintel & sunshade details for Block work

11 A1-05170- STD -1-111 : Typical details of Doors, Windows & ventilators (In
Block Masonry)

12 A1-05170- STD -1-112 : Detail of Septic Tank, Soak Pit and & Manhole for
Toilet Type- 'A', 'B', 'C' and 'D'

13 A1-05170- STD -1-113 : Standard Stair Details (Stringer Channel 203 with
grating) - Sheet 1 of 2

14 A1-05170- STD -1-114 : Standard Stair Details (Stringer Channel 203200 with
grating) - Sheet 2 of 2

15 A1-05170- STD -1-115 : Connection details for Rolled Steel Sections

16 A1-05170- STD -1-116 : Standard Waterproofing & Roof Treatment Details

13187-R-1-01 9 Mar’ 14
 17 A1-05170- STD -1-117 : Tolerances

18 A1-05170- STD -1-118 : Typical pipe sleeve in beam and details of handrail

To ensure timely/early commissioning of the plant, additional innovative standardised

design/detailing shall be incorporated with the progress of the work.

(Kapil Goyal) ([Link])

13187-R-1-01 10 Mar’ 14
 ANNEXURE - 1

REINFORCED CEMENT CONCRETE

BASIC PARAMETERS

1.1 CONCRETE GRADE

Controlled Mix. concrete shall be used :

Structural Concrete : Substructure works - not less than C40 with

Sulphate resisting Portland Cement (SRC)

: For superstructure works - not less than C25

with Ordinary Portland Cement (OPC)
1.2 REINFORCEMENT STEEL

High yield strength deformed bars fy = 460 N./[Link] shall be used.

Sizes of bars to be adopted :

- 8mm, 10 mm, 12 mm, 16 mm, 20 mm, 25 mm, 28 mm , 32 mm

1.3 SIZES OF RCC MEMBERS

1.3.1 Footings : Minimum Width : 1200 mm

Minimum thickness : 300 mm
Higher size increments of 100 mm
Pedestals shall be provided at bottom of heavily loaded
columns to economise on footing reinforcement.

1.3.2 Slabs : Minimum thickness : 150 mm

Higher sizes : 200 mm
: 250 mm
: 300 mm

Note :

Minimum Slab thickness may be reduced in case of roofs for electrical buildings to suit
design requirements.

[Link] Maximum span of 150 mm thick slab :

a) One way slabs :

- Cantilevers : 0.90 M
- Simply supported : 2.60 M
- Continuous : 3.5 M

b) Two way slabs (Smaller spans)

- Live load : Upto 4000 N/M2 6000 N/M2

- Simply supported : 3.50 M 2.90 M
- Continuous : 3.50 M 3.30 M

Slab openings upto 500 mm without any loads acting may be provided without trimmer
beams.

13187-R-1-01 11 Mar’, 2014

1.3.3 Beams : Width x Depth
250 x 400
x 500
x 600
x 700
300 x 600
x 700
x 800
x 900
x 1000
400 x 800
x 1000
x 1200
x 1400
500 x 1200
x 1400
x 1600
600 x 1400
x 1600
x 1800
x 2000
700 x 2000
x 2200
x 2400

Preferred ratio of depth to width: from 2.5 to 3.4

Beam depths : In increments of 100 mm upto 1000 mm depth.
Subsequently in increments of 200 mm

[Link] Width of Beams:

a) Minimum width of beams 200/250 mm :

- Normal width : 300 mm and 400 mm

- Higher widths may be provided to meet design requirements

b) Width shall be provided on the following basis :

- Framing beams around small openings/cutouts for stairs and secondary

beams upto 4.0 M spans : 200 mm/250 mm.
- All Secondary beams with spans larger than 4.0 M having slab atleast on one
side on top : 300 mm, and 400 mm in case of heavy loads.

