University of Western Australia CIVL4150 Engineer Practice Unit Resource Project Aurecon

1. Introduction
Your design consultancy has been engaged to design a new conveyor system at an existing export facility on the Pilbara coast of Western Australia. The new conveyor system will transfer ore from a rail dump station to the stockyard via a tripper tower. Your responsibility is the structural design of the tripper tower and associated footings, including the following: Suspended concrete slab Steel members (beams, columns and bracing) Steel connections Concrete footings (bored piles and spread footing) Concrete ground slab Concrete retaining wall

Refer to Sketch 01 and Sketch 02 in Appendix A for the general layout of these elements. Another engineer has designed the conveyor galleries, tripper galleries and tripper headframes. Reactions from these structures where they are supported by the tripper tower are summarised in Appendix B. To facilitate the cleanup of spillages, the top floor of the tripper tower is to have a concrete slab with a 550 high bund wall around the perimeter. Other levels providing access for maintenance will have grated floors with bracing as necessary. The tripper tower columns will be seated on concrete pedestals a minimum of 200 mm above the surface of the concrete ground slab. There will be a bored pile or spread footing below each column, extending through four metres of gravely clay residual soil to the underlying moderately weathered rock (refer Appendix C for extracts from the Geotechnical Report). The ground slab will be bounded by a concrete kerb 200 mm high. When the wind velocity is consistently in excess of 20 m/s the facility will cease to operate ore on the belts will be discharged, the trippers will be lowered and the conveyor drives switched off.

2. Environmental Requirements
Certain undertakings have been made by the client in the project Environmental Impact Statement to address noise, dust and spillage issues: elevated portions of conveyors are to be clad and concrete floored towers containing drives are to be clad to base of drive floor floors at conveyor transfers are to be concrete with washdown facilities

As the tripper tower does not house a conveyor drive, it does not need to be clad. The above items need to be addressed as part of the tripper tower design.

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3. Safe Design
The final report shall document the measures taken to comply with legislative requirements relating to designers of structures (commonly referred to as Safe Design). Safe design is a process defined as the integration of hazard identification and risk assessment methods early in the design process to eliminate or minimise the risks of injury throughout the life of the product being designed. It encompasses all design including facilities, hardware, systems, equipment, products, tooling, materials, energy controls, layout and configuration. Source: Australian Safety and Compensation Council, 2006, Guideline on the Principles of safe design for work, Australian Government Department of Employment and Workplace Relations The life cycle of a structure is deemed to include the following phases: Design Construction, manufacture Commissioning, use, operation Maintenance, repair, cleaning, modification Decommissioning, removal, disposal References for Safe Design: Safe Design of Buildings and Structures Code of Practice (Government of Western Australia): (http://www.safetyline.wa.gov.au) Guidance on the Principles of Safe Design for Work (http://www.ascc.gov.au/ascc/HealthSafety/SafeDesign)

4. Design Schedule
The following design schedule is proposed:
Term Week 2 3 4 5 6 7 8 9 10 11 12 13 Tutorial No. 1 2 3 4 5 6 7 8 9 10 Date 11 Aug 18 Aug 25 Aug 1 Sep 8 Sep 15 Sep 22 Sep 29 Sep 6 Oct 13 Oct 20 Oct 27 Oct Mon 31 Oct Topic Briefing / Framing Layout Suspended Slab Design Loads and Load Combinations Structural Analysis Steel Member Design Steel Member Design contd Steel Connection Design Mid semester break Symposium Steel Connection Design contd Footing and Retaining Wall Design Ground Slab Design Final report due

Although there are no formal hold points, additional information may be provided during the course of the project so students should not progress too far ahead of the proposed design schedule.

