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SPECIFICATION DETAILS
Discipline:
Civil
Equipment:
Ags Specifications
Title:
Description:
Design
AGS019
02
-AGS019-02~1.doc
Status:
Issued
SPECIFICATION No.:
AGS019
SPECIFICATION TITLE:
PROJECT TITLE:
N/A
BUSINESS UNIT:
TBE
AREA:
ALL
EQUIPMENT No.:
N/A
DISCIPLINE:
CIVIL
Rev No
Date
01
8/2/99
02
Description
Orig.
Project
Man.
CM&EE
LF
KBF
WvdO
EM
CME
H.O.E
JJAB
KW
JJAB
Revision Notes
Master Specification No.- AGS 019
Rev.- 02
Page 2 of 21
Spec No AGS019
Revised By
LF
WvdO
CONTENTS
1.0 SCOPE
3.0 DEFINITIONS
4.0 REQUIREMENTS
15
16
APPENDIX C: ULTIMATE LIMIT STATE LOAD FACTORS AND LOAD COMBINATIONS FOR
GENERAL STRUCTURES AND BUILDINGS
17
APPENDIX D: SERVICEABILITY LIMIT STATE LOAD FACTORS AND LOAD COMBINATIONS
FOR GENERAL STRUCTURES AND BUILDINGS
18
APPENDIX E: DYNAMIC EFFECTS OF ROTATING, VIBRATING OR IMPACTING MACHINERY
AND EQUIPMENT
19
1.0
SCOPE
This specification details the requirements for the design of mass concrete, reinforced concrete,
precast concrete and prestressed concrete structures for underground and surface applications in
mine shafts and plants.
It is intended for use in the design of concrete structures constructed in South Africa only, but it can
also be used for concrete structures constructed in other countries, provided all specific
requirements, as set out in the relevant structural design and construction standards, and legislation
of those countries, are taken into account.
Structures covered unconditionally by this specification include:
Industrial structures and buildings, e.g. plant structures, stores and workshops.
Page 3 of 21
Spec No AGS019
Dynamically loaded structures, e.g. mill foundations and crusher support structures.
2.0
Offshore structures.
3.0
DEFINITIONS
For the purposes of this specification the following definitions shall apply:
APPROVED
BS
: British Standard
C&CI
CP
CLIENT
: The company appointing the Engineer to carry out the structural design
DESIGN
DRAWINGS
DIN
ECSA
ENGINEER
: The company responsible for the structural design, for preparation of the
with their size, concrete grade and reinforcement layout, and any other
information required for construction
SABS/SANS
Standards
Page 4 of 21
Spec No AGS019
4.0
REQUIREMENTS
4.1 Design standards and related publications
The design standards, specifications and related publications listed in Appendix A form part of this
specification and all structural design shall comply with the relevant requirements of these
documents.
4.2 Design responsibility
The design of concrete structures shall be performed by, or under the direction, control and
supervision of, a professional engineer or a professional engineering technologist, who shall accept
legal responsibility for the design. Such professional engineer or professional engineering
technologist shall be registered with ECSA and shall have appropriate knowledge of, and
appropriate experience in the analysis and design of concrete structures in the particular application.
4.3 Quality management of design process
The quality management of the design process shall comply with the requirements of SANS 9001.
4.4 Design calculations
4.4.1
General
Formal calculations shall be prepared for all concrete structures. Calculations shall be recorded on
calculation sheets and shall be neat, logically set out, short and descriptive, and easy to follow.
Calculations shall be documented in such a way that they can be easily audited. An index shall be
provided for each set of calculations applicable to a particular structure.
Calculations shall be retained for a minimum period of 10 years from the date of commissioning of
the particular structure.
4.4.2
Name of person who carried out the calculations and date when calculations were carried out.
Name of person who reviewed the calculations and date when calculations were reviewed.
References
Reference numbers of all relevant drawings (e.g. suppliers plant and equipment drawings,
mechanical layout drawings).
Page 5 of 21
Spec No AGS019
Geotechnical information.
Headings
A logical system of main headings and sub-headings shall be used to define, on each calculation
sheet, the particular area of the structure and the particular structural component(s) under
consideration. All headings shall be underlined.
Example
4.4.5
Main heading
Sub-heading
:
:
Foundations
Column foundation F5
Information
For each structure or structural element, the following information shall be shown on the relevant
calculation sheet(s):
Geometry: The geometry of each structure or structural element shall be clearly defined by
way of a sketch or drawing, included in the calculations. This also applies to simply supported
beams.
