Construction Management and Design of Industrial Concrete and Steel Structures

Contents

1. Introduction
2. Construction Management for Industrial Projects

2.1 Introduction
2.2 Project Characteristics
2.3 Project Life Cycle
2.3.1 Feasibility Study
2.3.2 FEED (Preliminary) Engineering
2.3.3 Detail Engineering
2.3.4 Design Management
2.3.5 Execution Phase
2.3.6 Commissioning and Start-Up
2.4 Is This Project Successful?
2.5 Project Management Tasks
2.6 Project Manager Skill
2.7 Project Planning
2.7.1 Who Will Make the Plan?
2.7.2 Where Do You Start the Plan?
2.7.3 Work Breakdown Structure
2.8 Responsibilities of the Planning Team
2.9 Estimating Time Required for an Activity
2.9.1 Calculating Time Required for an Activity
2.9.2 Time Schedule Preparation
2.9.3 Arrow Diagram
2.9.4 Precedence Diagram
2.9.5 Gantt Chart
2.9.6 Critical Path Method
2.9.7 Program Evaluation and Review Technique
2.9.8 Example
2.9.9 Applications for the PERT Method
2.9.9.1 Statistical Calculation of Activity Time
2.9.9.2 Example
2.10 Cost Management
2.10.1 Cost Estimate
2.10.2 Cost Types
2.10.3 Construction Cost Estimate
2.10.4 Steel Structure Cost Estimate
2.10.5 Detailed Cost
2.10.6 Tendering Cost Estimate
2.10.7 Cost Estimate to Project Control
2.10.8 Economic Analysis of Project Cost
2.10.8.1 Work Breakdown Structure
2.10.8.2 Organization Breakdown Structure
2.10.8.3 OBS and WBS Matrix
2.10.8.4 Work Packages 2.10.8.5 Cost Control
2.10.8.6 The Cost Curve
2.10.9 Cash Flow Calculation
2.10.9.1 Cash Flow during the Project
2.10.9.2 Impact on Increasing Cost
2.10.9.3 Project Late Impact
2.10.9.4 Impact of Operation Efficiency
2.11 Project Risk Management
2.11.1 Project Risks
2.11.2 Risk Assessment
2.11.3 Defining Risk Using Quantitative Risk Assessment
2.11.4 Qualitative Risk Assessment
References

3. Loads on Industrial Structures

3.1 Introduction
3.2 Loads
3.2.1 Dead Load
3.2.1.1 General Design Loads
3.2.1.2 Pipe Rack
3.2.1.3 Ground-Supported Storage Tank Loads
3.2.2 Live Loads
3.2.3 Wind Loads
3.2.3.1 Basic Wind Load Formula
3.2.3.2 Wind Loads on Pipe Racks and Open-Frame Structures
3.2.4 Earthquake Loads
3.2.4.1 Design Spectral Response Acceleration Parameters
3.2.4.2 Architectural, Mechanical, and Electrical Components Systems
3.2.4.3 HVAC Ductwork
3.2.4.4 Piping Systems
3.2.4.5 Boilers and Pressure Vessels
3.2.4.6 General Precaution
3.2.4.7 Building and Nonbuilding Structures
3.2.4.8 Flexibility of Piping Attachments
3.2.4.9 Design Review for Seismic Loads
3.2.5 Impact Loads
3.2.6 Thermal Loads
3.2.7 Bundle Pull Load
3.2.8 Ice Loads
3.2.8.1 Site-Specific Studies
3.2.8.2 Loads due to Freezing Rain
3.2.8.3 Design Ice Thickness for Freezing Rain
3.2.8.4 Wind on Ice-Covered Structures
3.3 Load Combinations
3.3.1 Load Combinations
3.3.1.1 Vertical Vessels
3.3.1.2 Horizontal Vessels and Heat Exchangers
3.3.1.3 Pipe Rack and Pipe Bridge Design
3.3.1.4 Ground-Supported Storage Tank Load Combinations
3.3.2 Test Combinations
References