- In case of inverted secondary beams/beams without slab, lateral slenderness

should be considered. Beam widths shall be in multiples of 100 mm.

c) Minimum widths of main beams shall be 300 mm for Auxiliary buildings and 400
mm for Main plant buildings like Mill Houses, Cooler House, Kiln Feed House etc.
[Link] Depth of beams
a) Unless dimensional restrictions are there from functional requirements, it is
recommended to adopt deeper beams from the standard sizes given above.

13187-R-1-01 12 Mar, 2014

 b) Supporting Main beam's depth shall be minimum 100 mm more than the secondary
beam depth unless unavoidable.
c) Secondary Beams :
- Depth - 1/12 Span
All beams having identical spans shall be of same depth, unless required to be very
much different due to imposed loads and other considerations.
d) Main beams :
- Depth - 1/12 Span
e) Continuous beams :
Uniform depths shall be adopted in adjacent spans as far as possible for both
secondary and main beams.
Only in cases of wide variations in spans, imposed loads and/or for clearances of
ducts/equipment etc., beam depths may be different to meet design requirements.

1.3.4 Columns
[Link] Rectangular/Square Columns

- Minimum dimension : 300 mm

- Higher sizes : In increments of 100 mm upto 600 mm
dimension. Subsequently, in
increments of 200 mm
[Link] Circular Columns

- Minimum dimension : 300 mm

- Higher sizes : In increments of 200 mm

1.4 MAXIMUM PERCENTAGE OF MAIN REINFORCEMENT STEEL

- Slabs and footings : 0.60

- Beams : 1.35% for concrete grade M30
- Columns : 3.00

1.5 The reinforcement bars and its estimated Quantity for this project are as follows :

Total Phase-wise Procurement Plan

S. Dia.
Quantity
No. (mm I II III IV
(MT)
)
1 32 1710 450 450 500 310
2 28 740 190 190 200 160
3 25 1660 450 450 550 210
4 20 1070 300 300 250 220
5 16 805 225 225 200 155
6 12 590 160 160 140 130
7 10 600 165 165 140 130
8 8 325 90 90 80 65
Total
7500 2030 2030 2060 1380
Quantity (MT)

13187-R-1-01 13 Mar, 2014

 ANNEXURE - 2

APPROX. STRUCTURAL STEEL QUANTITY FOR

INITIAL PROCUREMENT PLANNING PURPOSE

1.1 STANDARD SECTIONS

Following are the structural steel sections to be adopted:

Sl. Section Assigned Approx. Remarks
No. Mark No. Quantity
(if any) (MT)

01 UNIVERSAL BEAMS 611.9 x 229.0 x 125 B1 200

528.3 x 208.7 x 82 B2 200
461.3 x 152.7 x 74 B3 150
406.4 x 177.8 x 60 B4 300
303.8 x 165.1 x 40 B5 250
256. x 146.4 x 37 B6 150
203.2 x 133.4 x 25 B7 110
152.4 x 88.9 x 16 B8 75

02 CHANNELS 432 x 102 C1 100

381 x 102 C2 40
305 x 89 C3 100
254 x 76 C4 145
203 x 76 C5 280
178 x 76 C6 85
152 x 76 C7 325
127 x 64 C8 330
102 x 51 C9 90
76 x 38 C10 65

04 ANGLE 150 x 150 x 12 A1 25

120 x 120 x 10 A2 25
120 x 120 x 8 A3 15
100 x 100 x 12 A4 15
100 x 100 x 10 A5 100
90 x 90 x 6 A6 235
75 x 75 x 8 A7 90
75 x 75 x 6 A8 240
60 x 60 x 6 A9 305
50 x 50 x 6 A10 275

05 MS Plate 6 mm 35
8 mm 150
10 mm 200
12 mm 150
16 mm 100
20 mm 80
25 mm 30
32 mm 15

13187-R-1-01 14 Mar, 2015

 06 Chequered Plate 6 thick 100

13187-R-1-01 15 Mar, 2015

 Sl. Section Assigned Approx. Remarks
No. Mark No. Quantity
(if any) (MT)

07 MS Flats 300 x 10 -
125 x 10 -
100 x 8 - To be
100 x 6 - reviewed
75 x 10 - later
50 x 8 2
50 x 6 10
25 x 6 65 Please
25 x 3 300 see Note-
7 below

