Structural Design-Calculation Report - PDF
Structural Design-Calculation Report - PDF
Revision History
Rev. Date Designed by Checked by Approved by Description
A 30.08.2017 EU MH MH First issue: DRAFT for review only
Responsible Dept. Prepared by : Checked by: Approved by: Date: Lang. Format Pages
Mat Bacon Emilian Ursu Martin Hyde Martin Hyde 30.08.2017 Eng. A4 27
(MB) (EU) (MH) (MH)
Document Title:
Strucutral design report –Steel bracings removal
Project: Document Number Rev.
Fokker Logistics Park, Amsterdam S.3114.00- A1– 001_A A
Project title : Fokker Logistics Park, Amsterdam
Project no: S.3114.00
Section: Calculation report
TABLE OF CONTENT
1. Introduction………………………….………………….…………………….…………....………..3
1.1 Project description.. ……… ………………………………………….……………………………....3
1.2 System of units..……………….……………… ………….. ………………….………..…………....5
1.3 General statements…………………….………………………………………….………………......5
2. Design norms…………………………………………………………..………..………….………….......5
2.1. Design norms.………………………...………………………….….…………….…….…………....5
2.2. Norms for materials………..…………………....………………………………….………………....6
3. Materials……………………………………………………………………….…………………...……....7
3.1. Structural steel and the steel connections………………………....…………. ………………………...7
3.2. Concrete and reinforcement steel…………………………..……. ….………………………………....7
3.3. Sustainability consideration….………………........…………. ………………………………………...8
6. Structural design………………….………...…………………………………………………......……....19
1. Introduction
1.1. Project description
The purpose of this report is to summarise the main design parameters, principles and to present the supporting
report /calculations for the alteration works to the existing bracing system within an existing logistic building located
at Fokkerweg 3A, 1438 AN Oude Meer, Amsterdam, Netherlands.
The existing building has been designed as a warehouse and it was developed in two stages. The first stage
entailed the construction of a building with the overall dimensions of 178.60m (gridlines A to J ) x 83.75m (gridlines
1 to 8). The phase 1 construction was divided in two parts (called hereafter DC11 compartiment A and B) by a
separation joint located on gridlines E and F. Each compartiment was desined as an independend building with steel
bracings within the lateral walls and in the plan of the roof, in order to ensure the lateral stability. From the available
archive information, the foundations along gridline 8 were designed to accommodate a future extension which took
place in a later stage.
The phase 2 construction (gridlines A to J and 9 to 16) is a mirrored construction of Phase 1 building and
separated by a joint along gridlines 8 and 9. Similar to Phase 1 building, the second phase has been divided in two
parts (called hereafter DC12 compartiment C and D) by a separation joint along gridlines E and F (see figure 2 for
more details). The separation joint between both phases, along gridlines 8 and 9 has a width of 170mm and is filled by
a separation wall 150mm thick. The first 2.60m of the separation wall is made in pre-cast concrete and the remainder
up to the roof level is made of aerated concrete planks.
The project consists of the permanent removal of an existing bracing system made of flat steel plates
(15x120mm, grade S355) located on gridlines 8 and 9 and the replacement with two portal braces, in order to ensure
the free manouvering of an automated machince between the DC 11 compartiment B and DC 12 compartiment D (see
figures 3 and 4). On both grids, the bracings sytem is located between gridlines G and I. The total height of the
warehouse is about 13.65m and the roof is sloping towards gridlines G and I, where at the lowest point, the total height
is about 13.20m. The typical span between the grids is 21.68m.
Along the gridlines 8 and 9 and between the main grids, intermediate steel post have been provided in order
to support the roof construction. The steel post are IPE 400 and are placed at equal spaces of 5.42m. The edge posts,
in the corners of the compartiment are HEA200. In order to reduce the effective length of the steel posts, horizontal
rails made of box sections 80x80x4 were provided. These rails do not contribute to the bracing system of the building.
The top members wich supports the roof construction and spans between the vertical post are HEA 180.
