Industrial Building Design

Guidelines and Rules of Thumb

William Kussro, PE, SE, P.Eng., LEED AP BD+C
Director of Structural Engineering
IBI Group Michigan, LLC - Southfield, MI

SE University - May 2014

www.LearnWithSEU.com

Industrial Buildings - Overview

Introduction
Structural Design Criteria





Documented basis of design

Process loads
Information required from Owner and other disciplines
Coordination with process requirements

Superstructures







Conventional construction
Light-duty construction (joist & joist girder, PEMB, etc.)
Mechanical and Electrical equipment supports
Top-running bridge cranes
Under-running bridge cranes and monorails
Supported slabs

Industrial Buildings - Overview

Substructures





Miscellaneous Topics







Foundation systems
Process equipment foundations and pits
Press foundations
Slabs-on-ground
Floor finishes
Life safety requirements
Blast-resistant construction
Value engineering
Building Information Modeling
Quality Management Program

Summary, conclusions and lessons learned

References and technical resources
Questions and Answers

Industrial Buildings - Introduction

Usually classified as utilitarian structures (function over form)

Some topics universal and others specific to industrial
buildings
Typical project challenges








Sometimes viewed as simple buildings to design

Fast-track design schedule based on start of production (SOP)
Budget constraints
Value Engineering after the fact
Information from Owner not available at design inception
Ongoing design changes with no design/construction schedule
adjustment
Others

Design Guides & Reference Standards

IBC 2009 (or IBC 2012)

ASCE 7-05 (or ASCE 7-10)
AISC 360-05 (or AISC 360-10)
ACI 318-08 (or ACI 318-11)
AISC Design Guide No. 7 Industrial Buildings
AIST Technical Report No. 13 Design of Mill Buildings
CMAA 70-10 Specification for Top Running Bridge and
Gantry Type Multiple Girder Electric Overhead Cranes
CMAA 74-10 Specification for Top Running and Under
Running Single Girder Electric Overhead Cranes
Utilizing Under Running Trolley Hoist

Structural Design Criteria

Documented design criteria and basis of design

Environmental loads
Process-related design loads







Process hanging live loads

Process utility loads
Process stack loads
Crane and monorail design loads
Construction design loads (e.g. process equipment installation)
Others

Information required from Owner or Client (if not Owner)





Bay sizes - usually dictated by process

Clear Heights - usually dictated by process
Crane hook coverage
6

Structural Design Criteria

Information required from Owner or Client (if not Owner)





Information required from other disciplines










Provisions for future expansion

Insurance Company design requirements (e.g. Factory Mutual, etc.)
Others...
Definition of building envelope (e.g. metal siding, precast concrete
panels, etc.)
Mechanical unit locations, sizes and operating weights
Mechanical ASH roof openings and ventilation louver openings
Building utility corridors
Stairs and elevators
Structural fire resistance requirements
Fire wall requirements
Others

Request client sign-off on Structural Design Criteria

7

Structural Design Criteria

Insert design criteria page

Construction Type

Conventional construction


Light-duty construction



Joist and joist girder

Pre-engineered metal building (PEMB)

Steel frame design





Truss and purlin

Stepped construction - upper & lower column tiers

Crane columns
Partial base restraint - linear rotational springs

Foundation design




Conventional shallow spread footings

Spread footings on improved ground
Deep foundations (e.g. drilled shafts, driven piling, ACIP piling, etc.)
9

Construction Type

Thermal Expansion Joints




Seismic Joints




Review expansion joint dimensions based on SRSS method

Federal Construction Council TR 65 Expansion Joints in Buildings
Required in high seismic regions, irregular building geometry, etc
Review expansion joint dimensions based on SRSS method
Requirements defined in IBC and ASCE 7

Structural steel surface prep and cleaning






SSPC-SP3 Power Tool Cleaning - base level surface prep

SSPC-SP6 Commercial Blast Cleaning - consider when primer is
finish coat
Prime paint - sometimes serves as finish coat
Finish painting - selected structural elements only (e.g. columns
below truss bottom chord)
10

M & E Equipment Supports

Coordination with purchased equipment is critical

Add boxed notes to Structural CDs alerting Contractor to
Confirm all locations, dimensions and weights with
certified and approved manufacturer equipment shop
drawings
Equipment supports



Pre-fabricated equipment curbs

Structural pre-fabricated curbs

Equipment supports deflection limits

Supports for self-supporting & guyed stacks
Roof hatches for equipment installation and maintenance
Roof openings

11

Bridge Crane Design Considerations

Types of bridge crane runway elements






Top-running or under-running bridge?

