Australian Code-Structural Design Criteria-Rev A

AUSTRALIAN CODE- Civil/Structural DESIGN CRITERIA (Onshore)

000/00000/0 – Document Number December 2015

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DESIGN CRITERIA TEMPLATE (CIVIL/STRUCTURAL ONSHORE)

SYNOPSIS This document presents the Civil/Structural Design Criteria for the Australian Code.

Disclaimer This report has been prepared on behalf of and for the exclusive use of WorleyParsons and is subject to and issued in accordance with the agreement between Customer and WorleyParsons. WorleyParsons accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any third party. Copying this report without the permission of Customer and WorleyParsons is not permitted.

PROJECT 000/00000/0 – DESIGN CRITERIA TEMPLATE (CIVIL/STRUCTURAL ONSHORE) REV

DESCRIPTION

ORIG

REVIEW

WORLEYPARSONS APPROVAL

DATE

A

Issued for internal review

U Gavas Author

N Walavalkar A Reviewer

V Patole N/A

31-Jan -16

CLIENT APPROVAL

DATE

N/A

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CONTENTS 1

INTRODUCTION ................................................................................................................ 1 1.1

2

Basis of Design ................................................................................................................... 1 CODES AND STANDARDS ............................................................................................... 1

2.1

Australian Standards .......................................................................................................... 1

2.2

Process Industry Practices ................................................................................................. 2

3

MATERIALS ........................................................................................................................ 3 3.1

Concrete ............................................................................................................................. 3

3.2

Grout ................................................................................................................................... 3

3.3

Reinforcement and Anchor Bolts ........................................................................................ 3

3.4

Structural Steel ................................................................................................................... 4

3.5

Bolts and Masonry Anchors ................................................................................................ 4

3.6

Miscellaneous ..................................................................................................................... 4

3.7

Drainage ............................................................................................................................. 5

4

3.7.1

Storm water Drainage ............................................................................................ 5

3.7.2

Bund Drainage ....................................................................................................... 5

DESIGN DETAIL................................................................................................................. 5 4.1

4.2

4.3

Design Loads ...................................................................................................................... 5 4.1.1

Dead Loads ............................................................................................................ 5

4.1.2

Live Loads .............................................................................................................. 6

4.1.3

Wind Loads ..........................................................................................................10

4.1.4

Earthquake Loads ................................................................................................11

4.1.5

Earth Loads ..........................................................................................................11

4.1.6

Retaining Walls (Earth Pressure Loads) ..............................................................12

Design Load Combinations ...............................................................................................12 4.2.1

Loading Combinations .........................................................................................12

4.2.2

Stability.................................................................................................................12

Concrete Design ...............................................................................................................12 4.3.1

General ................................................................................................................12

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4.4

4.5

4.6

4.7

4.3.2

Geotechnical Properties for Foundation Design ..................................................13

4.3.3

Concrete Strength and Durability .........................................................................13

4.3.4

Stability of Surrounding Structure Footings .........................................................13

4.3.5

Footing and Foundation Design ...........................................................................13

4.3.6

Concrete Slabs.....................................................................................................13

4.3.7

Holding Down Bolts for Concrete .........................................................................14

Steelwork Design ..............................................................................................................14 4.4.1

Specific Serviceability Requirements ...................................................................14

4.4.2

Structural Member Sizes ......................................................................................15

4.4.3

Connection Details ...............................................................................................15

4.4.4

Constructability and Transport .............................................................................15

4.4.5

Deflection Limitations ...........................................................................................16

4.4.6

Corrosion Considerations ....................................................................................16

4.4.7

Access Clearance ................................................................................................16

Drainage and Spillage Containment .................................................................................17 4.5.1

Design Basis ........................................................................................................17

4.5.2

Drainage Containment .........................................................................................17

4.5.3

Spillage Containment Bunds................................................................................17

4.5.4

Piped Drainage ....................................................................................................18

4.5.5

Open Drains .........................................................................................................18

Roadworks and Paving .....................................................................................................19 4.6.1

Geometry .............................................................................................................19

4.6.2

Pavement Design .................................................................................................19

4.6.3

Design Vehicle .....................................................................................................19

4.6.4

Traffic Volumes ....................................................................................................19

4.6.5

Design Speed.......................................................................................................20

4.6.6

Road Signage and Pavement Markings ..............................................................20

4.6.7

Seal ......................................................................................................................20

Sewerage ..........................................................................................................................20

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4.8

4.9

4.7.1

Design ..................................................................................................................20

4.7.2

Specific Criteria ....................................................................................................21

Hydrocarbons and Oily Wastes ........................................................................................22 4.8.1

Management Plan ................................................................................................22

4.8.2

Storage of Hydrocarbons .....................................................................................22

4.8.3

Waste Collection ..................................................................................................23

4.8.4

Degreasing Bays ..................................................................................................23

4.8.5

Vehicle Gearbox and Machine Oils......................................................................24

4.8.6

Oily Rags ..............................................................................................................24

4.8.7

Effluent .................................................................................................................24

Solid Waste Management .................................................................................................24 4.9.1

General ................................................................................................................24

4.9.2

Collection .............................................................................................................24

4.9.3

Disposal Site ........................................................................................................24

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1

INTRODUCTION

This document presents the Civil/Structural Design Criteria for the Australian Code to be used for the design of civil, structural and building works. Specific information to be used in conjunction with this document may be contained in the project Basis of Design. If any conflict arises between this document and the applicable standards or codes, this shall be resolved either by application of the most severe design conditions or resolution by the Principal Civil/Structural Engineer.

