Night School 23 Session 2

AISC Night School 23 Topics on Industrial Building Design and Design of Non-building Structures
June 23, 2020 Session 2: Industrial Buildings Part 1
Night School 23:

Topics on Industrial
Building Design and
Design of Non-building
Structures
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Session 2 – Industrial Buildings -- Part 1

June 23, 2020
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The information presented herein is based on recognized engineering principles and is for general
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Course Description
Industrial Buildings -- Part 1 (submitted for AIA continuing education
approval)
June 23, 2020
This session will provide a general review of the design of industrial buildings. The session
will address planning, including project requirements, building layout, roof and wall system
and selection of column spacing. Loads will be addressed including process loads, material
handling requirements and load combinations. Lastly, the session will framing systems will
be reviewed.
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Learning Objectives
• Define what an industrial building is and what makes it unique or different than other buildings.
• List the common participants in the design team for an industrial building and describe their
roles and responsibilities.
• Describe the development of structural design criteria and “Basis of Design” document.
• Describe the process of determining the building layout and column spacing requirements.
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Night School 23: Industrial Structures

Session 2: Industrial Buildings – Part 1
June 23, 2020
John Rolfes, PE, SE, CSD Structural Engineers
INTRODUCTION
SESSION 1 INTRODUCTION AND CODE PROVISIONS

SESSION 2 INDUSTRIAL BUILDINGS – PART 1
SESSION 3 INDUSTRIAL BUILDINGS – PART 2
SESSION 4 CRANE SUPPORTING STRUCTURES
SESSION 5 FATIGUE DESIGN FOR INDUSTRIAL STRUCTURES
SESSION 6 HIGH & LOW TEMPERATURE DESIGN FOR INDUSTRIAL STRUCTURES
SESSION 7 NON-BUILDING STRUCTURES –PART 1
SESSION 8 NON-BUILDING STRUCTURES –PART 2
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SESSION 2: INDUSTRIAL BUILDINGS - PART 1

LEARNING OBJECTIVES:
• Define what an industrial building is and what makes it unique or different
than other buildings
• Who are the common participants in the design team for an industrial
building? What are their roles and responsibilities
• Development of structural design criteria and “Basis of Design” document
• Determination of building layout and column spacing requirements
• Selection of roof and wall systems
• Inspection and Maintenance requirements for industrial buildings
INSPECTION AND MAINTENANCE REFERENCE

than other buildings.
building? What are their roles and responsibilities?
• Development of structural design criteria and “Basis of Design” document.
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DEFINITION OF INDUSTRIAL BUILDING
An industrial building is typically considered to be any structure

that encloses or supports a manufacturing or industrial process
and/or is used to store manufactured product.
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MANUFACTURING BUILDING
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INDUSTRIAL BUILDING
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LARGE OR HEAVY INDUSTRIAL BUILDING
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POWER PRODUCTION FACILITY
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AIRPLANE HANGAR
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WAREHOUSE
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DIFFERENCES BETWEEN COMMERCIAL & INDUSTRIAL BLDGS

 Commercial Building  Industrial Building
• Typically designed and configured to • Typically designed and configured to
support a specific occupancy accommodate and support the enclosed
• The objectives, requirements and manufacturing or industrial process.
resulting configuration of a • The configuration and layout of an
commercial building is typically industrial buildings is defined by the
determined by an architect working enclosed industrial process. This process
in conjunction with the owner is developed by process engineers and
• Commonly one to four-story equipment vendors working with the
buildings with floor-to-floor heights owner
ranging from 11 ft. to 15 ft. and • Commonly one-story building (possibly
column/bay spacings of 20 ft. to 30 with mezzanine framing) with eave
ft. heights ranging from 20 ft. to 100 ft. and
typical column/bay spacings of 25 ft. to 60
ft.
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• Design loads • Design loads
• Environmental Loads per • Environmental Loads per Building
Building Code Code
• Prescriptive Live Loads based on • Prescriptive Live Loads provided in
occupancy per Building Code Building Code
• Higher Live Loads may be applicable
for certain activities
• Process Loads and Equipment Loads
per Process Engineers and Equipment
Vendors. Equipment Loads include
material handling equipment such as
cranes, conveyors, forklift trucks, etc.,
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• Design Criteria • Design Criteria
• Strength Criteria established by • Strength Criteria established by the Building
the Building Code Code and possibly other design standards
• Serviceability Criteria generally and guides related to type of facility
include drift and deflection • Fatigue Design Criteria established by the
criteria and potentially Building Code for repetitive equipment or
acceleration criteria in high-rise process loading
buildings. Design limits based on • Serviceability Criteria include drift and
occupancy and building deflection criteria, vibration criteria. Design
materials used limits commonly established by process
• Tolerances established by AISC engineer or equipment vendors
Code of Standard Practice • Tolerances based on AISC Code of Standard
(typically) Practice and Process Requirements
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• Maintenance requirements for industrial buildings
• Inspection requirements / recommendations
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INDUSTRIAL BUILDING DESIGN TEAM
DESIGN TEAM
• Owner
• Process Engineer
• Process Equipment Vendor
• Structural Engineer
• Industrial Architect
• Other Engineering Disciplines (Geotechnical, Civil, Electrical, Mechanical,
Plumbing)
• Contractor
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ROLES OF TEAM MEMBERS