Separation
joint
Steel
bracing
s
Separation Separation
joint joint
Separation
joint
Ridge Ridge
The geometry and the position of the 8 no. openings (2.0m wide and 12.20m high) is presented in the
following figure.
Fig. 4. The proposed openings within the existing separation concrete wall
1.3.General statements
This document has been developed based on the following design information:
Input from the client:
- Drawings in CAD format with the openings required for the automated machine: 8 no. openings
2.0m wide and 12.20m high;
- Design information in relation to the construction of the existing building: the steel frame, the base
plates and the anchor bolts, the ground floor construction and the foundation details;
Eurocode standards and the National Annexes for Netherlands;
Local specific regulations;
The structural system proposed for the alteration works is complying with the specific design criteria (lateral
deflections, the capacity of the existing foundation system) and the relevant site constraints. The final detailing / design
work and the construction programme will be discussed and agreed with the main contractor prior the tender issue
(Developed Design Stage): the erection sequences for the steel frame, lateral stability during construction, temporary
propping/ temporary bracings, the replace of the steel posts etc. The design work will be coordinated with the
construction programme.
Prior the tender issue (Developed Design Stage), the following aspects will be agreed with the client and the
main contractor:
The loads/loading scenarios during the construction sequence;
The design of the connections between the steel members: typical details;
The strategy for a safe erection on site and the water tightness during construction.
In terms of health and safety, a risk assessment for site specific hazards has been prepared separately by the
design team. The findings were disseminated to all the relevant parties and special measurement will be undertaken if
required.
Action on structures:
- NEN EN 1991-1-1:2002, - Eurocode 1. Actions on structures. General actions. Densities, self-weight,
imposed loads for buildings
- EN 10219-1:2006 Cold formed welded structural hollow sections of non-alloy and fine grain steels — Part
1: Technical delivery conditions;
- DIN EN 10025-5. Hot rolled products of structural steels. Technical delivery conditions for structural steels
with improved atmospheric corrosion resistance;
3. Materials
3.1. Structural steel and the steel connections
All the structural steel used for rolled profiles, circular hollow sections, square/rectangular hollow sections,
equal/unequal angles, steel plates, gussets, stiffeners and end-plates will be S355 in accordance with NEN EN 1993-
1-1:2006 and NEN EN 10025-5. The structural steel S355 has the following properties, in accordance with NEN EN
10025-2:
nominal value of the yield strength: fy = 355 N/mm2;
tensile strength: fu = 510 N/mm2;
elongation at failure not less than 15%;
the ratio of the specified minimum ultimate tensile strength fu to the specified minimum yield strength fy
not less than 1.10.;
The partial safety coefficient applied to the material properties is γM,0= 1.0;
The high strength bolts used for all the bolted connection of the structural steel elements will be only from
the group of bolts 8.8 and 10.9., as they are defined in NEN EN 1993-1-8:2006:
group 8.8:
- yield limit of bolts: fyb = 640 N/mm2;
- resistance to fracture of the bolts: fub = 800 N/mm2;
group 10.9:
- yield limit of bolts: fyb = 900 N/mm2;
- resistance to fracture of the bolts: fub = 1000 N/mm2;
The anchor bolts/rods are used for the connections between the structural steel elements and the existing
foundation system. The anchor rods are obtained from round steel threaded subsequently. The washer and the nuts
used for the connection will be in accordance with provisions of the following standards: EN ISO 898-1:2002 and EN
14399-3:2005. All nuts and washers used in connections shall be galvanized.
The allowed diameters Ø for the anchor bolts are as follows: 20, 24, 30, 36, 42, 48, 56, and 64.
For connections with more than 2 anchor bolts, an embedded steel case will be provided in order to ensure the
stability and to maintain the design position of the anchor bolts when the concrete is poured. The embedded case will
be made up of steel S235. If the main contractor has a different proposal, this must be discussed with, agreed and
approved by the structural engineer prior the concrete pours.
