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PT Kaltim Prima Coal Engineering Report
Structural Analysis Conveyor CV02 Structural Engineering
H356799 Calculation Report
Table of Contents
1. Executive Summary ....................................................................................................................... 1
2. Introduction ..................................................................................................................................... 3
3. Scope of Work................................................................................................................................. 3
3.1 Battery Limit ............................................................................................................................ 3
3.2 Deliverables ............................................................................................................................ 4
4. Referenced Document ................................................................................................................... 4

5. Structural Analysis ......................................................................................................................... 8
5.1 General Arrangement ............................................................................................................. 8

5.2 Assumption ........................................................................................................................... 12
5.3 Design Load .......................................................................................................................... 13
5.3.1 Permanent Load ...................................................................................................... 13
5.3.2 Imposed Load .......................................................................................................... 13
5.3.3 Environmental Load ................................................................................................. 15
5.3.4 Coal Lateral Pressure .............................................................................................. 18
5.4 Load Combination ................................................................................................................. 21
5.5 Structural Model .................................................................................................................... 24
5.6 Structural Analysis Result ..................................................................................................... 25
5.6.1 Trestle ...................................................................................................................... 25
5.6.2 Gantry ...................................................................................................................... 27
5.6.3 Tripper Support Beam ............................................................................................. 27
5.6.4 Base Plate Check .................................................................................................... 28
5.6.5 Gantry -Trestle Pinned Connection ......................................................................... 28
6. Conclusion .................................................................................................................................... 30
List of Tables
Table 4-1: List of Reference Document .................................................................................................. 4
Table 5-1: Structural General Arrangement ............................................................................................ 8
Table 5-2: Earthquake Design Parameters........................................................................................... 16
Table 5-3: Spectrum Response ............................................................................................................ 17
Table 5-4: Maximum Height of Buried Trestle ...................................................................................... 19
Table 5-5: Extreme Stockpile Formation ............................................................................................... 20
Table 5-6: Load Combination without Coal Lateral Pressure ............................................................... 21
Table 5-7: Load Combination without Coal Lateral Pressure ............................................................... 22
List of Figures
Figure 1-1: Model View ........................................................................................................................... 2
Figure 3-1: Scope of Work, Gantry Structure Conveyor CV02 ............................................................... 3
Figure 5-1: General Arrangement ........................................................................................................... 8
Figure 5-2: Space Gass Model ............................................................................................................. 12
Figure 5-3: Coal Profile on Conveyor (Normal)..................................................................................... 14
Figure 5-4: Coal Profile on Conveyor (Flooded) ................................................................................... 14
Figure 5-5: Tripper Wheel Location ...................................................................................................... 15
Figure 5-6: Tripper Load Input to Model ............................................................................................... 15
Figure 5-7: Response Spectrum Design ............................................................................................... 17
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© Hatch 2020 All rights reserved, including all rights relating to the use of this document or its contents.
Figure 5-8: Coal Lateral Pressure on Buried Trestles .......................................................................... 18

Figure 5-9: Full Stockpile Formation ..................................................................................................... 19
Figure 5-10: Model View ....................................................................................................................... 24
Figure 5-11: Trestle Steel Stress Check ............................................................................................... 25
Figure 5-12: Trestle Steel Stress Check - Limiting Height of Buried Trestle to 11m ............................ 26
Figure 5-13: Trestle Leg Strengthening - Pile Jacketing ....................................................................... 26
Figure 5-14: Gantry Steel Stress Check ............................................................................................... 27
Figure 5-15: Tripper Support Beam Steel Stress Check ...................................................................... 27
Figure 5-16: Base Plate Detail .............................................................................................................. 28
Figure 5-17: Gantry-Trestle Pinned Connection ................................................................................... 29
List of Appendices
Appendix A Structure Self-weight Calculation
Appendix B Wind Load Calculation
Appendix C Coal Lateral Load Calculation
Appendix D Load Case Location
Appendix E Tripper Support Beam – Strengthening Works

Appendix F Stared Angle Capacity Calculation
Appendix G Trestle Strengthening
Appendix H Gantry-Trestle Pinned Connection Calculation

Appendix I Trestle Base Plate Calculation
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1. Executive Summary
Hatch was assigned by KPC to provide detailed engineering services to upgrade the CV02
Tripper car’s travelling drive, including to assess on the required power demand, to select
of the new travelling drive components (i.e. motor, gearbox, brake, chains, and sprocket)
and to assess the required modification on the structural member attaching to the travelling
drive components. These scopes were fully completed, and all drawings and reports have
been submitted to KPC. The new drive system and the required structural modification
works (including counterweight to balance the new drive installation) increase the tripper
car’s weight by approximately 3.5t from the original design at approximately 40t.
As an additional scope, Hatch has been assigned by KPC to complete structural calculation
and modelling on the existing conveyor CV02 galleries and trestles (which support the
tripper car).
The structural analysis has been performed by using Space Gass v12.80 with the following
assumptions.
• The boundary for structural model starts from the existing backstay acting as
longitudinal restraint at the west and the drive tower at east side.
• All members are modelled and connected to provide complete load path from tripper
car transmitting to tripper-frame support and continued to gantry and the trestles.
• The support system on the trestle end has been model as pinned connection,
(considering its connection detail as shown on the as built drawing).
• The tripper car will travel along the rail beam, the load from tripper car has been
modeled as an automatic moving load in Space Gass.
• The ground elevation is varying in accordance to KPC drawing 924S001 Rev D.
• The existing drawing has indicated the trestle leg will be filled with concrete after
erection. However, there is no information on concrete filling preparation, procedure
and strength. Based on this fact the concrete contribution to steel strength is not
accounted in this assessment.
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Figure 1-1: Model View
Conclusion
The structural analysis has revealed the following conclusion.
• There is no overstress occurs in the gantry structure from all load cases.
• The tripper support beam will undergo overstress by 30% due to both lateral coal
pressure and no lateral coal pressure. The location of overstressed bracing can be
seen in Appendix E.
• The trestle has been analyzed with the following results.
 Without considering the coal lateral pressure, the trestle will not overstress
 By considering the coal lateral pressure, the trestle legs at grid 8 will undergo
overstress by more than 100%. The trestle at grid 6 and 7 is also overstress but
not as significant as grid 8.
Recommendation
• The force in overstressed members at tripper support bracing shall be reduced by

installing additional steel angle L120 x120x12. See Appendix E for detail location.
The strengthening could be conducted during regular maintenance period.
• Trestle Leg – Short Term Recommendation.
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The trestle leg strengthening could be complicated and time consuming. Therefore,
for time being, limiting the stock pile height on buried trestle shall be conducted.
Limiting the buried trestle height from asymmetric formation to maximum of 11m will
result the stress ratio still under the limit. (Note: the load factor for coal lateral
pressure has been reduced from 1.5 to 1.2 for this option)
• Trestle Leg – Long Term Recommendation
Strengthening the trestle by “steel jacketing” which consists of existing trestle pile
(ø800x12) covered by additional circular hollow steel section (ø1000x14). The gap
between existing and new steel plate shall be filled with concrete 30 MPa includes
shear connector installation to maintain the composite action between two members.
Detail of the strengthening presented in Appendix G.
2. Introduction
Hatch was assigned by KPC to provide detailed engineering services to upgrade the CV02
Tripper car’s travelling drive, including to assess on the required power demand, to select
of the new travelling drive components (i.e. motor, gearbox, brake, chains, and sprocket)
and to assess the required modification on the structural member attaching to the travelling
drive components. These scopes were fully completed, and all drawings and reports have
been submitted to KPC. The new drive system and the required structural modification
works (including counterweight to balance the new drive installation) increase the tripper
car’s weight by approximately 3.5t from the original design at approximately 40t.
As an additional scope, Hatch has been assigned by KPC to complete structural calculation
and modelling on the existing conveyor CV02 galleries and trestles (which support the
tripper car).
3. Scope of Work
3.1 Battery Limit
Hatch’s boundary of work included gantry structure carrying tripper car from backstay at
grid 4 to grid 9 with additional modelling of drive tower as lateral resistance.
Figure 3-1: Scope of Work, Gantry Structure Conveyor CV02
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The structural analysis only conducted to the structural element above the ground level.
3.2 Deliverables
• Technical Memo, submitted to KPC on 11th February 2020
• Structural Analysis Report (this report).
4. Referenced Document
Reference is made to the following data as provided by KPC.
Table 4-1: List of Reference Document
No. Rev. Document Title Originator