08 MS Round 32mm 4
25mm 3
20mm 12
16mm 18
12mm 15
10mm 5
8mm 3

09 MS Pipe 33.7 mm 3
26.9 mm 5

Total Quantity 5625

Notes:

1. The above quantities are very approximate and are for initial procurement planning purpose only.
These quantities are based upon pro-rata estimates of similar structures of other similar Plants.
2. Since actual design has just commenced, and that these listed quantities are based upon initial
estimates, only a maximum of 25-30% of the above respective quantities shall be procured
initially. Balance of the quantities shall be further procured sage-wise after commencement of
detailed design of all the major structures and review/updation of these quantities/sections only.
3. All Structural Steel materials shall conform to BS:5950 Part 1 & 2.
4. Above quantities do not include wastages, rolling margin, splice quantities etc.
5. Approximate quantity of gusset plates has been included in the above quantity.
6. The tentative quantities have been updated keeping in view the inputs of supplier’s drawings and
design scheme.
7. The specified quantities of MS Flats 25x6 and 25x3 are mostly for the fabrication of gratings.
The quantities shall be adjusted in case readymade gratings are foreseen to be procured. [A
sample catalogue of such ready-made gratings shall be sent separately for ready reference
purpose, as desired].
8. On commencement of actual design process of structures, requirement of any new section(s),
other than those listed above, may arise in future due to certain design parameters.

13187-R-1-01 15 Mar, 2015

 ANNEXURE - 3

STRUCTURAL STEEL STAIRS, HAND RAILS AND LADDERS

1.0 STAIRS

1.1 Structural Steel stair cases shall be provided in all multistoreyed process buildings except
in case of Electrical and Laboratory buildings (which are of predominantly architectural
nature) where RCC stairs shall be provided.

1.2 Minimum width of stairs shall be 900 mm. However, local maintenance ladders shall be
600 mm. Recommended width of stairs in the process buildings are as follows :

- Cement Mill House and Main entry to cable cellar in : 1000 mm

substation and Load Centre buildings

- All other process buildings including Storage Silos and : 900 mm

Hoppers

- Approach to top of equipment foundations (ladder) : 600 mm

- Central Control Rooms and Laboratories : 1200 mm

1.3 For plant structures, stairs shall be provided with landings at intervals of not more than 3.0
metres measured vertically. Landings shall be 1.0 metre or more in length measured in
the direction of travelling. Minimum head-room clearance height to the lowest point of
over-head structural framing, piping, lighting or equipment shall be 2.25 metres as far as
possible. However it may be reduced to 2.1 metres clear in exceptional cases.

For Architectural buildings, maximum height between landings shall not be greater than
3.O M.

1.4 Slope of stair-ways shall not be more than 40o and the rise shall not exceed 175 mm.
Recommended tread-run is 275 mm. Local maintenance stairs may be provided at not
more than 45 deg with 225 mm tread-run and riser. Gratings/Chequered plates shall be
used for all steps and landings unless otherwise required due to local conditions.

Maximum tread-run and greatest riser height within any flight of stairs shall not exceed the
smallest by more than 10 mm.

1.5 Recommended size of stringers are Channel 152x76 for stairs of 600 mm and Channel
203x76 for stairs of 900/1000 mm.

2.0 HAND RAILINGS

2.1 Hand rails shall be provided :

- On Periphery of every uncladdded floor or platform

- On Periphery of larger floor openings
- On Periphery of accessible flat roofs of buildings and silos.
- To all Stairs and walkways

13187-R-1-01 16 Mar, 2015

 - For window with Sill height less than 750 mm from floor level.
- Around all pits where depth is more than 1.0 metre
- Along the conveyor galleries
- Along the Decks/platforms with plinth height more than 1.0 M.

2.2 These shall consist of 32 mm NB steel tubes for the hand-rail and the vertical post.
Vertical posts shall be spaced at about 1.5 to 2.0 metres centres. Secondary horizontal
rods shall be 25 mm NB tube. Height above floor shall be 1.0 metre.