1.1 Basis of Design Refer to the Basis of Design document for the following information: 

Documents to be referenced where available



Codes, Standards, Specifications and Regulatory Requirements



Units



General Equipment Requirements



Site Conditions and Seasonal Variations



Provision for Future Expansion

2 2.1

CODES AND STANDARDS Australian Standards



AS 1170 Structural Design Actions



AS 1250 The Use of Steel in Structures



AS 1289 Methods of Testing for Soils Engineering Purposes



AS 1418 Cranes, Hoists and Winches



AS 1554 Structural Steel Welding



AS 1657 Fixed Platforms, Walkways, Stairways and Ladders - Design, Construction & Installation



AS 1720 Timber Structures



AS 1940 The Storage and Handling of Flammable and Combustible Liquids



AS 2870 Residential Slabs and Footings



AS 3500 Plumbing and Drainage

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

AS 3600 Concrete Structures



AS 3610 Formwork for Concrete



AS 3678 Structural Steel - Hot rolled plates, Floorplates and Slabs



AS 3679 Structural Steel - Hot rolled bars and sections



AS 3700 Masonry Structures



AS 3735 Concrete Structures Retaining Liquids



AS 3780 The Storage and Handling of Corrosive Substances



AS 3990 Mechanical Equipment – Steelwork



AS 4100 Steel Structures



AS 4600 Cold Formed Steel Structures



AS 4680 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles



AS 5100 Bridge Design



IEA Australian Rainfall and Runoff



NCC National Construction Code



AS 3972 Portland and Blended CementsMaterials

2.2 Process Industry Practices Process Industry Practices provide excellent resources for Petrochemical plant design. 

PIP STC01015 Structural Design Criteria



PIP STE01100 Constructability Design Guide



PIP STE03020 Guidelines for Tank Foundation Designs



PIP STE03350 Vertical Vessel Foundation Design Guide



PIP STE03360 Heat Exchanger and Horizontal Vessel Foundation Design Guide



PIP STE05121 Anchor Bolt Design Guide



3

MATERI ALS

Engineers should use the Safety in Design (SID) Discipline Standard Civil (EPP-0256-COR-EN) and SID Discipline Standard (Structural) (EPP-0257-COR-EN) for reference and guidance when completing this document. Adjust the following grades of concrete to suit the project and country specific design and environmental requirements. The minimum standard materials to be specified are as follows:

3.1 Concrete 

Blinding

f’c = 15 MPa



Lean mix concrete

f’c = 15 MPa



Pavement, slabs and bund walls

f’c = 40 MPa



Foundations

f’c = 40 MPa



Catch basins / manholes

f’c = 40 MPa



Fireproofing

f’c= 40 MPa

Concrete compressive strength f’c quoted at 28 days. All cement to be Type GP Portland Cement to AS 3972 or Project Specific.

3.2 Grout 

Machinery base plates

Non Shrink Epoxy Grout, f’c = 40 MPa



Column base plates, vessels and

Non Shrink Cementitious Grout, f’c = 40 MPa

non rotating equipment

3.3 Reinforcement and Anchor Bolts 

Reinforcement

High Yield Strength D500N bar (fy = 500MPa)



Welded steel fabric

Ribbed Square Mesh to AS/NZS 4671



Anchor Bolts

Minimum 20 mm diameter Low Strength: Grade 300 Rod to AS 3679 or Grade 4.6 to AS 1111 High Strength: Grade 8.8 to AS 1252 or Class B7 to ASTM A193 Anchor bolts to be hot dip galvanized



3

Modulus of elasticity of reinforcement, Es, shall be taken as 200 x 10 MPa. Bending and splicing of reinforcement bar shall be in accordance with the latest edition of AS 3600.

3.4 Structural Steel 

Rolled Open Sections

Grade 300 Plus



Structural Hollow Sections

Grade 350



Pipe Sections

ANSI B 36.1



Plate

Grade 250 (AS 3678)

The minimum thickness of any part of structural sections shall be 6mm or Project Specific. The minimum thickness of plates used for structural connections shall be 10mm or Project Specific. All structural steel to be hot dip galvanized, unless noted otherwise on project documents.

3.5 Bolts and Masonry Anchors 

Minimum Size

- structural connection

M20 (20 mm diameter)

- non structural connections

M16 (16 mm diameter)



Grade

8.8 high strength fuf = 830 MPa



Tightening

- Standard

S - Snug Tight

- Slip Critical

TB - Fully Tensioned



Masonry Anchors

M20 Chemical Set Anchors (minimum)

All bolts and masonry anchors to be hot dip galvanized unless noted otherwise on project document. Lock nuts or approved equivalent shall be used for connections subject to vibration and/or supporting hanging (tension) loads.

3.6 Miscellaneous 

Access Platform Flooring

32mm grating



Stair Treads

32mm grating treads



Handrail

Tubular handrail or equivalent



3.7 Drainage 3.7.1 Storm w ater Drainage All storm water pipes shall be reinforced concrete to AS 4058 Precast Concrete Pipes

3.7.2 Bund Drainage All bund drainage shall be HDPE pipes to AS 5065 Polyethylene and Polypropylene.

4

DESIGN DETAIL

Refer to the Civil and Structural Safety and Design (SID) Discipline Standards (EPP-0256-COREN and EPP-0257-COR-EN respectively) in EMS when creating this document.