KPC-C-01 4 Standard Specification for Civil and Structural Design Criteria
Sangatta Coal Handling System PT KPC, Tanjung Bara 1800mm
Storage Transfer Conveyor CV02 Roberts &
924S001 D
Schaefer
General Arrangement
Roberts &
924S002 E Storage Transfer Conveyor CV02
Tail End Deck Section Schaefer
Roberts &
924S003 C Storage Transfer Conveyor CV02
18m Truss “T1” Bent 0.5 to 1 Schaefer
Roberts &
36m Truss “T2” Bent 1 to 2 Schaefer
Roberts &
Roberts &
Standard Truss Sections and Details Schaefer
Roberts &
924S007 D Storage Transfer Conveyor CV02
Bents and Sampling Details Schaefer
Roberts &
924S008 E Storage Transfer Conveyor CV02
Take-up Tower Schaefer
Roberts &
Tripper Deck Plan & Elevation, Bent 4 through 5 Schaefer
Roberts &
Roberts &
Roberts &
Tripper Support Plan T/S EL. 72m, Bent 4 through 5 Schaefer
Roberts &
924S013 B Storage Transfer Conveyor CV02
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Roberts &
Roberts &
Bents 3.5 & 4 Connection Schaefer
Roberts &
Roberts &
36m Truss “T4” Bent 5 through 8 Schaefer
Roberts &
Roberts &
14.400m Truss “T4” Bent 9 to 10 Schaefer
Roberts &
Truss Support, Bracing, Splice Detail Schaefer
Roberts &
Connection Detail Schaefer
Roberts &
Connection Detail Schaefer
Roberts &
Bents 3.5 and 4 Schaefer
Roberts &
Bents 5 through 9 Schaefer
Roberts &
924S025 D Storage Drive Tower
Plans, Sections and Details Schaefer
Roberts &
924S026 C Storage Drive Tower
Elevation @ Column Line A & 11 Schaefer
Roberts &
Elevation @ Column Line B & 10 Schaefer
Roberts &
Sections and Details Schaefer
Roberts &
924S029 B Storage Drive Tower
Roberts &
Roberts &
924S031 B Sangatta Coal Handling System PT KPC, Tanjung Bara 1800mm
Storage Drive Tower Schaefer
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Sections and Details
Roberts &
924S032 D Storage Transfer Conveyor CV02
Details Schaefer
Roberts &
Roberts &
Standard Truss Sections and Details Schaefer
Roberts &
Clamp Bars @ Tripper Belt Seal Plan & Details Schaefer
Roberts &
Roberts &
Tripper Conveyor Chain Support Schaefer
Sangatta Coal Handling Facility
924S039 A Storage Transfer Conveyor (CV02) KPC
Take-up Tower – Arrangement Additional Platform
Take-up Tower – Additional Platform EL. +57.78
Take-up Tower – Additional Platform EL. +62.58
Take-up Tower – Additional Platform EL. 68.08 and Details
Take-up Tower – Detail Guard
924S048 B Storage Transfer Conveyor (CV02) KPC
Additional Monorail – General Arrangement & Detail
Additional Monorail – Detail Sheet 1 of 2
Additional Monorail – Detail Sheet 2 of 2
Roberts &
924S054 C Storage Transfer Conveyor (CV02)
Tripper Storage - Drive Tower modification Plan, Sections & Details
Schaefer
Roberts &
924S055 C Storage Transfer Conveyor (CV02)
Tripper Storage - Drive Tower modification Plan, Sections & Details
Schaefer
Roberts &
924M010 D Sangatta Coal Handling System PT KPC, Tanjung Bara 1800mm
Storage Conveyor Schaefer
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Tripper – Elevation
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5. Structural Analysis
5.1 General Arrangement
A full set structural model was created to accommodate all load combinations and its
possibility on primary structural members during tripper movement. Tripper car traveling
in limited span only between grid 4 through 9. Therefore, trestles and galleries within this
area were being assess. In order to develop overall lateral stiffness of structure, the drive
tower on east side and backstay on west side (grid 4) were also included in structural
model.
The structural model has been prepared based on the received as-built drawings with the
general arrangement as shown in Figure 5-1.
Backstay Drive Tower
Figure 5-1: General Arrangement
In General, the structure is divided into 3 major components; Trestle, Gantry and Tripper
Support Beam. General arrangement of these structural components is described in
Table 5-1.
Table 5-1: Structural General Arrangement
Category Description Drawing

Trestle Drawing No.
924S001
Trestle Height
Grid 4 = 17.5 m
Grid 5 = 19.2 m
Grid 6 = 20.9 m
Grid 7 = 22.6 m
Grid 8 = 24.3 m
Grid 9 = 26.0 m
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Trestle Drawing No.
924S023
Trestle on Grid 4
Vertical Trestle
(CHSø800x12)
Diagonal Back Stay

(CHSø600x12)
Trestle Drawing No.

924S024
Trestle on Grid 5
through Grid 9
Vertical Trestle
(CHSø800x12)
Distance between
each leg
2.29m at top
10.0m on bottom
Trestle legs are

filled with concrete
for protection
against impact load.
Therefore, concrete
is not considered on
strength calculation.
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Gantry Drawing No.
924S016, 924S017,
924S018,
Gantries from Grid

4 through Grid 9
Both end of gantry

is pinned to trestle
Top & Bottom

Chord (HB400x400)
End Portal
(HB200x200)
Diagonal Vertical
Bracing
(2Ls130x130x12)
Vertical Bracing
(HB150x150)
Top Lateral Bracing

(2Ls80x80x8)
Bottom Lateral
Bracing
(2Ls80x80x8) at
mid span
(2Ls 100x100x10)
at end span
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Tripper Drawing No.
Support 924S009, 924S010,
Beam 924S0121
Cross Beam
supporting Column
(HB200x200)
Stringer Column
(HB150x150)
Stringer Beam
(C250x90)
Stringer Diaphragm
(HB150x150)
Stringer Lateral
Bracing
(L100x100x10)
Vertical Bracing
(L100x100x10)
Tripper Rail Beam

(HB250x250)
Rail Bar (Solid

Rectangular Bar
76x76)
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Tripper Drawing No.
Support 924S012, 924S013,
Beam 924S014,
(Walkway)
Walkway Support
Cross Beam
(HB200x200)
Longitudinal
Walkway Support
(C200x80)
Intermediate Cross
Beam (WF200x100)
Separator Rod
(ø30)
Grating 32 mm thick
5.2 Assumption
The structural analysis has been performed by using Space Gass v12.80 with the following
assumptions.
Figure 5-2: Space Gass Model
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• The boundary for structural model starts from the existing backstay acting as
longitudinal restraint at the west and the drive tower at east side.
• All members are modelled and connected to provide complete load path from tripper
car transmitting to tripper-frame support and continued to gantry and the trestles.
• The support system on the trestle end has been model as pinned connection,
(considering its connection detail as shown on the as built drawing).
• The tripper car will travel along the rail beam, the load from tripper car has been
modeled as an automatic moving load in Space Gass.
• The ground elevation is varying in accordance to KPC drawing 924S001 Rev D.
• The existing drawing has indicated the trestle leg will be filled with concrete after
erection. However, there is no information on concrete filling preparation, procedure
and strength. Based on this fact the concrete contribution to steel strength is not
accounted in this assessment.
5.3 Design Load

Generally, the load being considered in this analysis are divided into 3 major
category/group as shown below.
• Permanent Load (structural self-weight, grating, handrail, idler, belt, pulley, tripper
equipment)
• Imposed Load (live load on walkway, service load, coal load on conveyor, coal
spillage, coal load on chute, conveyor belt tension, thermal load)
• Environmental Load (wind load, earthquake/seismic load and coal pressure on

trestles).
5.3.1 Permanent Load
5.3.1.1 Structural Self-weight – SW

Self-weight of the structure is automatically computed using Space Gass. The basic unit
weights are 24.5 kN/m3 for concrete and 78.5 kN/m3 for steel.
5.3.1.2 Permanent Dead Load, Structural – G (D, S)

Permanent structural loads include floor grating, floor plate and handrails. All loads are
calculated and applied to structural model based on drawings provide by KPC.
5.3.1.3 Permanent Dead Load, Mechanical Equipment – G (D, ME)

Mechanical permanent dead loads include chutes, liners, motors, drives, idlers and belt.
All loads are provided by mechanical calculation.
The calculation of permanent loads is described in Appendix A.
5.3.2 Imposed Load
5.3.2.1 Imposed Live Load on Floors and Walkways – Q (L)

Live load in conveyor walkway taken as 2.5kPa for local effect and 1.25kPa for global
truss design. This load applied as line load along walkway on both side of conveyor.
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5.3.2.2 Service Load, Electrical and Piping – Q (S)

Piping and electrical loads are both taken as 1kN/m. Piping loads include pipe, contents
and bolts, while electrical loads include cable, cable trays and tray cover. Both loads
applied along north side of conveyor.
5.3.2.3 Material Loads carried on Conveyors – Q (ML1)

This load considered when conveyor on normal operation. Density of coal is taken as
13.5 kN/m3 (1.5 times of normal density). Shape of coal cross section determine coal load
on conveyor, cross section of coal provide by mechanical calculation.
Area cross section

0.310 m2
Figure 5-3: Coal Profile on Conveyor (Normal)
Thus, material loads carried on conveyor taken as 4.2kN/m. The loads applied on stringer
column. Therefore, load of 5 kN shall be applied on each stringer column.
5.3.2.4 Flooded Conveyor Belt Load – Q (FB)

Conveyor shall be flooded by coal if operational malfunction occurs. Density of coal is
taken as 1.35 kN/m3 (1.5 times of normal density). Shape of coal cross section determine
coal load on conveyor, cross section of coal provide by mechanical calculation.
Area cross section

0.681 m2
Figure 5-4: Coal Profile on Conveyor (Flooded)
Thus, material loads carried on conveyor taken as 9.2kN/m. The loads applied on stringer
column. Therefore, load of 11kN shall be applied on each stringer column.
5.3.2.5 Tripper Load – Q (Tr)

Tripper load based on previous analysis with all load combination. Tripper has 10 wheels
with it. Therefore 10 point-loads shall be applied on model. Reaction force from prior
tripper model had been inputted to current model as moving load so all tripper location will
be considered in gantry structure analysis.
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Tripper Wheels Location

indicate with red arrow (5 on each side)
Figure 5-5: Tripper Wheel Location
A 20% additional load also applied for compensate impact load from moving tripper.
Tripper Load has been distributed to 27 location along its rail (grid 4 through grid 9) for
each load combination. As can be seen in Figure 5-6, tripper load input to structural
model as moving load and each color group represent tripper load at specific period.
T-17 T-25
T-9 T-13
T-1 T-5
T-21
Figure 5-6: Tripper Load Input to Model
5.3.3 Environmental Load
5.3.3.1 Thermal Load – Q (T)