2.3 Hand rails shall be fully welded to steel structures and to embedment plates provided in
case of RCC floors.

2.4 In case of pits shallower than 1.0 M, all round dwarf walls of height 300 mm shall be
provided.

3.0 LADDERS

3.1 Ladders shall be provided at such places where no regular maintenance is necessary and
only occasional access is needed.

3.2 Normally these shall be placed at 600 slope. However, where there are limitations and
space constraints these can be placed vertically.

3.3 These shall be 450 mm wide with 20 mm Dia MS rod rungs placed at 300 mm centre. 75 x
6 Flats shall be provided as stringers. Suitable railing shall be given to these as per the
standard details. In case of ladders more than 2.50 M height cage shall be provided as
detailed in the standard drawing.

For vertical ladder more than 2.5 M, height safety rings shall be provided at 600 C/C.

13187-R-1-01 17 Mar, 2015

 ANNEXURE - 4

ALLOWABLE DEFLECTION

1.0 The deflection of structural members is limited to the following so as not to make them too
slender to impair the functional response of the structure to control cracks and damage to
finishings. This is also necessitated to avoid critical secondary stresses that interlinked
process ducts and components be subjected to subsequently.

2.0 Structural Elements :

Allowable deflections expressed in parts of span

2.1 Floor beams and girders :

i) Main beams and girders : = 1/360

ii) Secondary Beams : = 1/250

2.2 Roof and roofing beams :

i) Main beams : = 1/250

ii) Purlins : = 1/200

2.3 Vertical frame work elements :

i) Posts/wall columns, collar beams : = 1/250

ii) Side Runners : = 1/200

2.4 Beams supporting masonry walls : = 1/600 or max. 8 mm

2.5 Crane Girders :

i) Manually operated cranes : = 1/500

ii) Electric cranes upto 50 T capacity : = 1/600
iii) Electric Cranes 50 T above : = 1/750

2.6 Monorail tracked cranes : = 1/400

3.0 Buildings

Horizontal deflection of building frames shall be limited to H/500 or 100 mm whichever is

less under wind or earthquake conditions.

4.0 Members subject to vibratory loads (other than cranes)

These shall be proportioned to suit the dynamic characteristics of the supporting structural
system under operational imposed loads.

13187-R-1-01 18 Mar, 2015

13187-R-1-01 19 Mar, 2015
 ANNEXURE - 5

GEOTECHNICAL PARAMETERS

NET SAFE BEARING CAPACITY AT VARIOUS LOCATIONS AND DEPTHS

SOIL PROFILE

Profiles

Wadi Formation
H

Rock

SOIL PROFILE – BOREHOLE NO. CORRELATION

Profile Depth of Wadi Representative Borehole

Formation, H (m)
1 0.00 BH 2 BH 3 BH 4

2 0.75 BH 10

3 2.25 BH 19

4 2.75 BH 1

5 3.00 BH 6

6 3.75 BH 5

7 4.00 BH 7 BH 11 BH 14 BH 17 BH 18

8 5.00 BH 8 BH 13

9 6.00 BH 16

10 6.25 BH 9

11 12.5 BH 12

13187-R-1-01 20 Mar, 2015

 BUILDING – PROFILE CORRELATION

Sl. No. Building Profile

1 Limestone Prehomogenizing Bed 8
2 Primary Crusher 1
3 Secondary Crusher 1
4 Sandstone Stockpile 8
5 Iron Ore Stockpile 8
6 Clay Stockpile 8
7 Raw Material Hoppers 2
8 Raw Mill House 6
9 Kiln Bag House and Electrical Room 6
10 Raw Meal Blending Silo 4
11 Preheater 5
12 Kiln 7
13 TA Duct 7
14 Clinker Cooler 7
15 Cooler ESP and Electrical Room 11
16 Reject Clinker Silo 1
17 Clinker Silo 1
18 General Stores 11
19 Pozzalana Stockpile 6
20 Limestone Stockpile 6
21 Gypsum Stockpile 6
22 Cement Mill Hoppers 6
23 Cement Mill 10
24 Cement Silos 1
25 Packing Plant 3
26 Empty Bags Godown 3
27 Truck Loading Platform 3
28 Coal Mill 7
29 Alkali By-pass System 7
30 CCR/Lab/Tech. Office 7
31 Water Treatment Plant 7
32 Load Centre 11
33 Cement Mill Substation 10
34 Security Office 11
35 Time Office 11
36 Road Weigh Bridge 11
37 Weigh Bridge Cabin 11
38 Elec./Mech. Workshop 11