Loading: Each load case and each load combination adopted in the design shall be defined in
an unambiguous manner by way of clear descriptions or sketches. All loading calculations
shall be shown, and assumed loads shall be fully justified. It shall be clearly stated whether
the indicated loads are nominal loads (unfactored loads) or whether they are design loads
(factored loads).
Analysis: For manual analysis, all analysis calculations shall be shown together with the
results of the analysis, e.g. bending moment, shear force or axial load diagrams, or values.
For computer analysis, the following information shall be shown:
Software name and version, data file name and location.
Sketch defining structural computer model, e.g. node numbers, element numbers, member
releases, etc.
Summary of all computer input, e.g. load cases and load combinations considered.
Summary of computer output providing all relevant analysis results, e.g. bending moments,
shear force or axial load diagrams, or values.
When diagrams or values are shown, it must always be stated whether these values are
nominal values (unfactored) or whether they are design values (factored).
Design calculations: If the design is done manually, all relevant manual calculations shall be
shown. If computer software is used for the design, the relevant computer calculations,
proving the adequacy of the selected section, shall be pasted onto calculation sheets or printed
Page 6 of 21
Spec No AGS019
out on electronic calculation sheets. All relevant load effects, e.g. bending, shear, punching
shear, torsion, axial load, deflection, etc. shall be considered in the calculations and the
adequacy of the selected section to sustain all the relevant load effects shall be proven.
Conclusion: For each structural element under consideration, a conclusion shall always be
stated in the calculations. This might be in the form of a fully dimensioned sketch, clearly
showing the extent and quantity of reinforcing required.
4.4.6
Units
Moments
kNm
Stresses
MPa
Section properties
Deflections
mm
Linear dimensions
4.4.7
Symbols
All symbols used in the calculations shall be consistent with the symbols used in the particular code
of practice or standard being used.
4.4.8
Terminology
Terminology used shall be consistent with the relevant code of practice or standard used. The terms
permanent load and imposed load shall be used, rather than dead load and live load.
Page 7 of 21
Spec No AGS019
4.4.9
All structural calculations shall be thoroughly checked by the person conducting the design. In
addition, all structural calculations shall be reviewed for accuracy by the responsible person referred
to in Clause 4.2.
4.5 Approval of designs and design drawings
All designs and design drawings of concrete structures shall be approved by the responsible person
referred to in Clause 4.2 by way of a full signature, affixed to the relevant design drawings.
In addition, the following information shall be shown on the design drawings:
Name and address of the engineer (See Section 3.0 for definition).
Approval of a design means that the design is complete, that the design constitutes an appropriately
engineered solution, that the design complies with this specification in terms of structural strength,
stability and serviceability, and that the design is fit for the intended service. Approval of a design
drawing means that the drawing is complete, that the drawing conforms to the design and that the
structural content of the drawing is correct. A signature on a design drawing confirms that both the
design and the drawing are approved.
4.6 Materials
4.6.1
Concrete
The specified concrete grade shall be determined in accordance with the provisions of SANS
10100-1 and SANS 10100-2, with due consideration of the strength requirements, conditions of
exposure and required durability.
The minimum concrete grade shall be in accordance with Table 1.
TABLE 1
ELEMENT
Mass concrete and
blinding
Foundations, ground
beams, piles and pile
caps
Floor beams and slabs
Surface beds
Page 8 of 21
Spec No AGS019
15
35
25
30
30
40
30
35
Under no circumstances shall concrete of grade 50 (50 MPa) and higher be used without prior
approval from the client.
4.6.2
Reinforcement
Mild steel reinforcement shall only be used for chairs, stools, links, stirrups and pull-out bars.
Cold worked high yield steel shall not be used.
4.7 Loads
4.7.1
Nominal loads
Nominal permanent and imposed loads shall be determined in accordance with SANS 10160 and,
where required, in accordance with the relevant design standards listed in Appendix A. In addition,
the following provisions shall apply:
4.7.2
Imposed floor and roof loads shall be assessed with due regard to the intended use or occupancy of
the structure. Imposed loads shall be approved by the client prior to commencement of design. The
loads adopted in the design shall be noted on the design drawings. The minimum uniformly
distributed load adopted shall be as follows:
7,5 kN/m2
5,0 kN/m2
Office floors
3,0 kN/m2
3,0 kN/m2
2,0 kN/m2
1,0 kN/m2
4.7.3
Plant and equipment loads shall be obtained from certified equipment drawings, provided by the
suppliers of the equipment. Such drawings shall form part of the design calculations. The loads
adopted in the design shall be indicated on the drawings. Where certified loading information is
unavailable, equipment loads shall be assessed in consultation with, and approved by, the client
prior to commencement of design, and shall be verified once certified information becomes
available.
