THE 7th INTERNATIONAL CONFERENCE
"CIVIL ENGINEERING - SCIENCE AND PRACTICE"
GNP 2020 – Kolašin, Montenegro, 10-14 March 2020
Duško Lučić1, Ivana Tešović2, Miloš Vučinić3, Teodora Bulatović4, Milena Janković5,
Mladen Muhadinović,6 Slavica Dopuđa7, Nikola Luković8, Predrag Koprivica9,
Svetlana Kastratović10, Ivan Gorašević11, Vladimir Božović12
DESIGN AND EXECUTION OF WAREHOUSE IN BAR
Abstract
The topic of this paper is a presentation of the process of designing and construction of
structure for warehouse in Bar. For designing and supervision of works, Employer KIPS ltd
Podgorica engaged Institut za građevinarstvo ltd from Podgorica. The Contractor was „Bar
gradnja“ from Bar, who engaged subcontractors specialized for every phase during the
execution of works. The building consists of a warehouse area and auxiliary building with a
water tank for sprinkler installations. In the base, the building has a trapeze shape with
dimensions 86.905x55.05 m and with gross area 4995 m2. The building is located at Topolica
4, Bar municipality in Montenegro. The Main Design consists of 15 books, which includes the
following phases: architecture, structure, mechanical installations, electrical installations,
plumbing and sewage installations, sprinkler installations, traffic and traffic signs, landscape
architecture, fire protection, labour protection, landscape architecture, energy efficiency and
organization and technology of construction. The Main Design was completed in two months.
Works on the execution of this building started in July 2017 and the building was put into
service in June 2018. The works were executed according to the Main Design, except for some
modifications, caused by subsequent Employer's requirements and specified circumstances,
which were not predictable during the development of the Main Design. This building
represents one successful structural solution, wherein it is successfully systematized procedure
of execution of steel structures.
Key words
Steel structure; warehouse; construction; designing; 3D modeling
1 Prof. PhD, Faculty of Civil Engineering, Podgorica, Montenegro, dusko.lucic @ izgmne.com
2 Civil Engineer, Institut za građevinarstvo ltd, Podgorica, Montenegro, ivana.tesovic@ izgmne.com
3 Civil Engineer, Institut za građevinarstvo ltd, Podgorica, Montenegro, milos.vucinic@ izgmne.com
4 Civil Engineer, Institut za građevinarstvo ltd, Podgorica, Montenegro,
[email protected]5 Civil Engineer, Institut za građevinarstvo ltd, Podgorica, Montenegro, milena.jankovic@ izgmne.com
6 Teaching Assistant, Faculty of Civil Engineering, Podgorica, Montenegro,
[email protected]7 Architect, Institut za građevinarstvo ltd, Podgorica, Montenegro,
[email protected]8 Traffic Engineer, Institut za građevinarstvo ltd, Podgorica, Montenegro, nikola.lukovic@ izgmne.com
9 Traffic Engineer, VIA ING, Nikšić, Montenegro,
[email protected]10 Civil Engineer, MMK Control ltd Bar, Montenegro,
[email protected]11 BApp, Institut za građevinarstvo ltd, Podgorica, Montenegro, ivan.gorasevic@ izgmne.com
12 Student, Faculty of civil engineering, Podgorica, Montenegro,
[email protected] 323
Civil En g in eerin g – S cien ce a n d Pra ctice
1. GENERAL
For needments of KIPS ltd company from Podgorica, Institut za građevinarstvo ltd from
Podgorica developed the Main Design for business building – warehouse. The Main Design
consisted of 15 books, which included the following phases: architecture, structure, mechanical
installations, electrical installations, plumbing and sewage installations, sprinkler installations,
traffic and traffic signs, landscape architecture, fire protection, labour protection, landscape
architecture, energy efficiency elaborate and organization and technology of construction. The
Main Design was completed in two months. The total price of works of the designed structure was
2,747,650.58€.
This paper focuses on the design of the steel structure of the warehouse and the conduction
of building operations. The main Contractor on this building was Bar gradnja ltd from Bar, with a
Subcontractor for the execution of the steel structure Monting Bitolj ltd. Supervisor during the
construction was Institut za građevinarstvo ltd from Podgorica.
2. DESCRIPTION OF THE DESIGNED STEEL STRUCTURE
The building consists of a business part – warehouse area, manipulative area and auxiliary
building, with a water tank for sprinkler installation. The loadbearing structure is a steel structure,
founded on foundation slab (d= 50 cm), that is deepened on building edges and on the border
between warehouse area and manipulative area, to the 180 cm. The ground on which the building
had to be founded was of bad quality. Underground water was also noticeable, particularly during
the rainy period. Because of that, bad soil was replaced with better quality soil and together with
adequate compaction is brought to the designed values.