Top-running - Rolled girder or built-up plate girder
Under-running - W or S beam (with or without cap channel)
Under-running - Patented track or enclosed track

Critical Design Questions










How many cranes on a runway?

How many cranes can be expected to operate simultaneously?
How often will cranes lift their maximum loads?
What allowance should be made for impact?
What lateral thrusting forces can occur simultaneously?
What is the distance from floor to the lowest overhead obstruction?
What objects (i.e. light fixtures, suspended piping, etc.) will project
below the roof structure?
Stiffness requirements of the supporting roof structure?
12

Top-Running Bridge Cranes

Design standards



Crane runway accessories





CMAA 70-10 Specification for Top Running Bridge and Gantry

Type Multiple Girder Electric Overhead Cranes
CMAA 74-10 Specification for Top Running and Under Running
Single Girder Electric Overhead Cranes Utilizing Under Running
Trolley Hoist
Crane rails and rail pads
Crane rail clips
Crane girder tie-backs allow free rotation of girder ends

Crane bumpers



Rigid bumpers
Hydraulic bumpers

13

Crane Rails, Rail Pads & Rail Clips

14

Crane Rails, Rail Pads & Rail Clips

15

Crane Rails, Rail Pads & Rail Clips

16

Crane Girder Tie-Backs

17

Crane Girder Tie-Backs

18

Crane Girder Tie-Backs

19

Crane Girder Tie-Backs

20

Under-Running Cranes & Monorails

CMAA 70-10 Specification for Top Running Bridge and

Gantry Type Multiple Girder Electric Overhead Cranes
Single Girder Bridge Crane



Double Girder Bridge Crane




Up to 10 Ton Capacity
Up to 175 Feet Span (Multi-Runway Cranes)
Up to 15 Ton Capacity
Up to 200 Feet Span (Multi-Runway Cranes)

Capacity can be as much as 25T

Practical limit of 15T
Typical capacities of 1T to 7.5T

21

Under-Running Bridge Crane Systems

22

CMAA 74 2010

23

Design Considerations Loads

Lateral crane loads oriented perpendicular to the crane

runway and applied at the top of the bottom flange





Longitudinal crane loads oriented parallel to the crane

runway and applied at the top of the bottom flange



Acceleration and deceleration of the trolley and loads

Non-vertical lifting resulting in load sway
Unbalanced drive mechanisms
Oblique or skewed travel of the bridge

Acceleration or deceleration of bridge crane

Crane impacting bumper

Information from crane manufacturer is essential in

determining the proper design forces
Runways must be surveyed, aligned and re-aligned on a
regular basis to minimize forces, especially lateral forces
24

Crane Loads per IBC and ASCE 7

Maximum Wheel Load



Vertical Impact = 25%



Percentage of rated capacity + hoist weight + trolley weight

Acts horizontally at traction surface of runway beam (top of
bottom flange) perpendicular to the beam

Longitudinal Tractive Force = 10%




Percentage of maximum wheel load

Lateral Side Thrust = 20%



Rated capacity + Bridge weight + Trolley/hoist weight

Percentage of maximum wheel load

Acts horizontally at traction surface of runway beam (top of
bottom flange) parallel to the beam

End Stop Force



Rigid end stops or buffer end stops

25

Load Combinations

IBC 2012 and ASCE 7-10 are generally silent in regards to

load combinations regarding cranes
ASD Combinations per AIST Technical Report No. 13
For members designed for repeated loads (i.e. fatigue):
D + Cvs + 0.5Css + Ci
For all members:
D + L + (Lr or R or S) + Cvs + Ci + Css + Cls (Single crane)
D + L + (Lr or R or S) + Cvm + Css + Cls (Multiple cranes)
D + L + (Lr or R or S) + Cvs + Ci + W
D + L + (Lr or R or S) + Cvs + Ci + Css + 0.5W
D + L + (Lr or R or S) + Cvs + Ci + 0.67 Cbs
D + L + (Lr or R or S) + Cd + E