13187-R-1-01 20 Mar, 2015

Figures in Appendix (2) of Geotechnical Investigation Report show the ultimate and allowable bearing
capacity for footings of various sizes, shapes, and depth of embedment calculated at different areas of
the project.

The following table summarizes the results:

Bearing Capacity of a Circular Footing of a Diameter Ranging between 0.5 to 5.0m

Depth Allowable Bearing Capacity (Mpa)

(m) Profile 1-2-3 Profile 4-5 Profile 6-7 Profile 8 Profile 9-10 Profile 11
2.5 3.47 0.36 0.36 0.36 0.36 0.36
3.0 3.53 3.53 0.42 0.42 0.42 0.42
4.0 3.66 3.66 0.54 0.54 0.54 0.54
5.0 3.79 3.79 3.79 3.79 0.66 0.66
7.0 4.05 4.05 4.05 4.05 4.05 0.89

Bearing Capacity of Wall Footing of a Width Ranging between 0.5 to 5.0m

Depth Allowable Bearing Capacity (Mpa)

(m) Profile 1-2-3 Profile 4-5 Profile 6-7 Profile 8 Profile 9-10 Profile 11
2.5 2.35 0.31 0.31 0.31 0.31 0.31
3.0 2.39 2.39 0.35 0.35 0.35 0.35
4.0 2.48 2.48 2.48 0.43 0.43 0.43
5.0 2.56 2.56 2.56 2.56 0.51 0.51
7.0 2.74 2.74 2.74 2.74 2.74 0.67

Bearing Capacity of a Circular Raft of a Diameter Ranging between 20.0 to 65.0m

Depth Allowable Bearing Capacity (Mpa)

(m) Profile 1-2-3 Profile 4-5 Profile 6-7 Profile 8 Profile 9-10 Profile 11
2.5 4.57 1.36 1.36 1.36 1.36 1.36
3.0 4.63 4.63 1.42 1.42 1.42 1.42
4.0 4.76 4.76 4.76 1.54 1.54 1.54
5.0 4.89 4.89 4.89 4.89 1.65 1.65
7.0 5.15 5.15 5.15 5.15 5.15 1.89

Figures in Appendix (3) of Geotechnical Investigation Report show the expected settlement of footings of
various sizes, shapes, and depth of embedment calculated at different areas of the project. Flexible and
rigid footing conditions are considered. Settlement of raft foundation is also estimated.

Bearing Capacity of Circular Footing of 10 m2 Surface Area

13187-R-1-01 21 Mar, 2015

 Depth in metres

Bore From 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0
Hole No.
To 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0

BH 1 0.97 3.69 3.94 2.45 4.32 3.28 8.72 5.24

BH 2 3.43 3.69 5.06 3.01

BH 3 1.02 6.07 1.40

BH 4 0.67 0.72 0.77 0.98

BH 5 0.97 1.68 3.94 4.20

BH 6 0.97 1.56 0.34 3.33 4.46 9.81

Allowable Bearing Capacity (Mpa)