4.1 Design Loads 4.1.1 Dead Loads The dead loads shall be those loads specified as dead loads in AS 1170.1 Structural design actions - Permanent, imposed and other actions & PIP STC01015 and shall include: 

Total weight of all structural and non-structural components



The self-weight of permanent building elements



Miscellaneous permanent loads



Fixings (including floor decking, cladding and insulating or fire proofing materials) which are permanently attached to the structure



Fixtures integrally constructed with the structure or forming part of the structure including empty permanently fixed equipment, cable ladders and the self-weight of piping



For lighting elements and utility piping allow 0.1 kPa dead load



Process piping ducts and major electrical runs shall be assessed individually



Cable and cable tray loads shall also be considered as dead loads

The densities of the materials shall be in accordance with AS 1170.1, and shall include: 

Reinforced Concrete - 2500 kg/m3 (for 2% reinforcement, dense aggregate)



Steel - 7850 kg/m3



4.1.2 Live Loads The weight and position of live loads shall be considered including the method of load application. The 'live loads' shall be those loads specified as such in the AS 1170.1- Structural Design actions & PIP STC01015 and shall include the following: 

Personnel, portable machinery and equipment and portable tools.



Fluid loads caused by liquids moving in equipment, tanks or piping.



Moving loads caused by the non-stationary bulk materials in chutes, bins, hoppers, tanks and conveyors.



Thermal loads due to solar or process temperature changes.



Materials and items which could be temporarily or permanently stored during normal operation or maintenance or plant shutdown such as pallets of refractory bricks.



Operating loads (e.g. dynamic forces, thrusts or reactions).



Belt tension loads for conveyors during normal operation, flooded belt and at motor start up.



Platform and flooring live load.



Impact loads.

The design loads for flooring, platforms, walkways, stairs, and ladders shall be as follows:

4.1.2.1 F L O O R I N G A floor live load of 5 kPa uniform distributed load (over the floor), or a moveable concentrated load of 4.5 kPa shall be applied, whichever has the greater affect.

4.1.2.2 S T AI R S A stair live load of 4 kPa uniform distributed load or a moveable concentrated load of 1.4 kPa shall be applied, whichever has the greater effect.

4.1.2.3 S E R V I C E A C C E S S W A L K W A Y S A N D P L A T F O R M S A service access walkway live load of 2.5 kPa uniform distributed load, a moveable concentrated load of 1.4 kPa or the maintenance load shall be applied, whichever has the greater effect. This applies to sloping and stepped access for equipment and walkways for pipe racks.

4.1.2.4 C O N V E Y O R W A L K W A Y S A conveyor walkway load of 2.5 kPa uniform load on each walkway or a moveable concentrated load of 2 kN or the material spillage load shall be applied, whichever is the greater. The material spillage load shall be calculated for the maximum burden at the full rill angle from the edge of the walkway.



This loading applies to walkways alongside and integral with the conveyor. In particular, attention shall be given to spillage loads at all conveyor head chutes and other change points.

4.1.2.5 W O R K S H O P F L O O R S A N D H E AV Y L A Y D O W N A R E AS A floor live load of 10 kPa uniform distributed load, a moving concentrated load of 30 kN on 50 mm square area or loads caused by heavy moveable or stored loads shall be applied, whichever has the greater effect. This applies to concrete floors for maintenance workshops. Allowance shall be made in the design for jacking loads for vehicles or equipment. A floor live load of 10 kPa uniform distributed load shall be applied to laydown areas around heavy machinery.

4.1.2.6 W A R E H O U S E A N D S T O R E R O O M F L O O R S A floor live load of 2.4 kPa uniform distributed load for each clear meter of height above the floor level (minimum 5 kPa unless shown otherwise on the drawings). Special consideration shall also be given to point loads put on the floor from storage rack posts.

4.1.2.7 I M P A C T L O A D S The forces caused by impact due to the movement of vehicles shall be in accordance with: 

AS 1170.1 for general buildings and structures.

For preliminary design purposes the following factors shall be applied as a multiplier to the static load of equipment to allow for impact loads caused by operating equipment. Reciprocating machinery, crushers & pumps

3.0

Rotating machinery

2.0

Elevator supports

2.0

Mobile equipment

1.25

Hangers supporting floors and balconies

1.35

Cranes, monorails and hoists

1.25

Carry return idlers at loading points

2.0

4.1.2.8 D Y N A M I C L O A D S Dynamic loads shall include vibrating or moving machinery impact forces from screens, crushers, feeders, chutes, etc., and liquid surge forces from flotation cells, aeration tanks and the like. The magnitude of the static loads, impact forces in the horizontal and vertical directions for start-up and normal operation and the machine operating speed shall be obtained from the supplier of the



equipment or from supplier data information. The final design shall be checked using certified forces shown on the drawings provided by the equipment supplier.

4.1.2.9 C R A N E A N D H O I S T L O A D S The design loads for cranes, hoists and monorails shall be calculated from the rules given in AS 1418 Cranes, hoists and winches – General requirements. The wheel loads, speeds and acceleration rates and component loads shall be obtained from the crane or hoist supplier. The Working Load Limit (WLL) of the crane or hoist shall be shown on the customer design drawings. The design drawings shall contain a note to indicate that the WLL shall be painted on the crane runway beams or monorail.

4.1.2.10 D AV I T L O A D S Each davit shall be designed to support the heaviest piece of equipment required to be lifted plus a dynamic force. The davit WLL shall be shown on the design drawings. The design impact forces for davits shall include: 

Vertical impact force 25% of lifted load.



Horizontal impact force 20% of weight of the moving equipment load).

(davit, plus attachments, plus

4.1.2.11 T H E R M AL M O V E M E N T S L O A D S Thermal loads in piping, equipment and structural members shall include those produced by solar and process temperature change. Where details of site temperature conditions are not provided the structures shall be designed for a minimum range of -5°C to 60°C with an ambient temperature of 25°C for structures exposed to sunlight. Structures shaded from the sunlight shall be designed for a minimum temperature range of 40°C. Where significant temperature changes occur, sliding or rolling joints will be required to allow for the dimensional change. Where sliding joints are used the following friction coefficients shall be used to determine the friction forces: Teflon on Steel

0.05

Steel on Steel

0.30

Steel on Concrete

0.45

Pipe racks shall be designed to resist the horizontal transverse forces expected. Such forces may be induced by friction or thermal movements. Where structures are more than 50m long, movement joints shall be provided or specific thermal movement loads shall be applied to the structure. Movement joints or loops shall be also provided in the piping.