26

Load Combinations Notations

Cvs = vertical loads due to a single crane in one aisle only

Css = side thrust due to a single crane in one aisle only

Ci = vertical impact due to a single crane in one aisle only

Cls = longitudinal traction due to a single crane in one aisle

only

Cvm = vertical loads due to multiple cranes

Cbs = bumper impact due to a single crane in one aisle

only at 100% speed

Cd = dead load of all cranes, parked in each aisle,

positioned for maximum seismic effects

27

Crane Runway Girder Details

28

Joist Supported Cranes Details

29

Joist Supported Cranes Details

30

Joist Supported Cranes Details

31

Joist Supported Cranes Details

32

Under-Running Girder Comparison

W Section Advantages



Can provide lighter total section depending on runway span and

loads
No additional shop fabrication involved in welding multiple rolled
shapes together

W + Channel Section Advantages






Higher weak axis moment strength to resist sidethrust loads

Better torsional properties
Rule of thumb: Wide flange + cap channel is economical if it is
20 lb/ft lighter than wide flange alone.
See design example in AISC Engineering Journal: New Fatigue
Provisions for the Design of Crane Runway Girders by Duane
S. Ellifritt and Dung-Myau Lue, 2nd Quarter 1998)

33

Crane Runway Design Criteria

Runway beams shall be straight, parallel and at a constant

elevation
Must meet applicable tolerances given in CMAA 74 Table
1.4.1-1 for crane runways
CMAA and OSHA also require crane-to-building tolerances (horizontal and
vertical clearances)
 Consider increasing tolerances above legal requirements to allow for
unforeseen conditions or problems


Deflection limitations
Vertical Deflection: Lr/1000 based on maximum wheel w/o impact (toprunning)
 Vertical Deflection: Lr/450 based on maximum wheel w/o impact (underrunning)
 Lateral Deflection: Lr/400 based on maximum side thrust (both TR & UR)
 Angular Twist: Per crane manufacturer recommendations, actual design
conditions, etc.


34

CMAA 74-2010 Runway Tolerances

35

Design Considerations Fatigue

AISC 360 Appendix 3 - Design For Fatigue

 Applies

to members and connections subject to

high cycle loading within the elastic range of stresses
of frequency and magnitude sufficient to initiate
cracking and progressive failure
 Applies to certain components in crane buildings (e.g.
runway girders or monorails, bracing, tie-backs,
hangers, connections, etc.)
 Fatigue stresses evaluated at service level
 Stress range is numerical sum of maximum repeated
tensile and compressive stresses or shearing
stresses resulting from application of repeated
service-level live load
36

Design Considerations Fatigue

AISC 360 Appendix 3 - Design For Fatigue

 No

evaluation of fatigue resistance required if number

of repetitive load cycles less than 20,000 (N=Design
Life Stress Range Fluctuations)
 No evaluation of fatigue resistance required if live
load stress range is less than the Threshold Stress
Range FTH - maximum stress range for indefinite
design life. See AISC Appendix 3 Table A-3.1.
 No evaluation if stress ranges are completely in
compression
 No evaluation for transient wind loads or seismic
loads
37

Design Considerations Fatigue

Different types of bridge crane system ratings based on

expected service
CMAA 74 Crane Service Classifications




A, B C, D, E or F - Top-running cranes
A, B C or D - Under-running cranes
Indirectly related to AISC Loading Conditions

AISC Loading Conditions (1, 2 , 3 or 4)






Loading Condition 1: 20,000 to 100,000 load cycles

Loading Condition 2: 100,000 to 500,000 load cycles
Loading Condition 3: 500,000 to 2,000,000 load cycles
Loading Condition 4: greater than 2,000,000 load cycles

38

CMAA Service Classifications

SERVICE
CLASS

DUTY SERVICE

DESCRIPTION

Standby or Infrequent
Service

Slow speeds with long, idle periods

between lifts

Light Service

Loads vary from no load to occasional

full rated loads with 2 to 5 lifts per
hour, averaging 10 feet per lift

Moderate Service

Loads averaging 50 percent of rated

capacity with 5 to 10 lifts per hour,
averaging 15 feet, not over 50
percent of the lift at rated capacity

Heavy Service

High speeds with loads approaching

50 percent of the rated capacity
handled constantly during the work
period. 10 to 20 lifts per hour
averaging 15 feet, not over 65
percent of the lifts at rated capacity
39

