Structural Design Calculations-Secondary Clarifier & Sludge Sump-Kaithal

CLIENT NAME: KAITHAL CO-OPERATIVE SUGAR MILLS LTD.
, KAITHAL
PROJECT: CONDENSATE POLISHING UNIT (CPU) CAPACITY- 700KLD
STRUCTUIRAL DESIGN CALCULATIONS OF SECONDARY CLARIFIER OF CPU

TITLE: UNIT
SUBMITTED BY - DEW PROJECTS AND CHEMICALS PRIVATE LIMITED

STRUCTURAL DESIGN CALCULATIONS FOR SECONDARY CLARIFIER - 7.5 DIA & Sludge Sump
A. Basic Data:
Secondary Clarifier
Dia = 7.5 m
GL = 0.00
IL of Tank = -1.45
SWD = 2.50 m
Top of wall = 1.55
Total height of tank = 3.000 m
Total height of tank
= 1.45 m
below GL
Launder width = 0.600 m
Launder depth = 0.600 m
Sludge pit width = 0.500 m
Sludge Sump
Length = 2 m
Width = 2 m
GL = 0.00
IL of Tank = -2.3
SWD = 2.30 m
Top of wall = 0.30
Total height of tank
= 2.30 m
below GL
B. Material Data:
Grade of Concrete = M-30
Grade of Steel = Fe-500
Clear Cover For Walls = 40 mm
Clear Cover For Raft = 50 mm
Clear Cover For Columns = 40 mm
Clear Cover For Beams = 30 mm
Coeff. of earth pressure = 0.5
Density of dry soil Yd = 18 Kn/m3
Density of Water Yw = 10 Kn/m3
Dead load on Top Slab = 1.2 Kn/m2

Live load on Walkway = 3 Kn/m2
C. REFERNCES :
The analysis of the walls of tank is done through Staad Pro.
D. CLEAR COVER
Foundation= 50 mm
Column = 40 mm
Beam = 30 mm
Wall = 40 mm
Slab = 20 mm
Waist slab = 25 mm
E. SOIL DATA ASSUMED FOR DESIGN :
Net allowable bearing capacity considered = 7.5 t/m2

= 75 Kn/m2
Settlement assumed for raft = 25 mm
Subgrade modulus = =(75x1000)/25 = 3000 Kn/m2/m
230mm Rubble Soiling and 150mm sand filling should be done below PCC.
F. DESIGN METHOD :
Design has been done using cracked section approach as per Limit State Method of design.
LOADING ON WALL - SECONDARY CLARIFIER
Basic data-
3
Density of dry soil/sand = 18 Kn/m
3
Density of liquid = 10.0 Kn/m
Coeff. Of earth pressure = 0.5
2
Surcharge = 10 Kn/m
TOW
3.00 m
NGL / FGL = 0.00 q1
1.45 m
q3 q2
Loads
2
a). q1 (Hydrostatic pressure inside the tank)) = (3) x 10 = 30.00 Kn/m
2
b). q2 (Earth pressure due to dry soil) = (1.45) x 18 x 0.5 = 13.05 Kn/m
2
c). q3 (Surcharge) = 10 x 0.5 = 5.00 Kn/m
LOADING ON WALL - SLUDGE SUMP
Basic data-
3
Density of dry soil/sand = 18 Kn/m
3
Density of liquid = 10.0 Kn/m
Coeff. Of earth pressure = 0.5
2
Surcharge = 10 Kn/m
TOW
2.60 m
NGL / FGL = 0.00 q1
2.30 m
q3 q2
Loads
2
a). q1 (Hydrostatic pressure inside the tank)) = (2.6) x 10 = 26.00 Kn/m
2
b). q2 (Earth pressure due to dry soil) = (2.3) x 18 x 0.5 = 20.70 Kn/m
2
c). q3 (Surcharge) = 10 x 0.5 = 5.00 Kn/m
DESIGN OF RING WALL -
From the computer output, the design values of Ring Tension (Denoted by Sx multiplied by thickness)
ZONE A 0.250 m have been found out and tabulated below.
Diameter of wall = 7.5 m with 36 No. of intervals
Reinforcement has been computed as follows :