4.1.2.12 P I P E L O A D S Pipe racks shall be designed for the applicable loading condition or a uniform distributed load of 2.0 kPa (vertical) per deck, whichever is the greater loading. The pipes shall be assumed to be full. Piping loads shall include the weight of pipes plus fittings, valves, insulation, instruments and contents.

4.1.2.13 C A B L E L A D D E R L O A D S For allowable loads to be applied to proprietary cable ladders, refer to the cable ladder manufacturer. The ladder and splices shall be designed to support a 1 kN point load at any position on the ladder in addition to any other loads. Structures supporting cable ladders shall be designed for a uniform load of 0.8 kPa (which includes the cable ladder weight) unless a heavier load is required for a particular project.

4.1.2.14 F L U I D L O A D S A N D S U R G E F O R C E S Fluid loads in tanks, thickeners, cells, etc., shall be calculated using the maximum possible liquid weight in the vessel and the maximum density of the liquid. Fluid surge forces shall include forces resulting from rapid fluid flow change or movement such as valve closure. Fluid surge loads due to the change of the center of mass in aeration tanks, flotation cells and the like shall be assumed to act horizontally in all directions. The magnitude of the surge force shall be taken to be 10% of the tank contents weight. The application frequency of the surge shall be assumed to be approximately 3 to 5 Hertz.

4.1.2.15 B U L K S O L I D S L O A D S Vessels such as silos, hoppers, chutes and bins which contain bulk solids shall be designed to be full of contents (or empty if this produces a more severe loading condition e.g., for stability). For the design calculations, the bulk solid density shall be taken to be the maximum possible, as advised by supplier data information.

4.1.2.16 F L O W A B L E M AT E R I A L S L O A D S Fluid and moving material loads shall include loads due to liquid or bulk materials in piping, equipment, tankage, on conveyors or any other material transfer system with due allowance for increases above normal operational loads, levels or flow rates. Surge loads shall also be taken into account (see 'Fluid Loads and Surge Forces'). Fluid and moving material loads shall be the most adverse of the operating and test conditions. For well mixed contents, fluid and flowable materials loads shall be calculated using the maximum density.



4.1.2.17 B U O Y A N C Y L O A D S The effect of buoyancy from ground water and flooding on the weight of foundations shall be considered when assessing the stability of foundations.

4.1.2.18 B L A S T L O A D S If deemed necessary by customer requirements and the Safety and Risk engineer, structures within the blast zone shall be checked for adequacy for the applied blast loads. Shock wave pressures for the design of blast walls shall be taken as 70 kPa, unless more detailed information is available.

4.1.2.19 T E S T L O A D S Test loads shall be allowed for in the design if applicable. Pipeline thrust blocks should be tested at twice the normal operating pressure. Cranes and hoists should be tested by lifting a load of 1.1 times the safe working load.

4.1.2.20 E R E C T I O N A N D C O N S T R U C T I O N L O A D S Allowance shall be made in the design for erection and construction loads e.g., moving heavy equipment over floors, the lifting of trusses, the stacking of bricks, liners, materials etc.

4.1.3 Wind Loads The wind loads shall comply with AS 1170.2. The average return interval to be adopted shall be as follows:For ultimate limit state

: 500 years

For serviceability limit states (for wind in conjunction with permanent effects only)

: 20 years

The following wind loads shall be considered based on Wind Region:

4.1.3.1 P E R M A N E N T S T R U C T U R E S Unless advised otherwise, the basic wind speed for the project area shall be that specified in AS 1170.2. Regional Wind Speed, V500, and Terrain Category 2 shall be applicable to the project area unless advised otherwise by the customer Principal Civil/Structural Engineer. The dynamic wind pressures and surface wind forces shall be calculated in accordance with that standard. # Refer Appendix-I : Wind Load Calculation_1172.xls for calculating wind actions on structures.



4.1.3.2 W I N D L O A D O N G R O U P E D P I P E S The wind load on a group of pipes which are at the same level on a pipe rack shall be calculated assuming a single equivalent pipe.

4.1.4 Earthquake Loads Earthquake loading shall be as determined in AS 1170.4 adopting the following parameters: Table 4.1: Earthquake Loading Parameters Importance level Annual probability of exceedance Probability factor, Kp Hazard factor, Z Site sub-soil class Earthquake design category The seismic weight of vessels such as tanks, bins and silos which contain bulk solids or liquids shall be the weight of the full vessel. Where the site sub-soil class is not specified, Class De shall apply. # Refer Appendix-II : Earthquake Loading Calculation.xls for calculating Seismic actions on structures

4.1.5 Earth Loads Unless advised otherwise, dry densities shall be taken as: 

For soil, 18 kN/m³



For rock, 25 kN/m³

For lateral earth pressures: 

Active earth pressures shall be used for the design of flexible structures, such as cantilever retaining wall constructed from unbraced steel sheet piling, or gravity retaining walls.



At rest earth pressures shall be used for the design of rigid structures as tied retaining walls, concrete tunnels and concrete ring beams for tanks. The at rest pressure coefficient shall be taken as not less than K o = 0.5.





Passive earth pressures shall not be assumed to resist lateral forces unless substantial movement can be accommodated. The upper 300 mm of soil shall not be considered to be contributing to the passive resistance of lateral forces.



Lateral earth pressure coefficients on retaining structures subject to repeated traffic loads shall take into consideration the resulting long term compaction, which in some cases has been measured as giving coefficient as high as the passive coefficient K p. Where roads approach within half the height of the wall, the retaining wall shall be designed for a minimum surcharge of 10 kPa.