4. Design of Foundations for Vibrating Equipment………………………….. 129

4.1 Introduction
4.2 Machine Requirements
4.3 Foundation Design Guidelines
4.3.1 Trial Foundation Sizing Guidelines
4.3.2 Foundation Dynamic Analysis
4.3.3 Soil Parameter
4.4 Vibration Isolation
4.4.1 Isolating Liners
4.4.2 Spring and Rubber Mounts
4.4.3 Inertia Block Bolt or Pad Mounting Bolt Installation
4.4.4 Grouting
4.5 Design Checklist
References

5. Storage Tank Design

5.1 Introduction
5.2 Concrete Storage Tanks
5.2.1 Rectangular Wall—Concrete
5.2.2 Circular Tank
5.3 Retaining Wall
5.3.1 Preliminary Retaining Wall Dimensions
5.3.1.1 Check Stability against Overturning
5.3.1.2 Check Stability against Sliding
5.3.1.3 Check Stability against Bearing Capacity
5.4 Steel Storage Tank
5.4.1 Tank Capacity
5.4.2 Bottom Plates
5.4.3 Annular Bottom Plates
5.4.4 Shell Design
5.4.4.1 Allowable Stress
5.4.4.2 Calculation of Thickness by the 1-Foot Method
5.4.4.3 Calculation of Thickness by the Variable- Design-Point Method
5.4.5 Roof System
5.4.5.1 Allowable Stresses
5.4.5.2 Supported Cone Roofs
5.4.5.3 Self-Supporting Cone Roofs
5.4.5.4 Self-Supporting Dome and Umbrella Roofs
5.4.6 Tank Design Loads
5.4.7 Load Combination
5.4.8 Design Basis for Small Tanks
5.4.9 Piping Flexibility
5.4.10 Differential Settlement Tank Bottom Designs
5.5 Ring Beam Design Consideration
5.5.1 Wind and Earthquake Stability and Pressures
5.5.2 Earthquake Stability
5.5.3 Soil Bearing
5.5.4 Soil Pressure (Uplift Is Present)
5.5.5 Concrete Ring Beam Design
5.5.6 Ring Wall Reinforcement
References

6. Static Equipment Foundation Design

6.1 Introduction
6.2 Design Procedure
6.2.1 Dead Loads
6.2.2 Live Loads
6.2.3 Wind Loads
6.2.4 Earthquake Loads
6.2.5 Bundle Pull Load (Exchangers)
6.2.6 Thermal Forces
6.2.7 Load Combinations
6.3 Anchor Bolts
6.4 Slide Plates
6.5 Pier Design
6.5.1 Anchorage Considerations
6.5.2 Reinforcement for Piers
6.6 Foundation Design
6.6.1 Foundation Reinforcement
6.6.1.1 Bottom Reinforcement
6.6.1.2 Top Reinforcement
6.7 Example: Heat Exchanger Data
6.7.1 Design Data
6.7.2 Design Criteria
6.7.3 Loads Calculation
6.7.4 Design Elements
6.7.4.1 Size Steel Slide Plate
6.7.4.2 Pier Size
6.7.4.3 Pier Design
6.7.4.4 Footing Size
6.7.4.5 Footing Design
6.8 Separator Design Example
6.8.1 Design Data
6.8.2 Loads Calculation
6.8.3 Design Elements
6.9 Vertical Vessel Foundation Design
6.9.1 Dead Loads
6.9.2 Pedestal Design
6.9.3 Footing Design
6.9.4 Soil Bearing on the Octagon Footing
6.9.5 Check Stability and Sliding
6.9.6 Check for Foundation Sliding
6.9.7 Reinforced Concrete Design
6.9.7.1 Top Reinforcement
6.9.7.2 Shear Consideration
6.10 Example for Vertical Vessel
6.10.1 Design Data
6.10.2 Pedestal Design
6.10.3 Anchor Bolt Check
6.10.4 Footing Design
6.11 Pipe Support
References