 Owner: Manufacturer, Industrial Process Company, or Developer
that is purchasing the process and building and commonly will
operate this facility upon its completion.
• Generally works hand-in-hand with the Process Engineer and Equipment
Vendor to define and procure the process equipment and develop the layout
of the facility that aligns with the intended operational or material flow
through the facility
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 Process Engineer: Engineering group responsible for the design of
the overall process, incorporating the purchased equipment.
• Often operates as the Owner’s Representative on the Design Team.
• The Process Engineer works with the owner and equipment vendors to
develop the general arrangement drawings for the process
• Commonly designs the associated process piping, power supply, controls and
automation for the equipment.
• The Equipment Vendor sometimes operates as the Process Engineer.
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 Process Equipment Vendor: Equipment Manufacturer
responsible for providing the Process Equipment for the Project.
Typically this is the same entity that manufactures the equipment.
• As noted above, may operate as the Process Engineer for the project too.
• Material handling equipment vendors may also be integrated into the team
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 Structural Engineer: Entity responsible for the structural design of
the building structure containing (and sometimes supporting) the
process equipment.
• Commonly retained by the Owner and, in these instances, also acts as the
Owner’s representative on the Design Team. May play a larger role in the
project as compared to commercial building projects.
• Services can also include the design of the equipment foundations (when
needed), elevated platforms for support or maintenance of equipment, and
possibly other non-building structures associated with the process that are
supported on the building structure or on separate foundations (e.g. storage
bins, silos, stacks, etc.,).
• The Structural Engineer needs to work closely with the Owner, Process
Engineer, and Equipment Vendors to understand all pertinent process loading
and design criteria related to these structures and foundations. 38
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 Industrial Architect: Entity responsible for verifying the building
complies with the building code and for developing requirements
for the weather tightness of the structure.
• This entity sometimes will play a more significant role in the project,
working with the Owner, Process Engineer, Equipment Vendors and
Engineers to coordinate and plan the overall project. To do this, the
Industrial Architect must have a strong understanding of the industrial
process for the project
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 Industrial Architect:
• Duties include:
o Determination of Bldg. Code Occupancy Classification
o Determination of Bldg. Code restrictions on height and area of the
building
o Development of Architectural Layouts for internal program requirements
o Development of exiting requirements to meet Bldg. Code
o Location and layout of Toilet Room Requirements
o Development of Site Plan / Site Circulation
o Compliance with ADA requirements
o Advocate for client with state and local building code officials and zoning
departments
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 Other Engineering Disciplines: Geotech, Civil, MEP Engineers
• Work together with the Process Engineer, Structural Engineer and Industrial
Architect to develop designs for utilities, power, lighting, ventilation, etc., for
the building and to support the process and material handling equipment.
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 Contractor: In some instances, the Owner may elect to use a
Design-Build process with the General Contractor acting as the
Owner’s representative and all, or some, of the other Design Team
members procured by the General Contractor.
• Owner typically still very involved on the project.
• Common arrangement is to have the Process Engineer/Equipment Vendors
working directly for the Owner and for the Owner to enter into a Design-Build
arrangement with the Contractor for the building/foundation work that may
or may not include the equipment and process installation related to these
structures and foundations.
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DESIGN TEAM COORDINATION

1. For each project, must clearly define specific responsibilities for all
members of the design team. These responsibilities should be
very detailed and complete and should be clearly stated in scope
statements of contracts for each member of team.
2. Determine specific information that each design team member
needs to perform their work.
3. Determine required time durations for each work activity
4. Develop a project schedule, including dates when pertinent
information is required for each party to perform their work in
accordance with the developed schedule.
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DEVELOPMENT OF STRUCTURAL DESIGN CRITERIA

