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February 2006
PIP STC01015
Structural Design Criteria
This Practice is subject to revision at any time by the responsible Function Team and will
be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.
PIP will not consider requests for interpretations (inquiries) for this Practice.
PRINTING HISTORY
December 1998
Issued
February 2002
Technical Revision
April 2002
Editorial Revision
Not printed with State funds
August 2004
February 2006
Complete Revision
Technical Correction
TECHNICAL CORRECTION
February 2006
PIP STC01015
Structural Design Criteria
Table of Contents
1. Introduction................................. 2
1.1 Purpose ............................................. 2
1.2 Scope................................................. 2
2. References .................................. 2
2.1 Process Industry Practices (PIP)....... 2
2.2 Industry Codes and Standards.......... 2
2.3 Government Regulations................... 4
3. Definitions ................................... 5
4. Requirements.............................. 5
4.1
4.2
4.3
4.4
Design Loads..................................... 5
Load Combinations.......................... 14
Structural Design ............................. 23
Existing Structures........................... 30
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PIP STC01015
Structural Design Criteria
1.
TECHNICAL CORRECTION
February 2006
Introduction
1.1
Purpose
This Practice provides structural engineering design criteria for the process
industries.
1.2
Scope
This Practice describes the minimum requirements for the structural design of
process industry facilities at onshore U.S. sites. This Practice is intended to be used in
conjunction with PIP ARC01015, PIP ARC01016, PIP CVC01015, PIP CVC01017,
and PIP CVC01018, as applicable.
2.
References
Applicable parts of the following Practices, industry codes and standards, and references shall
be considered an integral part of this Practice. The edition in effect on the date of contract
award shall be used, except as otherwise noted. Short titles will be used herein where
appropriate.
2.1
2.2
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ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs, 60,000
psi Tensile Strength
ASTM A325 - Standard Specification for Structural Bolts, Steel, Heat Treated,
120/105 ksi Minimum Tensile Strength - AASHTO No.: M 164
ASTM A325M - Standard Specification for Structural Bolts, Steel, Heat
Treated 830 MPa Minimum Tensile Strength [Metric]
ASTM A354 - Standard Specification for Quenched and Tempered Alloy Steel
Bolts, Studs, and Other Externally Threaded Fasteners
ASTM 490 - Standard Specification for Structural Bolts, Alloy Steel, Heat
Treated,150 ksi Minimum Tensile Strength - AASHTO No.: M 253
ASTM A615/A615M - Standard Specification for Deformed and Plain
Carbon-Steel Bars for Concrete Reinforcement
ASTM A706/A706M - Standard Specification for Low-Alloy Steel Deformed
and Plain Bars for Concrete Reinforcement
ASTM A992/A992M - Standard Specification for Structural Steel Shapes
ASTM F1554 - Standard Specification for Anchor Bolts, Steel, 36, 55, and
105-ksi Yield Strength
American Welding Society (AWS)
AWS D1.1/D1.1M - Structural Welding Code - Steel
American Forest and Paper Association
National Design Specification for Wood Construction (NDS)
NDS Supplement - Design Values for Wood Construction
Crane Manufacturers Association of America (CMAA)
CMAA No. 70 - Specifications for Top Running Bridge and Gantry Type
Multiple Girder Overhead Electric Traveling Cranes
CMAA No. 74 - Specifications for Top Running and Under Running Single
Girder Overhead Electric Traveling Cranes Utilizing Under Running Trolley
Hoist
Precast/Prestressed Concrete Institute (PCI)
PCI MNL 120 - Design Handbook - Precast and Prestressed Concrete
Steel Joist Institute (SJI)
SJI Standard Specifications, Load Tables and Weight Tables for Steel Joists
and Joist Girders
2.3
Government Regulations
Federal Standards and Instructions of the Occupational Safety and Health
Administration (OSHA), including any additional requirements by state or local
agencies that have jurisdiction in the state where the project is to be constructed, shall
apply.