In case of the connections of new steel members to existing concrete elements, chemical or mechanical anchors
will used instead. The chemical/ mechanical anchors specifications have been included within the structural drawings
and comprises the manufacturer, the anchor type, minimum embedment, mechanical properties and the installation
conditions.
The weld will be used for the connections of the structural steel elements and for the connections of the various
steel plates: end-plates, stiffeners and gussets. All welding consumables shall be in accordance with specified reference
standards in chapter 1.2.5 of NEN EN 1993-1-8:2006. For all the weld seams, it must be used electrodes with
mechanical characteristic higher than those corresponding to the steel types of the various combined steel
elements/plates.
The weld on site will be restricted as much as possible and limited to connections on the existing structures.
Site welding must be discussed with, agreed and approved by the structural engineer.
exposure classes: XC2 / XA1 – the exposure class confirmed by the avaialbe documentation
XC4 /XC3- External concrete expoised / sheltered from rain;
maximum aggregate size: 20mm;
structural class: S4;
air entrainment: min. 3.5% and max.6%- optional and if concrete is poured during winter time;
All the reinforcement bars will be in accordance with EN 10080 and will have the following mechanical
properties:
reinforcing steel type: S500B;
characteristic yield strength: fyk=500N/mm2;
the concrete cover of the reinforcement bars for foundations: 50mm to all faces.
the concrete cover of the reinforcement bars for floor slabs: 25mm to all faces.
NOTE: the above values may chance based on the local conditions and will be specified in the structural drawings;
The wind load: according to NEN EN 1991-1-4:2005 –Eurocode 1: Action on structures – Part 1-3: General
action- Wind action and the National Annex of Netherlands.
According to the National Annex of NEN EN 1991-1-4:2005, the fundamental value of the basic wind velocity
vb,0 , for sites located within Zone II, is given in Table NB.1:
vb,0 = 27.00 m/s
qb,0 = 0.456 kN/m2
This is water.
The maximum height of the warehouse at the ridge is about 13.565m, therefore, by using linear interpolation
between the above values, the value of peak velocity pressure qp(z) is:
𝒒𝒑 (𝒛 = 𝟏𝟑. 𝟓𝟔𝟓) = 𝟎. 𝟗𝟐𝟏 𝐤𝐏𝐚;
The wahrehouse is made of four independent units: DC 11 compartiment A and B and DC 12 compartiment
C and D. The overall dimensions of the wharehouse are 167.00m x 178.60m. The overall dimensions of one unit are
83.50m x 89.30m. Each unit has a braced frame on the perimeter gridlines, therefore two braced frames for each wind
direction. The overall height of the building is 13.565m.
According to the National Annex of NEN EN 1991-1-4:2005, table NB.6, for buildings with h/d <1.0, the
pressure coefficients are as follows:
lateral wall subject directely to wind pressure (zone D): cpe = +0.800;
we,1 = 0.80· 0.921 = 0.736 kPa
lateral wall in suction (the wall opposite to the wall subject to wind pressure): c pe = -0.500;
we,2 = -0.50· 0.921 = 0.460 kPa
Pressure Suction
Steel
bracing
s Steel
bracing
s
Suction Pressure
Fig. 6. Wind pressure/suction on the building envelope
Conservatively, since the sutructre is not sensitive to wind vibrations, the dynamic reposne coefficient c scd=1.00.
