PROJECT:

DESIGN OF SUPERSTRUCTURE AND FOUNDATIONS FOR A UTILITY SOLAR PLANT

CLIENT:
UJAAS ENERGY
STRUCTURAL DESIGN
REPORT

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
Revisions

No: Date Engineer-in-charge Notes

A 12 June 2017 Nimish P. First Draft

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
Table of Contents
Title
1.0 Project Information and Scope
2.0 Design Criteria
3.0 Proposed MMS System and Foundations
4.0 Loads on Structure
5.0 FE Modelling
6.0 Design of Superstructure
7.0 Design of Foundations
APPENDIX A: Eccentric Load Calculation
APPENDIX B: Validation of CFS
APPENDIX C: CFS DESIGN REPORTS
APPENDIX D: PROTOTYPE TESTING CRITERIA (TBC)

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
1.0 Project Information
The following is a design calculation report for module mounting system of a Utility Ground Mount Solar Project with the following attributes:
a) Tilt Angle: 20 degrees
b) Location: Nashik, Maharashtra
c) Wind Speed: 140 kmph
d) Minimum Ground Clearance 500mm
e) Module Configuration: 4LX20 (4 in landscape, with a table length of 40m)

2.0 Design Criteria:

The structures can be subjected to Dead, Wind, Earthquake and Temperature loads. The design is as per the following Codes:
LOADS:
DEAD LOADS: The weight of a single module is taken as 28 kg.
IMPOSED LOADS: A 200 kg point load applied at end of a purlin, to simulate any unforeseen maintenance loads.
WIND LOADS: As per IS 875: Part 3, at a wind speed of 140 kmph, as per client requirements. For more details for wind load calculations, Refer Section XX
DESIGN CODES:
DESIGN OF COLD FORMED STEEL AS PER AISI S100-16 LRFD
DESIGN OF BORED INSITU PILES AS PER IS 2911: 1-2.

MATERIAL:
For superstructure: cold formed steel with the following properties would be used:
Yield strength 550 mpa, Tensile strength 700 mpa.
module clamps: stainless steel grade SS304L. YIELD STRENGTH 241 mpa TENSILE STRENGTH 586 mpa.
Other fasteners: grade 4.6 as per IS 1367: part 3

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MMS Design for Utility Ground Mount
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DURABILITY:
Expected life of structure would be minimum 25 years. For durability, Hot Dip Galvanizing of 80 μm or POSCO Magnesium Alloy Coating is proposed.

3.0 Proposed MMS System and Foundations:

1) The Panels rest on secondary purlins in the North-South Direction

Figure a : Plan view of Panels with secondary purlins Figure a Secondary purlins seating on 3 primary purlins
Figure c Primary purlins on portal frame

2) As shown in figure 2, the secondary purlins rest on 3 primary purlins PU1. This results in ease of construction, as tolerances in system can be adjusted in the purlins at the very end. The purlins would be provided
slotted joints to take care of tolerance. See Appendix C for Tolerance Design.
3) The primary purlins rest on a 2-column portal rafter system.
Considering that there is a 4m chord, 2-legged foundation is proposed for robustness. The spacing between the legs is kept at 3.75m. There is a 1.25m overhang from both sides.
Primary Structural System consists of a portal frame in North South Direction and a braced portal in East West Direction.
3 Primary Purlins span East West, on the rafter, and subsequent secondary purlins span perpendicular to finally catch the modules. Here is a sketch of the system.
VERTICAL LOAD RESISTING SYSTEM:
Fasteners=> Secondary Purlins (PU2) => Primary Purlins (PU1) => Rafter => Column => Pile => Hence, all loads in STAAD are applied on PU2.
LATERAL LOAD RESISTING SYSTEM: NORTH-SOUTH
The main governing lateral load is wind. Panel wind load follows the same load path as above. Fasteners=> Secondary Purlins (PU2) => Primary Purlins (PU1) => Portal Frame => Pile
LATERAL LOAD RESISTING SYSTEM: EAST-WEST

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
Along east west direction, framing capacity of columns is non-existent. Hence a brace is provided in the middle spans to take the lateral load to ground. The primary purlins PU1s act as ties to bring the load into the
braced bay, where a tension brace transfers it to ground.

Figure d Load Path along EW Direction

FOUNDATIONS:

Bored pile footings of appropriate depth would be proposed for this project. The design of footings is done assuming M25 concrete “grout” around a main steel member. The
required bending and shear strengths are equated to that of the bare cold formed steel column.
The design of foundation is done as per the maximum compression, tension and lateral load encountered in the analysis.
LPILE software is used for lateral check of pile. IS 2911:1:2 has no method for calculating deflection for short-piles.