CMAA Service Classifications

40

Design Considerations Fatigue

AISC Design Fatigue Stress Range FSR




AISC Threshold Fatigue Stress Range FTH



Allowable fatigue stress range

Greater than or equal to FTH
Maximum fatigue stress range for indefinite design life

AISC Stress Categories (A, B, B, C, D, E or E)




Provided in Appendix 3 Table A-3.1

Organized into 8 sections dependent on general conditions for
fatigue design including base material & welded/bolted
connections

41

Fatigue Design AISC 13th Edition

42

Fatigue Design AISC 13th Edition

43

Enclosed Track Systems

ANSI MH27.2 2009 Specifications for Enclosed Track

Underhung Cranes and Monorail Systems






Specification applies to underhung cranes whose end trucks

operate on the internal flange of a runway using enclosed track
sections and to trolleys operating on single-track monorail
systems
Specification considers crane and monorail equipment only
Does not consider design of the building, supporting structure or
erection
Duty Service Classifications

Infrequent Usage (Light Service)

Frequent Usage (Heavy Service)

Severe Usage (Continuous Service)

44

Enclosed Track Systems

DUTY SERVICE CLASSIFICATION
DUTY SERVICE

DESCRIPTION

Infrequent Usage
(Light Service)

Operation time does not exceed 20% of the work

period

Frequent Usage
(Heavy Service)

Either:
A. Operation time is up to 100% of work period and
lifted load is 50% or below of rated capacity.
B. Operation time is less than 50% of work period
and lifted load is greater than 50% of rated
capacity.

Severe Usage
(Continuous Service)

Operation time is consistently greater than 50% of the

work period and lifted load is consistently greater than
50% of rated capacity.
Note: Applications involving vacuums, magnets or
other high impact lifting devices fall within this
classification category.
45

Enclosed Track Systems

ANSI MH27.2 2009 Specifications for Enclosed Track

Underhung Cranes and Monorail Systems


Runway and Monorail Track

Specially rolled, extruded or fabricated section

Tread of load carrying flange shall be compatible with the
trolley wheel

Maximum vertical deflection of 1-1/4 or per manufacturer,
whichever is less

Straightness, center-to-center distance, elevation shall be
within tolerances per this specification

Specific provisions for curved tracks, transfer cranes, track
switches

46

Enclosed Track Systems

47

Enclosed Track Manufacturers

48

Patented Track Systems

ANSI MH27.1 2009 Specifications for Patented Track

Underhung Cranes and Monorail Systems






Specification applies to underhung cranes whose end trucks

operate on the internal flange of a runway using patented track
sections and to trolleys operating on single-track patented-track
monorail systems
Specification considers crane and monorail equipment only
Does not consider design of the building, supporting structure or
erection
Duty Service Classifications

Range from Class A (Infrequent Handling) to Class E
(Continuous Handling)

49

Patented Track Systems

ANSI MH27.1 2009 Specifications for Patented Track

Underhung Cranes and Monorail Systems


Runway and Monorail Track

Specially rolled or fabricated section

The minimum hardness of the lower load carrying (tension)
flange shall be 195 Brinell

High-carbon steel lower flange (rail) for longer track life

The tread of the load carrying (tension) flange shall be flat

Maximum vertical deflection limited to 1/450 times the crane
span or unsupported length, or 1-1/4

Straightness, center-to-center distance, elevation shall be
within tolerances per this specification

Specific provisions for curved tracks, transfer cranes, track
switches
50

Patented Track Systems

51

Patented Track Manufacturers

52

Bridge Cranes - Lessons Learned

Supporting joist deflection limits for under-running cranes

 Crane wheel loads without impact: Lr/450 (CMAA 74-2010)
 Roof snow load: Lr/360 (recommendation)
Locate crane runway support points so that the differential deflection
between successive supports under crane wheel loads without
impact is limited to in 20-0 (recommendation)
Crane runways parallel to joists
 Consider two or more joists to support each runway load
sharing to control deflections
Locate crane runways symmetrical to supporting joists to avoid
differential deflection and rotation of runway beams
Provide lateral and longitudinal bracing for runways and support
system to transfer loads to top chord of joists and roof deck
Provide for vertical, lateral and longitudinal adjustments in detailing
the support systems, for rail alignment
53