2.1. STRUCTURAL SYSTEM OF THE WAREHOUSE
2.1.1. Static-dynamic analyses of structure and analyzed loads
The loadbearing structure of the building was simulated in the software for structural
analysis SAP 2000. The 3-dimensional model was built with beam elements with corresponding
supporting conditions and real geometrical characteristics.
Static and dynamic analysis was carried out respecting the Urban-planning and Technical
Requirements and Terms of reference, and according to the corresponding technical rules and
standards. The structure was analyzed for the following load cases: dead load with self-weight,
snow, wind and earthquake loads.
Wind load simulation is based on the wind speed of approximately 23.0 m/s, averaged on
60 minutes, with a 50 years return period, exposure factor for a 10 m high object and topography
factor for industrial areas. Based on building geometry and elastic characteristics of the structure,
and for simulation of wind load, the building is classified as a low rigid building. According to
that, the dynamic coefficient and force coefficient were determined.
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Climatic conditions of environment order to take into calculation snow load intensity of
0.75 kN/m2.
For earthquake load is used ESO (equivalent static load) method for the IX seismic degree,
return period of 50 years with seismic coefficient for horizontal direction k= 0.065. The building is
classified into II category.
Comparing the results for wind load with results for an earthquake load, it was concluded
that for calculation of structure are relevant wind loads.
2.1.2. Description of structural elements
The building has a trapeze-shape base, with dimensions 86.905 x 55.05 m. It consists of the
warehouse area and manipulative are, with car parking lots. A warehouse area building is designed
as double-storey building, with finished floor lines at +0.00 m and +5.00 m.
Figure 1. 3D model of the structure
The manipulative area is designed as a single-storey building. The roof structure of the
warehouse and manipulative areas is at the same level. The highest point of the building is the top
of the attic wall at level +12.5 m. The roof is double pitched with slope ≈6°, covered with steel
polyurethane panels, which are supported on purlings. Facade to the level +1.50 m is made from
Ytong bricks, 20 cm thickness, and above them are installed steel panels, supported on steel
columns.
Purlings are designed as a simply supported beam, from cold-formed C profiles. The steel
structure of the facade consists of facade columns, main columns, and facade beams (only at the
area with attic). The main loadbearing system is a space frame structure, additional stiffened with
vertical bracing at all planes and horizontal bracings in storey and roof levels, in goal to achieve
precise geometry during mounting. Main beams (Figure 2) bridges the structure on a shorter span,
with a mutual distance of 5.025 m. Beams are designed as hot rolled I profiles.
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Figure 2. Main beams at axis 12, 14, 16 i 18
First-floor slab at level +5.00 m is a composite slab, which consists of trapezoidal steel
sheet TR 85/300/0.75 (S280), at the bottom side and reinforced concrete from above, with 16 cm
total thickness. Trapezoidal steel sheet has a role of formwork and as a reinforcement of the slab
also, in reinforcement concrete (composite) section. Concrete is lightweight concrete SCC, MB 20,
γ= 18.0 kN/m3. Reinforcement at the upper zone is MAR 500/560. With main design is predicted
additional support for seismic load transition from concrete to steel part, with rigid shear stud ≠
140x5 that is welded at upper flanges of floor beams. Considering the proposal of the Contractor,
together with supervisor approval, rigid studs were replaced with “Nelson” anchors. They were
welded for the steel beams in the workshop.
Figure 3. Characteristic connection details
The first-floor slab is supported on the main and secondary steel beam system. All structural
elements are from hot-rolled profiles. Connections between main and secondary beams are
designed with base plates and unfinished bolts. Splices are predicted at roof beams, which are
formed from plates and unfinished bolts. Characteristic connection details are represented in Figure
3.
At the place of the manipulative area, the Employer's request was to have an area without
columns. For this reason, are designed girders that are supported on columns at axis 6 and 12.
Girders are designed as truss beam from rectangular cold-formed sections. Truss beam is designed
with cambering of 6.0 cm. Main columns are placed with mutual distance of 10,05 m at longer
span direction, and 9,21 m at shorter span direction. Columns are designed as hot rolled I profiles.
The connection between columns and footing is designed as pinned joint, built from base plates
and anchors.
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Vertical bracing is designed from cold-formed square sections. At the places of vertical
bracings at secondary columns is predicted an adequate number of anchors that have sufficiently
pull-out strength. Bracings at first storey level and roof level are designed as cold-formed L
profiles.
Eave structure, above the entrance of the building, on the south side of the building, is
designed as girder with tie-beams. Main girders are hot rolled profiles, and tie-beams are cold-
formed circular hollow section.
2.1.3. Designed material for structure
The material for steel structure is Č.0361 (S 235JR), and for purlings is predicted material
S350GD+Z. Unfinished bolts and anchors are 8.8 and 10.9 class.
Reinforced concrete footings, beams, water tank walls and slab are from concrete MB30.