4.0 LOADS ON STRUCTURE:

DEAD LOADS:
Weight of Single Panel = 27 kgs. Supported on 2m length of purlins. Load per unit length would be 270/2 = 0.135 kN/m

LIVE LOADS:
A point load of 200 kgs is applied at tip of purlins to simulate any maintainence loads that might occur.

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
WIND LOADS:

LOAD CASES AND LOAD COMBINATIONS:

As the design for Cold Formed Steel is to be done as per AISI S-2016, which is a LRFD code, the following load combinations as per ASCE 7_2005 are used in the STAAD Model:
1.2DEAD + 1.6LIVE
1.2DEAD + 1.6WIND (where DEAD is unfavourable)
0.9DEAD + 1.6WIND (where DEAD is favourable)

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
THE FOLLOWING LOAD CASES ARE DEFINED AS PER THE ABOVE:

1:DEAD: Has Panels Dead Load

2:LIVE: 200 kg point load on selected purlins
3:WIND+XUP : Wind with upward Cp, in +X direction
4:WIND-XUP: Wind with upward Cp, in -X direction (only eccentric moment changes wrt previous)
5:WIND+XDOWN: Wind with downwardCp in +X direction
6:WIND-XDOWN : Wind with downwad Cp in -X direction(only eccentric moment changes wrt previous)
7:WIND+Z : Wind along EAST WEST Direction
8: WIND-Z: Reversed Directions.
As negative direction are covered in load cases itself, this results in 6 LOAD COMBINATIONS.
0.9DEAD is used with UP cases, and 1.2DEAD with rest.

5.0 FE MODELLING
As per the previous, a finite element model for a table is created in STAAD with the above loads and combinations.
Note that STAAD is used for analysis and getting the final actions, and an independent Cold Formed Design Package is used for Designing out the cold formed members. Given below are some screenshots of the
model.

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6.0 DESIGN OF SUPERSTRUCTURE:
6.1 DESIGN OF PURLINS 2(SECONDARY PURLINS BELOW PANELS)

Mx My
Beam L/C Node Fx kN Fy kN Fz kN kNm kNm Mz kNm
Max Fx 13 1 DEAD 17 0 0 0 0 0 0
Min Fx 13 1 DEAD 17 0 0 0 0 0 0
Max Fy 265 1002 DL+WIND-XUP 53 0 1.857 0 0 0 -0.545
Min Fy 264 1001 DL+WINDXUP 54 0 -1.86 0 0 0 -0.546
Max Fz 392 1005 DL+WINDZ 291 0 -0.102 0.133 0 0.065 0.019
Min Fz 15 1007 DL+LIVE 14 0 -0.284 -0.18 0 0.181 -0.577
Max Mx 14 1007 DL+LIVE 13 0 0.513 -0.063 0 0.01 0.022
Min Mx 15 1007 DL+LIVE 14 0 -0.284 -0.18 0 0.181 -0.577
Max My 15 1007 DL+LIVE 14 0 -0.284 -0.18 0 0.181 -0.577
Min My 15 1007 DL+LIVE 12 0 -0.513 -0.18 0 -0.089 0.021
1004 DL+WIND-
Max Mz 264 XDOWN 54 0 1.306 0 0 0 0.383
Min Mz 14 1007 DL+LIVE 14 0 0.285 -0.063 0 -0.084 -0.577

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
See full Report in Appendix D

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6.2 DESIGN OF PRIMARY PURLINS PU1 (BELOW SECONDARY PURLINS)

Beam L/C Node Fx kN Fy kN Fz kN Mx kNm My kNm Mz kNm

Max Fx 382 1005 DL+WINDZ 288 3.723 -0.489 0.041 0 -0.015 0.065
Min Fx 8 1005 DL+WINDZ 8 -3.725 0.369 0.041 0 -0.015 0.297
Max Fy 335 1001 DL+WINDXUP 255 0.164 6.482 0.004 0.004 0.006 -2.044
Min Fy 38 1001 DL+WINDXUP 24 0.164 -6.482 -0.004 -0.004 0.007 -3.664
Max Fz 402 1007 DL+LIVE 14 0.117 -2.438 1.095 0 -0.265 -0.025
Min Fz 67 1007 DL+LIVE 68 0.082 0.69 -0.216 0 -0.254 -1.195
Max Mx 335 1001 DL+WINDXUP 255 0.164 6.482 0.004 0.004 0.006 -2.044
Min Mx 38 1001 DL+WINDXUP 24 0.164 -6.482 -0.004 -0.004 0.007 -3.664
Max My 403 1007 DL+LIVE 8 0.214 -2.545 1.095 0 0.97 3.028
Min My 258 1007 DL+LIVE 202 0.101 -2.374 0.879 0 -0.367 -1.372
Max Mz 131 1004 DL+WIND-XDOWN 104 0.009 4.254 -0.001 0.003 -0.008 3.205
Min Mz 131 1001 DL+WINDXUP 104 -0.026 -6.103 -0.002 -0.004 0.023 -4.592