Compaction loads due to the compaction of backfill shall be considered on the structure where applicable.

4.1.6 Retaining Walls (Earth Pressure Loads) Allow for surcharge at retained ground surface as follows: Normal

5.0kPa

Road Traffic

a moving standard tandem axle with 80 kN load on each axle

The ‘at rest’ lateral earth pressure (Ko) shall be used unless calculations justify the use of ‘active’ pressure (Ka) by demonstrating sufficient movement to mobilize active pressure. In any case active pressure shall not be used where dynamic or vibratory loading is expected due to progressive creep required to maintain active pressures.

4.2 Design Load Combinations 4.2.1 Loading Combinati ons The loading combinations given in AS 1170.0 shall generally be used to determine the most severe condition for design. # Refer Appendix-III for Basic Load Combinations.

4.2.2 Stabilit y Each building, wall or structure shall be designed to prevent instability & shall be stable against overturning, sliding and uplift. A structure shall be stable as required by AS 1170.0.

4.3 Concrete Design 4.3.1 General The concrete design shall comply with the current edition of AS 3600-2009 Concrete Structures.



4.3.2 Geotechni cal Properties for Foundation Design For geotechnical data for use in the design of foundations and slabs, refer to: Provide reference to geotechnical investigation and interpretative reports The allowable bearing pressure and other soil parameters shall be taken from the reports as listed above. The maximum soil bearing pressure shall not exceed the allowable bearing pressure. Bearing pressures may need to be considerably less than the allowable bearing pressure for settlement sensitive structures.

4.3.3 Concrete Strength and Durabilit y Design for durability shall be in accordance with AS 3600-2009.

4.3.4 Stabilit y of Surrounding Structure Foot ings New footings founded near existing footings, underground services or in ground at the upper edge of a batter slope should be founded at a depth such that the base of the new footing is outside the zone of influence of the existing footing, underground service or batter slope. The zone of influence of any footing, underground service or batter slope is defined as the volume of soil outside planes drawn at 1 vertical to 2 horizontal (above and below) from the base of the existing footing, underground service or batter slope, unless otherwise noted in the geotechnical report.

4.3.5 Footing and Foundation Design Concrete pedestals under steel column baseplates or tank rims shall have a minimum of 50 mm edge distance from the baseplate or rim. Pedestals shall be made sufficiently large to accommodate the holding down bolts (and tolerance tubes) and the pedestal reinforcement. All pedestals which are more than 200 mm high shall be reinforced. The minimum total area of main pedestal steel reinforcement provided shall be 0.5% of the gross cross sectional area of the pedestal. A 50 mm thick concrete blinding layer will be required under all footings and foundations. This should be poured within 24 hours of foundation excavation.

4.3.6 Concrete Slabs 4.3.6.1 D E S I G N P R O C E D U R E S The design method for ground slabs shall be in accordance with the method given in “Guide To Industrial Floors and Pavements” by Cement Concrete and Aggregates Australia.

4.3.6.2 M O D U L U S O F R U P T U R E The modulus of rupture of concrete shall be taken as:



MR28 days = 0.438 (f’c)

2/3

The modules of rupture for 90 days shall be taken as: MR90 days = 1.10 x MR28 days The value of MR90 shall be used for design, unless it is intended to subject the slab to substantial loading prior to 90 days.

4.3.6.3 S U B G R A D E R E A C T I O N C O E F F I C I E N T Stresses are not critically dependent on the value selected for the subgrade reaction coefficient ‘k’. Therefore the following list of values may be used for preliminary design in the absence of a proper soil investigation results. Table 4.2: Subgrade Reaction Coefficient Soil Type

K MPa/mm

(a)

Clays of high plasticity and organic silts

18 x 10

(b)

Low Plasticity clays and silts. Poorly graded fine sands

36 x 10

(c)

Well graded sands. Poorly graded gravels.

90 x 10

(d)

Well graded gravels, crushed rock.

175 x 10

E MPa

-3

35

-3

70

-3

105

-3

350

4.3.7 Holding Dow n Bolts for Concrete Holding down bolts shall be designed to transfer the entire column or equipment loads to the concrete pedestal or plinth. Shear keys on the baseplate should be provided where there are large base shear loads. Holding down bolts shall be sized to take into account the effects of corrosion

4.4 Steelw ork Design Structural steel design shall generally comply with AS 4100 Steel Structures. For all designs, the member slenderness ratio shall not exceed 300 for tension members or 180 for compression members (except for those in which the compressive forces result from wind load only where the slenderness ratio may be increased to 300).

4.4.1 Specific Serviceabi lit y Requirements In addition to the design requirements of the design code used, the following design requirements shall be adhered to: k:\civil\civil\001 civil structural\australian codes capability\australin code workings\australian code-structural design criteria-rev a.doc Page 14 000/00000/0 : Document NumberRev 3 : September 2015




Member slenderness shall be limited in order to minimize secondary effects. The slenderness ratio of any member shall be limited to 180, except for building wind bracing which shall be limited to 300.



Where K-bracing is used, the bracing members should be restricted to angles of between 30 and 60 to the vertical.



Machine guards should be planned into the design of the equipment and should not in themselves constitute a hazard. Further, they shall be easily removable/replaceable to facilitate maintenance of the equipment. Guards shall be constructed of appropriate material of adequate strength and shall be effectively attached and maintained. Such guards should not be capable of removal or adjustment without the use of tools.

4.4.2 Structural Member Sizes The designer shall establish the size of each structural member and bolted connection required for each of the design drawings for the project. For bolt design, the shear plane shall be taken to be through the threaded part of the bolt. The Design Engineer shall: 

Check that the member, fastener and weld sizes are shown correctly on the design drawing and the stiffener and baseplate details are adequate.