Expansion and contraction of structural steel due to temperature change need to be
considered when analyzing gantry structure. The differential thermal load is taken
accordance to Standard Specification for Civil and Structural Design Criteria (KPC-C-01
rev.4) which is 20ºC.
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5.3.3.2 Wind Load – Wo, Ws, Wu

Wind load applied to the structure at primary orthogonal angle of attack (0º=X+, 90º=Z+,
180º=X-, 270º=Z-). Wind load calculated accordance to AS1170.2. Three different wind
speeds were considered in this analysis as follow.
• Shut down wind speed (Wo)
The maximum operating wind speed is wind speed at which plant operation is
stopped. This shutdown is generally conducted in a controlled and orderly manner.
The maximum operating wind speed is 20m/s based on KPC standard specification
(KPC-C-01).
• Serviceability wind speed (Ws)
The serviceability wind speed is used to check serviceability criteria for structure. The
serviceability wind speed is 32m/s (V25).
• Ultimate wind speed (Wu)
The ultimate wind speed is the wind speed used for ultimate strength limit state
calculations. This ultimate wind speed shall be taken as V500 which is 40m/s.
Terrain category 2 are taken as parameter in this exercise. The wind on particular
direction will hit the perpendicular area of structure and creates pressure on structure.
The detailed calculation is presented in Appendix B.
5.3.3.3 Earthquake Load – E

Earthquake load assessment using respond spectra method and accordance to SNI
1726:2012. Earthquake forces in the model are automatically generated in Space Gass
by the response spectra input with the following parameters.
Table 5-2: Earthquake Design Parameters
Coefficient Description Value Source of Information

Importance factor, 𝑰𝑰𝒆𝒆 1 (Category II) Clause 4.1.2 of SNI 1726:2012
Site classification SE (Soft Soil) Table 3 clause 5 SNI 1726:2012
Spectral response acceleration for Figure 9 SNI 1726:2012
0.355 g
short period, 𝑆𝑆𝑆𝑆
Spectral response acceleration for Figure 10 SNI 1726:2012
0.140 g
1-sec period, 𝑆𝑆1
Amplification factor for short Table 4 clause 6.2 SNI 1726:2012
2.162
period, Fa
Amplification factor for 1-sec Table 5 clause 6.2 SNI 1726:2012
3.381
period, Fv
Amplified spectral response Clause 6.2 SNI 1726:2012
0.769
acceleration for short period, 𝑆𝑆𝑚𝑚𝑚𝑚
Amplified spectral response Clause 6.2 SNI 1726:2012
0.473
acceleration for 1-sec period, 𝑆𝑆𝑚𝑚1
Designed spectral response Clause 6.3 SNI 1726:2012
0.512
acceleration for short period, 𝑆𝑆𝐷𝐷𝐷𝐷
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Coefficient Description Value Source of Information

Designed spectral response Clause 6.3 SNI 1726:2012
0.315
acceleration for 1-sec period, 𝑆𝑆𝐷𝐷1
Response modification coefficient Table 9 SNI 1726: 2012
1.5
R
Thus, the spectrum response of seismic load on site is as shown in Table 5-3 and
Figure 5-7.
Table 5-3: Spectrum Response
No T S No T S
1 0 0.205 20 TS+1.6 0.136
2 T0 0.512 21 TS+1.7 0.13
3 TS 0.512 22 TS+1.8 0.125
4 TS+0 0.441 23 TS+1.9 0.12
5 TS+0.1 0.387 24 TS+2 0.116
6 TS+0.2 0.344 25 TS+2.1 0.112
7 TS+0.3 0.31 26 TS+2.2 0.108
8 TS+0.4 0.283 27 TS+2.3 0.104
9 TS+0.5 0.259 28 TS+2.4 0.101
10 TS+0.6 0.24 29 TS+2.5 0.098
11 TS+0.7 0.223 30 TS+2.6 0.095
12 TS+0.8 0.208 31 TS+2.7 0.092
13 TS+0.9 0.195 32 TS+2.8 0.09
14 TS+1 0.184 33 TS+2.9 0.087
15 TS+1.1 0.174 34 TS+3 0.085
16 TS+1.2 0.165 35 TS+3.1 0.083
17 TS+1.3 0.156 36 TS+3.2 0.08
18 TS+1.4 0.149 37 4 0.079
19 TS+1.5 0.142
Figure 5-7: Response Spectrum Design
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5.3.4 Coal Lateral Pressure

The coal pressure on buried trestle needs particular attention as the designer may
underestimate their magnitude during the design. There is possibility that the stockpile
may formed a single or multiple downslope that creates Asymmetric loading from earth
pressure to be carried by the buried trestles. This load will quickly increase following the
increment of the stockpile depth.
The “spill-through abutment” approach has been adopted for determination of lateral load
from coal stockpile on buried trestles. The analysis of the trestle legs were performed in
two conditions, the first condition is analyzing all load combination including lateral load
from stockpile and secondly without lateral load from stockpile with the objective to
provide clear information whether the structures is overstressed as a result from
additional load from tripper car only or includes coal pressure which existed long time
before the tripper car being modified.
Asymmetric loading, creates

lateral pressure on buried trestles
Symmetric loading on
trestles (balance pressure)
Figure 5-8: Coal Lateral Pressure on Buried Trestles
Randolph method of “spill-through abutment is used for this exercise. The net lateral force
due to coal lateral pressure can be determined by this following formula.
𝛾𝛾𝐻𝐻2
𝑊𝑊 = 𝐾𝐾𝑎𝑎 𝐸𝐸𝐸𝐸
2
where,
𝑑𝑑 = pile diameter 𝑠𝑠 = pile spacing
𝐻𝐻 = height of embankment 𝛾𝛾 = material density
𝐸𝐸 = effective width factor

𝑠𝑠 𝑠𝑠 5/3 𝐾𝐾𝑚𝑚 −𝐾𝐾𝑠𝑠 𝑠𝑠
= � − 0.164 � − 1� � for <8
𝑑𝑑 𝑑𝑑 𝐾𝐾𝑎𝑎 𝑑𝑑
𝐾𝐾𝑚𝑚−𝐾𝐾𝑠𝑠 𝑠𝑠
= 3.8 for ≥8
𝐾𝐾𝑎𝑎 𝑑𝑑
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𝐾𝐾𝑚𝑚 = maximum pressure coefficient on upslope side

𝛥𝛥
= Ko (at rest pressure coefficient) for stiff piles where head deflection < 0.03 to 0.06%
𝐻𝐻
𝛥𝛥
= Ka (active pressure coefficient) for flexible piles where head deflection > 0.6%
𝐻𝐻
Ks = pressure coefficient on downslope side

𝑐𝑐𝑐𝑐𝑐𝑐∅ cos (θ+∅)
= (𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐+𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡)sin
(𝜃𝜃+2∅)
Following parameters are used in exercise.
• Coal Angle of Repose (β) 37º
• Coal Effective Angle of Internal Friction (∅) 50º
• Coal Unit Weight (γ) 9 kN/m3
Tripper will discharge the coal only at designate point which is right in the middle of each
gantry span on grid 4 through 8. In contrast, the loading point on gantry span between
grid 8 and 9 is located 12m from grid 8, instead of the middle point. Particular stockpile
formation is created when it was fully filled as shown in Figure 5-9 with maximum height
of buried trestle as describe in Table 4-1.
Table 5-4: Maximum Height of Buried Trestle
Trestle Grid Buried Trestle Height (m)
4 4.3
5 6.0
6 7.7
7 9.4
8 15.6
9 8.0
Figure 5-9: Full Stockpile Formation
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In this analysis, couple of extreme stockpile formations are considered, those formation
are presented in Table 5-5.
Table 5-5: Extreme Stockpile Formation
Case Stock Pile Formation
The detail calculation for this load is described in Appendix C.
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5.4 Load Combination

The following tables contain load combinations were used in the assessment.
Table 5-6: Load Combination without Coal Lateral Pressure
Q(Tr) BNR, NW
Q (Tr) BO, NW
Q (Tr) BNR, W
Q (Tr) BS, NW
Q (Tr) BES, B
Q (Tr) BES, S
Q (Tr) BES, F
Q (Tr) M, NW
Q (Tr) BO, W
Q (Tr) M, W
Q(Tr) DLO
Comb No. Description G (D, ME)
Q (ML1)
G (D, S)
Q (FB)
Q (S)
Q (L)
Q(T)
SW
Wo
Wu
Ws
Ex
Ez
Strength Limit State Load Combination - Normal Operational
1.35
1.35
1.35
1.0
6001-6027 Dead Load Only
Belt Not
0.75
1.2
1.2
1.2
1.5
1.5
1.0
6031-6057 Running, No
Wind
Belt Not
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.0
6061-6177
Running, Wind
Belt Operating,
1.2
1.2
1.2
1.5
1.5
1.5
1.0
6181-6207
No Wind
Belt Operating,
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.0
6211-6327
Wind
Belt Start, No
1.2
1.2
1.2
1.5
1.5
1.5
1.0
6331-6357
Wind
Strength Limit State Load Combination - Maintenance
Maintenance,
1.2
1.2
1.2
1.5
1.5
1.0
6361-6387 No Operating
Wind
Maintenance,
1.2
1.2
1.2
1.5
1.5
1.0
1.0
6391-6507
Operating Wind
Strength Limit State Load Combination - Mechanical Loading Extremes
Belt Extreme
1.2
1.2
1.2
1.5
1.2
1.0
6511-6537
Start, Flooded
Belt Extreme
1.2
1.2
1.2
1.5
1.0
6541-6567
Start, Blocked
Belt Extreme
1.2
1.2
1.2
1.5
1.0
6571-6597
Start, Spillage
Strength Limit State Load Combination - Extreme Environmental Loads