Page 9 of 21
Spec No AGS019
4.7.4
Dynamic loads
See Appendix E.
4.7.5
Loads induced during conveyor belt start-up conditions shall be accurately assessed and in no case
shall be taken as less than 1,4 times the normal operating loads. The start-up loads shall be used for
both structural framework and foundation design.
4.7.6
Wind loads
The relevant terrain category shall be assessed in consultation with, and approved by, the client. The
terrain category adopted for inland terrains shall not be less severe than a category that falls midway
between Category 2 and Category 3.
4.7.7
Loads imposed by stored bulk materials on walls of bunkers, silos and bins shall be assessed in
accordance with DIN 1055 Part 6.
Material coefficients for bulk materials not listed in DIN 1055 Part 6 shall be determined by testing.
Due regard shall be given to variations in the characteristics of bulk materials, resulting from
process modifications, moisture content variations, compaction, etc. All material coefficients used
in the design, must be approved by the client.
In the absence of test results, the values given in Appendix B may be used for preliminary design
purposes. In the calculation of material pressures, the material coefficients for pressure ratio and
wall friction s hall be adjusted 10% upwards and 10% downwards and the pressures shall be
obtained as follows:
Horizontal pressures
Vertical pressures
Wall friction
4.7.8
:
:
:
Loads imposed by retained soil shall be determined on the basis of a rational analysis. The active
horizontal pressure coefficient adopted shall not be less than 0,4 and the passive horizontal pressure
coefficient adopted shall not exceed 3,0.
4.7.9
Provision shall be made in the design of structures and structural elements for expansion and
contraction resulting from elevated temperatures, temperature changes and temperature
differentials. For the assessment of the effects of climatic temperature changes on exposed
structures or structural elements, a temperature variation of plus or minus 20 C shall be considered.
The temperature load assessment shall be based on the un-cracked section modulus of the various
structural elements.
The coefficient of linear expansion of mass and reinforced concrete shall be taken as 10 x 10 -6 / C .
Page 10 of 21
Spec No AGS019
Equipment failure
Explosion
Fire
Extraordinary climatic conditions: hurricane winds, floods, rain, hail, snow, etc.
Load factors and load combinations shall be determined in accordance with SANS 10160 and,
where required, in accordance with the relevant design standards, specifications and related
publications listed in Appendix A. In addition, the following provisions shall apply.
4.8.1
Load factors and load combinations for general structures and buildings
The load factors and load combinations referenced in SANS 10160 shall be interpreted as shown in
Appendix C for ultimate limit states and in Appendix D for serviceability limit states.
4.9 Foundation loads
Foundation loads shall be based on nominal loads. A foundation loading schedule, clearly
indicating the magnitude and direction of all foundation loads, for each specific nominal load case,
shall be prepared for all structures.
4.10
4.10.1 General
The provisions of SANS 10160 and the provisions of the relevant design standards, specifications
and related publications listed in Appendix A shall apply. In addition, the following provisions shall
apply:
4.10.2 Dynamic effects of rotating, vibrating or impacting machinery and equipment
See Appendix E.
4.10.3 Foundations
4.10.3.1 Foundations with less than 1 m soil cover
Foundations shall have a stability safety factor of 1,5 when the effect of the soil cover is considered,
and 1,2 when the effect of the soil cover is ignored"
Page 11 of 21
Spec No AGS019
Construction details
4.11.1 Cover
The minimum cover shall be clearly indicated on the drawings. The minimum cover shall be
determined in accordance with the provisions of SANS 10100-1 and SANS 10100-2, with due
consideration of the conditions of exposure, required durability, fire risk, aggregate size and fixing
tolerances. The minimum cover shall not be less than that shown in Table 2.
Cover shall not exceed 60 mm without prior approval from the client, except where concrete is cast
directly against excavated surfaces.