Structural Engineer is dependent on the Process Engineer and
Equipment Vendor for much of the information pertaining to design
criteria. This information includes:
• Process layout (General Arrangement Drawings) and associated process loads for
building and foundation design
• Equipment drawings, loads and anchorage requirements for building and
foundation design
• Material handling equipment layouts and loadings
• Building geometry requirements to accommodate process and material handling
requirements
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GENERAL ARRANGEMENT DRAWINGS

Plans, Section Views and
Elevations that show:
• Equipment layout
• Equipment geometry and
spacing
• Process flow
• Layout and geometry for
associated equipment support
platforms and maintenance
platforms
• Routing of associated process
piping and utilities
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DEVELOPMENT OF DESIGN CRITERIA

Key Project Design Parameters
o Site and soil information o Loading dock and door
o Wall and roof material preferences requirements
o Utility routing and support o Material-handling requirements
requirements including conveyors, overhead
o Equipment maintenance access cranes, fork-lift trucks and other
conveyance equipment
o Future expansion plans
o Conveyor routing and support
o Building Code prescribed building requirements
height and area restrictions
o Crane types, quantities and
o Preferred building bay and module capacity requirements
sizes
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DETERMINATION OF PROJECT REQUIREMENTS

Additional Key Project Design Parameters
o Serviceability design criteria based o Fire protection requirements
on building materials, process o Exiting requirements
equipment and material handling o Expansion joint requirements and
equipment requirements type of expansion joint detail to be
o Equipment foundation used
requirements o Building environment
o Floor slab design criteria (for slab- considerations based on the
on-grade and elevated floors) contained process or generated by
o Fall protection and fall arrest the contained process
system requirements o Project budget and schedule
requirements
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BASIS OF DESIGN DOCUMENT

Structural Engineer should consider incorporating all critical design
parameters and loading requirements into a single written “Basis of
Design” document.
• Document to be reviewed with the Owner and Process Engineer or
Contractor before proceeding with design.
• As project progresses, the “Basis of Design” should be periodically reviewed
and updated when necessary as additional design considerations evolve.
• Provides a good record summary document that can be used when reviewing
future alterations or additions to the facility.
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INDUSTRIAL BUILDING LAYOUT
• For industrial facilities with significant process equipment, the

structural configuration for the building is driven by process
layout
• General Arrangement Drawings required to develop building
layout
• Input from structural engineer is useful to guide Process
Engineer / Equipment Vendor
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For Industrial Facilities with less significant process equipment

and warehouse facilities, layout of building may be more flexible,
allowing layout to be driven by economics
• What configuration provides the necessary space for the
least dollars?
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INDUSTRIAL BUILDING LAYOUT FOR ECONOMY
For large one-story industrial buildings, improved economy is

obtained with square or nearly square building layout.
• Length of the building perimeter and subsequent cost of exterior wall
system is minimized for a given footprint area with a square layout
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INDUSTRIAL BUILDING LAYOUT FOR ECONOMY
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COLUMN SPACING (BAY SPACING AND MODULE SIZE)

Module Width:
• Typically based on process requirements
• Common dimensions range from 40 ft. to
100 ft.
Bay Length:
• Function of type of secondary framing
Process Flow members used (light gage Z or C), hot rolled
purlins and girts, or bar joists
• When light gage secondary framing is used,
bay length commonly 20 ft. to 30 ft.
• For hot rolled secondary framing, bay length
commonly 20 ft. to 40 ft.
• For bar joists, bay length commonly 20 ft. to
60 ft.
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RESULTS OF ECONOMIC STUDIES

Based on economic studies that CSD has performed for a variety
of industrial buildings, most economical bay spacing is typically
between 40 ft. and 50 ft. long
• This incorporates consideration for cost of building superstructure and
building foundations.
• Also incorporates potential fabrication and erection savings
o Least cost is often not least weight
o Fewer pieces often leads to reduced cost
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RESULTS OF ECONOMIC STUDIES

Note that for crane loads, maximum column load may not
change appreciably with increased bay length
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USE OF WIND COLUMNS WITH LARGER BAY LENGTHS
Wind columns may be used with larger bay lengths to reduce the
span of wall girts, allowing use of light-gage steel girts
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FOUNDATION CONSIDERATIONS
Shallow Foundations (spread ftgs.)
• Typical cost of installed spread
footings is a fraction of the erected
building superstructure cost, even for
a one-story building
• For one-story building with 50 ft. x 50
ft. bays,
spread footing cost ≈ 5% of erected
steel roof and column framing
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FOUNDATION CONSIDERATIONS
Deep Foundations
(Piles or Drilled Shafts / Caissons)
• Cost of deep foundations is an order of
magnitude higher than shallow
foundations
• Typical installed pile cost ≈ $2,500/pile
• Cost of Drilled Shafts varies depending
on size, depth, soil conditions, and
presence of ground water
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SELECTION OF ROOF AND WALL SYSTEMS