BH 7 0.97 1.68 2.38 4.20 4.46 4.72

BH 8 0.97 1.68 2.38 4.20 4.46 4.72

BH 9 0.97 1.68 2.38 4.43 1.71 7.37 1.67

BH 10 0.97 1.68 3.94 4.20 4.46

BH 11 0.97 1.68 2.38 3.09 4.46

BH 12 0.97 1.68 2.38 3.09 3.80 4.50 5.21

BH 13 0.97 1.68 3.94 4.25

BH 14 0.97 1.68 3.94

BH 15 0.97 1.68 3.94 4.20 3.30

BH 16 0.97 1.68 6.01 2.75 3.67

BH 17 0.97 1.68 3.94 4.20 4.46

BH 18 0.97 1.68 3.94 4.20

BH 19 0.97 1.68 3.94

5. ELASTIC AND DYNAMIC PARAMETERS

Elastic and dynamic parameters of the Wadi Formation are calculated based on cyclic plate test results.
Figures 8 shows the summation of the results obtained and the correlations made to calculate these
parameters. Elastic and dynamic rock parameters are calculated based on the selected Young’s

13187-R-1-01 22 Mar, 2015

Modulus. Internal damping factor of Wadi Formation is selected according to Richard et al.3. The
following Table is obtained:

Wadi deposits Rock deposits

Young’s Modulus(E) 80.0 Mpa 570.0 Mpa
(800.0 Kg/cm2) (5700.0 Kg/cm2)
Shear Modulus(G) 58.0 Mpa 475.0 Mpa
(580.0 Kg/cm2) (4750 Kg/cm2)
Coefficient of Elastic Uniform 24.0 Kg/cm3 252.4 Kg/cm3
Compression (Cu)
Coefficient of Elastic Uniform 2.0 Kg/cm3 126.2 Kg/cm3
Shear (Ct)
Plate Spring Modulus(Ks) 7.0 Kg/cm3 Equal to (Cu)=252.4
Kg/cm3
Internal Damping factor () 0.05

6. FOUNDATION RECOMMENDATIONS

Shallow foundations are recommended for the different types of structure in the project. The following
recommendations are made:

1. One major concern is the continuity of the bearing formation. Since Wadi formation is expected
to be the main bearing layer, rock formations could be found in small block. It is also expected to
have the same structure to be constructed partly on the Wadi Formation and partly a rock
formation. This case will result in differential settlement because of variation of stiffness
underneath the foundation system. Hence, its is recommended to inspect the ground at
foundation level. In the case a rock formation is partially covering the area, it is recommended to
excavate the Wadi formation to at least 1.5m below the foundation level and the rock formation to
0.5m and replace a fill material of compacted pit run gravel composed of coarse siliceous sand
and gravel 1:1. The gravel used should have maximum particle size of 22mm. This soil
replacement will be carried out in lifts not exceeding 25cm. Each layer will be compacted
equivalent to 95% of the soil maximum dry density as determined by Modified Proctor Test.

2. The project site, being located in Yemen, lies in Seismic Zone No.3 according to 1997 Uniform
Building Code for Calculation of loads and forces on structural and building works. According to
Uniform Building Code, a peak ground acceleration of about 0.3g may be considered in dynamic
analysis in absence of a value based on site specific seismic hazard assessment.

3. An environmental study should be carried out especially to establish the paths of torrential rains
from the high ground to the sea and to investigate possible rock falls from the nearby high
ground that may cause in danger the facilities to be constructed

4. Based on the results of the chemical analysis carried out on soil samples selected from the
project site, it was observed that the Sulphate concentration has a maximum value of 1.3%, while
the Chloride concentration has a maximum value of 0.18%. Accordingly, the following
requirements shall be considered in the reinforced concrete design and construction:
 Sulphate Resisting Cement will be used in the concrete foundation.

 Minimum concrete cover must not be less than 7cm

 Water/Cement Ratio should not exceed 0.43.

 Reinforced concrete should be dense with minimum cement content of 400Kg/m3 of

concrete.
13187-R-1-01 23 Mar, 2015
  Plain concrete should be dense with minimum cement content of 300 Kg/m3 of concrete.

 All reinforced concrete in the foundations should be properly and thoroughly isolated using
three layers of modified bituminous coatings.

Note:

1. For Bore Logs refer Soil Investigation Report.

2. For Bore Hole locations refer enclosed drawing.

13187-R-1-01 24 Mar, 2015

13187-R-1-01 25 Mar, 2015