7. Steel Structures in Industry

7.1 Introduction
7.2 Stress–Strain Behavior of Structural Steel
7.3 Design Procedure
7.3.1 Tension Members
7.3.1.1 Slenderness Ratio
7.3.2 Compression Members
7.3.2.1 Steps of Preliminary Design
7.3.3 Beam Design
7.3.3.1 Lateral Torsion Buckling
7.3.3.2 Allowable Deflection
7.3.4 Design of Beam Column Member (Allowable Stress Design)
7.3.5 Design of Beam Column Member (LRFD)
7.4 Steel Pipe Rack Design
7.4.1 Pipe Rack Design Guide
7.4.2 Pipe Rack Superstructure Design
7.4.2.1 Structural Steel Expansion
7.5 Stairway and Ladders
7.5.1 Stairways
7.5.2 Handrails and Railings
7.6 Crane Supports
7.7 Connections
7.7.1 Bolts
7.7.2 Welding
7.7.2.1 Welding Symbols
7.7.2.2 Strength of Welds
7.7.2.3 Welding in Existing Structures
7.7.3 Connection Design
7.7.4 Base Plate Design
7.8 Anchor Bolt Design
7.8.1 Anchor Bolts, Nuts, and Washers
7.8.1.1 Anchor Bolts
7.8.1.2 Washers
7.8.1.3 Sleeves
7.8.2 Anchor Bolt Plate Design
7.8.3 Coatings and Corrosion
7.8.4 Bolt Types, Details, and Layout
7.8.4.1 Anchor Bolt Projection
7.8.4.2 Edge Distance
7.8.4.3 Embedment Depth
7.8.5 Calculation of Vessel Anchor Bolts
7.8.6 Anchor Bolt Strength Design
7.8.6.1 Ultimate Strength Design
7.8.6.2 Allowable Stress Design
7.8.6.3 Calculate Required Embedment Length
7.8.7 Anchor Design Considerations
7.8.8 Pretensioning
References

8. Assessment of Existing Structures

8.1 Introduction
8.2 Preliminary Inspection
8.2.1 Collecting Data
8.2.2 Visual Inspection
8.2.2.1 Plastic Shrinkage Cracking
8.2.2.2 Settlement Cracking
8.2.2.3 Drying Shrinkage
8.2.2.4 Thermal Stresses
8.2.2.5 Chemical Reaction
8.3 Detailed Inspection
8.3.1 Methods of Structure Assessment
8.3.2 Concrete Test Data
8.3.2.1 Core Test
8.3.2.2 Rebound Hammer
8.3.2.3 Ultrasonic Pulse Velocity
8.3.2.4 Inherent Variations in In Situ Strength
8.3.2.5 Comparison between Different Tests
8.3.3 Sources of Concrete Failure
8.4 Test Methods for Corroded Steel in Concrete
8.4.1 Manual Method
8.4.2 Concrete Cover Measurements
8.4.3 Half-Cell Potential Measurements
8.4.4 Electrical Resistivity Measurement
8.4.5 Measurement of Carbonation Depth
8.4.6 Chloride Test
8.5 Structure Evaluation Technique
8.5.1 Case Study One: Structural Evaluation
8.5.2 Case Study Two: Structural Assessment
8.5.3 Case Study Three: Structural Assessment
8.5.4 Case Study Four: Structural Assessment
8.6 Structural Assessment
References