Purlin PU1 is the most critical element of the structure, it bridges an unsupported length of 3.75m rafter to rafter. On top of its flange, orthogonal PU2s are kept.
There is a large chance of lower flange undergoing lateral torsional buckling, when it is in compression. As per CFS design, restraints have to be provided every 1m against LTB of lower flange.
A simple way of achieving this is factory-welding stiffeners of size 1.2mm at c/c distance of 1m inside the C as shown.

Figure e Stiffners welded 1m c/c

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
See full Report in Appendix D

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Client: UJAAS ENERGY
6.3 DESIGN OF RAFTERS

Beam L/C Node Fx kN Fy kN Fz kN Mx kNm My kNm Mz kNm

Max Fx 128 1002 DL+WIND-XUP 110 5.982 -0.774 -0.127 0 0.088 -0.096
Min Fx 35 1003 DL+WIND-XDOWN 30 -4.007 1.169 0.003 0 -0.002 0.59
Max Fy 34 1001 DL+WINDXUP 24 0.081 11.516 0.01 0 -0.003 0.006
Min Fy 36 1002 DL+WIND-XUP 31 -0.098 -11.494 -0.004 0 0 -6.25
Max Fz 129 1006 DL+WIND-Z 111 -0.108 0.624 3.462 0.001 -1.481 0.34
Min Fz 5 1005 DL+WINDZ 4 -0.108 0.624 -3.462 -0.001 1.481 0.34
Max Mx 70 1005 DL+WINDZ 54 -0.005 -0.69 0.462 0.001 -0.029 -0.015
Min Mx 70 1006 DL+WIND-Z 54 -0.005 -0.69 -0.462 -0.001 0.029 -0.015
Max My 5 1005 DL+WINDZ 4 -0.108 0.624 -3.462 -0.001 1.481 0.34
Min My 129 1006 DL+WIND-Z 111 -0.108 0.624 3.462 0.001 -1.481 0.34
Max Mz 130 1003 DL+WIND-XDOWN 111 -3.744 -5.074 -0.117 0 -0.108 4.372
Min Mz 34 1001 DL+WINDXUP 30 0.081 11.516 0.01 0 0.002 -6.262

RESULTS

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
See full Report in Appendix D

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6.4 DESIGN OF COLUMN

Mx My
Beam L/C Node Fx kN Fy kN Fz kN kNm kNm Mz kNm
Max Fx 1003 DL+WIND-
(COMP) 33 XDOWN 32 13.699 0.618 -0.001 0 0.002 0.881
Min Fx
(TENSION) 33 1002 DL+WIND-XUP 32 -19.605 -0.998 -0.003 0 0.003 -1.204
1004 DL+WIND-
Max Fy 125 XDOWN 109 12.086 5.094 -0.017 0 0.011 3.24
Min Fy 125 1002 DL+WIND-XUP 109 1.187 -6.22 0.006 0 -0.004 -3.96
Max Fz 68 1006 DL+WIND-Z 59 0.968 0.683 1.566 -0.001 -0.9 0.437
Min Fz 68 1005 DL+WINDZ 59 0.968 0.683 -1.566 0.001 0.9 0.437
Max Mx 68 1005 DL+WINDZ 59 0.968 0.683 -1.566 0.001 0.9 0.437
Min Mx 68 1006 DL+WIND-Z 59 0.968 0.683 1.566 -0.001 -0.9 0.437
Max My 68 1005 DL+WINDZ 59 0.968 0.683 -1.566 0.001 0.9 0.437
Min My 68 1006 DL+WIND-Z 59 0.968 0.683 1.566 -0.001 -0.9 0.437
1004 DL+WIND-
Max Mz 125 XDOWN 109 12.086 5.094 -0.017 0 0.011 3.24
Min Mz 125 1002 DL+WIND-XUP 109 1.187 -6.22 0.006 0 -0.004 -3.96

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DESIGN OF BRACES
SUMMARY TABLE