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5. Deliverables
Design report: Project background Scope of design commission Design calculations Pencil sketches (or CAD drawings) including: Plans at tripper level, intermediate level and ground level defining member sizes Elevations on each grid line Steel connection details Reinforced concrete details Evidence of design verification Discussion of Safe Design principles and description of actions undertaken as part of your design

6. Assessment
Exam (guest lectures) Design project Reflection 30% 60% 10%

7. Load Data
7.1 Primary Load Cases
1. Self Weight 2. Superimposed Dead Load Tripper head frame Tripper gallery Conveyor gallery Concrete slab and parapet wall Grating Chute self weight 700 kg/m 3. Live Load Tower floors Tripper head frame LL Tripper operation reactions Tripper gallery LL Conveyor gallery LL 4. Blocked Chute (ore load only) 5. Encrustation Load

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6. Cyclonic Wind Load Cross Wind from South Tower (conc. parapet, beams and columns, chute) Tripper head frame WL Tripper gallery WL Conveyor gallery WL 7. Cyclonic Wind Load Cross Wind from North Tower (conc. parapet, beams and columns, chute) Tripper head frame WL Tripper gallery WL Conveyor gallery WL 8. Cyclonic Wind Load Longitudinal Wind from West Tower (conc. parapet, beams and columns, chute) Tripper head frame WL Tripper gallery WL Conveyor gallery WL 9. Cyclonic Wind Load Longitudinal Wind from East Tower (conc. parapet, beams and columns, chute) Tripper head frame WL Tripper gallery WL Conveyor gallery WL

7.2 Load Combinations

Combination load cases to consider (refer Section 4.0 of AS1170.0): a) Ultimate Load Combinations for stability b) Ultimate Load Combinations for strength c) Load Combinations for serviceability Types of loads combinations to consider: I. II. III. Operating Loads Working winds from any direction Accidental Blocked Chute Load working wind from any direction Non-operating Cyclonic Wind Load from any direction

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Appendix A Sketches Tripper in position for discharging to stockyard conveyor Tripper gallery Conveyor gallery

Top of steel 5000

Provide appropriate bracing members

Top of steel 4000

Top of steel 4500

Stockyard conveyor means that no bracing can be used at this level for the South and North sides

U/S base plate Spread footing Bored pile SOUTH ELEVATION SCHEMATIC ONLY

Provide appropriate bracing members at each level

Stockyard conveyor

Pedestals, slab, kerb and retaining walls not shown WEST ELEVATION - SCHEMATIC ONLY Sketch 01

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Kerb 1800

C Stockyard conveyor under L 1200 sq chute opening 1200 1200 2200 Steel grating 2200 Ramp up 4500 NTS Sketch 02 Conveyor gallery support beams

6500

2800

2800

Tripper gallery support beams

Fall 1:100

Wash down sump 600 x 600 Tripper support points 2800 4200 3000 1200 sq chute opening

PLAN AT TOP LEVEL 5000 1800 1200 min typ PLAN AT INTERMEDIATE LEVELS

Retaining walls (by others)

Kerbs

Pedestals

PLAN AT GROUND LEVEL

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Appendix B Design Loads Wind: Region D Terrain Category 2 Average recurrence interval, ARI = 500 years Vop = 20 m/s

Live load on concrete slabs 5.0 kPa UDL 20 kN point load over 200 mm x 200 mm Live load on grated floors 2.5 kPa UDL Encrustation on all floors 1.0 kPa UDL Retaining wall surcharge 20 kPa Loads applied from the tripper frame to the four tripper support points on the concrete slab Tripper operating reactions 300 kN per upstream leg, 20 kN per downstream leg (originating from belt tensions there are no net horizontal loads due to belt tension in this case) Tripper dead load 50 kN per leg Blocked chute load 1500 kg/m including self weight Tripper live load 20 kN per leg Tripper cross wind loads* +/- 250 kN per leg vertically and +/- 55 kN per leg horizontally Tripper longl wind loads* +/- 70 kN per leg vertically and +/- 35 kN per leg horizontally

Loads applied from the two tripper gallery support beams (at 5400 centres) to the tower at the slab level Tripper gallery dead load 70 kN per beam Tripper gallery live load (including burden) 70 kN per beam Tripper gallery cross wind loading* 190 kN total horizontal acting 5m above TOS Tripper gallery longitudinal wind loading* 20 kN total horizontal Loads applied from the two conveyor gallery support beams (at 4200 centres) to the tower at the slab level Conveyor gallery dead load 50 kN per beam Conveyor gallery live load (including burden) 60 kN per beam Conveyor gallery cross wind loading* 50 kN total horizontal acting 2m above TOS Conveyor gallery longitudinal wind loading* 10 kN total horizontal * Wind load reactions are for ultimate case

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Appendix C Extracts of Geotechnical Report

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