0.87 x Fy
Ast Required = Ring Tension (kn/m) x 1000 / 435 (Above Base Slab)
435 (Above Base Slab)
+ Indicates Ring Tension and - Indicates Ring Compression
Wall has been divided in 13 parts I.e Zone A
Minimum Reinforcement for 250mm thick wall :

2
0.175 % I.e 437.5 mm /m in each direction.
Location Ring Tension Ast Ast Provided in

Required Each Face
2 2
( Kn/m ) mm /m mm2/m
ZONE A
(Element no. 6015/100 + 251.207 X 0.25 1.5 x 63 x 1000 217 10 DIA@ 175
(Maximum) 435 on each face
2
= 63 = 449 mm
ZONE B
(Element no. 6015/100 + 251.207 X 0.25 1.5 x 63 x 1000 217 10 DIA@ 175
(Maximum) 0 on each face
= 63 = 449 mm2
Check For Tensile Stresses (For Water Retaining Portion)
Modular ratio for M-30 grade concrete : 280 = 9.33

3 x 10
Maximum direct tensile stress for Zone-A:

= 1.5 x 63 x 1000
[1000 x 250 + (9.33 - 1 ) x (2 x 449)]
2
= 0.37 N/mm < 2 N/mm2
O.k
From the computer output, the design values of Bending Moments (Denoted by My) have
been found out and tabulated as below.
Reinforcement has been computed as follows :
2
Ast Reqd as per pt as per Mu/bd for Limit State Design (For portion below base)
Ast Reqd = B.M (Kn-m/m) x 1000000 / (Stress x 0.87 x 210) (For portion above base)
(As per IS 3370 part-II : 2009, permissible stress in steel is 130 N/ mm2.)
Vertical R/F Calculation
+ Indicates Tension Outside Face and - Indicates Tension Inside Face
Designed as uncracked section.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ __ _
2
Location Bending Mu/bd pt Ast Ast Provided in
Moment RequiredEach Face
2 2 2
( Kn-m /m) (N/mm ) mm /m mm /m
R/F CALCULATION FOR FIXED BASE
ZONE A
MAXIMUM MY Mu/bd2
(Element no./LC 5837/100 + 1.611 0.07 0.02 40 10 DIA@ 175
(Maximum) +
0 DIA@ 175
= 449
6376/101 - 10.257 0.44 0.1 200 10 DIA@ 175
+
0 DIA@ 175
= 449
DESIGN OF RING WALL WATER FACE
Limit State cracked section approach
fck = 30 N/mm2
2
fy = 500 N/mm
2
Es = 200000 N/mm
2
Ec = 27386.1 N/mm
k = 0.46
j = 1-k/3 = 0.85
Q = 0.36 fck j k = 4.22
Partial factor of safety for Loads, gm = 1.5
B = 1000 mm
Crack width = 0.2 mm

Stress Summary of entire wall from STAAD
Absolute maximum moment magnitude = 1.61 t-m
Thickness required = (Mu / Q B)^0.5

= (1.61 x 10^7 / (4.22 x 1000)) ^0.5
= 61.77 mm
Provide wall thickness = 250 mm Hence Ok

Clear cover = 40 mm
Consider maximum diameter of bar = 16 mm
Effective thickness = 250 - 40 - 16 - 8 = 186 mm
Reinforcement : Vertical
Group : RING WALL-VSUPP

Location : Wall Support
Load Condition : Water Face
Face Element/Load combination

Maximum moment = 1.611 Kn-m Water Face 5837/100
My = 1.611 t-m Water Face

2
Mu/bd = 1.5 x 1.611 x 10^6 / 1000 x 186^2
2
= 0.07 N/mm
Ast = 29.96 mm2
pt = 0.02 %
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2
Ast provided = 448.8 mm Hence Ok
pt provided = 0.24 %
0.36 fck b d xu = 0.87 fy Ast d
Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