The total lateral forces produced by the wind dynamic action have the following values:
lateral wall subject to wind pressure (zone D);
Fw,1 = cscd·we,1 ·Awall =1.00· 0.80· 0.921 = 834.6 kN
lateral wall subject to wind sunction (zone E);
Fw,2 = cscd·we,2 ·Awall =1.00· -0.50 · 0.921 = 521.6 kN
friction along the roof surface (enhancedrough surface cfr=0.03);
Ffr = cfr·qp (z)·4h·b=0.03·0.921·4·13.565·83.50= 125.2 kN
The total wind load in each scenario (pressure /suction) will be devided between two braced bays, as follows:
lateral wall subject to wind pressure (zone D);
Fwt,1 = (Fw,1 + Ffr) / 2 = (834.6+125.2) / 2 = 480 kN
lateral wall subject to wind suction (zone E);
Fwt,1 = (Fw,1 + Ffr) / 2 = (521.6+125.2) / 2 = 324 kN
Further, the load cases considered relevant for the structural desing have been detail in table 1, as follows:
Table 1. The load cases considered within the structural analysis
The load combination considered for the structural desing are as follows:
a) Ultimate limit state (ULS): I would advise to make the following load
- ULS 1 : 1.35·DL + 1.35·PL +1.50·LL + 1.05 WXP combinations:
- ULS 2 : 1.35·DL + 1.35·PL +1.05·LL + 1.50 WXP ULS:
- ULS 3 : 0.90·DL + 0.90·PL + 1.50 WXP 1.2 DL + 1,2 PL + 1,5 WX
- ULS 4 : 1.35·DL + 1.35·PL +1.50·LL + 1.05 WXN
- ULS 5 : 1.35·DL + 1.35·PL +1.05·LL + 1.50 WXN SLS:
- ULS 6 : 0.90·DL + 0.90·PL + 1.50 WXN 1,0 DL + 1,0 PL + 1,5 WX
b) Serviceablity limit state (SLS):
- SLS 1 : 1.00·DL + 1.00·PL +1.00·LL + 0.60 WXP The following load case does not lead to a
- SLS 2 : 1.00·DL + 1.00·PL +0.70·LL + 1.00 WXP normative cobintion because ψ0 = 0 and can
- SLS 3 : 0.90·DL + 0.90·PL + 1.00 WXP thus be omitted.
- SLS 4 : 1.00·DL + 1.00·PL +1.00·LL + 0.60 WXN 1.35 DL + 1,35 PL + 1,5 ψ0 WX
- SLS 5 : 1.00·DL + 1.00·PL +0.70·LL + 1.00WXN
- SLS 6 : 0.90·DL + 0.90·PL + 1.00 WXN.
BUCKLING PARAMETERS:
VERIFICATION FORMULAS:
Section strength check:
NEd /Nc,Rd = 0.32 < 1.00 (6.2.4.(1))
Global stability check of member:
λy= 110.64 < λmax = 120 λz = 110.64 < λmax = 210.00 STABLE
NEd /Min(Nb,Rd ; Nb,T,Rd ; Nb,TF,Rd) = 0.99 < 1.00 (6.3.1) >> Section OK
Based on the reverse engineering calculation, the central column is able to withstand the loads assumend in
the initial assessement with an utilisation ratio of 0.99. Therefore, the loads assumed are conservative and will not
exceed the estimated values.
5. FEM model
The structural analysis of both, the existing bracings system and the proposed portal frames, have been carried
out using the software Robot Structural Analysis 2016. In this respect, a 3D FEM model has been elaborated by
modelling the steel frames along the gridlines 8 and 9,including the flat steel bracings, the steel posts and the horizontal
rails. Each element has been considered with the relevant geometric configuration, section size or thickness and
appropriate boundary conditions (supports, releases etc.)
The purpose of the structural analysis was as follows:
the determination of stress level in various members;
the design of the structural members based on the above level of stress;
the determination of deflections and lateral displacements;
to assess the overall behaviour of the proposed system and the lateral stability.
Existing flat
Existing flat
steel bracings
steel bracings
Haunch
Haunch
Fig. 9.The section sizes for the steel members of the portal frame.
In case of each scenario (existing steel bracings or portal frames), the assosciated loads have been
calculated based on the affrent areas and the loading conditions assessed at chapter 4.2.
NOTE: In order to simplify the calculations and to have a better control of the 3D model, the self-weight of
the roof construction has been included in the permement load case. In all the combinations, the self-weight
and the permanent loads have the same coefficient and therefore the results will not be affected. On the other
hand, the dead load case will contain only the self-weight of the steel memembers calculated automatically
by the software.
a) Loads on the top edge beams HEA 180
The metal deck of the roof construction spans between the secondary steel truss and the edge beam.