• Roof and wall system should be selected early in the design
process, before starting significant work on the structural
design of the building
• Structural Engineer, Industrial Architect and Owner may all
have a hand in selecting the roof and wall system for the
project
• Decision typically based on cost, functionality, durability, and
standards for large industrial corporations
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ROOF SYSTEMS
Options:
• Built-up roofs (BUR)
• Membrane roofs
o Ethylene Propylene Diene Terpolymer (EPDM)
o Thermosplastic Polyolefin (TPO)
• Exposed metal roofs
o Screw-down metal roof
o Standing seam metal roof
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BUILT-UP ROOF (BUR)

• Have been in use for over 100 years
• Good for low-slope roofs
• Composed of alternating layers of
reinforcing fabric and bitumen
• Top layer has small stone or fine
gravel finish to protect roof from
UV, blown or falling debris and to
provide good walking surface Advantages Disadvantages
• Bitumen may be applied hot or cold Waterproofing Slow installation
and serves as adhesive UV protection Fumes
Low Maint. High install. cost
• Life Span – 15 to 30 years Fire-resist. Wind problems
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MEMBRANE (EPDM) ROOF

• Durable, synthetic, single-ply rubber
roof membrane
• Widely used for low-slope roofs
• Installed as either
– Fully adhered
– Mechanically Fastened
– Ballasted
Advantages
• Seams are sealed with liquid Low Cost Disadvantages
adhesive or specially formulated Fast Install UV deterioration
tape Few seams Easy to damage
• Life Span – 25 to 35 years Low Weight Appearance
Fire-resist. Maintenance
Long Lasting
Penetrations
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MEMBRANE (TPO) ROOF

• Durable, synthetic, single-ply roof
membrane
• Actually typically a membrane
made from a blend of rubbers
• Installed as either
– Fully adhered
– Mechanically Fastened
Advantages
• Seams are heat welded Low Cost Disadvantages
• Life Span – 15 to 20 years Fast Install Newness
Low Weight Quality Variation
Fire-resist. More seams
Penetrations Laminations
Color
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METAL ROOF – SCREW DOWN

• Metal roof deck provides structural
support and weather tightness
• Roof deck fastened to underlying
roof secondary framing with either
self-drilling screws or screw bolts
with rubber gaskets beneath screw
head
• End laps and side laps of deck are Advantages
Disadvantages
Long life
screwed together also Water tightness
Low Cost
• Use mastic tape to provide sealed Fastener problems
Low Weight
joint at end laps and side laps. Maintenance
Appearance
No low-slope
Penetrations
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METAL ROOF – STANDING SEAM

• Metal roof panel provides structural
support and weather tightness
• Roof panel fastened with screws at
eave and supported on sliding clips
on remaining roof purlins
• Roof side laps are commonly seamed
• Roof panel allowed to move beneath
ridge cap Advantages Disadvantages
• End laps are screwed together Long life Expensive
Water Tightness Penetrations
• Use mastic tape to provide sealed Low Weight
joint at end laps Appearance
Low-slope
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ROOF DRAINAGE
Roof drainage is an important variable to consider when evaluating building
geometry and roof system options.
• Min. roof slope = ¼:12 for BUR, EPDM, TPO and Standing Seam Metal Panel roof
systems (IBC criteria)
• Min. roof slope = ½:12 for most Screw Down Metal Panel roof systems
• Exposed metal roof panel systems are generally restricted to buildings with
perimeter drainage systems
• When interior drainage systems are used, design must evaluate for potential
impounded water
– IBC requires consideration of blocked primary drain system for this evaluation
– Plumbing engineer to provide height of impounded water based upon characteristics of secondary
drainage system and code-prescribed design level rainstorm
– Controlled-Flow Roof Drainage Systems
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RAIN LOADS – INTERIOR DRAIN SYSTEM
Note:
1. Prediction of water depth is a function of the
design rainfall intensity and the tributary area
to the roof drain
2. Evaluation used principles of hydraulics / fluid
mechanics
3. Plumbing engineer should provide this
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PONDING
Section 8.4 ASCE 7-16 Ponding Instability &
Ponding Load
• “Ponding” refers to the retention of water due solely to
the deflection of relatively flat roofs.
• Roof framing bays must possess adequate stiffness to
preclude progressive deflection (i.e. instability) as rain
falls on them or meltwater is created from snow on them
• Susceptible bays include bays with a roof slope less than
¼:12 or on which water is impounded upon them (in
whole or in part) when the primary drain system is
blocked, but the secondary drain system is functional.
• Larger of snow load or the rain load equal to the design
condition for a blocked primary drain system shall be
used in this analysis
• Reference SJI Technical Digest #3 (2018 Edition) and SJI
Ponding Tool https://www.aisc.org/education/continuingeducation/education-
archives/roof-design-using-iterative-analysis-for-ponding-loads-n24/
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WALL SYSTEMS
Options:
• Metal wall panel (insulated or uninsulated)
• Masonry
• Precast concrete wall panels
• Tilt-up concrete wall panels
• Combined (wainscot) wall system
• Hardwall (masonry or concrete) lower wall section with metal wall panel above
• Hardwall system provides durability for lower section of wall that is likely more subject
to abuse
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IMPORTANCE OF INSPECTION & MAINTENANCE