9. Methods of Protecting Foundations from Corrosion

9.1 Introduction
9.2 Corrosion Inhibitor
9.2.1 Anodic Inhibitors
9.2.2 Cathodic Inhibitor
9.3 Epoxy Coating of Steel Reinforcement
9.4 Galvanized Steel Bars
9.5 Stainless Steel
9.6 Fiber Reinforcement Bars
9.7 Protecting Concrete Surfaces
9.7.1 Sealers and Membranes
9.7.1.1 Coating and Sealers
9.7.1.2 Pore Lining
9.7.1.3 Pore Blocking
9.7.2 Cathodic Protection by Surface Painting
9.8 Cathodic Protection System
9.8.1 Cathodic Protection
9.8.2 Cathodic Protection Components and
Design Consideration
9.8.2.1 Source of Impressed Current
9.8.2.2 Anode System
9.8.2.3 Conductive Layer
9.8.2.4 Precaution in Anode Design
9.8.2.5 Follow-Up Precaution
9.8.3 A Comparison between Cathodic Protection and Other Methods
9.8.4 Cathodic Protection for the Prestressed Concrete
9.8.5 Bond Strength in Case of Cathodic Protection
References

10. Repair of Industrial Structures

10.1 Introduction
10.2 Main Steps to Execute Repair
10.2.1 Strengthening the Structure
10.2.2 Removal of Concrete Cracks
10.2.2.1 Manual Method
10.2.2.2 Pneumatic Hammer Methods
10.2.2.3 Water Jet
10.3 Cleaning the Concrete Surface and Steel Reinforcement
10.3.1 Concrete
10.3.2 Cleaning the Steel Reinforcement Bars
10.4 New Patches of Concrete
10.4.1 Polymer Mortar
10.4.2 Cement Mortar
10.5 Execution Methods
10.5.1 Manual Method
10.5.2 Casting Way at the Site
10.5.2.1 Grouted Preplaced Aggregate
10.5.2.2 Shotcrete
10.5.3 Complete Member Casting
10.6 Repair Steps
10.7 New Methods for Strengthening Concrete Structures
10.8 Using Steel Sections
10.9 Fiber-Reinforced Polymer
10.9.1 CFRP Types
10.9.2 Application on Site
10.10 General Precaution
References

11. Economic Study for Maintenance Plan

11.1 Introduction
11.2 Basic Rules of Cost Calculation
11.2.1 Present Value Method
11.3 Repair Time
11.3.1 Capacity Loss in Reinforced Concrete Sections
11.3.2 Required Time to Corrosion
11.3.3 Time Required to Deterioration
11.4 Repair and Inspection Strategy and Optimization
11.4.1 Repair
11.4.2 Expected Total Cost
11.4.3 Optimization Strategy
11.5 Maintenance Plan
11.5.1 Assessment Process
11.5.2 RBI Maintenance Plan
11.5.3 RBI Plan for Offshore Structures
11.5.3.1 Risk Matrix
11.5.3.2 Development of Likelihood
11.5.3.3 Development of Consequence
11.5.3.4 Inspection Planning for Offshore Structure
References

12. Overview of Fixed Offshore Structures

12.1 Introduction
12.2 Types of Offshore Platforms
12.2.1 Fixed Offshore Platforms
12.2.1.1 Drilling or Well Protector Platforms
12.2.1.2 Tender Platforms
12.2.1.3 Self-Contained Platforms
12.2.1.4 Production Platform
12.2.1.5 Quarters Platform
12.2.1.6 Flare Jacket and Flare Tower
12.2.1.7 Auxiliary Platform
12.2.1.8 Catwalk
12.2.1.9 Heliport
12.2.2 Concrete Gravity Platforms
12.2.3 Floating Production, Storage, and Offloading
12.2.4 Tension Leg Platforms
12.3 Major Steps in Constructing an Offshore Structure
12.4 Offshore Platform Design Overview
12.4.1 Loads
12.4.1.1 Gravity Load
12.4.1.2 Impact Load
12.4.1.3 Wind Load
12.4.1.4 Wave Load
12.4.1.5 Comparison between Wind and Wave Calculation
12.4.1.6 Current Loads
12.4.1.7 Earthquake Load
12.4.1.8 Other Loads
12.4.2 Platform Configuration
12.4.3 Approximate Design Dimensions
12.4.4 Topside Structures
12.4.5 Jacket Design
12.4.6 Bracing System
12.4.7 In-Place Structure Analysis
12.4.8 Dynamic Structure Analysis
12.4.9 Tubular Joint Design
12.4.9.1 Tubular Joint Calculation
12.4.9.2 Tubular Joint Punching Failure
12.4.10 Fatigue Analysis
12.4.11 Boat Landing
12.4.11.1 Calculation of Collison Force
12.4.11.2 Cases of Impact Load
12.4.11.3 Cases of Impact Load
12.5 Design Quality Control
12.6 Construction Procedures
12.6.1 Engineering of Execution
12.6.2 Fabrication
12.6.2.1 Joint Fabrication
12.6.3 Jacket Assembly
12.6.4 Jacket Erection
12.6.5 Loads from Transportation, Launch, and Lifting Operations
12.6.6 Lifting Forces
12.6.7 Loadout Forces
12.6.8 Transportation Forces
12.6.9 Launching and Upending Forces
12.6.10 Installation
References

