TATA STEEL

SUMMER INTERNSHIP PROGRAM 2011

DESIGN OF JUNCTION HOUSE FOR CONVEYOR GALLERY AT RAW MATERIAL HANDLING PROJECT

Under the Guidance Of

Presented By:

Mr. Manoj Kumar

Head Civil & Structural TATA STEEL

ARIJIT MONDAL
08CE1013, 4th Yr. UG IIT Kharagpur

Introduction
TATA STEEL Ltd. is presently undergoing 3 MTPA

expansion project .
This include a new blast furnace I , new coke oven

battery 10 & 11 , a new steel making shop LD-3 etc.

Raw materials are conveyed by conveyors which in turn

are supported by trestles and transferred to the Junction Houses.

Objective

Reduction in Steel Consumption

Suggest better Designs

Check the original structure

Purpose of Junction House

Transfer points of Conveyor systems

Sieving and Purification of the Raw material

Dumping of Raw material

Often starting point or ending point of number of conveyor galleries
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Requirements

Functional Requirement

Adequacy & Strength

Aesthetic Beauty

Economical Requirement
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General Features of Junction House

Steel structure building with Beams , Columns & Bracings

Consists of (1)Platform for monorail maintenance

(2)Prism gate operation platforms etc.

Supports for the conveyor galleries

General Features of Junction House

Steel sheets are used for Side sheeting & Roofing R.C.C Floors or chequered Plate Proper floor slope for drainage The floor openings such as Erection Hatches , Stair Case entries

etc. should be covered with Removable covers or Hand rails

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General Features of Junction House

Junction House may be equipped with Lifting devices like

EOT cranes , Electrical Hoists (as per requirement)

Pulley frames , Base frames , chutes are be provided

Provisions for Junction House

Effective ventilation Adequate lighting Cleaning facilities Fire fighting arrangements Adequate space for maintenance

Power socket outlets

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Description of JP11
Height 36.7 meter 11.5 meter 9 meter 9
PC 13 CKC 7 SCI 3 & SCI 4
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Length
Width Floors

Conveyors

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Main Components of JP 11
Beams (IS sections) Columns (IS sections & Crucified I sections)

Trusses
Chequered plates R.C.C slabs Monorails Stair cases Pulley (for SCI - 3)
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Sections Used

I Sections

Channel Sections Ex:ISMC150

Single Angle sections Ex:ISA50506

Double Angle sections

Ex:ISA50506LD

Ex:ISMB200

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Approach
Load Analysis in Staad.Pro of Original Structure

Manual calculation for failed members

Changing of sections for overly designed as well as under designed members

R.C.C foundation Design

Changing of geometry & section prop. of the original structure to make it Economical
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IS Code Followed
IS 800-2007 : for Steel Design purpose
IS 875 part 1 : for dead load calculation IS 875 part 2 : for live load calculation IS 875 part 3 : for wind load calculation SP 6(1)1964 : for sectional properties IS 456-2000 : for R.C.C foundation design SP 16 : for reinforcement of R.C.C Foundation Design
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Loads Considered

Dead loads Live loads

Wind loads
Dust loads Belt tension of the conveyor

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Loads in form of UDL

Dead Load & Live Load Wind Load

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Failed Members

Here the red marked members are failing in Original Design

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Alternate Design 1
Design (original) Design 1

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Comparisons of Support Reaction

Footing

Design (original)
Fy(-1) Fy(+1) Fx Fz Fy(-1) 348 160 185 187 0 0 173 0 0 516 377 638 222 449 238 280 569 267 -2.175 70 19.43 0.56 64 0.40 16.43 59 2.2 -0.543 4 -0.785 0.144 5.4 14.25 53 16 23 380 278 247 175 0 0 274 0 146

Design 1
Fy(+1) Fx Fz 398 349 458 413 496 435 241 635 297 -3.5 59 22 -0.6 69 0.053 -7 55 -1 -2.25 -1.4 1 95 25 65 3 27 5

1 2 3 4 5 6 7 8 9

10
11 12 13 14

107
0 0 518 0

795
435 952 224 800

2
69.5 10 -2.273 76.1

15.37
1 54 2.25 0.506

161
0 0 488 0

743
538.452 852 184 719

-0.832
69 14 -2.4 72

4.17
0.754 47 2 -0.113 21

Alternate Design 2
Design (original) Design 2

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Comparisons of Support Reaction

Footing

Design (original)
Fy(-1) Fy(+1) Fx Fz Fy(-1) 348 160 185 187 0 0 173 0 0 516 377 638 222 449 238 280 569 267 -2.175 70 19.43 0.56 64 0.40 16.43 59 2.2 -0.543 4 -0.785 0.144 5.4 14.25 53 16 23 372 207 225 228 0 0 197 0 0

Design 2
Fy(+1) Fx Fz 382 343 469 290 485 320 346 619 339 -3 62 22 0.4 66 0.26 17 61.71 2.3 -2 0.6 2 -2 8 12.5 56 19 21.6

1 2 3 4 5 6 7 8 9

10
11 12 13 14

107
0 0 518 0

795
435 952 224 800

2
69.5 10 -2.273 76

15.37
1 54 2.25 0.506

161
0 0 489 0

651
523 811 204 715

-2
67 12.25 -3.6 73

6.3
1 54 1.7 0.325 23

Comparisons in Steel Consumption

Original Design
Steel Consumption (Tonnes) Reduction Of Steel

Design 1

Design 2

142.4089

115.3388

116.0277

19%

18.52%

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Why Design-2 is better than Design-1

Higher uplift force is coming in case of Design-1

compared to Design-2
Horizontal sway of the top most point is less More adequate in strength

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Final Outcome

Detection of Under designed members Evolvement of two different designs in different approaches Economically viable designs

Reduction of steel consumption(19%)

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Benefits to Company

Reduction of steel consumption

Cost reduction
Expertise in analysis of structures

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Personal Learnings
Proper Practical application of Theoretical knowledge
How to study engineering drawing in detail Multiple sites visit increase 3-D visualization Sound knowledge in application of Staad.Pro Load analysis of giant structures
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Pics of Sites Visit

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