4.4.3 Connection Details If available, the customer standard steel connection drawings shall be used where practicable and are fit for purpose. The following information is given for the standard pinned type connection details: 

For beam to column connections, flexible end-plates should generally be used. For beam to beam connections, web side plates should generally be used. For beam to beam connections with horizontal bracing in place, flexible end plate connection shall be used with web side plate connection at the far end of the member.



The Design Engineer should check that any customer standard connections will be adequate for the project design loads. Should the standard connection be unsuitable or inadequate, the Design Engineer shall provide the appropriate detail for a suitable connection for the design drawings.



Flexible end-plate connections which are subject to axial tension should have a detail design check done.

4.4.4 Constructabilit y and Transport At the design stage, special consideration shall be given to prefabrication in shop and pre-assembly on the ground prior to erection for structures, vessels, tanks, equipment, etc. The location of splices should be designed to suit the transport limitations. Welded cleats which project proud of the overall member should be avoided where possible.



Unless advised otherwise equipment which falls within the size envelope, 3.10 meters wide by 2.80 meters high by 19 meters long will not require an escort. Consideration shall be given to matching prefabricated section sizes to galvanizing baths.

4.4.5 Deflection Limitations Structures should be designed such that the structural deflections at design loads are limited to those detailed in Appendix C of AS1170.0 and as follows: 

Buildings

max 1/400 of the overall height



Wall columns

max 1/300 of the height at the column



Purlins and girts

max 1/180 of the span



Supporting beams max 1/360 of the span



Crane runway beams



-

Vertical

max 1/500 of the runway span

-

Lateral

max 1/600 of the runway span

-

Cantilevers

max 1/300 of the cantilever span

Portal frames

max 1/250 (horiz.) of the column height to the portal knee

4.4.6 Corrosion Considerations At the design stage the following should be considered: 

An adequate space between the structural components should be provided to facilitate painting.



Where possible, orientate structural sections in such a way as to avoid the collection of water or dust or spillage materials.



Provide adequate drain holes in the members where required.



Welds which are exposed to the elements or to a corrosive environment should be continuous welds.

4.4.7 Access Cl earance Access clearances shall conform to the following: Over Primary Roads:

6100mm

Over Maintenance Roads:

5000mm

Floor Headroom:

All overhead piping shall allow a minimum of 2200mm clearance over walkways, platforms and the like and 1000mm horizontal clearance.



4.5 Drainage and Spillage Containment 4.5.1 Design Basis Drainage design shall be carried out on a rational basis in accordance with IEA's book, Australian Rainfall and Runoff. The Average Recurrence Interval (ARI) for design storms shall be: 

500 years:

Diversion drains around open cuts mine, shafts and portal entrances.



100 years:

Global diversion drains around plant sites and major facilities.



50 years:

Plant facilities and permanent all weather roads and airstrips.



20 years:

In-plant local drainage, building drainage.

Notwithstanding the above, runoff from events of greater return periods should be provided for by provision of alternative flood routes and sensible provision of freeboard to all bunding and diversion channels, designed in accordance with the above criteria. The minimum freeboard provided should be 500 mm, except for mines which have an expected life of less than 10 years, in which case, the freeboard may be reduced to 300 mm.

4.5.2 Drainage Containment In-plant stormwater runoff should be totally contained during the initial flush of the first storm or rainfall. Refer also to AS 1940 and AS 3780. Design Flow = Max of Qfire or Qrain ( ## INPUT FOR THIS PARA AWAITED FROM AMIT BHAMRE)

4.5.3 Spillage Contai nment Bunds In-plant drainage design shall allow for the containment and recycling or treatment of day-to-day washdown runoff, accidental spillages and plant excursions. Spillages shall be confined to the smallest practicable area by use of appropriate bunding. Bunded areas for tanks and vessels containing fuels or dangerous goods must be able to contain the contents of all major vessels in case of spillage of total contents. The bund capacity shall be 110% of the capacity of the largest vessel in the case of flammable and combustible liquids, and for corrosive substances and oxidizing agents of packaging groups II and III. For corrosive substances and oxidizing agents of packaging group I, the bund capacity shall be 100% of the TOTAL storage capacity of all containers located within the bunded area. If tanks are interconnected the bund must be capable of containing the combined volume in the case of a leak or spill. Clearance between the bund wall and the tank(s) must be not less than 1 metre and the Tan  requirement (i.e.  > 26.5°) must also be met. To further minimize the impact of leaks, tank fittings should be located inside the bunded area.



Bunding is required for package stores (i.e. drum stores) and intermediate bulk containers (IBCs), such as 1000 L bulk boxes. In addition, bunding should be provided for storage of acids in excess of 500 L (i.e. 3 drums ) and lubricating oils in excess of 5000 L (25 drums). Bunding should also be used to ensure adequate segregation of incompatible process streams. Any earthen bunds must be suitable for the material being contained, suitably compacted and/or sealed to required permeability standards, and remain clear of vegetation. Spoon drains should be utilized where practicable for channeling minor spills and to facilitate hosing down. Suitable access to spoon drains is required in the event of blockage. Concrete paving slabs for process areas subject to exposure of aggressive contaminants or containment of contaminants (e.g. acids) should be protected by a suitable chemically resistant covering.

4.5.4 Piped Drainage In-plant drainage should avoid the use of piped drains where possible. For preliminary design the following information shall be used unless specified otherwise. Roughness factors ‘n’ to be used in Manning’s formula: 

Concrete pipe

0.12



Unlined channels

0.020 - .040



Concrete lined channels

0.011 - 0.020



Rubble or rip rap lined channels

0.020 - 0.040

Culvert and open channel velocity: 

Unlined channel

0.8 m/s maximum



Lined channels

4.0 m/s maximum 0.7 m/s minimum

General: 

Permanent culverts shall have concrete headwalls;



Drainage channel outfalls shall have protection (stone pitching or lining) as required.