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3.
Definitions
engineer of record: The owners authorized representative with overall authority and
responsibility for the structural design
owner: The party who owns the facility wherein structure will be used
4.
Requirements
4.1
Design Loads
4.1.1
General
4.1.1.1 New facilities, buildings, and other structures, including floor slabs
and foundations, shall be designed to resist the minimum loads
defined in SEI/ASCE 7, local building codes, this section and the
loads defined in PIP CVC01017 and CVC01018.
4.1.1.2 In addition to the loads in this section, other loads shall be
considered as appropriate. These loads shall include, but are not
limited to, snow, ice, rain, hydrostatic, dynamic, upset conditions,
earth pressure, vehicles, buoyancy, and erection.
4.1.1.3 Future loads shall be considered if specified by the owner.
4.1.1.4 For existing facilities, actual loads may be used in lieu of the
minimum specified loads.
4.1.1.5 Eccentric loads (piping, platforms, etc.), particularly on horizontal
and vertical vessels and exchangers, shall be considered. For
additional information regarding eccentric loads on horizontal
vessels and exchangers, see PIP STE03360.
4.1.2
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Concentrated**
2
Operating, Access
Platforms, and
Walkways
75 psf
(3.6 kN/m2)
Control, I/O,
HVAC Room Floors
Manufacturing Floors
and Storage Areas:
125 psf
(6.0 kN/m2)
2,000 lb
(9.0 kN)
Heavy
250 psf
(12.0 kN/m2)*
3,000 lb
(13.5 kN)
Ground-Supported
Storage Tank Roof
25 psf
(1.2 kN/m2)
NA
Light
*This 250 psf (12.0 kN/m2) live load includes small equipment.
**The loads provided in this table are to be used unless noted otherwise
on the owners data sheet.
4.1.3.4 Uniform and concentrated live loads listed in Table 1 shall not be
applied simultaneously.
4.1.3.5 According to SEI/ASCE 7, concentrated loads equal to or greater
than 1,000 lb (4.5 kN) may be assumed to be uniformly distributed
over an area of 2.5 ft (750 mm) by 2.5 ft (750 mm) and shall be
located to produce the maximum load effects in the structural
members.
4.1.3.6 Stair treads shall be designed according to OSHA regulations or
building code as applicable.
4.1.3.7 Live load reductions shall be in accordance with SEI/ASCE 7.
4.1.3.8 For manufacturing floor areas not used for storage, the live load
reduction specified by SEI/ASCE 7 for lower live loads may be used.
4.1.3.9 The loadings on handrails and guardrails for process equipment
structures shall be in accordance with OSHA 1910.
4.1.3.10 The loadings on handrails and guardrails for buildings and structures
under the jurisdiction of a building code shall be in accordance with
the building code.
4.1.4
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Impact Loads
4.1.6.1 Impact loads shall be in accordance with SEI/ASCE 7.
4.1.6.2 Impact loads for davits shall be the same as those for monorail cranes
(powered).
4.1.6.3 Lifting lugs or pad eyes and internal members (included both end
connections) framing into the joint where the lifting lug or pad eye is
located shall be designed for 100% impact.
4.1.6.4 All other structural members transmitting lifting forces shall be
designed for 15% impact.
4.1.6.5 Allowable stresses shall not be increased when combining impact
with dead load.
4.1.7
Thermal Loads
4.1.7.1 For this Practice, thermal loads are designated by the following
nomenclature:
Tp, T, Af, and Ff, where
Tp = Forces on vertical vessels, horizontal vessels, or heat
exchangers caused by the thermal expansion of the pipe
attached to the vessel
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T=
0.4
Steel to Concrete
0.6
According to Manufacturers
Instructions
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4.1.9
Traffic Loads
4.1.9.1 Buildings, trenches, and underground installations accessible to truck
loading shall be designed to withstand HS20 load as defined by
AASHTO Standard Specifications for Highway Bridges.