Page 12 of 21
Spec No AGS019
TABLE 2
ELEMENT
Foundations, ground
beams and pile caps
cast directly against
excavated surfaces
75
Foundations, ground
beams, and pile caps
not cast directly against
excavated surfaces
Floor beams and slabs
Surface beds
50
30
40
60
50
40
TABLE 3
ELEMENT
MINIMUM REINFORCEMENT
Piles
0,008 Ac
Pile caps
Foundations
H < 600 mm
H > 1200 mm
Columns
4Y16
Beams
Slabs
Walls
Y 10 @ 300 EF horizontal
Notes
1.
2.
3.
4.
Ac
H
EW
EF
Page 14 of 21
Spec No AGS019
:
:
:
:
BS 8007
CP 2012
C&CI
Concrete industrial floors on the ground Louis R Marais & Bryan D Perrie
DIN 1055
ISO2631-1978 :
SANS 9001
SANS 10100
SANS 10160
SANS 10161
SANS 10208
Page 15 of 21
Spec No AGS019
Bulk material
3
1
2
Overpressure
coefficient
Material
coefficient
eh
Anthracite
11,5
40
0,45
0,55
0,40
0,35
1,4
0,5
Coal: crushed
11,0
40
0,45
0,60
0,45
0,40
1,4
0,5
Coal: pulverised
17,5
35
0,55
0,70
0,60
0,50
1,5
0,5
Chrome ore
26,0
35
0,45
0,65
0,50
0,45
1,3
0,5
Carbon
6,2
35
0,45
0,55
0,40
0,35
1,4
0,5
Gold ore
18,0
40
0,45
0,65
0,50
0,40
1,3
0,5
Ilmenite
27,0
25
0,60
0,60
0,40
0,30
1,5
0,5
Iron ore
22,0
40
0,45
0,65
0,55
0,45
1,3
0,5
Kimberlite
16,0
45
0,35
0,70
0,55
0,40
1,4
0,5
Platinum ore
(Merensky)
24,0
40
0,45
0,70
0,60
0,50
1,3
0,5
Rutile
24,0
30
0,60
0,60
0,45
0,35
1,4
0,5
Zinc ore
21,0
45
0,35
0,70
0,60
0,50
1,3
0,5
Zircon
25,0
30
0,50
0,70
0,60
0,50
1,4
0,5
NOTE:
Where the effective coefficient of internal friction has been established by testing, the pressure ratio may
be calculated as follows:
= 1,1 (1 Sin )
Page 16 of 21
Spec No AGS019
APPENDIX C: ULTIMATE LIMIT STATE LOAD FACTORS AND LOAD COMBINATIONS FOR
GENERAL STRUCTURES AND BUILDINGS
The following table gives load factors to be applied to commonly encountered nominal loads when
determining design load combinations at the ultimate limit state.
The listed load factors are not applicable to headgear and collar structures, stages, conveyances and shaft
system structures. For these structures refer to SANS 10208.
LOAD
COMBINATION
1
2
3
4
5
6
7
8
9
10
Qn
Qm n
Qf n
Qr n
Wn
Cv n
Ch n
Tn
1,6
0,5 +
0,5 +
0,5 +
0,5 +
0,5 +
0,5 +
0,5 +
1,6
1,6
1,6
1,6
1,6
1,6
1,6
1,6
1,3
1,3
1,3
1,3
1,3
1,3
1,3
1,3
0,5 #
0,5 #
0,5 #
1,6
0,5 #
0,5 #
0,5 #
0,5 #
0
0
0
0
1,3 $
0
0
0
1,3 $
0,8
0,8
0,8
0,8
0,8
1,6
1,2
0,8
0,8
0,8
0,8
0,8
0,8
1,2
1,6
0,8
0,6
0,6
0,6
0,6
0,6
0,6
0,6
1,2
NOTES:
1.
2.
3.
4.
5.
6.
7.
8.
Page 17 of 21
Spec No AGS019
Qn
Qm n
Qf n
Qr n
Wn
Cv n
Ch n
Tn
1,1
1,0
1,0
1,0
0,3 #
0,5
0,5
0,5
1,1
0,3 +
1,0
1,0
0,3 #
0,5
0,5
0,5
1,1
0,3 +
1,0
1,0
0,3 #
0,5
0,5
0,5
1,1
0,3 +
1,0
1,0
1,0
0,5
0,5
0,5
1,1
0,3 +
1,0
1,0
0,3 #
0,6
0,5
0,5
0,5
1,1
0,3 +
1,0
1,0
0,3 #
1,0
0,75
0,5
1,1
0,3 +
1,0
1,0
0,3 #
0,75
1,0
0,5
1,1
0,3 +
1,0
1,0
0,3 #
0,5
0,5
1,0
1,0
0,6
NOTES:
1.