4.5.5 Open Drains Modify the section based on Project requirements. The following are the common types of open drains used in road drainage design, including but not limited to: 1. Table drains k:\civil\civil\001 civil structural\australian codes capability\australin code workings\australian code-structural design criteria-rev a.doc Page 18 000/00000/0 : Document NumberRev 3 : September 2015


2. Diversion drains 3. Side Drains 4. Catch/ Cut off Drains – at cut/fill batters to protect batter slopes typically 0.3m deep Table drains shall be a minimum depth of 0.3 m from the edge of the subgrade to the drain invert and generally V-shaped. If higher discharge capacity is required the table drain shall be trapezoidal shaped. Depending on local soil conditions, scour protection is generally required:  where flow velocities exceed 2 m/s;  where drain materials have high scour potential;  at all culvert inlets and outlets;  at substantial changes in direction of open channels and drains;  changes in invert levels at falls along any open drain alignment.

4.6 Roadw orks and Paving 4.6.1 Geometry Geometric design of roadways shall comply with the current Austroads Standards. Public roads should additionally comply with the requirements of the Local Authority or with the State Road Authority Main Roads requirements, as appropriate. Within the plant, hardstanding areas should be graded to a minimum grade of 1.0% if sealed or 1.5% if unsealed. Roads should have a cross fall of 3.0% and road drains falling at least 0.66%. The valleys and spoon drains in the plant should be graded at a minimum of 0.66%. Pavement geometry shall allow for the wash-down of all in-plant paving (for hygiene) and shall provide containment of all wash-down and spillage. This requires all areas to be free draining with no local hollows or low spots.

4.6.2 Pavement Design Pavement design shall be carried out on a rational basis relating the predicted wheel load applications to the base course California Bearing Ratio (CBR).

4.6.3 Design Vehicle Include as required.

4.6.4 Traffic Volumes Include as required.



4.6.5 Design Speed Modify the section based on Project requirements. The geometric design will be based on 48 km/h (30 mph) design speed as per Customer Specification/Standard. Normal practice is for design speed to be 10 km/h higher than the posted operational speed. Posted speed limits shall be 10 km/h less than the design speed, except as signed for specific sections of road in curves.

4.6.6 Road Signage and Pavement Markings Modify the section based on Project requirements. All road signage and pavement marking shall be in accordance with local standards and codes, or alternatively to American Association of State Highway and Transportation Officials (AASHTO) standards.

4.6.7 Seal The seal of roadways and carpark areas should consist of a primer coat and one or more seal coats. Areas of hardstanding should be sealed with prime and asphalt seal of minimum thickness 30 mm. Hardstand asphalt shall be designed for the maneuvering and the turning of vehicles and forklifts. In principle, all sealing should be carried out on the basis of design supply and install by the specialist sealing Contractor. In remote areas, particular attention should be given to avoiding salt in the base course material as this has catastrophic effects on bitumen. All water for compaction of base course should be of potable quality.

4.7 Sew erage 4.7.1 Design The design of a sewer system (inclusive of collection, treatment and disposal of effluent and sludge) shall comply with the provisions of AS/NZS 3500 Plumbing and drainage and the requirements of the relevant ruling Authority. Unless specified otherwise the design flows in sewers shall be based upon a daily average dry weather flow rate of 40 litres/person/day for persons showering at the plant site. For day staff at the plant site (non-showering) an allowance of 70 litres/person/day shall be made. Peak flow rate shall be assessed on specific analysis. If this is not possible a peak flow rate of 4 times the average dry weather flow should be used.



4.7.2 Specific Criteria Sewer systems to service plant facilities shall consist of the following:

4.7.2.1 C O L L E C T I O N O F S E W A G E Sewage collection systems of soil lines, etc., shall comply with the Plumbing Regulations. These systems shall be limited to a maximum length of pipe line of 100 m between the fixture and the main sewer.

4.7.2.2 M AI N S E W E R The main sewer shall consist of the sewer, manholes, etc., in accordance with the relevant Authority.

4.7.2.3 P U M P S T A T I O N S Where possible sewage pump stations should be a pre-plumbed pump station inclusive of a duty and standby macerator pump, automatic levels control operation and a proprietary electrical control system.

4.7.2.4 P R E S S U R E M AI N S Sewer pressure mains shall be of continuously welded polyethylene construction.

4.7.2.5 S E P T I C T A N K S A N D L E AC H D R A I N S For a contributing population of 25 people or less the treatment of the sewage shall be by septic tank with effluent disposal to a leach drain. This should be to the approval of the local authority, who will nominate the leach drain requirements.

4.7.2.6 P AC K A G E T R E A T M E N T P L A N T For a contributing population of more than 25 people a package sewage treatment plant shall be used for sewage treatment. The plant shall be an aerobic system and should be a proprietary system procured on a design, supply, install commission and train operator’s basis. The effluent disposal shall be to either evaporation ponds or to storage ponds for recycling. Provisions should be made for sludge drying beds.

4.7.2.7 R E C Y C L E D E F F L U E N T Where effluent is recycled for plant watering then a management plan must be submitted the local authority. This plan shall be strictly enforced.



Recycled effluent shall be chlorinated prior to entering the recycle system and spray or sprinkler irrigation is forbidden. Guidelines for effluent recycling are published by the relevant government Health or Environmental Department.