4.1.9.2 Maintenance or construction crane loads shall also be considered
where applicable.
4.1.9.3 Truck or crane loads shall have the same load factor as live load.
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Load Combinations
4.2.1
General
Buildings, structures, equipment, vessels, tanks, and foundations shall be
designed for the following:
a. Appropriate load combinations from SEI/ASCE 7 except as otherwise
specified in this Practice
b. Local building codes
c. Any other applicable design codes and standards
d. Any other probable and realistic combination of loads
4.2.2
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Load Combination
Allowable
Stress
Multiplier
Ds + Do + L
1.00
Operating Weight +
Live Load
Ds + Do +
(W or 0.7 Eoa)
1.00
Operating Weight +
Wind or Earthquake
Ds + De + W
1.00
Empty Weight +
Wind
(Wind Uplift Case)
4a
1.00
Operating Weight +
Earthquake
(Earthquake Uplift
Case)
4b
1.00
Empty Weight +
Earthquake
(Earthquake Uplift
Case)
Ds + Df + Wp
1.00
Erection Weight +
Partial Windb
(Wind Uplift Case)
Ds + Dt + Wp
1.20
Test Weight +
Partial Wind
Description
Notes:
a. For skirt-supported vertical vessels and skirt-supported elevated tanks
classified as SUG III in accordance with SEI/ASCE 7-02, Section 9,
the critical earthquake provisions and implied load combination of
SEI/ASCE 7-02, Section 9.14.7.3.10.5, shall be followed.
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b.
c.
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PIP STC01015
Structural Design Criteria
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Load Combination
Description
Operating Weight
5a
5b
Test Weight
Notes:
a. For skirt-supported vertical vessels and skirt-supported elevated tanks
classified as SUG III in accordance with SEI/ASCE 7-02, Section 9, the
critical earthquake provisions and implied load combination of
SEI/ASCE 7-02, Section 9.14.7.3.10.5, shall be followed.
b.
c.
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Load Combination
Allowable
Stress
Multiplier
Description
Ds + Do +
(T or Ff)b
1.00
Operating Weight +
Thermal Expansion or
Friction Force
Ds + Do + L +
(T or Ff)b
1.00
Operating Weight +
Live Load +
Thermal Expansion or
Friction Force
Ds + Do +
(W or 0.7 Eo)
1.00
Operating Weight +
Wind or Earthquake
Ds + De + W
1.00
5a
1.00
Operating Weight +
Earthquake
(Earthquake Uplift Case)
5b
1.00
Empty Weight +
Earthquake
(Earthquake Uplift Case)
Ds + Df + Wp
1.00
Erection Weight +
Partial Windc
(Wind Uplift Case)
Ds + Dt + Wp
1.20
Test Weight +
Partial Wind
(For Horizontal Vessels
Only)
Ds + De + Bp
1.00
Empty Weight +
Bundle Pull
(For Heat Exchangers
Only)
Notes:
a. Wind and earthquake forces shall be applied in both transverse and
longitudinal directions, but shall not necessarily be applied
simultaneously.
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b.
The design thermal force for horizontal vessels and heat exchangers
shall be the lesser of T or Ff.
c.
d.
Heat exchanger empty dead load will be reduced during bundle pull
because of the removal of the exchanger head.
e.
TECHNICAL CORRECTION
PIP STC01015
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f.
Load Combination
Description
b
Operating Weight +
Thermal Expansion or Friction Force
Operating Weight +
Wind or Earthquake
5a
5b
Test Weight
(For Horizontal Vessels Only)
10
Notes:
a. Wind and earthquake forces shall be applied in both transverse and longitudinal
directions, but shall not necessarily be applied simultaneously.
b.
The design thermal force for horizontal vessels and heat exchangers shall be
the lesser of T or Ff.
c.
Erection weight + partial wind is required only if the erection weight of the vessel
or exchanger is significantly less than the empty weight of the vessel or
exchanger.
d.