Bridge Cranes - Lessons Learned

Detail support system for height adjustment from rail to sloping

bottom chord. Can incorporate shims for a level installation for
smooth crane operation.
Specify joist design, detailing and fabrication to comply with fatigue
loading corresponding to the Class of Service (Class A Standby or
Infrequent Service to Class D Heavy Service)
 There are no SJI design standards for fatigue loading
 Can use AISC recommendations in the absence of other criteria
(AISC 13th Edition Manual Appendix 3)
Installation Contractor shall meet required tolerances - vertical,
lateral, longitudinal, differential, straightness
Beneficial to work with the selected Crane Manufacturer to agree
upon the criteria, develop details and avoid possible issues at a later
time

54

Bridge Cranes Summary

Industrial buildings supporting bridge cranes

have generally performed successfully when the
following items considered:
 Understand

crane parameters (i.e. the intended use,

life cycle, etc.)
 Limit applied stress range to acceptable levels
 Avoid unexpected restraints at the attachments and
supports
 Avoid stress concentrations at critical locations
 Perform periodic maintenance on runway systems to
ensure rails and runways are aligned and level

55

Fabricated vs. Pre-Engineered Clamps

Clamp Design: Three major factors to consider:

1.

2.
3.

Structural design and performance

Three main components: Bolt, Clamp & Supporting Steel
QA/QC in manufacturing
Economic cost of the connection

Quality Control and Quality Assurance



Fabricated clamps

No standardized testing for finished product

Performance dependent on workmanship of fabricator and
proper installation.
Pre-engineered clamps

Manufacturers perform internal quality control

Random product testing: Dimensional tolerances, impact
tests, material ductility, finish uniformity
56

Fabricated vs. Pre-Engineered Clamps

Structural Design and Performance





Bolt Design
Clamp Design
Support Design

57

Pre-Engineered Clamps

58

Fabricated vs. Pre-Engineered Clamps

Economic Cost of the Connection



Must consider design, material, fabrication and installation costs

Cost comparisons show up to 17% savings by using preengineered clamps vs. fabricated clamps

Self-adjusting clamps allow a universal design and eliminates

the potential for installing the wrong clamp at a given location

Less waste since excess clamps can be used on future jobs,

even with different beam sizes

59

Fabricated vs. Pre-Engineered Clamps

Advantages of Pre-Engineered Clamps
Pre-Engineered Clamps

Fabricated Clamps

Bolts act in pure tension with factor of

safety of 5 to 1 (machine specs). Also
tested for fatigue resistance

Bolts are subjected to prying action with

undetermined load capability and
reduced factor of safety

Published load capacities verified by

physical tests

No accurate design methodology and no

published testing on performance

Can accommodate both frictional and

tensile loads

Can only handle tensile loads

Easy to install. Fully pre-tensioned high

strength bolts (ASTM or SAE) used

Installation subject to interpretation of

the installer

Clamp selector software makes

evaluation of connection simple

Each clamp must be individually

designed

60

Process Equipment Foundations/Pits

Understand type of process equipment being installed

Press OEM foundation design criteria required at design
inception
Rotating or reciprocating equipment foundations
Dynamic analysis and design may be required
Foundation isolation to limit incoming/outgoing vibrations





Coordinate Measuring Machines (CMM)

Milling Machines
Stamping Presses
Test equipment (four-posters, dynamometers, etc.)

61

Process Equipment Foundations/Pits

Crack control for shrinkage restraint stresses




Foundation drainage
Damp-proofing/waterproofing



Positive-side waterproofing
Negative-side waterproofing

Waterstops




ACI 224 Control of Cracking in Concrete Structures

ACI 224.3 Joints in Concrete Construction

PVC industry standard

Rubber (SBR & neoprene) high-demand applications
Hydrophilic ease of placement

Concrete coatings

62

Press Foundations

Understand type of press equipment to be supported

Progressive Press Line
 Tandem Press Line
 Shear Press (cut-to-length)
 Forge Press


Press OEM foundation design criteria required at project inception

Dynamic or equivalent static design loads
Document press foundation construction tolerances
Utilize a precision survey to verify construction tolerances prior to
press installation
Bolster rail supports and loading
Die cart rail supports and loading
Scrap handling systems
FOL and EOL equipment supports
Design loads 1,000-1,500 psf
Floor deflection tolerances L/600 or greater
63