2.
3.
4.
5.
Page 18 of 21
Spec No AGS019
General
Suitable provision shall be made in the design for the dynamic effects of rotating, vibrating or
impacting machinery and equipment. Dynamic effects shall be determined and interpreted in
accordance with this Appendix.
2.0
Structural framing
In general, the transmission of dynamic loads from floor members to columns and foundations shall
be by the shortest and most direct route possible. Where practical, the vibrating part(s) of the
structure shall be isolated from the rest of the structure.
3.0
Dynamic loads
The magnitude, direction and exciting frequency of all dynamic loads induced by machinery and
equipment such as feeders, screens, shaking tables and crushers, shall be obtained from the
manufacturers of the equipment. The nature of the dynamic excitation i.e. harmonic, periodic or
random impulse-type excitation shall be clearly established. Dynamic loads, obtained from
manufacturers, shall be verified from dynamic data such as motor torque, eccentricity of unbalanced
masses, spring stiffness, screen stroke and screen stroke angle.
Where a single structure supports multiple machinery units, the worst combination of any two
machines acting in phase shall be considered, unless machines are electrically or mechanically
coupled. Where multiple machines are electrically or mechanically coupled, the worst combination
shall be based on a rational assessment.
4.0
Modal analysis
A modal analysis shall be conducted to obtain the mode shape and natural frequency of each
significant vibration mode. A significant vibration mode is a mode, which is compatible with the
displacement(s) produced by the dynamic load(s).
5.0
Dynamic response
The following dynamic responses shall be obtained at all strategic locations on the structure:
amplitude of acceleration and displacement
amplitude of dynamic stress
6.0
Resonance
For the purposes of this Clause, resonance is defined as the condition in which the exciting frequency
fe equals the natural frequency fn of any significant vibration mode of the structure.
To avoid resonance or near-resonance, the following conditions shall be satisfied:
fn 1,4 fe or fn 0,6 fe where fn = natural frequency of any significant vibration mode.
Page 19 of 21
Spec No AGS019
When fn1 1,4 fe the structure is considered high tuned and when fn1 0,6 fe the structure is considered
low tuned.
(fn1 = the fundamental [lowest] natural frequency of the structure).
High-tuning is generally preferred. However, where it can be demonstrated that high tuning is
unrealistic, low tuning may be accepted provided the following conditions are met.
The dynamic analysis must include all vibration modes up to a frequency of at least 1,5 f e .
Vibration limits
Vibration limits for rotating machinery shall be obtained from BS 4675, or from the manufacturer.
7.2. Structural integrity
The integrity of all structural components subject to cyclic dynamic stresses shall be evaluated on the
basis of a rational analysis.
7.3. Human response
For the assessment of vibrations, K-values shall be calculated from the equations given in the
following table:
EXCITING
FREQUENCY
(Hz)
1 to 2
2 to 4
4 to 8
8 to 80
Where
fe
ah
au
av
=
=
=
=
K-VALUE
HORIZONTAL
VIBRATIONS
28 a h
56 a h / f e
VERTICAL
VIBRATIONS
10 a v f e
20 a v
160 a v / f e
33,5 a u f e
0,25
160 a u / f e
Page 20 of 21
Spec No AGS019
VIBRATIONS OF
UNDETERMINED
DIRECTION
28 a u
K-value
7,0
4,2
3,5
NOTES:
1.
2.
3.
4.
5.
6.
The K-value procedure followed above is equivalent to the assessment of vibrations in accordance with
ISO 2631-1978, using two thirds of the vibration limits obtained from the fatigue-decreased
proficiency boundary, as defined in ISO 2631.
Unless otherwise stated an exposure time of 8 hours shall be adopted.
For harmonic loads, a (rms value) = a' / 2, where a' = amplitude of acceleration.
When vibration occurs simultaneously at more than one discrete frequency within the range 1 to 80 Hz,
each frequency component shall be evaluated separately with reference to the appropriate limit at that
frequency.
For the evaluation of narrow-band and broad-band vibrations, refer to ISO 2631-1978.
If vertical and horizontal vibration occurs at the same location, an equivalent K-value shall be
evaluated from the following equation:
K = (Kh2 + Kv2) 0.5
Where :
Page 21 of 21
Spec No AGS019