Heat exchanger empty dead load will be reduced during bundle pull because of
the removal of the exchanger head.
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e.
f.
Load Combination
Allowable
Stress
Multiplier
Ds + Do + Ff + T + Af
1.00
Operating Weight +
Friction Force +
Thermal Expansion +
Anchor Force
Ds + Do + Af +
(W or 0.7 Eo)
1.00
Operating Weight +
Anchor + Wind or
Earthquake
Ds + Dec + W
1.00
4a
1.00
Operating Weight +
Earthquake
(Earthquake Uplift
Case)
4b
1.00
Empty Weight +
Earthquake
(Earthquake Uplift
Case)
Ds + Dt + Wp
1.20
Test Weight +
Partial Winde
Description
Notes:
a. Considerations of wind forces are normally not necessary in the
longitudinal direction because friction and anchor loads will normally
govern.
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b.
c.
d.
e.
Test weight + partial wind normally is required only for local member
design because test is not typically performed on all pipes
simultaneously.
TECHNICAL CORRECTION
PIP STC01015
Structural Design Criteria
February 2006
Load Combination
Description
Operating Weight +
Friction Force +
Thermal Expansion + Anchor
Operating Weight +
Anchor + Wind or
Earthquake
4a
Operating Weight +
Earthquake
(Earthquake Uplift Case)
1.0 Eo
4b
Test Weight
Notes:
a. Considerations of wind forces are normally not necessary in the
longitudinal direction because friction and anchor loads will normally
govern.
b.
c.
d.
Test weight + partial wind normally is required only for local member
design because test is not typically performed on all pipes
simultaneously.
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Load Combination
Description
Ds + Do + Pi
Operating Weight +
Internal Pressurea
Ds + Dt + Pt
Test Weight +
Test Pressure
Empty or Operating
Weight + Wind +
Internal Pressurea
Empty or Operating
Weight + Wind +
External Pressure
Ds + Do + (L or S) + 0.4 Peb
Operating Weight +
Live or Snow +
External Pressure
Empty or Operating
Weight +
Live or Snow +
External Pressure
Operating Weight +
Snow + Earthquake +
Internal Pressurea
(Earthquake Uplift
Case)
Ds + Do + 0.1 S + Eoc
Operating Weight +
Snow + Earthquake
Notes:
a. For internal pressures sufficient to lift the tank shell according to the
rules of API Standard 650, tank, anchor bolts, and foundation shall be
designed to the additional requirements of API Standard 650
Appendix F.7.
b.
c.
Earthquake loads for API Standard 650 tanks taken from SEI/ASCE 7
bridging equations or from API Standard 650 already include the
0.7 ASD seismic load factor.
Test Combinations
4.2.3.1 Engineering judgment shall be used in establishing the appropriate
application of test load combinations to adequately address actual
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Structural Design
4.3.1
Steel
4.3.1.1 Steel design shall be in accordance with AISC ASD or AISC LRFD
specifications.
4.3.1.2 For cold-formed shapes, design shall be in accordance with AISI
specifications.
4.3.1.3 Steel joists shall be designed in accordance with SJI standards.
Comment: Supplement number 1 to the AISC ASD
specification deleted the one-third stress increase
for use with load combinations including wind or
earthquake loads. Because of the deletion of the
one-third stress increase, designs made to the AISC
LRFD specifications should be considered for
economy.
4.3.1.4 Steel design, including steel joists and metal decking, shall be
designed in accordance with OSHA 29 CFR 1926, Subpart R, to
provide structural stability during erection and to protect employees
from the hazards associated with steel erection activities.