1.2
1.2
1.2
1.5
1.5
1.5
1.5
4000 Thermal Load
Ultimate Wind
1.2
1.2
1.2
1.5
1.0
4020-4023
Load
1.0
1.0
1.0
1.0
1.0
1.0
1.0
0.3
4030 Earthquake X1
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Q(Tr) BNR, NW
Q (Tr) BO, NW
Q (Tr) BNR, W
Q (Tr) BS, NW
Q (Tr) BES, B
Q (Tr) BES, S
Q (Tr) BES, F
Q (Tr) M, NW
Q (Tr) BO, W
Q (Tr) M, W
Q(Tr) DLO
G (D, ME)
Comb No. Description
Q (ML1)
G (D, S)
Q (FB)
Q (S)
Q (L)
Q(T)
SW
Wo
Wu
Ws
Ex
Ez
-0.3
1.0
1.0
1.0
1.0
1.0
1.0
1.0
4031 Earthquake X2
-1.0
1.0
1.0
1.0
1.0
1.0
1.0
0.3
4032 Earthquake X3
-1.0
-0.3
1.0
1.0
1.0
1.0
1.0
4033 Earthquake X4 1.0

1.0
1.0
1.0
1.0
1.0
1.0
0.3
1.0
4034 Earthquake Z1
-0.3
1.0
1.0
1.0
1.0
1.0
1.0
4035 Earthquake Z2 1.0

-1.0
1.0
1.0
1.0
1.0
1.0
1.0
0.3
4036 Earthquake Z3
-0.3
-1.0
1.0
1.0
1.0
1.0
1.0
1.0
4037 Earthquake Z4
Table 5-7: Load Combination without Coal Lateral Pressure
Q(Tr) BNR, NW
Q (Tr) BO, NW
Q (Tr) BNR, W
Q (Tr) BS, NW
Q (Tr) BO, W
Q(Tr) DLO
G (D, ME)

Q (ML1)
G (D, S)
Q (FB)
Q (S)
Q (L)
Co 1
Q(T)
Co2
SW
Wo
Wu
Ws
Ex
Ez
Strength Limit State Load Combination - Normal Operational with Coal Lateral Pressure 1
1.35
1.35
1.35
1.0
1.5
0.75
Belt Not Running,

1.2
1.2
1.2
1.5
1.5
1.0
1.5
7031-7057
No Wind
Belt Not Running,

1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.0
1.5
7061-7177
Wind
Belt Operating,
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.5
7181-7207
No Wind
Belt Operating,
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.0
1.5
7211-7327
Wind X+
Belt Start, No
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.5
7331-7357
Wind
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Q(Tr) BNR, NW
Q (Tr) BO, NW
Q (Tr) BNR, W
Q (Tr) BS, NW
Q (Tr) BO, W
Q(Tr) DLO
G (D, ME)
Q (ML1)
G (D, S)
Q (FB)
Q (S)
Q (L)
Co 1
Q(T)
Co2
SW
Wo
Wu
Ws
Ex
Ez
Strength Limit State Load Combination - Normal Operational with Coal Lateral Pressure 2
1.35
1.35
1.35
1.0
1.5
Belt Not Running, 0.75

1.2
1.2
1.2
1.5
1.5
1.0
1.5
7531-7557
No Wind
Belt Not Running,

1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.0
1.5
7561-7677
Wind
Belt Operating,
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.5
7681-7707
No Wind
Belt Operating,
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.0
1.5
7711-7827
Wind X+
Belt Start, No
1.2
1.2
1.2
1.5
1.5
1.5
1.0
1.5
7831-7857
Wind
Note:
SW Structural Self-weight
G (D, S) Permanent Dead Load, Structural
G (D, ME) Permanent Dead Load, Mechanical Equipment
Q (L) Imposed Live Load
Q (S) Service Load, Electrical and Piping
Q (ML1) Material Load carried on Conveyors
Q (FB) Flooded Conveyor Belt Load
Q(T) Thermal Load
Ex, Ez Earthquake Load on respective direction X & Z
Wo, Ws, Wu Wind Load with respective wind speed (shut down wind speed, serviceability wind
speed, ultimate wind speed)
Q(Tr) DLO Tripper Load, dead load only combination
Q(Tr) BNR, NW Tripper Load, belt not running, no wind combination
Q(Tr) BNR, W Tripper Load, belt not running, wind with 4 major direction combination
Q(Tr) BO, NW Tripper Load, belt operating, no wind combination
Q(Tr) BO, W Tripper Load, belt operating, wind with 4 major direction combination
Q(Tr) BS, NW Tripper Load, belt start, no wind combination
Q(Tr) M, NW Tripper Load, maintenance, no wind combination
Q(Tr) M, W Tripper Load, maintenance, wind with 4 major direction combination
Q(Tr) BES, F Tripper Load, belt extreme start, flooded combination
Q(Tr) BES, B Tripper Load, belt extreme start, blocked combination
Q(Tr) BES, S Tripper Load, belt extreme start, spillage combination
Co1, Co2 Coal Lateral Pressure scenario 1 and 2
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5.5 Structural Model

Structural modelling was performed in Space Gass version 12.80 based on all information
in Section 5.1, 5.2, 5.3 and 5.4, with the following assumption and constraints.
• All steel grade is 240 MPa, (There is no indication of steel grade on the drawings.
However, most of the existing structural members are identical to “Gunung Garuda”
steel section which has 240 MPa Grade).
• The model only covers the structures above ground level.
• The structural analysis has been performed in accordance to Australian standard AS

4100 which automatically calculated by Space Gass.
• The existing structural member assumed to be in good condition, current corrosion

and rust only contributes to reduction of paint protection only and not reducing the
cross section of steel member.
• Damping ration of 0.05 is used for seismic load.
• X-axis as longitudinal direction, Y-axis as vertical direction, and Z-axis as transversal

direction
Graphic of the model frame elements, pinned end support and materials are shown in
Figure 5-10.
Figure 5-10: Model View
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5.6 Structural Analysis Result

The steel stress check in accordance to AS 4100 was conducted in Space Gass program.
Space Gass present steel stress as load factor (ratio of member stress capacity and
acting stress) instead of stress ratio (ratio of acting stress and member stress capacity)
due to the most critical load combination.
5.6.1 Trestle
The most critical condition is when the tripper position on top of each trestle. The
dominant stress on trestle is due to coal lateral pressure. As shown in Figure 5-11, the
maximum stress ratio on trestle was 2.18 on grid 8 (based on load combination no.7204:
from combination of belt operating with no wind and coal lateral pressure 1).
Stress Ratio = 2.18 > 1.0 Overstress

on Trestle grid 8
Figure 5-11: Trestle Steel Stress Check
This indicate that trestle legs in grid 8 were overstress, some countermeasure needs to
be performed in order to maintain acting stress will not exceed member stress capacity.
Basically, 2 options may be carried out, the first one is to limiting acting stress on member
by controlling height of buried trestle with asymmetric formation; The other one is to
increase member capacity by strengthen it. Both options were carried out in this analysis.
Limiting height of buried trestle to 11m is considered as controlled scenario. Therefore,

coal lateral load factor of 1.5 had been reduced to 1.2 for this case. Height limit of buried
trestle need to be maintained on every trestle to ensure no overstress occur in trestle leg.
The maximum stress ratio on trestle was 0.96 on grid 8 (based on load combination
no.7204: from combination of belt operating with no wind and coal lateral pressure 1), this
shown in Figure 5-12.
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Stress Ratio = 0.96 < 1.0

on Trestle grid 8
Figure 5-12: Trestle Steel Stress Check - Limiting Height of Buried Trestle to 11m
Strengthening on grid 7, 8 and 9 need to be performed to ensure stockpile can be fully

filled as it is. Pile jacketing with larger pipe shall be conducted as strengthening option on
trestle leg along its member from bottom (connection with concrete pedestal) to 21m
above, as shown in Figure 5-13. The stress ratio of trestle leg after strengthening is 0.95
which is acceptable. The detail calculation for trestle strengthening is presented in
Appendix G.
Figure 5-13: Trestle Leg Strengthening - Pile Jacketing
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5.6.2 Gantry
The maximum stress ratio on gantry was 1.075 (from load combination no.7183:
combination of belt operating with no wind and coal lateral pressure 1), this shown in
Figure 5-14. The slightly overstress member was located on end span at diagonal bracing
(2Ls130x130x12). This steel member was modelled as back-to-back angle instead stared
angle as per installed to simplify the model. The capacity of stared angle is greater than
back-to-back angle. Therefore, the steel member was analyzed separately as stared
angle with the identical actual stress, the stress ratio is 0.93. Detail calculation is
presented in Appendix F.
Stress Ratio = 1.07 > 1.0

on Diagonal Bracing
Figure 5-14: Gantry Steel Stress Check
5.6.3 Tripper Support Beam

Tripper support beam has been modeled together with gantry structure below. The
maximum stress ratio of 1.51 (based on load combination no.7682: This is from
combination of belt operating with no wind and coal lateral pressure 2). The overstress
members are found on several vertical bracing as shown in Figure 5-15.
Stress Ratio = 1.51 > 1.0

on Vertical Bracing
Figure 5-15: Tripper Support Beam Steel Stress Check
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Ver: 04.03
Hatch recommend addition vertical bracing at particular locations to distribute the load
better in order to increase tripper support beam capacity. Steel angle L120x120x12 shall
be installed along tripper support beam. The strengthening detail location can be seen in
Appendix E. The maximum stress after additional vertical bracing is reduced to 0.94
which is acceptable.
5.6.4 Base Plate Check