Reinforced concrete floor slab is from concrete that is resistant to fraying. First-floor slab was from
self-compacting concrete (SCC) MB20, but that solution has changed during execution, as
explained in next capture. All longitudinal and transversal reinforcement is B500B. Mesh
reinforcement is MAR500/560.
The procedure of corrosion protection of steel structure is executed in accordance with
Rulebook for technical requirements for steel structures ("Official Gazette of Montenegro",
No.025/18 from 20/04/2018.) and standards EN ISO 12944 - Paints and varnishes — Corrosion
protection of steel structures by protective paint systems. Protective paint systems consist of
primer, intermediate/build coat, and finish coat. Primer and intermediate coat are based on
epoxide, with a high content of Zn and finish coat is resistant to UV radiation and atmospheric
influence. Dry film thickness of coatings is 320 µm. Requested method for surface preparation was
abrasive blast cleaning and grade of cleanliness was SA 2 ½. Requested duration of coatings –
more than 15 years.
3. CONSTRUCTION PROCESS
3.1. PRESENTATION OF CONSTRUCTION WORKS
Execution of works started in July 2017, and the building was finished in Jun 2018. On
figures below is displayed the process of building construction. The steel structure is executed
according to details and specifications from the main design. In the workshop and at the site was
conducted control of welded connections and corrosion protection of steel elements. In the
workshop was executed test mounting of some assemblies. The whole process of mounting was
followed by geodetic surveying. Mounting of the structure was organized in a way that in every
separate area is first mounted stabilized area, after what mounting can be continued successively.
On figures below are perceived photos created during construction and building view during
operation.
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Figure 4. Installation of hydroisolation Figure 5. Installation of the anchor block
Figure 6. Steel elements on site Figure 7. Assembling of stabilized areas
Figure 12. Installation of columns of Figure 13. Main truss beam of manipulative
manipulative area area
Figure 14. Manipulative area Figure 15. Manipulative area
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Figure 16. Double-storey area of the
Figure 17. Assembled steel structure
warehouse
Figure 18. Installation of 1st-floor slab’s
Figure 19. Manipulative single-storey area
reinforcement
Figure 22. Executed floor finishing – epoxy
Figure 23. Building during operation
coating
Figure 24. Building during operation Figure 25. Building during operation
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3.2. MODIFICATIONS OF THE MAIN DESIGN DURING CONSTRUCTION
During the execution of works, and concerning the scope of works, there happened some
problems that were resolved on the move, with a goal to not treat dynamic of a contractor and to
put the building into operation as soon as possible. Below are listed some of the problems that
happened during execution.
At Employers request, finishing of the 1st-floor slab is executed with epoxy coating. This
type of finishing requested concrete class MB30, and with the main design was predicted concrete
class MB20. Considering that the density of SCC concrete was extended from 1800 kg/m3 to 2200
kg/m3, the main designer executed static analyse of structure, with new characteristics of concrete.
Based on a new concrete mix design that was made for the purpose of this calculation, the
conclusion was that concrete density was extended for 22 %. Increasing of concrete density caused
total load increasing on the slab for 6.80%. A designer brought out conclusion that 1st-floor slab
can resist this load increasing. Relevant steel beam exceeds allowed stress for 3.75%, which is at
boundaries that rulebook allows (max 5%). At main girder, allowed stresses were exceeded, but
concerning that during designing “Nelson” anchors assistance was not taken into account, the stress
in beams is reduced for 20% on account of anchors assistance, and in this way remained in the
domain of allowed stresses.
Next problem that happened during the execution of works was related to the concrete class
of raft foundation, slab and walls of water tanks and auxiliary building. Based on concrete cube
test, it is determined that designed concrete class MB 30 was not achieved. The main designer built
calculation of these concrete elements, with achieved concrete strength and concrete density. A
designer brought out conclusion that installed reinforcement in foundations of the warehouse, at
places of columns, at the bottom zone of the slab, has increased allowed stresses. At the expense of
safety factor utilization for 2%, slab resistance was satisfied. Installed reinforcement in water tank
walls has increased allowed stresses. At the expense of safety factor utilization for 6%, wall
resistance was satisfied. Resistance was satisfied ultimate bearing capacity was satisfied at the
expense of safety factor utilization, that is usually predicted to happen over a longer service period
of building. The conclusion was that stability and safety of the above-mentioned elements, that was
the topic of this control, is not endangered.
CONCLUSION
This design represents one successful structural solution, wherein is successfully applied 3D
modelling of structure, in order to systematize procedure of manufacturing, mounting and control
during execution of steel structures.
LITERATURE
[1] Main design of business building – warehouse KIPS ltd in Bar, A7-UP3, Toplica, Bar, Montenegro;
designer and supervisor: Institut za građevinarstvo ltd, Podgorica, mart 2017.
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