Comment: Common requirements that affect steel design areas
follow (this is not an all inclusive list):
a. All column base plates shall be designed with a minimum of
four anchor bolts. Posts (which weigh less than 300 lb [136 kg])
are distinguished from columns and are excluded from the fouranchor bolt requirement.
b. Columns, column base plates, and their foundations shall be
designed to resist a minimum eccentric gravity load of 300 lb
(136 kg) located 18 inches (450 mm) from the extreme outer
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Concrete
4.3.2.1 Concrete design shall be in accordance with ACI 318/318R.
4.3.2.2 Concrete design for liquid-containing structures shall also be
designed in accordance with ACI 350R.
4.3.2.3 Unless otherwise specified, all reinforcing steel shall be in
accordance with ASTM A615/A615M Grade 60 deformed.
4.3.2.4 ASTM A615/A615M Grade 60 plain wire conforming to
ASTM A82/A82M may be used for spiral reinforcement.
4.3.2.5 Welded wire fabric shall conform to ASTM A185/A185M.
4.3.2.6 Reinforcement designed to resist earthquake-induced flexural and
axial forces in frame members and in wall boundary elements shall
be in accordance with ASTM A706/A706M. ASTM A615/A615M
Grade 60 reinforcement is acceptable for these members under the
following conditions:
a. The actual yield strength based on mill tests does not exceed the
specified yield strength by more than 18,000 psi (124 MPa).
Retests shall not exceed this value by more than an additional
3,000 psi (20.7 MPa).
b. The ratio of the actual ultimate tensile strength to the actual
tensile yield strength is not less than 1.25.
4.3.2.7 Precast and prestressed concrete shall be in accordance with the
PCI Design Handbook.
4.3.3
Masonry
Masonry design shall be in accordance with ACI 530/ASCE 5.
4.3.4
Elevator Supports
Elevator support design shall be in accordance with ASME A17.1.
4.3.5
Crane Supports
4.3.5.1 Vertical deflection of support runway girders shall not exceed the
following limits given in Table 10 if loaded with the maximum
wheel load(s), without impact (where L = the span length).
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L/600
L/800
L/1000
L/450
Monorails
L/450
4.3.5.2 Vertical deflection of jib crane support beams shall not exceed L/225
(where L = the maximum distance from the support column to load
location along the length of the jib beam) if loaded with the
maximum lifted plus hoist load(s), without impact.
4.3.5.3 Lateral deflection of support runway girders for cranes with lateral
moving trolleys shall not exceed L/400 (where L = the span length)
if loaded with a total crane lateral force not less than 20% of the sum
of the weights of the lifted load (without impact) and the crane
trolley. The lateral force shall be distributed to each runway girder
with consideration for the lateral stiffness of the runway girders and
the structure supporting the runway girders.
4.3.5.4 Crane stops shall be designed in accordance with the crane
manufacturers requirements or, if not specified, for the following
load:
F = W V2/(2gTn)
where:
4.3.6
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4.3.6.3 Allowable wind drift limits for pre-engineered metal buildings shall
not exceed H/80 (where H = building height).
4.3.6.4 Allowable wind drift limits for a building with a bridge crane that is
required to be in service even during hurricanes shall not exceed
H/400 or 2 inches (50 mm), whichever is less (where H = the height
from the base of the crane support structure to the top of the runway
girder).
4.3.6.5 Allowable wind drift limits for buildings with bridge cranes that will
not be in service during hurricanes shall not exceed H/140 or
2 inches (50 mm), whichever is less (see Section 4.3.6.4 for
definition of H).
4.3.6.6 Allowable wind drift limits for process structures and personnel
access platforms shall not exceed H/200 (where H = structure height
at elevation of drift consideration).
4.3.6.7 Allowable seismic drift limits shall be in accordance with
SEI/ASCE 7.
4.3.7
Foundations
4.3.7.1 Foundation design shall be based on the results of a geotechnical
engineering investigation.
4.3.7.2 The minimum overturning stability ratio for service loads other
than earthquake shall be 1.5 (see Section 4.3.7.4 for the minimum
overturning stability ratio for earthquake loads). For foundation
design of buildings and open frame structures, if the dead load factor
is 0.6 in accordance with SEI/ASCE 7-02, Section 2, the minimum
overturning stability ratio shall be 1.0.