End pinned connection at base plate connecting steel trestle to concrete pedestal shall be
reviewed due to coal lateral load. The base plate connection consists of 8 anchor bolts
with 30mm diameter, assumed equal to 4.6 bolt with 400MPa tensile strength (𝑓𝑓𝑢𝑢𝑢𝑢 ) with
32mm thick base plate as shown in Figure 5-16.
Figure 5-16: Base Plate Detail
The maximum shear force occurred at end pinned connection is 950kN. The analysis
consists of bolt in shear check and ply in bearing check, the bolt shear strength
determined the capacity of the connection. The total of bolt shear capacity is 1122kN
which is greater than ultimate shear force occurred. Therefore, the connection is sufficient
to withstand all load case in the assessment. Detail calculation is presented in Appendix I.
5.6.5 Gantry -Trestle Pinned Connection

Gantry pinned connection to trestle shall be checked against all load cases. The end
pinned connection consist of mild steel Grade 350 pin with 100mm diameter, a pair of
25mm thick plate attached to gantry bottom chord, and 38 mm thick plate attached to
trestle as shown in Figure 5-17.
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Figure 5-17: Gantry-Trestle Pinned Connection
The maximum shear load occurred at end pinned connection is 800kN. The analysis
consists of pin in shear check, pin in bearing check, and ply in bearing check, the pin
shear strength determined the capacity of the connection. The pin shear capacity is
1363kN which is greater than maximum shear force occurred. Therefore, the connection
is sufficient to withstand the all load case. Detail calculation is presented in Appendix H.
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Ver: 04.03
6. Conclusion
The structural analysis has revealed the following conclusion.
• There is no overstress occurs in the gantry structure from all load cases.
• The tripper support beam will undergo overstress by 30% due to both lateral coal
pressure and no lateral coal pressure. The location of overstressed bracing can be
seen in Appendix E.
• The trestle has been analyzed with the following results.
 Without considering the coal lateral pressure, the trestle will not overstress
 By considering the coal lateral pressure, the trestle legs at grid 8 will undergo
overstress by more than 100%. The trestle at grid 6 and 7 is also overstress but
not as significant as grid 8.
7. Recommendation
• The force in overstressed members at tripper support bracing shall be reduced by
installing additional steel angle L120 x120x12. See Appendix E for detail location.
The strengthening could be conducted during regular maintenance period.
• Trestle Leg – Short Term Recommendation
The trestle leg strengthening might be more complicated and time consuming.
Therefore, for time being, limiting the stock pile height on buried trestle shall be
conducted. Limiting the buried trestle height from asymmetric formation to maximum
of 11m will result the stress ratio still under the limit. (Note: the load factor for coal
lateral pressure has been reduced from 1.5 to 1.2 for this option)
• Trestle Leg – Long Term Recommendation
Strengthening the trestle by “steel jacketing” will consist of existing trestle pile
(ø800x12) covered by additional circular hollow steel section (ø1000x14). The gap
between existing and new steel plate shall be filled with concrete 30 MPa includes
shear connector installation to maintain the composite action between two members.
Detail of the strengthening presented in Appendix G.
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Appendix A
Structure Self-weight Calculation
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Permanent Load Calculation

Structural Self-weight
Unit Weight Length Area Weight/m
Steel Member Description
(kN/m3) (m) (m2) (kN/m)
UNP 250x90x9x13 Stringer Beam 78.5 2.4 0.0044 0.342

WF 150x150x31.5 Stringer Lateral Bracing 78.5 2.4 0.0040 0.315
UNP 200x80x7.5x11 Walkway Support 78.5 2.4 0.0025 0.194
WF 200x100x4.5x7 Walkway Cross Beam 78.5 0.88 0.0023 0.182
D30 Rod Discharge Area Screen 78.5 0.8 0.0007 0.055
Solid Bar 76x76 Tripper Rail 78.5 2.4 0.0058 0.453
Permanent Load (Structural)

Unit Weight Length Area Weight/m
(kN/m3) (m) (m2) (kN/m)
ø48.3x3.2 Hand Rail Post 78.5 1.1 0.000486 0.035

ø42.4x3.2 Hand Rail Beam 78.5 2.4 0.000426 0.067
32 mm Thick Grating 78.5 0.8 0.0048917 0.768
Permanent Load (Mechanical)

Unit Weight Weight/m
(kg/m) (kN/m)
Carry Idler 3 numbers/1.2 m 85 0.850

Return Idler 2 numbers/3 m 26.667 0.267
Belt Weight 2 number per m 71 0.710
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix B
Wind Load Calculation
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Wind Speed taken for 3 specific scenarios.
Wind Speed
State V Md Mz Ms Mt Vsit
m/s m/s
Shutdown 20 1 1.12 1 1 22.4
Service 32 1 1.12 1 1 35.8
Ultimate 40 1 1.12 1 1 44.8
Wind Load on Trestle calculated as shown in table below.

Wind Load on Trestle
State l b l/b b . Vdes ht Cd Kar Ki Cfig ρair Cdyn p q
m m m²/s m kg/m³ kPa kN/m
Shutdown 26 0.8 32.5 17.92 3.00E-06 0.6 1 0.975 0.585 1.2 1 0.18 0.14
Service 26 0.8 32.5 28.7616 3.00E-06 0.6 1 0.975 0.585 1.2 1 0.45 0.36
Ultimate 26 0.8 32.5 35.7504 3.00E-06 0.6 1 0.975 0.585 1.2 1 0.70 0.56
Wind Load on Gantry calculated as shown in tables below.

Wind Load on Gantry (X direction)
State l b s δ λ Cfig.1 Ksh Cfig ρair Cdyn p P P1 P2
m m kg/m³ kPa kN kN kN
Shutdown 2.29 4.075 3.6 0.65 0.9 1.291 0.3 1.6783 1.2 1 0.51 3.1 2.4 0.7
Service 2.29 4.075 3.6 0.65 0.9 1.291 0.3 1.6783 1.2 1 1.29 7.8 6.0 1.8
Ultimate 2.29 4.075 3.6 0.65 0.9 1.291 0.3 1.6783 1.2 1 2.02 12.3 9.4 2.8
Wind Load on Gantry (Z direction)

State l b s δ λ Cfig.1 Ksh Cfig ρair Cdyn p P P1 P2
m m kg/m³ kPa kN kN kN
Shutdown 36 4.075 2.3 0.45 0.6 1.343 0.4 1.8802 1.2 1 0.57 37.4 26.7 10.7
Service 36 4.075 2.3 0.45 0.6 1.343 0.4 1.8802 1.2 1 1.45 95.7 68.3 27.3
Ultimate 36 4.075 2.3 0.45 0.6 1.343 0.4 1.8802 1.2 1 2.26 149.5 106.8 42.7
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix C
Coal Lateral Load Calculation
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Buried Trestle Height 15.6 m

Top of buried Bottom of
Position
Trestle buried Trestle
Pile Diameter d m 0.8 0.8
Heigh of Pile H m 0 15.6
Distance of Piles s m 5 10
Distance/ Height of Pile s/d 6.25 12.5
Unit Mass of Coal ϒ kN/m3 9 9
Effective Internal Shear Angle φ 50 50
Angle of Repose β 37 37
Angle of Failure θ 30 30
cos φ 0.64 0.64
sin φ 0.77 0.77
cos (θ+φ) 0.17 0.17
cot θ + tan β 2.49 2.49
sin (θ+2φ) 0.77 0.77
Maximum Pressure Coefficient on upslope side Km 0.23 0.23
Pressure Coefficient on Downslope side Ks 0.06 0.06
Active Pressure Coefficient Ka 0.13 0.13
Effective Width Factor E 4.83 5.03
Net Lateral Pressure W kN/m 0 74.84
Depth z m 0 2.23 4.46 6.69 8.91 11.14 13.37 15.6
Additional Coal Vertical Load Qp kN 874.8 874.8 874.8 874.8 874.8 874.8 874.8 874.8
Horizontal Distance x m 12 12 12 12 12 12 12 12
Depth of Buried Trestle H m 15.6 15.6 15.6 15.6 15.6 15.6 15.6 15.6
m 0.77 0.77 0.77 0.77 0.77 0.77 0.77 0.77
n 0 0.14 0.29 0.43 0.57 0.71 0.86 1.00
Effective Width Factor x Pile Diameter Exd m 3.86 3.86 3.86 3.86 3.86 3.86 3.86 3.86
H²/Qp m²/kN 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
Horizontal Stress σH kN/m² 0 0.33 1.01 1.48 1.59 1.44 1.19 0.93
Additional Coal Lateral Pressure q kN/m 0 1.29 3.89 5.73 6.13 5.54 4.58 3.60
q ave kN/m 4.0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Position
cos φ 0.64 0.64
sin φ 0.77 0.77
cos (θ+φ) 0.17 0.17
cot θ + tan β 2.49 2.49
sin (θ+2φ) 0.77 0.77
Depth z m 0 1.34 2.69 4.03 5.37 6.71 8.06 9.4
m 0.77 0.77 0.77 0.77 0.77 0.77 0.77 0.77
n 0 0.09 0.17 0.26 0.34 0.43 0.52 0.60
H²/Qp m²/kN 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
q ave kN/m 4.0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Buried Trestle Height 8 m