449 18 180 20 186.0 0.00014 0.0012 -0.0011 178.44 -0.26 O.K.
Group : RING WALL-VSPAN
Location : Wall Span


2
Mu/bd = 1.5 x 1.611 x 10^6 / 1000 x 186^2
2
= 0.07 N/mm
2
Ast = 29.96 mm
pt = 0.02 %
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 20 186.0 0.00014 0.0012 -0.0011 178.44 -0.26 O.K.
Reinforcement : Horizontal
Group : RING WALL-HSUPP


0
2
Mu/bd = 1.5 x 0.274 x 10^6 / 1000 x 186^2
2
= 0.01 N/mm
2
Ast = 5.08 mm
pt = 0%
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 3 186.0 0.00002 0.0012 -0.0012 178.44 -0.28 O.K.
Group : RING WALL-HSPAN



2
Mu/bd = 1.5 x 0.274 x 10^6 / 1000 x 186^2
2
= 0.01 N/mm
2
Ast = 5.08 mm
pt = 0%
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 3 186.0 0.00002 0.0012 -0.0012 178.44 -0.28 O.K.
DESIGN OF RING WALL EARTH FACE
fck = 30 N/mm2
2
fy = 500 N/mm
2
Es = 200000 N/mm
2
Ec = 27386.1 N/mm
k = 0.46
j = 1-k/3 = 0.85
Q = 0.36 fck j k = 4.22
B = 1000 mm


= (10.26 x 10^7 / (4.22 x 1000)) ^0.5
= 155.93 mm

Clear cover = 40 mm
Group : RING WALL-VSUPP


Maximum moment = -10.257 Kn-m Earth Face 6376/101
My = -10.257 t-m Earth Face

2
Mu/bd = 1.5 x 10.257 x 10^6 / 1000 x 186^2
2
= 0.44 N/mm
Ast = 193.61 mm2
pt = 0.1 %
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 127 186.0 0.00088 0.0012 -0.0003 178.44 -0.08 O.K.
Group : RING WALL-VSPAN


2
Mu/bd = 1.5 x 10.257 x 10^6 / 1000 x 186^2
2
= 0.44 N/mm
2
Ast = 193.61 mm
pt = 0.1 %
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 127 186.0 0.00088 0.0012 -0.0003 178.44 -0.08 O.K.
Group : RING WALL-HSUPP


0
2
Mu/bd = 1.5 x 1.744 x 10^6 / 1000 x 186^2
2
= 0.08 N/mm
2
Ast = 32.44 mm
pt = 0.02 %
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 22 186.0 0.00015 0.0012 -0.0010 178.44 -0.25 O.K.
Group : RING WALL-HSPAN



2
Mu/bd = 1.5 x 1.744 x 10^6 / 1000 x 186^2
2
= 0.08 N/mm
2
Ast = 32.44 mm
pt = 0.02 %
Provide 10 @ 175
mm dia mm c/c
+
0 @ 175
mm dia mm c/c
2

449 18 180 22 186.0 0.00015 0.0012 -0.0010 178.44 -0.25 O.K.
DESIGN OF LAUNDER WALL - BOTH FACE
fck = 30 N/mm2
2
fy = 500 N/mm
2
Es = 200000 N/mm
2
Ec = 27386.1 N/mm
k = 0.46
j = 1-k/3 = 0.85
Q = 0.36 fck j k = 4.22
B = 1000 mm


= (0.52 x 10^7 / (4.22 x 1000)) ^0.5
= 35.1 mm

Clear cover = 40 mm
Group : LAUNDER WALL --VSUPP

Load Condition : Both Face


2
Mu/bd = 1.5 x 0.517 x 10^6 / 1000 x 86^2
2
= 0.1 N/mm
Ast = 20.82 mm2
pt = 0.02 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 83 25 86.0 0.00023 0.0017 -0.0015 202.65 -0.27 O.K.
Group : LAUNDER WALL --VSPAN