Slabs-on-Ground

Often referred to as Slabs-on-Grade

ACI 360-10 Guide to Design of Slabs-on-Ground



Typical Thicknesses of Non-structural SOGs






Structural slabs-on-ground
Non-structural slabs-on-ground
4-5 - Light duty
6-7 - Moderate duty
8-9 - Heavy duty
10-12 - Severe duty

Typical Thicknesses of Structural SOGs




6-9 - Single mat reinforcing

10-24 Double mat reinforcing

64

Slabs-on-Ground - Industrial Buildings

65

Slabs-on-Ground Design Loading

Design loading
 Partial

uniform loads
 Concentrated loads - static or dynamic
 Electric or Gas Forklift truck loads
 Pallet jack or hand truck loads
 Concrete truck loads
 Highway truck loads
 Pattern loads rack loading
 Others specialty loading conditions confirm with Owner

66

Slabs-on-Ground Design Loading

67

Slabs-on-Ground

Floor Finish Classes



Vapor Barrier/Retarder



Based on floor application - table in ACI 302

Is a vapor retarder required and if so where is the correct location?
Follow vapor retarder flowchart in ACI 302

Floor Flatness and Floor Levelness (FF/FL)









Based on floor application - table in ACI 302

ASTM E1155 Standard Test Method for Determining FF/FL
ACI 117 Specification for Tolerances for Concrete Construction
FF value measures local variation (flatness) of floor slab
FL value measures overall levelness of floor slab
Local and composite numbers are recorded
Note that floor slabs can be level but not flat and vice versa

68

SOGs - Floor Finish Classes

ACI 302, Table 2.1

69

SOGs Vapor Barrier/Retarder

70

SOGs - FF/FL Criteria

Typical FF/FL Specifications

 Non-critical

areas FF20/FL15
 Commercial/Office Buildings FF25/FL20
 Light Industrial Buildings FF25/FL20
 Warehouse or Heavy Industrial Buildings FF35/FL25
 Industrial Buildings (critical operations) FF45/FL35
 Industrial Buildings (super-flat floors) - FF50/FL50

71

SOGs - FF/FL Criteria

72

Slabs-on-Ground Fiber Reinforcing

Fiber reinforced concrete






Typical microsynthetic fiber dosage rates

General duty 2-3 pcy

Typical macrosynthetic fiber dosage rates




Microsynthetic fibers plastic shrinkage crack control only

Structural macrosynthetic fibers drying shrinkage crack control
Steel fibers drying shrinkage crack control
Blended fibers (synthetic & steel)

Light to moderate duty 3-4 pcy

Heavy duty 5-7 pcy

Typical steel fiber dosage rates (SFRC)






Light duty less than 20 pcy

Moderate duty 20-35 pcy
Heavy duty 35-60 pcy
Jointless construction greater than 60 pcy
73

Slabs-on-Ground Fiber Reinforcing

Performance-based design/construction specifications





Design considerations




Thickness design (various options)

Equivalent post-crack flexural strength
Re method per ACI 360 Chapter 11
Consider all partial uniform, concentrated and pattern loading
conditions
Consider edge loading slab edge or load near
control/construction/isolation joint)
Concrete material testing per ASTM C1018

Key notes




Offer post-crack resistance but usually do not affect first crack strength
Concrete mix design key for placement, consolidation & finishing
Comparison chart for synthetic & steel fiber dosage available
74

Slabs-on-Ground Fiber Reinforcing

SFRC Characteristics







Ductile material
Flexural strength
Crack Control
Impact resistance
Fatigue resistance
Shear resistance

Why choose SRFC?








Reinforcement throughout entire concrete mix/matrix

Reinforcement placement issues eliminated
Increased loading capacity
Post-crack resistance (toughness)
Reduced construction time
Overall cost savings for Owner
75

Supported Slabs

Supported slab-on-metal deck (SOMD)

Formed cast-in-place concrete slabs
Dynamic loads to be considered
Acceptable floor vibrations to be reviewed
Determine slab thickness per concentrated forklift truck
loading punching shear or beam shear near supports
will usually control design
Supported slabs on metal deck supporting forklift truck
loads



6 minimum total slab for forklift trucks up to 3T rated capacity

8 minimum total slab for forklift trucks greater than 3T rated
capacity

76

Floor Finishes

Floor slabs classified per ACI 302

Flatness/Levelness classifies per (FF/FL)
Concrete sealers/dust-proofers
Liquid hardeners/densifiers
Mineral dry shake surface hardeners