Position
Heigh of Pile H m 0 8
cos φ 0.64 0.64
sin φ 0.77 0.77
cos (θ+φ) 0.17 0.17
cot θ + tan β 2.49 2.49
sin (θ+2φ) 0.77 0.77
Depth z m 0 1.14 2.29 3.43 4.57 5.71 6.86 8
m 0.77 0.77 0.77 0.77 0.77 0.77 0.77 0.77
n 0 0.07 0.15 0.22 0.29 0.37 0.44 0.51
H²/Qp m²/kN 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
q ave kN/m 4.0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Position
cos φ 0.64 0.64
sin φ 0.77 0.77
cos (θ+φ) 0.17 0.17
cot θ + tan β 2.49 2.49
sin (θ+2φ) 0.77 0.77
Depth z m 0 1.10 2.20 3.30 4.40 5.50 6.60 7.7
m 0.77 0.77 0.77 0.77 0.77 0.77 0.77 0.77
n 0 0.07 0.14 0.21 0.28 0.35 0.42 0.49
H²/Qp m²/kN 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
q ave kN/m 4.0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Buried Trestle Height 6 m

Position
Heigh of Pile H m 0 6
cos φ 0.64 0.64
sin φ 0.77 0.77
cos (θ+φ) 0.17 0.17
cot θ + tan β 2.49 2.49
sin (θ+2φ) 0.77 0.77
Depth z m 0 0.86 1.71 2.57 3.43 4.29 5.14 6
m 0.77 0.77 0.77 0.77 0.77 0.77 0.77 0.77
n 0 0.05 0.11 0.16 0.22 0.27 0.33 0.38
H²/Qp m²/kN 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
q ave kN/m 4.0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Position
cos φ 0.64 0.64
sin φ 0.77 0.77
cos (θ+φ) 0.17 0.17
cot θ + tan β 2.49 2.49
sin (θ+2φ) 0.77 0.77
Depth z m 0 0.61 1.23 1.84 2.46 3.07 3.69 4.3
m 0.77 0.77 0.77 0.77 0.77 0.77 0.77 0.77
n 0 0.04 0.08 0.12 0.16 0.20 0.24 0.28
H²/Qp m²/kN 0.28 0.28 0.28 0.28 0.28 0.28 0.28 0.28
q ave kN/m 3.0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix D
Load Case Location
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
SW
101
Self-Weight
G (D, S)
102 Permanent Dead
Load, Structural
G (D, S)
103 Permanent Dead
Load, Structural
Q (L)
201 Live Load on
Walkway
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
Q (S)
202
Service Load
Q (ML1)
203 Material Load
carried on
Conveyor
Q (FB)
204 Flooded Conveyor
Load
Q(T)
214
Thermal Load
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
EX
301 Earthquake Load in
X Direction
EZ
302 Earthquake Load in
Z Direction
Co 1
303 Coal Lateral
Pressure 1
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
Co 2
304 Coal Lateral
Pressure 2
Wou X+
401 Shut Down Wind
Load X+ Direction
Wou X-
402 Shut Down Wind
Load X- Direction
Wou Z+
403 Shut Down Wind
Load Z+ Direction
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
Wou Z+
404 Shut Down Wind
Load Z+ Direction
Wou X+
405 Serviceability Wind
Load X+ Direction
Wou X-
Load X- Direction
Wou Z+
Load Z+ Direction
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
Wou Z+
Load Z+ Direction
Wou X+
409 Ultimate Wind
Load X+ Direction
Wou X-
410 Ultimate Wind
Load X- Direction
Wou Z+
411 Ultimate Wind
Load Z+ Direction
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
Wou Z+
412 Ultimate Wind
Load Z+ Direction
Tripper Load –
9001-
Dead Load Only
9027
Combination
Tripper Load – Belt

9031-
Not Running, No
9057
Wind Combination

9061-
Not Running, Wind
9087
X+ Combination
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case

9091-
Not Running, Wind
9117
X- Combination

9121-
Not Running, Wind
9147
Z+ Combination

9151-
Not Running, Wind
9177
Z- Combination

9181-
Operating, No
9207
Wind Combination
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case

9211-
Operating, Wind
9237
X+ Combination

9241-
Operating, Wind X-
9267
Combination

9271-
Operating, Wind
9297
Z+ Combination

9301-
Operating, Wind Z-
9327
Combination
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case

9331-
Start, No Wind
9357
Combination
Tripper Load –
9361-
Maintenance, No
9387
Wind Combination
Tripper Load –
9391-
Maintenance, Wind
9417
X+ Combination
Tripper Load –
9421-
Maintenance, Wind
9447
X- Combination
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case
Tripper Load –
9451-
Maintenance, Wind
9477
Z+ Combination
Tripper Load –
9481-
Maintenance, Wind
9507
Z- Combination
Tripper Load –
9511-
Maintenance, Wind
9537
X+ Combination

9541- Extreme Start,
9567 Flooded
Combination
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Load
Definition Graphic
Case

9597 Blocked
Combination

9627 Spillage
Combination
Tripper Load data input.

X Z Force X Force Y Force Z
Name
m m kN kN kN
Dead Load Only 0 -1.22 0 -51.265 0
Dead Load Only 0 1.22 0 -50.19 0
Dead Load Only -3.2 -1.22 0 -68.767 0
Dead Load Only -3.2 1.22 0 -68.733 0
Dead Load Only -8.7 -1.22 0 -38.383 0
Dead Load Only -8.7 1.22 0 -39.359 0
Dead Load Only -9.995 -1.22 0 -12.226 0
Dead Load Only -9.995 1.22 0 -12.406 0
Dead Load Only -13.13 -1.22 0 -18.632 0
Dead Load Only -13.13 1.22 0 -18.561 0
Belt Not Running; No Wind 0 -1.22 0 -67.764 0
Belt Not Running; No Wind 0 1.22 0 -64.331 0
Belt Not Running; No Wind -3.2 -1.22 0 -99.529 0
Belt Not Running; No Wind -3.2 1.22 0 -98.917 0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Name
m m kN kN kN
Belt Not Running, Wind X+ 0 -1.22 38 -84.374 11.7
Belt Not Running, Wind X+ 0 1.22 0 -73.1 0
Belt Not Running, Wind X+ -3.2 -1.22 0 -96.1 10.4
Belt Not Running, Wind X+ -3.2 1.22 0 -105.92 0
Belt Not Running, Wind X+ -8.7 -1.22 0 -86.813 1
Belt Not Running, Wind X- 0 -1.22 -26 -68.81 8
Belt Not Running, Wind X- 0 1.22 0 -73.402 0
Belt Not Running, Wind X- -3.2 -1.22 0 -111.9 7
Belt Not Running, Wind X- -3.2 1.22 0 -101.22 0
Belt Not Running, Wind X- -8.7 -1.22 0 -86.93 0.8
Belt Not Running, Wind X- -9.995 -1.22 0 -31.53 0.2
Belt Not Running, Wind X- -13.13 -1.22 0 -24.2 0
Belt Not Running, Wind Z+ 0 -1.22 6 -79.9 7.17
Belt Not Running, Wind Z+ 0 1.22 0 -69.9 0
Belt Not Running, Wind Z+ -3.2 -1.22 0 -110.03 8.015
Belt Not Running, Wind Z+ -3.2 1.22 0 -97.575 0
Belt Not Running, Wind Z+ -13.13 -1.22 0 -26.518 4
Belt Not Running, Wind Z- 0 -1.22 6 -73.3 -3.5
Belt Not Running, Wind Z- 0 1.22 0 -76.6 0
Belt Not Running, Wind Z- -3.2 -1.22 0 -97.97 -11.3
Belt Not Running, Wind Z- -3.2 1.22 0 -109.57 0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Name
m m kN kN kN
Belt Operating, No Wind 0 -1.22 7.5 -53.28 2
Belt Operating, No Wind 0 1.22 0 -49.916 0
Belt Operating, No Wind -3.2 -1.22 0 -116.37 1.58
Belt Operating, No Wind -3.2 1.22 0 -98.75 0
Belt Operating, No Wind -8.7 -1.22 0 -111.453 0.4
Belt Operating, No Wind -9.995 -1.22 0 -42.8 0
Belt Operating, No Wind -13.13 -1.22 0 -23.9 0
Belt Operating, Wind X+ 0 -1.22 39.5 -52.241 11.88
Belt Operating, Wind X+ 0 1.22 0 -40.85 0
Belt Operating, Wind X+ -3.2 -1.22 0 -104 -10.3
Belt Operating, Wind X+ -3.2 1.22 0 -96.45 0
Belt Operating, Wind X+ -8.7 -1.22 0 -110.67 -1.27
Belt Operating, Wind X+ -9.995 -1.22 0 -42 -0.2
Belt Operating, Wind X+ -13.13 -1.22 0 -23.75 0
Belt Operating, Wind X- 0 -1.22 -24.5 -36.68 -7.86
Belt Operating, Wind X- 0 1.22 0 -41.15 0
Belt Operating, Wind X- -3.2 -1.22 0 -119.8 7.15
Belt Operating, Wind X- -3.2 1.22 0 -91.75 0
Belt Operating, Wind X- -13.13 -1.22 0 -21.8 0
Belt Operating, Wind Z+ 0 -1.22 7.5 -47.76 7.4
Belt Operating, Wind Z+ 0 1.22 0 -37.65 0
Belt Operating, Wind Z+ -3.2 -1.22 0 -117.95 8.1
Belt Operating, Wind Z+ -3.2 1.22 0 -88.1 0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Name
m m kN kN kN
Belt Operating, Wind Z+ -13.13 -1.22 0 -24.12 4
Belt Operating, Wind Z- 0 -1.22 7.5 -41.15 -3.322
Belt Operating, Wind Z- 0 1.22 0 -44.34 0
Belt Operating, Wind Z- -3.2 -1.22 0 -105.87 -11.23
Belt Operating, Wind Z- -3.2 1.22 0 -100.1 0
Belt Start, No Wind 0 -1.22 0 -33.9 0
Belt Start, No Wind 0 1.22 19.5 -28.8 5.65
Belt Start, No Wind -3.2 -1.22 0 -119 0
Belt Start, No Wind -3.2 1.22 0 -95.3 -4.7
Belt Start, No Wind -8.7 -1.22 0 -123.64 0
Belt Start, No Wind -8.7 1.22 0 -132.4 -0.85
Belt Start, No Wind -9.995 1.22 0 -47.05 0
Belt Start, No Wind -13.13 1.22 0 -22.8 0
Maintenance, No Operating Wind 0 -1.22 6 -55.5 1.75
Maintenance, No Operating Wind 0 1.22 0 -52.77 0
Maintenance, No Operating Wind -3.2 -1.22 0 -89.98 -1.5
Maintenance, No Operating Wind -3.2 1.22 0 -88.525 0
Maintenance, No Operating Wind -8.7 -1.22 0 -83.5 -0.2
Maintenance, No Operating Wind -9.995 -1.22 0 -23.2 0
Maintenance, No Operating Wind -13.13 -1.22 0 -14.6 0
Maintenance, Operating Wind X+ 0 -1.22 38 -63.26 11.63
Maintenance, Operating Wind X+ 0 1.22 0 -52.61 0
Maintenance, Operating Wind X+ -3.2 -1.22 0 -82.1 -10.22
Maintenance, Operating Wind X+ -3.2 1.22 0 -90.88 0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Name
m m kN kN kN
Maintenance, Operating Wind X- 0 -1.22 -26 -47.7 -8.12
Maintenance, Operating Wind X- 0 1.22 0 -52.9 0
Maintenance, Operating Wind X- -3.2 -1.22 0 -97.88 7.22
Maintenance, Operating Wind X- -3.2 1.22 0 -86.174 0
Maintenance, Operating Wind X- -8.7 -1.22 0 -83.54 0.7
Maintenance, Operating Wind X- -9.995 -1.22 0 -24 0.2
Maintenance, Operating Wind X- -13.13 -1.22 0 -13.6 0
Maintenance, Operating Wind Z+ 0 -1.22 6 -58.79 7.1
Maintenance, Operating Wind Z+ 0 1.22 0 -49.42 0
Maintenance, Operating Wind Z+ -3.2 -1.22 0 -96.02 8.16
Maintenance, Operating Wind Z+ -3.2 1.22 0 -82.53 0
Maintenance, Operating Wind Z+ -13.13 -1.22 0 -15.9 4
Maintenance, Operating Wind Z- 0 -1.22 6 -52.18 -3.6
Maintenance, Operating Wind Z- 0 1.22 0 -56.11 0
Maintenance, Operating Wind Z- -3.2 -1.22 0 -83.95 -11.17
Maintenance, Operating Wind Z- -3.2 1.22 0 -94.52 0
Maintenance, Operating Wind Z- -8.7 -1.22 0 -82.02 -6
Belt Extreme Start, Flooded 0 -1.22 13.2 -4.976 3.5
Belt Extreme Start, Flooded 0 1.22 0 -2 0
Belt Extreme Start, Flooded -3.2 -1.22 0 -108.7 -2.66
Belt Extreme Start, Flooded -3.2 1.22 0 -82.2 0
Belt Extreme Start, Flooded -8.7 -1.22 0 -134.87 -0.835
Belt Extreme Start, Flooded -9.995 -1.22 0 -60.1 0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