The value of the bay is about 6.0m, therefore the edge beams will support half of the loads:
- permement load: 1.20kN/m2 (1.0 kN/m2 from self weight and 0.20 kN/m2 from hanging services):
Linear load = 1.20kN/m2 · 6.0m/2 = 3.60 kN/m
- live load: 0.60 kN/m2;
Linear load = 0.60 kN/m2 · 6.0m/2 = 1.80 kN/m
b) Loads on the edge posts IPE 400 which support steel trusses
The reaction on each end of the main steel trusses are as follows:
- permement load: 1.20kN/m2 (1.0 kN/m2 from self weight and 0.20 kN/m2 from hanging services):
Point load = 1.20kN/m2 · ( 21.68m x 5.98m)/2 = 77.8 kN
Concentrated moment = Point load · Ecc = 77.8·0.20 = 15.60 kNm
NOTE: The bending moments considered on the perpendicular plan of the frame are due to the eccentricity
of the truss connection in repect to the centre line of the IPE 400 posts. These eccentricietes introduce
bending moments and the effect of these will be review in order to ensure a safe removal of the concrete
wall between the DC11 compartiment B and DC 12 compartiment D. In other words, it will be checked if
the concrete wall had a stabilisation role for the flange of the steel posts IPE400.
6. Structural analysis
Following on from the completion of the 3D modelling of the steel frames and the assignment of the
associated loads, both FEM models have been run independently. In first instance, the existing steel frame
has been cheked on the following aspects:
maximum lateral displacement:
δbraced,frame = 27mm < L/300 = 45mm OK
Fig.15. The maximum lateral displacement for the steel frame with flat plates bracings
Fig.16. The maximum tension force within the flat plates bracings
a) The tension capacity of the flat steel plate, 15x120mm (S355):
NT,Rd = Aplate· fyd = 15· 120· 355 / 103 = 639 kN
Ntension,max = 450 kN < NT,Rd = 639 kN Bracing safe in tension;
b) The capacity of the steel connection (3 no bolts M24 gr.8 8):
b.1) The shear capacity of the connection:
𝜋 · (0.89 · 24)2
𝛼𝑣 · 𝑓𝑢𝑏 · 𝐴 0.60 · 800 · 4
𝐹𝑉,𝑅𝑑 = = = 137.60 𝑘𝐾/𝑏𝑜𝑙𝑡
𝛾𝑀2 1.25
fub = 800 N/mm2 – bolts group 8.8;
αv= 0.60 – bolts group 8.8;
A- the area of the bolt in the threaded zone;
γM2=1.25 - partial safety coefficient ;
The shear apacity of the connection has the following value:
FRd, shear = 3 Fv,Rd = 412.80 kN
Ntension,max = 450 kN > FRd, shear = 412.80 kN Bracing not safe;
b.2) The capacity to pressure on the bolts holes:
𝑘1 · 𝑎𝑏 · 𝑓𝑢 · 𝑑 · 𝑡
𝐹𝑏,𝑅𝑑 =
𝛾𝑀2
- edge bolts:
𝑒1 55
𝛼𝑑 = = = 0.705
3𝑑0 3 · 26
- central bolts:
𝑝1 1 80 1
𝛼𝑑 = − = − = 0.776
3𝑑0 4 3 · 26 4
𝑓𝑢𝑏
𝑎𝑏 = 𝑚𝑖𝑛 (𝛼𝑑 ; ; 1.0)
𝑓𝑢
𝑓𝑢𝑏 800
= = 1.568
𝑓𝑢 510
- edge bolts:
𝑓𝑢𝑏
𝑎𝑏 = 𝑚𝑖𝑛 (𝛼𝑑 ; ; 1.0) = 𝑚𝑖𝑛(0.705; 1.568 ; 1.0) = 0.705
𝑓𝑢
- central bolts:
𝑓𝑢𝑏
𝑎𝑏 = 𝑚𝑖𝑛 (𝛼𝑑 ; ; 1.0) = 𝑚𝑖𝑛(0.776; 1.568 ; 1.0) = 0.776
𝑓𝑢
𝑒2 60
𝑘1 = 𝑚𝑖𝑛 (2.80 − 1.70; 2.50) = 𝑚𝑖𝑛 (2.80 − 1.70; 2.50) = 2.50
𝑑0 26
- the capacity for the edge bolt:
𝑘1 · 𝑎𝑏 · 𝑓𝑢 · 𝑑 · 𝑡 2.5 · 0.705 · 510 · 15 · 24
𝐹𝑏,𝑅𝑑,𝑒𝑑𝑔𝑒 = = = 258.9 𝑘𝑁
𝛾𝑀2 1.25
- the capacity for the central bolts:
𝑘1 · 𝑎𝑏 · 𝑓𝑢 · 𝑑 · 𝑡 2.5 · 0.776 · 510 · 15 · 24