Metallic dry shake surface hardeners




Emery
Trap rock
Quartz
Standard
Non-oxidizing

Heavy-duty deferred floor toppings (two-course floors)

77

Floor Finishes

78

Life Safety Code Compliance

Consult with Project Architect or Code Consultant

Review egress travel distances
Review required UL fire ratings of structural elements


Fire Protection of Structural Steel for Dummies NCSEA

Structure Magazine Nov 2005

Fire walls and fire-rated barrier walls

NFPA 221-2012 Standard or High-Challenge Fire Walls,
Fire Walls and Fire Barrier Walls)

79

Life Safety Code Compliance

NFPA 221-2012 Standard or High-Challenge Fire Walls,

Fire Walls and Fire Barrier Walls)
High-Challenge Fire Walls




Fire Walls




New terminology in NFPA similar to Factory Mutual Insurance

MFL (maximum foreseeable loss) Fire Wall
Allows collapse on either side - generally double walls
Has limits to height and openings. Has chapter of provisions in
NFPA 221 which in effect is the definition
Historical building code definition to separate buildings
Can be single or double definition per IBC Section 706
Requires structural collapse of either side

Fire Barrier Walls




Extend to underside of deck

Used to separate mixed occupancies, shafts, etc.
80

Blast-Resistant Construction

Required for certain hazards and occupancies





Governing Codes and Standards






Paint Mix Rooms

Paint & Solvent Storage Rooms
Durability Test Rooms
IBC (chapter 1)
NFPA 68
NFPA 69
Factory Mutual Insurance Loss Prevention Data Sheets

Calculation of blast relief pressures and blast resistant

pressures
Pressures based on nature and quantities of stored materials
Consult with Project Architect or Code Consultant
81

Blast-Resistant Construction

82

Value Engineering

Have typical VE list ready to discuss with Clients (Owners,

Architects, Design/Build Contractors, etc.)

Discuss VE opportunities at project kick-off meeting

Usually discussed after project bids are received and project

is already over-budget

83

Value Engineering

General Structural Engineering VE suggestions














1. Eliminate deep foundations

1A. Utilize ground improvement techniques and shallow foundations
2. Eliminate fabricated roof trusses
2A. Utilize PEMB or Joist & Joist Girder building framing
3. Minimize process hanging loads
3A. Utilize floor-supported process elements instead of overheadsupported
4. Minimize reinforcing in slabs-on-ground and slabs-on-metal-deck
4A. Utilize Steel Fiber Reinforced Concrete (SFRC)
5. Eliminate precast wall panels
5A. Utilize insulated metal wall panels or metal siding with exposed
insulation or insulation with liner panel (PEMB wall panels)
6. Mitigate structural interferences with process and facility elements
6A. Utilize BIM technology
84

Building Information Modeling

Utilize BIM (3D design tools) for the following:

 General

visualization of concepts
 Clash detection
 Design coordination
 Material procurement, construction scheduling and
sequencing Time element (4D)
 Project cost control Cost element (5D)
 Facility operation and maintenance Facility
Management element (6D)

85

Building Information Modeling

86

Building Information Modeling

87

Building Information Modeling

88

Building Information Modeling

89

Industrial Buildings - Quality Control

Technical design checklists

Coordination checklists
Interdepartmental coordination meetings
BIM coordination meetings
Internal peer reviews
Third party (external) peer reviews
Constructability reviews

90

Structural Design Checklist

ITEM
1

Has all criteria been obtained from the Owner (type of crane, lifted load capacity, usage
classification, hook height and coverage and equipment clearance requirements)?

Has all information been obtained from the crane manufacturer (crane weight, trolley weight,
maximum wheel loads, wheel spacing, rail size, end stop force, end stop elevation,
deflection requirements, bracing requirements, etc.)?

Are the crane girders designed with the crane(s) positioned for maximum moment?

Are the hangers designed with the crane(s) positioned for maximum hanger load?

Have the appropriate combinations of dead, live, lateral, longitudinal and impact loads been
designed for per the building code?

Is the total load deflection within limits (some manufacturers recommend to limit total runway
deflection to span divided by 450)?

Has the building structure itself been checked for the transfer of additional crane loads,
including lateral and longitudinal loads?

Have the fatigue requirements from the current addition of the AISC Manual been reviewed?