Name
m m kN kN kN
Belt Extreme Start, Flooded -13.13 -1.22 0 -23.25 0
Belt Extreme Start, Blocked 0 -1.22 13.2 -84.09 3.6
Belt Extreme Start, Blocked 0 1.22 0 -78.94 0
Belt Extreme Start, Blocked -3.2 -1.22 0 -136.715 -2.75
Belt Extreme Start, Blocked -3.2 1.22 0 -113.4 0
Belt Extreme Start, Blocked -8.7 -1.22 0 -134.36 -0.8
Belt Extreme Start, Blocked -9.995 -1.22 0 -53.76 0
Belt Extreme Start, Blocked -13.13 -1.22 0 -8.52 0
Belt Extreme Start, Spillage 0 -1.22 13.2 -10.02 3.5
Belt Extreme Start, Spillage 0 1.22 0 -7.08 0
Belt Extreme Start, Spillage -3.2 -1.22 0 -108.5 -2.61
Belt Extreme Start, Spillage -3.2 1.22 0 -82 0
Belt Extreme Start, Spillage -8.7 -1.22 0 -134.36 -0.84
Belt Extreme Start, Spillage -8.7 1.22 0 -143.43 0
Belt Extreme Start, Spillage -9.995 -1.22 0 -55.7 0
Belt Extreme Start, Spillage -9.995 1.22 0 -50.5 0
Belt Extreme Start, Spillage -13.13 -1.22 0 -16.5 0
Belt Extreme Start, Spillage -13.13 1.22 0 -19 0
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix E
Tripper Support Beam – Strengthening
Works
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Additional Angle L120x120x12 Detail; see the following sketch H356799-00000-230-260-0002.
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix F
Stared Angle Capacity Calculation
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix G
Trestle Strengthening
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Trestle Strengthening “Trestle Jacketing”

Existing trestle pile is 800mm in diameter and 12mm thickness, a trestle jacket of 1000mm diameter
and 14mm thickness pile need to be installed. The pile jackets need to be installed along the trestle
leg from base plate to 21m above it. The gap between the two need to be filled by concrete as a
composite section.
The exercise only considers steel pile without concrete as its capacity as
shown in figure below.
Trestle Jacket Existing Trestle Pile

Steel Pipe 1000x14 Steel Pipe 800x12
Grade = 250 Fy = 240.0 MPa

Fyw = 240.0 MPa Fu = 330.0 MPa
Ltot = 24.604 m Lseg = 24.604 m (FF Top-Bot)
kt = 1.00 (5.6.3) kl = 1.00 (5.6.3)
kr = 1.00 (5.6.3) Le = 24.604 m (Bending) (5.6.3)
Lx = 24.604 m (Compression) Ly = 24.604 m (Compression)
Lz = 24.604 m (Torsion)
Lx/rx = 73.94 (Compression) Le/ry = 73.94 (Bending)
Arf = 0.0 mm2 Arw = 0.0 mm2

An = 73777 mm2 Ae = 73777 mm2 (6.2.2)
Kf = 1.00 (6.2.2) Kt = 1.00 (7.3)
αm = 2.44 (5.6.1.1) αs = 1.02 (5.6.1.1)
αcx = 0.8 (6.3.3) αcy = 0.81 (6.3.3)
αb = -0.50 (6.3.3) βme = -1.00 (8.4.4.1)
βmx = 1.00 (8.4.2.2) βmy = -1.00 (8.4.2.2)
γ = 0.00 (8.3.4) ϕ = 0.90 (3.4)
N* = 1121.59 kN (Compact)
Vx* = 947.76 kN (not considered) Vy* = -2.69 kN
Mx* = -256.24 kNm (Non-compact) My* = 3637.82 kNm (Non-compact)
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
ϕNt = 0.00 kN (7.2) ϕNs = 15935.8 kN (6.2)

ϕNcx = 12748.6 kN (6.3.3) ϕNcy = 12748.6 kN (6.3.3)
ϕNoz = 0.00 kN (8.4.4.1)
ϕMsx = 4203.1 kNm (5.2) ϕMsy = 4203.1 kNm (5.2)
ϕMbx = 4203.1 kNm (5.6) ϕMox = 3824.8 kNm (8.4.4)
ϕMix = 3824.8 kNm (8.4.2.2) ϕMiy = 3824.8 kNm (8.4.2.2)
ϕMtx = 0.00 kNm (8.4.5.2) ϕMcx = 3824.8 kNm (8.4.5.1)
1.4
𝑀𝑀𝑥𝑥∗ 1.4 𝑀𝑀𝑦𝑦∗
� � +� � = 0.02 + 0.93 = 0.95 < 1.00 → 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃! Member biaxial bending (8.4.5.1)
𝜙𝜙𝑀𝑀𝑐𝑐𝑐𝑐 ϕMiy
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Trestle Strengthening
See the following sketch no H356799-00000-230-260-0001.
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix H
Gantry-Trestle Pinned Connection
Calculation
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Gantry-Trestle Pinned Connection Calculation

Shear force act at trestle base plate, 𝑉𝑉𝑓𝑓∗ = 800 𝑘𝑘𝑘𝑘
The consists of 1 Pin (Mild steel Grade 350 kN) with 100mm diameter and 38mm thick base plate.
Capacity factor ɸ = 0.8 for pin in shear

ɸ = 0.8 for pin in bearing
ɸ = 0.9 for ply in bearing
Yield stress of the pin 𝑓𝑓𝑦𝑦𝑦𝑦 = 350 𝑀𝑀𝑀𝑀𝑀𝑀
Pin diameter 𝑑𝑑𝑝𝑝 = 100 𝑚𝑚𝑚𝑚
Anchor bolt area 𝐴𝐴𝑝𝑝 = 7853.98 𝑚𝑚𝑚𝑚2
Number of shear planes 𝑛𝑛𝑠𝑠 = 1
Tensile strength of the ply 𝑓𝑓𝑢𝑢𝑢𝑢 = 330 𝑀𝑀𝑀𝑀𝑀𝑀
Base plate thickness 𝑡𝑡𝑝𝑝 = 38 𝑚𝑚𝑚𝑚
𝑘𝑘𝑝𝑝 = 1.0
Distance from center of hole to the edge of a ply 𝑎𝑎𝑒𝑒 = 130 𝑚𝑚𝑚𝑚
Pin in Shear Check