4.7.2.8 W I N D D I R E C T I O N /B U F F E R Z O N E When designing sewage treatment facilities consideration shall be given to the direction of the prevailing winds and the buffer areas in low wind conditions. Where possible, the treatment plant should be located so that the nearest residence and work place is at least one half of one kilometer away.

4.7.2.9 M A N A G E M E N T P L A N Prior to the use of new sewer systems, a management plan shall be prepared. This plan shall clearly set out the requirements for routine cleaning, maintenance, sampling, monitoring and reporting to the local authority.

4.8 Hydrocarbons and Oily Wastes This section sets out the design requirements for the storage and management of hydrocarbons and the disposal of the wastes. The design shall comply with the requirements of the relevant Environmental Authority. In general, oily wastes will need to be passed through a gravity separation system which will remove oil by use of a belt skimmer and a coalescing plate separator in series. Oil collected by the skimmer and separator shall be contained and disposed of in an appropriate way. Effluent water will either be recycled or drained to waste. If the waste is to be cleared in one pass the flows must be controlled to avoid overloading of the coalescer plate separator. Flowrates may not be as critical where the effluent is to be recycled as oil will be removed by several passes through the system and uses such as washdown generally are not affected by some oil in the wash water. For a more stringent control of hydrocarbons than the belt skimmer/coalescer plate method, a proprietary oil separator package plant may be required.

4.8.1 Management Plan A management plan for hydrocarbon and waste disposal shall be prepared for the site. The initial filling of fuel and oil tanks, etc., shall not be carried out until the management plan has been implemented and all the necessary licenses obtained.

4.8.2 Storage of Hydrocarbons The storage and handling of hydrocarbons shall be carried out in accordance with AS 1940 and all facilities shall be licensed with the relevant statutory authorities as necessary.



Additional conditions applicable which are designed to protect the environment by preventing the release of environmentally hazardous chemicals are listed below: 

Store environmentally hazardous chemicals including fuel, oil or other hydrocarbons (where the total volume of each substance stored on the premises exceeds 250 liters) within low permeability -9 (10 meters per second or less) compound(s) designed to contain not less than 110% of the volume of the largest storage vessel or inter-connected system, and at least 25% of the total volume of substances stored in the compound.

The compound(s) described above shall: 

Be graded or include a sump to allow recovery of liquid.



Be chemically resistant to the substances stored.



Include valves, pumps and meters associated with transfer operations wherever practical. Otherwise the equipment shall be adequately protected (e.g., bollards) and contained in an area designed to permit recovery of chemicals released following accidents or vandalism.



Be designed such that jetting from any storage vessel or fitting will be captured within the bunded area (see for example AS 1940).



Be designed such that chemicals which may react dangerously if they come into contact, are in separate bunds in the same compound or in different compounds.

Be controlled such that the capacity of the bund is maintained at all times (e.g., regular inspection and pumping of trapped uncontaminated rain water).

4.8.3 Waste Collection Oily wastes which will generally be a combination of oils, fuels and water are produced by spillage, leakage, wash-down and rainwater runoff from hydrocarbon storage and usage areas. These wastes shall be collected in a system of gravity drains and sumps and treated by a separator system to remove hydrocarbons (for disposal). The separator shall produce a water effluent suitable for disposal by either bioremediation or other means. Each site should have a main separator system. However, local separators may be required to service facilities such as wash-down bays.

4.8.4 Degreasing Ba ys Degreasing bays in workshops and the like shall use rapid breaking detergent degreasers in lieu of solvent based degreasers. Emulsions should be sent to a settling pond. Wastewater from degreasing bays shall be directed to a holding tank to allow sufficient time for oil to come out of suspension prior to further treatment. From the holding tank, effluent should be gravity fed to a local area oil plate separator for water recycling or to the site separator if the water is to be sent to waste.



4.8.5 Vehicle Gearbox and Machine Oils Oil from vehicle sumps, gearboxes, plant machinery and the like shall be drained into drums for disposal without entering into the collection system. Draining sumps into inspection pits shall not be allowed. The oil shall be disposed of by recycling, removal from site by a licensed/specialist contractor or used as furnace oil. Waste oil shall not be stored or disposed of on site.

4.8.6 Oil y Rags Oily rags and oil absorbing medium shall be disposed of by burying at an approved site or incineration. Oily rags etc. shall not be stored in cupboards or containers as this creates a potential fire hazard.

4.8.7 Effluent Effluent water from the site separator plant shall be disposed of by either directing to leach drains or a bioremediation plant. The manner of effluent disposal shall depend on the volume and the site and shall be to the approval of the statutory authorities.

4.9 Solid Waste Management 4.9.1 General Project sites shall have an approved system of solid waste management and disposal. Where possible, use should be made of the local municipal refuse collection and disposal system. For standalone sites which do not have a municipal refuse collection and disposal system, a Solid Waste Management Plan, which clearly sets out the requirements for collection and disposal of solid wastes, will be preferred. This management plan shall be prepared and implemented prior to commencing operations at any site.

4.9.2 Collection Collection and short term storage of wastes shall comply with local Authority by-laws and should be to the approval of its health surveyor. Consideration should be given to provision of cool rooms for short term storage of food wastes to prevent petrification. Industrial wastes such as reagent bags and drums should be carefully stored to prevent generation of wind borne dust or contaminants which may become a health hazard.

4.9.3 Disposal Site The disposal site for solid ‘domestic' waste should generally be a sanitary landfill site. This site and its management plan must be to the approval of the relevant statutory authority.



All sanitary landfill sites should be fenced with a chain mesh fence around the site. The fence shall be at least 2m high. The fence shall contain wind borne debris such as plastic wrappers and shall keep animals out of the site. Industrial wastes should generally be disposed of at a landfill site. This site and its management must be to the approval of the relevant statutory authority.


Australian Code-Structural Design Criteria-Rev A

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