Have details been provided for the following:

9a

All hanger types?

9b

Runway splices?

9c

Bracing, including lateral and longitudinal?

10

Yes

No

N/A

COMMENT

Is all design criteria on the drawings, including crane loads, number of cranes per bay or
system, etc.?

91

Industrial Buildings - Summary

Top 20 Hard Points:

1. Do not underestimate the design complexity of Industrial and
Manufacturing Buildings
2. Request client sign-off on Structural Design Criteria
3. Review need for structural joints (expansion & seismic joints)
4. Compare ASD / LRFD design procedures (LL/DL ratios)
5. Evaluate need for stepped columns versus crane columns
6. Understand intended bridge crane use, lifespan & load cycles
92

Industrial Buildings - Summary

Top 20 Hard Points (continued):

7(a). Coordinate with bridge crane manufacturer
7(b). Obtain a design basis and state on Structural CDs
7(c). Beneficial to work with the selected Crane Manufacturer
to agree upon the criteria, develop details and avoid
possible negotiations / deliberations at a later time
8. Verify crane stack-up dimensions and available hook heights
9. State CMAA runway installation tolerances on Structural CDs
and allow for vertical impact, side thrust and tractive forces
10. Apply correct crane load combinations per AIST TR 13

93

Industrial Buildings - Summary

Top 20 Hard Points (continued):

11. Check fatigue as required per AISC Spec Appendix 3 for all
elements directly receiving live load (e.g. runways, hangers,
bracing, header beams, supporting structure, etc.)
12. Consider use of pre-fabricated clamp connections with fully pretensioned bolts
13. Design supported slabs or concentrated forklift truck loads
14. Review supported slabs for deflection and vibration
15. Establish design basis for process equipment foundations, pits
and basements
94

Industrial Buildings - Summary

Top 20 Hard Points (continued):

16. Review floor finish requirements with client and Architect
17. Coordinate life safety requirements with Project Architect
18. Utilize BIM for design coordination, clash detection, etc.
19. Review Structural Engineering Value Engineering opportunities
with client at design inception
20. Utilize design checklists as part of the comprehensive Quality
Management Plan (QMP)

95

Reference Documents and Resources

AISC Design Guide 7: Industrial Buildings: Roofs to Anchor Rods,

Second Edition
CMAA Specification No. 74 2010: Specifications for Top Running
and Under Running Single Girder Electric Overhead Cranes Utilizing
Under Running Trolley Hoist
AIST Technical Report No. 6: Specification for Electric Overhead
Traveling Cranes for Steel Mill Service
AIST Technical Report No. 13: Guide for the Design and
Construction of Mill Buildings
ANSI MH27.1 2009 Specifications for Patented Track Underhung
Cranes and Monorail Systems
ANSI MH27.2 2009 Specifications for Enclosed Track Underhung
Cranes and Monorail Systems
Avoiding the Pitfalls of Crane Installation in a New Building, Larry
Dunville, The Fabricator, February 2001.
96

Reference Documents and Resources

AISC Engineering Journal Articles




Tips for Avoiding Crane Runway Problems, David T. Ricker,

Fourth Quarter, 1982
New Fatigue Provisions for the Design of Crane Runway
Girders, James M. Fisher and Julius P. Van De Pas, Second
Quarter, 2002

Designing with Vulcraft: Steel Joists, Joist Girders and

Steel Deck, 2nd Edition, James M. Fisher, Michael A.
West and Julius P. Van de Pas, Nucor Corporation,
2002.
Technical Note: Fabricated Clamps verses Lindapter
pre-engineered clamps, Patrick Collings, Lindapter North
America

97

Additional Technical Resources

AISC ePubs:
 http://www.aisc.org/content.aspx?id=2862

AISC Frequently Asked Questions:

 http://www.aisc.org/faq

AISC Steel Interchange:

 http://www.modernsteel.com/steelinterchange.php

98

Questions and Answers

Questions

and answers?

Thanks for attending

99

CHALLENGE QUESTION:
Which Reference Standard is the answer to this
sessions Challenge Question?
A.
B.
C.
D.

AIST Technical Report No. 13

CMAA 70-10
CMAA 74-10
AISC Design Guide No. 7

Please circle the answer that is announced so that you can use the
information to complete your quiz (NY) or form (FL) for PDH.
100