A pin subject to a design shear force (𝑉𝑉𝑓𝑓∗ ) shall satisfy
𝑉𝑉𝑓𝑓∗ ≤ ɸ𝑉𝑉𝑓𝑓
𝑉𝑉𝑓𝑓 = Nominal shear capacity of a pin
𝑉𝑉𝑓𝑓 = 0.62 × 𝑓𝑓𝑦𝑦𝑦𝑦 × 𝑛𝑛𝑠𝑠 × 𝐴𝐴𝑝𝑝 = 1704.3 𝑘𝑘𝑘𝑘
ɸ𝑉𝑉𝑓𝑓 = 1363.45 𝑘𝑘𝑘𝑘 > 𝑉𝑉𝑓𝑓∗ (= 800 𝑘𝑘𝑘𝑘)  PASS!
Pin in Bearing Check

A pin subject to a design bearing force (𝑉𝑉𝑏𝑏∗ ) due to a bolt in shear shall satisfy
𝑉𝑉𝑏𝑏∗ ≤ ɸ𝑉𝑉𝑏𝑏
𝑉𝑉𝑏𝑏 = Nominal bearing capacity of a pin
𝑉𝑉𝑏𝑏 = 1.4 × 𝑘𝑘𝑝𝑝 × 𝑓𝑓𝑦𝑦𝑦𝑦 × 𝑑𝑑𝑓𝑓 × 𝑡𝑡𝑝𝑝 = 1862 𝑘𝑘𝑘𝑘
ɸ𝑉𝑉𝑏𝑏 = 1489.6 𝑘𝑘𝑘𝑘 > 𝑉𝑉𝑏𝑏∗ (= 800 𝑘𝑘𝑘𝑘) PASS!
Ply in Bearing Check

A ply subject to a design bearing force (𝑉𝑉𝑏𝑏∗ ) due to a pin in shear shall satisfy
𝑉𝑉𝑏𝑏 = Nominal bearing capacity of a ply
𝑉𝑉𝑏𝑏1 = 3.2 × 𝑑𝑑𝑓𝑓 × 𝑡𝑡𝑝𝑝 × 𝑓𝑓𝑢𝑢𝑢𝑢 = 4012.8 𝑘𝑘𝑘𝑘
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
𝑉𝑉𝑏𝑏2 = 𝑎𝑎𝑒𝑒 × 𝑡𝑡𝑝𝑝 × 𝑓𝑓𝑢𝑢𝑢𝑢 = 1630.2 𝑘𝑘𝑘𝑘

𝑉𝑉𝑏𝑏 = min(𝑉𝑉𝑏𝑏1 , 𝑉𝑉𝑏𝑏2 ) = 1630.2 𝑘𝑘𝑘𝑘
ɸ𝑉𝑉𝑏𝑏 = 1467.18 𝑘𝑘𝑘𝑘 > 𝑉𝑉𝑏𝑏∗ (= 800 𝑘𝑘𝑘𝑘) PASS!
The connection still capable to withstand the load working at gantry-trestle intersection with pin in
shear as critical case.
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Appendix I
Trestle Base Plate Calculation
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03
Trestle Base Plate Calculation

Shear force act at trestle base plate, 𝑉𝑉𝑓𝑓∗ = 950 𝑘𝑘𝑘𝑘
Base plate consists of 8 Anchor bolts (assumed to be Grade 4.6 steel) with 30mm diameter and
32mm thick base plate.
Capacity factor ɸ = 0.8 for shear bolt in shear

ɸ = 0.9 for ply in bearing
Minimum tensile strength of bolts 𝑓𝑓𝑢𝑢𝑢𝑢 = 400 𝑀𝑀𝑀𝑀𝑀𝑀
Anchor bolt diameter 𝑑𝑑𝑓𝑓 = 30 𝑚𝑚𝑚𝑚
Anchor bolt area 𝐴𝐴𝑓𝑓 = 706.86 𝑚𝑚𝑚𝑚2
Number of Anchor bolt 𝑛𝑛𝑠𝑠 = 8
Tensile strength of the ply 𝑓𝑓𝑢𝑢𝑢𝑢 = 330 𝑀𝑀𝑀𝑀𝑀𝑀
Base plate thickness 𝑡𝑡𝑝𝑝 = 32 𝑚𝑚𝑚𝑚
Distance from center of hole to the edge of a ply 𝑎𝑎𝑒𝑒 = 60 𝑚𝑚𝑚𝑚
Bolt in Shear Check

A bolt subject to a design shear force (𝑉𝑉𝑓𝑓∗ ) shall satisfy
𝑉𝑉𝑓𝑓∗ ≤ ɸ𝑉𝑉𝑓𝑓
𝑉𝑉𝑓𝑓 = Nominal shear capacity of a bolt
𝑉𝑉𝑓𝑓 = 0.62 × 𝑓𝑓𝑢𝑢𝑢𝑢 × 𝑛𝑛𝑠𝑠 × 𝐴𝐴𝑓𝑓 = 1402.4 𝑘𝑘𝑘𝑘
ɸ𝑉𝑉𝑓𝑓 = 1121.9 𝑘𝑘𝑘𝑘 > 𝑉𝑉𝑓𝑓∗ (= 950𝑘𝑘𝑘𝑘)  PASS!
Ply in Bearing Check

A ply subject to a design bearing force (𝑉𝑉𝑏𝑏∗ ) due to a bolt in shear shall satisfy
𝑉𝑉𝑏𝑏 = Nominal bearing capacity of a ply
𝑉𝑉𝑏𝑏1 = 3.2 × 𝑑𝑑𝑓𝑓 × 𝑡𝑡𝑝𝑝 × 𝑓𝑓𝑢𝑢𝑢𝑢 = 1013.76 𝑘𝑘𝑘𝑘
𝑉𝑉𝑏𝑏2 = 𝑎𝑎𝑒𝑒 × 𝑡𝑡𝑝𝑝 × 𝑓𝑓𝑢𝑢𝑝𝑝 = 633.6 𝑘𝑘𝑘𝑘
𝑉𝑉𝑏𝑏 = min(𝑉𝑉𝑏𝑏1 , 𝑉𝑉𝑏𝑏2 ) = 633.6 𝑘𝑘𝑘𝑘
ɸ𝑉𝑉𝑏𝑏 = 570.24 𝑘𝑘𝑘𝑘 > 𝑉𝑉𝑏𝑏∗ (= 𝑉𝑉𝑓𝑓∗ /𝑛𝑛 = 118.75 𝑘𝑘𝑘𝑘) PASS!
The connection still capable to withstand the load working at trestle base plate with bolt in shear as
critical case.
H356799-00000-200-230-0002, Rev. A,
Ver: 04.03

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4. Referenced Document ................................................................................................................... 4

5.1 General Arrangement ............................................................................................................. 8

Figure 5-8: Coal Lateral Pressure on Buried Trestles .......................................................................... 18

Appendix A Structure Self-weight Calculation

Appendix B Wind Load Calculation

Appendix C Coal Lateral Load Calculation

Appendix D Load Case Location

Appendix E Tripper Support Beam – Strengthening Works

Appendix G Trestle Strengthening

Appendix H Gantry-Trestle Pinned Connection Calculation

• The ground elevation is varying in accordance to KPC drawing 924S001 Rev D.

Figure 1-1: Model View

The structural analysis has revealed the following conclusion.

• The trestle has been analyzed with the following results.

• The force in overstressed members at tripper support bracing shall be reduced by

• Trestle Leg – Short Term Recommendation.

• Trestle Leg – Long Term Recommendation

Figure 3-1: Scope of Work, Gantry Structure Conveyor CV02

• Structural Analysis Report (this report).

No. Rev. Document Title Originator

No. Rev. Document Title Originator

No. Rev. Document Title Originator

No. Rev. Document Title Originator

Backstay Drive Tower

Figure 5-1: General Arrangement

Category Description Drawing

Category Description Drawing

Diagonal Back Stay

Trestle Drawing No.

Trestle legs are

Category Description Drawing

Gantries from Grid

Both end of gantry

Top & Bottom

Top Lateral Bracing

Category Description Drawing

Tripper Rail Beam

Rail Bar (Solid

Category Description Drawing

Figure 5-2: Space Gass Model

• The ground elevation is varying in accordance to KPC drawing 924S001 Rev D.

5.3 Design Load

• Environmental Load (wind load, earthquake/seismic load and coal pressure on

5.3.1 Permanent Load

5.3.1.1 Structural Self-weight – SW

5.3.1.2 Permanent Dead Load, Structural – G (D, S)

5.3.1.3 Permanent Dead Load, Mechanical Equipment – G (D, ME)

The calculation of permanent loads is described in Appendix A.

5.3.2 Imposed Load

5.3.2.1 Imposed Live Load on Floors and Walkways – Q (L)

5.3.2.2 Service Load, Electrical and Piping – Q (S)

5.3.2.3 Material Loads carried on Conveyors – Q (ML1)

Area cross section

Figure 5-3: Coal Profile on Conveyor (Normal)

5.3.2.4 Flooded Conveyor Belt Load – Q (FB)

Area cross section

Figure 5-4: Coal Profile on Conveyor (Flooded)