13. Soil Investigation and Pile Design

13.1 Introduction
13.2 Soil Exploration Methods
13.2.1 Planning the Program
13.2.2 Organization of Fieldwork
13.2.3 Soil Boring Methods
13.2.3.1 Wash Borings
13.2.3.2 Sampling Methods
13.2.3.3 Spacing of Borings
13.2.3.4 Boring Depth
13.2.3.5 Boring Report
13.2.4 Standard Penetration Test
13.2.5 Cone Penetration Tests
13.2.6 Vane Test
13.2.7 Cross-Hole Test
13.2.7.1 Body Waves
13.2.7.2 Surfaces Waves
13.3 Deep Foundation
13.3.1 Timber Piles
13.3.2 Steel Piles
13.3.3 Concrete Piles
13.3.4 Precast and Prestressed Piles
13.3.5 Pile Caps
References
Index

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Author

Mohamed A. El-Reedy pursued a career in structural engineering. His main area of research is the reliability of concrete and steel structures. He has been a consultant to different engineering companies and oil and gas industries in Egypt as well as international companies such as the International Egyptian Oil Company (IEOC) and British Petroleum (BP). Moreover, he provides different concrete and steel structure design packages for residential buildings, warehouses, telecommunication towers, and electrical projects with WorleyParsons Egypt. He has participated in Liquefied Natural Gas (LNG) and Natural Gas Liquid (NGL) projects with international engineering firms. Currently, Dr. El-Reedy is responsible for reliability, inspection, and maintenance strategy for onshore concrete structures and offshore steel structure platforms. He has performed these tasks for hundreds of structures in the Gulf of Suez and in the Red Sea.

Dr. El-Reedy has consulted with and trained executives for many organizations, including the Arabian American Oil Company (ARAMCO), BP, Apache, Abu Dhabi Marine Operating Company (ADMA), the Abu Dhabi National Oil Company, King Saudi’s Interior Ministry, Qatar Telecom, the Egyptian General Petroleum Corporation, Saudi Arabia Basic Industries Corporation (SAPIC), the Kuwait Petroleum Corporation, and Qatar Petrochemical Com pany (QAPCO). He has taught technical courses on repair and maintenance for reinforced concrete structures and advanced materials in the concrete industry worldwide, especially in the Middle East, Malaysia, and Singapore.

Dr. El-Reedy has written numerous publications and presented many papers at local and international conferences sponsored by the American Society of Civil Engineers, the American Society of Mechanical Engineers, the American Concrete Institute, the American Society for Testing and Materials, and the American Petroleum Institute. He has published many research papers in international technical journals and has authored four books about total quality management, quality management and quality assurance, economic management for engineering projects, and repair and protection of reinforced concrete structures. He received his bachelor’s degree from Cairo University in 1990, his master’s degree in 1995, and his PhD from Cairo University in 2000.