Beam L/C Node Fx kN Fy kN Fz kN Mx kNm My kNm Mz kNm

Max Fx 396 1005 DL+WINDZ 22 8.597 0.315 0.01 0 0 0
Min Fx 398 1005 DL+WINDZ 102 -8.583 -0.315 0.009 0 0 0
Max Fy 398 1005 DL+WINDZ 111 -6.708 0.33 0.009 0 -0.038 0.031
Min Fy 398 1006 DL+WIND-Z 111 6.722 -0.33 -0.01 0 0.038 -0.031
1002 DL+WIND-
Max Fz 398 XUP 111 -0.216 0.017 0.247 0 -0.194 0.066
1002 DL+WIND-
Min Fz 396 XUP 4 -0.216 0.017 -0.247 0 0.194 0.066
Max Mx 399 1001 DL+WINDXUP 110 -0.112 -0.017 -0.237 0 0.179 -0.066
Min Mx 397 1001 DL+WINDXUP 3 -0.112 -0.017 0.237 0 -0.179 -0.066
1002 DL+WIND-
Max My 396 XUP 4 -0.216 0.017 -0.247 0 0.194 0.066
1002 DL+WIND-
Min My 398 XUP 111 -0.216 0.017 0.247 0 -0.194 0.066
1002 DL+WIND-
Max Mz 398 XUP 111 -0.216 0.017 0.247 0 -0.194 0.066
Min Mz 398 1001 DL+WINDXUP 111 0.102 -0.017 -0.246 0 0.191 -0.066

The braces are tension-braces.

Reqd Ast = P / ϒm Fu = 8590 / 1.1 / 620 = 12.5 mm2

Hence a nominal 40X30X10X1.2 Lipped Section ( Area 132 mm2) is provided.

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MMS Design for Utility Ground Mount
Client: UJAAS ENERGY
This completes design of all the members of the superstructure.

Wt
LENGTH SECTION (kN/m) total wt
COLUMNS 21.23 130CS60X2X15 0.0377 0.800371
RAFTER 33.02 120CS50X2X15 0.036432 1.20298464
PURLIN1 120 110CS45X2X15 0.0333 3.996
PURLIN2 164.07 55CS20X0.85X10 0.0070235 1.152345645
BRACES 15.54 70X70X3.15 0.01022 0.1588188
TOTAL 7.310520085
RAW TONNAGE 28.55671908 tons/MW
EXCLUDING WASTAGE AND CONNECTION

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Client: UJAAS ENERGY
6.0 FOUNDATION DESIGN
Horizontal Vertical Horizontal Moment
My
Node L/C Fx kN Fy kN Fz kN Mx kNm kNm Mz kNm
Max Fx 109 4 WINDUP-XUP 4.206 0.291 0.004 0.003 0 -2.679
6 WIND-
Min Fx 109 XDOWN -2.759 6.952 -0.01 -0.006 0 1.753
5
Max Fy 32 WIND+XDOWN -0.324 7.819 -0.001 -0.001 0 0.47
Min Fy 32 4 WINDUP-XUP 0.67 -12.811 -0.002 -0.002 0 -0.813
Max Fz 102 8 WIND-Z 0.007 1.589 5.681 0.437 0 -0.001
Min Fz 102 7 WIND+Z -0.007 -1.589 -5.681 -0.437 0 0.001
Max Mx 59 8 WIND-Z 0 0 0.979 0.562 -0.001 0
Min Mx 59 7 WIND+Z 0 0 -0.979 -0.562 0.001 0
Max My 59 7 WIND+Z 0 0 -0.979 -0.562 0.001 0
Min My 59 8 WIND-Z 0 0 0.979 0.562 -0.001 0
6 WIND-
Max Mz 109 XDOWN -2.759 6.952 -0.01 -0.006 0 1.753
Min Mz 109 4 WINDUP-XUP 4.206 0.291 0.004 0.003 0 -2.679

As per specs, foundation design is to be carried out at 150kmph windspeed. Hence, values adjusted by (150/140)^2 = 1.15
ALSO, DEAD LOAD REACTION PER COLUMN 1.7kN. AS SBC CAN BE INCREASED BY 25% FOR WIND EFFECTS,
DESIGN DOWNWARDS LOAD: WIND + 1.15*0.8*DEAD = 8.89 kN DOWN
DESIGN UPWARD LOAD : 1.15*0.8*WIND – DEAD = F= 10.1 kN UP
DESIGN LATERAL LOAD : F= 2.8 Kn M=1.7KN.m
Soil Characteristics:
As per geotechnical report supplied to us, the site has sound strata in the top 2 m. The following extract is from the report.
As per lab tests, soil properties would be taken as
Φ = 33 c=0
Design is carried out as per IS 2911:1:2
PILE DIA: 300mm | DEPTH BELOW GROUND: 1.6 m | PILECAP: 500MM dia and 300mm high.
The design should be verified by Pile Load Tests at Site.

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 APPENDICES

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