2
Mu/bd = 1.5 x 0.517 x 10^6 / 1000 x 86^2
2
= 0.1 N/mm
2
Ast = 20.82 mm
pt = 0.02 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 83 25 86.0 0.00023 0.0017 -0.0015 202.65 -0.27 O.K.
Group : LAUNDER WALL --HSUPP


0
2
Mu/bd = 1.5 x 0.517 x 10^6 / 1000 x 86^2
2
= 0.1 N/mm
2
Ast = 20.82 mm
pt = 0.02 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 83 25 86.0 0.00023 0.0017 -0.0015 202.65 -0.27 O.K.
Group : LAUNDER WALL --HSPAN



2
Mu/bd = 1.5 x 0.517 x 10^6 / 1000 x 86^2
2
= 0.1 N/mm
2
Ast = 20.82 mm
pt = 0.02 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 83 25 86.0 0.00023 0.0017 -0.0015 202.65 -0.27 O.K.
DESIGN OF LW‐SLAB BOTH FACE
fck = 30 N/mm2
2
fy = 500 N/mm
2
Es = 200000 N/mm
2
Ec = 27386.1 N/mm
k = 0.46
j = 1-k/3 = 0.85
Q = 0.36 fck j k = 4.22
B = 1000 mm


= (0.21 x 10^7 / (4.22 x 1000)) ^0.5
= 22.31 mm

Clear cover = 30 mm
Reinforcement : TOP
Group : LW-SLAB
Reinforcement : Top R/F

Maximum moment = 0.205 Kn-m TOP 3683/100

2
Mu/bd = 1.5 x 0.205 x 10^6 / 1000 x 96^2
2
= 0.03 N/mm
Ast = 7.38 mm2
pt = 0.01 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 93 9 96.0 0.00007 0.0015 -0.0014 200.36 -0.25 O.K.
Reinforcement : BOTTOM
Group :
Reinforcement : Bottom R/F

Maximum moment = 0.205 Kn-m BOTTOM 3683/100

2
Mu/bd = 1.5 x 0.205 x 10^6 / 1000 x 96^2
2
= 0.03 N/mm
2
Ast = 7.38 mm
pt = 0.01 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 93 9 96.0 0.00007 0.0015 -0.0014 200.36 -0.25 O.K.
DESIGN OF [email protected] - TOC BOTH FACE
fck = 30 N/mm2
2
fy = 500 N/mm
2
Es = 200000 N/mm
2
Ec = 27386.1 N/mm
k = 0.46
j = 1-k/3 = 0.85
Q = 0.36 fck j k = 4.22
B = 1000 mm


= (9.42 x 10^7 / (4.22 x 1000)) ^0.5
= 149.41 mm

Clear cover = 50 mm
Reinforcement : TOP
Group : [email protected] - TOC



2
Mu/bd = 1.5 x 5.423 x 10^6 / 1000 x 176^2
2
= 0.26 N/mm
Ast = 107.4 mm2
pt = 0.06 %
Provide 12 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

565 23 168 57 176.0 0.00042 0.0010 -0.0006 205.24 -0.15 O.K.


Maximum moment = -9.422 Kn-m BOTTOM 5203/101

2
Mu/bd = 1.5 x 9.422 x 10^6 / 1000 x 176^2
2
= 0.46 N/mm
2
Ast = 188.04 mm
pt = 0.11 %
Provide 12 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

565 23 168 99 176.0 0.00073 0.0010 -0.0003 205.24 -0.07 O.K.
DESIGN OF [email protected] ‐ TOC BOTH FACE
fck = 30 N/mm2
2
fy = 500 N/mm
2
Es = 200000 N/mm
2
Ec = 27386.1 N/mm
k = 0.46
j = 1-k/3 = 0.85
Q = 0.36 fck j k = 4.22
B = 1000 mm


= (5.18 x 10^7 / (4.22 x 1000)) ^0.5
= 110.79 mm

Clear cover = 30 mm
Reinforcement : TOP



2
Mu/bd = 1.5 x 5.175 x 10^6 / 1000 x 96^2
2
= 0.84 N/mm
Ast = 192.4 mm2
pt = 0.2 %
Provide 10 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

393 16 91 145 96.0 0.00122 0.0010 0.0003 200.00 0.04 O.K.