Comment: This requirement is consistent with SEI/ASCE 7
provisions, in which the factor of safety is built
into the 0.6 dead load factor in the load
combinations.
4.3.7.3 The minimum factor of safety against sliding for service loads other
than earthquake shall be 1.5 (see Section 4.3.7.4 for the minimum
sliding factor of safety for earthquake loads). For foundation design
of buildings and open frame structures, if the dead load factor is 0.6
in accordance with SEI/ASCE 7-02, Section 2, the minimum factor of
safety against sliding shall be 1.0.
Comment: This requirement is consistent with SEI/ASCE 7
provisions, in which the factor of safety is built
into the 0.6 dead load factor in the load
combinations.
4.3.7.4 Overturning and sliding caused by earthquake loads shall be checked
in accordance with SEI/ASCE 7-02, Section 9. The minimum
overturning stability ratio and the minimum factor of safety against
sliding for earthquake service loads shall be 1.0. In addition, the
minimum overturning stability ratio for the anchorage and
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PIP STC01015
Structural Design Criteria
4.3.8.4 For centrifugal machinery less than 500 horsepower, in the absence
of a detailed dynamic analysis, the foundation weight shall be
designed to be at least three times the total machinery weight, unless
specified otherwise by the equipment manufacturer.
4.3.8.5 For reciprocating machinery less than 200 horsepower, in the
absence of a detailed dynamic analysis, the foundation weight shall
be designed to be at least five times the total machinery weight,
unless specified otherwise by the manufacturer.
4.3.8.6 The allowable soil-bearing or allowable pile capacity for foundations
for equipment designed for dynamic loads shall be a maximum of
half of the normal allowable for static loads.
4.3.8.7 The maximum eccentricity between the center of gravity of the
combined weight of the foundation and machinery and the bearing
surface shall be 5% in each direction.
4.3.8.8 Structures and foundations that support vibrating equipment shall
have a natural frequency that is outside the range of 0.80 to
1.20 times the exciting frequency.
4.3.9
Anchor Bolts
4.3.9.1 Anchor bolts shall be headed type or threaded rods with compatible
nuts using ASTM A36/A36M, A307, F1554 Grade 36, F1554
Grade 55, F1554 Grade 105, A193/A193M Grade B7, A354
Grade BC, or A354 Grade BD material.
4.3.9.2 All ASTM A36/A36M, A307, and F1554 Grade 36 anchor bolts shall
be hot dip galvanized.
4.3.9.3 Anchor bolt design shall be in accordance with PIP STE05121.
4.3.10 Wood
Wood design shall be in accordance with the American Forest and Paper
Association National Design Specification for Wood Construction and with
the NDS Supplement - Design Values for Wood Construction.
4.3.11 Design of Drilled Shafts
4.3.11.1 Minimum vertical reinforcement shall be 0.50% of the pier gross
area or as required to resist axial loads and bending moments.
4.3.11.2 The minimum clear spacing of vertical bars shall not be less than
three times the maximum coarse aggregate size nor less than three
times the bar diameter.
4.3.11.3 Reinforcing steel shall allow a minimum of 3 inches (75 mm) of
concrete cover on piers without casing and 4 inches (100 mm) of
concrete cover on piers in which the casing will be withdrawn.
4.3.12 Design of Driven Piles
4.3.12.1 Unless otherwise specified or approved, the pile types specified in
PIP STS02360 shall be used.
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Existing Structures
If the owner and the engineer of record agree that the integrity of the existing
structure is 100% of the original capacity based on the design code in effect at the
time of original design, structural designs shall be performed in accordance with the
following:
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4.4.1
4.4.2
If the increased forces on the element or connection are greater than 5%, the
element or connection shall be analyzed to show that it is in compliance with
the applicable design code for new construction.
4.4.3