Industrial buildings are susceptible to abuse and wear and require
routine inspection and maintenance. Damage due to:
• Abuse from impact between structure and equipment or product
• Abuse from overload
• Damage associated with fatigue
• Damage associated with environment (e.g. corrosion or heat)
• Non-documented changes and modifications by personnel
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IMPORTANCE OF INSPECTION
Purpose of Regular Inspection Program
• Maintain safe structures and avoid risk to personnel & equipment
• Avoid cost of unplanned shutdowns
• Avoid excessive repair costs
• Allows for planned maintenance activities
• Address operational or maintenance problems
• Improve the service life of the structure and maintain the value of the structure
• Identify and correct operation activities or equipment malfunctions that are
damaging the structure
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REFERENCE FOR INSPECTION/MAINTENANCE
2020 Edition of AIST Technical Report #13, Guide for Design and
Construction of Mill Buildings
Appendix C - Recommended Practice for Inspection and Upgrading of
Existing Structures
• C1.0 – Purpose
• C2.0 – Reasons for Performing an Inspection
• C3.0 – Inspection
• C4.0 – Reasons for Upgrading an Existing Structure
• C5.0 – Upgrading
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Session 2
the End
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Thank you!
AISC | Questions?
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Find all your handouts, quizzes and quiz scores, recording access, and
attendance information all in one place!
Go to www.aisc.org and sign in.
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Go to www.aisc.org and sign in.
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AISC Night School 23 Topics on Industrial Building Design and Design of Non-building Structures

June 23, 2020 Session 2: Industrial Buildings Part 1

Night School 23:

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Session 2 – Industrial Buildings -- Part 1

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© The American Institute of Steel Construction 2020

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Night School 23: Industrial Structures

John Rolfes, PE, SE, CSD Structural Engineers

SESSION 1 INTRODUCTION AND CODE PROVISIONS

SESSION 2: INDUSTRIAL BUILDINGS - PART 1

INSPECTION AND MAINTENANCE REFERENCE

DEFINITION OF INDUSTRIAL BUILDING

An industrial building is typically considered to be any structure

LARGE OR HEAVY INDUSTRIAL BUILDING

POWER PRODUCTION FACILITY

DIFFERENCES BETWEEN COMMERCIAL & INDUSTRIAL BLDGS

DIFFERENCES BETWEEN COMMERCIAL & INDUSTRIAL BLDGS

 Commercial Building  Industrial Building

DIFFERENCES BETWEEN COMMERCIAL & INDUSTRIAL BLDGS

SESSION 2: INDUSTRIAL BUILDINGS - PART 1

INDUSTRIAL BUILDING DESIGN TEAM

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

ROLES OF TEAM MEMBERS

DESIGN TEAM COORDINATION

SESSION 2: INDUSTRIAL BUILDINGS - PART 1

DEVELOPMENT OF STRUCTURAL DESIGN CRITERIA

GENERAL ARRANGEMENT DRAWINGS

DEVELOPMENT OF DESIGN CRITERIA

DETERMINATION OF PROJECT REQUIREMENTS

BASIS OF DESIGN DOCUMENT

SESSION 2: INDUSTRIAL BUILDINGS - PART 1

INDUSTRIAL BUILDING LAYOUT

• For industrial facilities with significant process equipment, the

INDUSTRIAL BUILDING LAYOUT

INDUSTRIAL BUILDING LAYOUT

For Industrial Facilities with less significant process equipment

INDUSTRIAL BUILDING LAYOUT FOR ECONOMY

For large one-story industrial buildings, improved economy is

INDUSTRIAL BUILDING LAYOUT FOR ECONOMY

COLUMN SPACING (BAY SPACING AND MODULE SIZE)

RESULTS OF ECONOMIC STUDIES

RESULTS OF ECONOMIC STUDIES

USE OF WIND COLUMNS WITH LARGER BAY LENGTHS