Maximum moment = 0.899 Kn-m BOTTOM 998/100

2
Mu/bd = 1.5 x 0.899 x 10^6 / 1000 x 96^2
2
= 0.15 N/mm
2
Ast = 32.49 mm
pt = 0.03 %
Provide 8 @ 200
mm dia mm c/c
+
0 @ 200
mm dia mm c/c
2

251 10 93 39 96.0 0.00031 0.0015 -0.0012 200.36 -0.21 O.K.
Bearing pressure check for RAFT @ -1.5 TOC (STAAD)
Horizontal Vertical Horizontal
Node L/C Fx kN/m2 Fy kN/m2 Fz kN/m2
Max Px 2 100 DL+LL+WL 0 39.606 0
Min Px 2 100 DL+LL+WL 0 39.606 0
Max Py 512 100 DL+LL+WL 0 39.608 0
Min Py 235 101 DL+WL+SL 0 19.071 0
Max Pz 2 100 DL+LL+WL 0 39.606 0
Min Pz 2 100 DL+LL+WL 0 39.606 0
Maximum pressure = 39.61 Kn/m^2
Soil bearing capacity taken = 75.00 Kn/m^2
Ground level = 0.00
Depth of Foundation = 0.250 m
TOC of Foundation= -1.5
Depth of Foundation below GL = 1.750 m
Gross bearing Capacity = 106.50 Kn/m^2
HENCE OK

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CLIENT NAME: KAITHAL CO-OPERATIVE SUGAR MILLS LTD.

PROJECT: CONDENSATE POLISHING UNIT (CPU) CAPACITY- 700KLD

STRUCTUIRAL DESIGN CALCULATIONS OF SECONDARY CLARIFIER OF CPU

SUBMITTED BY - DEW PROJECTS AND CHEMICALS PRIVATE LIMITED

Dead load on Top Slab = 1.2 Kn/m2

Net allowable bearing capacity considered = 7.5 t/m2

NGL / FGL = 0.00 q1

NGL / FGL = 0.00 q1

Diameter of wall = 7.5 m with 36 No. of intervals

Reinforcement has been computed as follows :

Wall has been divided in 13 parts I.e Zone A

Minimum Reinforcement for 250mm thick wall :

Location Ring Tension Ast Ast Provided in

Modular ratio for M-30 grade concrete : 280 = 9.33

Maximum direct tensile stress for Zone-A:

Reinforcement has been computed as follows :

Limit State cracked section approach

Crack width = 0.2 mm

Thickness required = (Mu / Q B)^0.5

Provide wall thickness = 250 mm Hence Ok

Group : RING WALL-VSUPP

Face Element/Load combination

My = 1.611 t-m Water Face

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Face Element/Load combination

My = 1.611 t-m Water Face

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Group : RING WALL-HSUPP

Face Element/Load combination

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Group : RING WALL-HSPAN

Face Element/Load combination

My = 0.274 t-m Water Face

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Limit State cracked section approach

Crack width = 0.2 mm

Thickness required = (Mu / Q B)^0.5

Provide wall thickness = 250 mm Hence Ok

Group : RING WALL-VSUPP

Face Element/Load combination

My = -10.257 t-m Earth Face

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Face Element/Load combination

My = -10.257 t-m Earth Face

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Group : RING WALL-HSUPP

Face Element/Load combination

0.36 fck b d xu = 0.87 fy Ast d

Ast for Mu x z fs d Є1 Є2 Єm acr w Remark

Group : RING WALL-HSPAN

Face Element/Load combination

My = -1.744 t-m Earth Face