𝐹𝑏,𝑅𝑑,𝑐𝑒𝑛𝑡𝑟𝑎𝑙 = = = 285 𝑘𝑁
𝛾𝑀2 1.25
The capacityof the connection to pressure on the bolts holes is:
Fb,Rd = 3·min(Fb,Rd, central ; Fb,Rd, edge) = 775 kN
Ntension,max = 450 kN < Fb,Rd = 775 kN Connection safe for pressure on bolts holes;
Fig.17. The maximum axial force on the steel posts IPE 400
As a cursory check, the capacity of the top edge beam H180 has been reviewed, as follows:
Governing Load Case: 7 ULS2: 1.35*DL+1.35*PL+1.05*LL+1.50WL (2+1)*1.35+4*1.50+3*1.05
Following on from the complete review of the existing steel frame in the current conditions, the
analysis focused on the proposed portal frames. The flat steel bracings have been removed entirely
and replaced by a portal frame, one on each gridline. The section sizes of the steel portals have been
increased iteratively until the lateral displacement matched the displacements of the frame with flat
steel bracings. In order to reduce the steel consumption and to suit the 8 no. openings requested by
the client, additional haunches have been included. Also, where the new proposed openings clahsed
with the existing IPE 400 posts, the posts in question were removed and replaced with two stel
members UB 406x178x67 (S355) on each side of the opening.
In the structural analysis of the new lateral resisting system, the following items were checked:
maximum lateral displacement:
δportal,frame = 30mm < L/300 = 45mm OK
δportal,frame = 30mm ≈δbraced,frame = 27mm OK
Fig.18. The maximum lateral displacement for the new portal frames
In order to have a better evaluation of the lateral displacements and taking into consideration
the section sizes, a separate model has been created in which the portal frame has been modelled
with shell elements. The maximum lateral displacement obtain in this case was:
δportal,frame = 26mm ≈ δbraced,frame = 27mm OK
Fig.19. The maximum lateral displacement for the new portal frames modelled with shell elements.
The capacity of the remaining top beams HEA 180:
Governing Load Case: 6 ULS1: 1.35*DL+1.35*PL+1.50*LL+1.05WL (2+1)*1.35+3*1.50+4*1.05
Fig.20. The maximum shear forces for the columns/steel posts bases with flat steel bracings.
Fig.21. The maximum shear forces for the columns/steel posts bases with the new portal frames
VEd, max, bracings = 351.62 kN
VEd, max, portal frame = 366.02 kN
Δshear = 14.40 kN >> Λshear = 4.10 % slightly increase OK
b) the axial forces at columns/steel posts bases:
Fig.22. The maximum axial forces for the columns/steel posts bases with flat steel bracings.
Fig.21. The maximum shear forces for the columns/steel posts bases with the new portal frames
In case of the new portal frame, the concrete wall between the DC11 and DC12 will be
removed entirely. The selfweight of the concrete wall has the following value:
Gwall = 0.15m·13.565m· 3.0m· 22 kN/m3= 134.20 kN
1.35·Gwall = 181.17 kN
NEd, max, bracings = 561.12 kN
NEd, max, portal frame = 582.12 kN
Δshear = 21.09 kN >> Λshear = 3.76 % slightly increase OK