30 METER SELF SUPPORTING CHIMNEY

Design Data:

Total Height of Chimney: 30 meters

Design Codes: IS 6533 (Part 1 & 2)

IS 875 (Part 3)
IS 800

Type of Chimney: Self-Supporting Chimney

Material of Construction: Mild Steel for Chimney Shell

Inputs:

Height of Chimney: 30 meters

Range of Zone 1: 25 m to 30 m
Length of Zone 1: 5m Total Height 5m
Range of Zone 2: 20 m to 25 m
Length of Zone 2: 5m Total Height 5m
Range of Zone 3: 15 m to 20 m
Length of Zone 3: 5m Total Height 15 m
Range of Zone 4: 10 m to 15 m
Length of Zone 4: 5 m. Total Height 20 m
Range of Zone 5: 5 m to 10 m
Length of Zone 5: 6m Total Height 25 m
Range of Zone 6: 0 m to 5 m
Length of Zone 6: 5m Total Height 30 m

Size Requirement:

As per Clause 7.2.4 of I.S. 6533 Part 2,

Minimum Height of Flared Portion = 1/3 (Total Height)

= 1/3 (30)
= 10.00 m.

Minimum OD of Flared Portion at Shell Base = 1.6(OD at Top)

= 1.6(0.512)
= 0.8192 m.

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Wind Pressure Calculations:

Basic Wind Speed: Vb (m/sec) = 33.00

Risk Co efficient K1 =1.00
Risk Co efficient K2 (category 1, Class B) =1.10
Topography Factor K3 (assumed Flat Ground) =1.00

Calculations:

Vz = Design Wind Velocity

=(Vb x K1 x K2 x K3)
=(33 x 1 x 1.13 x 1)
=37.29 m/sec.

Design Wind Pressure =0.6 x Vz 2

=0.6 x 37.29 2
= 834 N/sqm
=83.4kg/sq. m

Safe Factor for Circular Exposed Surface =0.7

Calculations for Wind Moment and Checking for Stresses:

As Per I.S 6533 (part-2 ) Cl 8.2.2 of I.S.6533-part2, to determine the wind force acting at
different heights of the chimney, the chimney shall be divided in to five Zones.

Zone 1:
Thickness of Shell (cm.) =0.6
Outside Diameter (OD) =51.2 cm
Inside Diameter (ID) =50.0 cm

Calculations:

Moment of Inertia I =(3.142/64) x (OD4 – ID4)

=0.049 x (51.24 – 504)
=30475.4360 cm4

Modulus of Section Z =I x (2/OD)

=30475.4360 x (2/51.2)
=1190.44 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at 20 m. from Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. x
20% dia. of ladder x (sq of height of
zone) / 2] x 105

2
 =[0.512 x 83.4 x 0.7 x (52/2)] + [0.7
x 83.4 x 0.2 x 0.7 x (52/2)] x 102
=47580.00 kg – cm

Self-Weight of Stack and Ladder P =1900 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (51.2)2
=2059.14 sq. cm.

Stress at 20 m. from base (Kgs/cm2) =(M/Z) + (P/A)

=(47580/1190.44)+ (1900/2059.14)
=40.89kg/[Link]

Height to Dia. Ratio =Height/Mean Dia.

=5/0.506
=9.88

Diameter to Thickness Ratio =Diameter/Thk.

=0.506/0.006
=84.33

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1260 Kgs/sq. cm..
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))
t =0.32mm
Assume corrosion allowance 3 mm.
Total thickness reqd = 0.32+3 = 3.23 mm say 6.0 mm

Calculations for Wind Moment and Checking for Stresses:

As Per I.S 6533 (part-2 ) Cl 8.2.2 of I.S.6533-part2, to determine the wind force acting at
different heights of the chimney, the chimney shall be divided in to five Zones.
Zone 2:
Thickness of Shell (cm.) =0.6
Outside Diameter (OD) =51.2 cm
Inside Diameter (ID) =50.0 cm

Calculations:

Moment of Inertia I =(3.142/64) x (OD4 – ID4)

=0.049 x (51.24 – 504)
=30475.4360 cm4

Modulus of Section Z =I x (2/OD)

=30475.4360 x (2/51.2)
=1190.44 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at 20 m. from Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. x

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 20% dia. of ladder x (sq of height of
zone) / 2] x 105
=[0.512 x 83.4 x 0.7 x (102/2)] +
[0.7 x 83.4 x 0.2 x 0.7 x (102/2)] x
102
=190318 kg – cm

Self-Weight of Stack and Ladder P =1900 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (51.2)2
=2059.14 sq. cm.

Stress at 20 m. from base (Kgs/cm2) =(M/Z) + (P/A)

=(190318/1190.44)+ (1900/2059.14)
=160.79kg/[Link]

Height to Dia. Ratio =Height/Mean Dia.

=10/0.506
=19.76

Diameter to Thickness Ratio =Diameter/Thk.

=0.506/0.006
=84.33

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1260 Kgs/sq. cm..
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))
t =1.28 mm
Assume corrosion allowance 3 mm.
Total thickness reqd = 1.28+3 = 4.27 mm say 6.0 mm

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Therefore Section is Safe
Zone 3:

Thickness of Shell (cm.) =0.6

Outside Diameter (OD) =51.2 cm
Inside Diameter (ID) =50.0 cm

Calculations:

Moment of Inertia I = (3.142/64) x (OD4 – ID4)

=0.049 x (51.24 – 504)
=30475.4 cm4

Modulus of Section Z =I x (2/OD)

=30475.4 x (2/51.2)
=1190.44 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at 15 m. from Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. X
20% dia. of ladder x (sq of height of
zone) / 2] x 102
=[0.512 x 83.4 x 0.7 x (152/2)] +
[0.7 x 83.4 x 0.2 x 0.7 x (152/2)] x
102
=428216.5 kg - cm

Self Weight of Stack and Ladder P =3047 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (51.2)2
=2059.14 sq. cm.

Stress at 15 m. from base (Kgs/cm2) =(M/Z) + (P/A)

=(428216.5/1190.44)+
(3047/2059.14)
=361.19

Height to Dia. Ratio =Height/Mean Dia.

=1600/60.6
=24.75

Diameter to Thickness Ratio =Diameter /Thk.

=0.606/0.008
=75.75

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1260 Kgs/sq. cm..
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))
t =2.86 mm
Assume corrosion allowance 3 mm.
Total thickness reqd = 2.86+3 = 5.86 mm say 8.0 mm

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Therefore Section is Safe
Zone 4:

Thickness of Shell (cm.) =0.8

Outside Diameter (OD) =71.6
Inside Diameter (ID) =70.0

Calculations:

Moment of Inertia I = (3.142/64) x (OD4 – ID4)

=0.049 x (71.64 – 704)
=111309.25 cm4

Modulus of Section Z =I x (2/OD)

=111309.25 x (2/71.6)
=3109.19 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at 22 m. from Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. X
20% dia. of ladder x (sq of height of
zone) / 2] x 102
=[0.716 x 83.4 x 0.7 x (202/2)] +
[0.7 x 83.4 x 0.2 x 0.7 x (212/2)] x
102
=999465 kg-cm

Self Weight of Stack and Ladder P =4001 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (71.6)2
=4024.34 sq. cm.

Stress at 10 m. from base (Kgs/cm2) =(M/Z) + (P/A)

=(999465/3190.19)+ (4001/4024.34)
=314.28

Height to Dia. Ratio =Height/Mean Dia.

=2000/70.8
=28.2

Diameter to Thickness Ratio =Diameter/Thk.

=0.708/0.008
=88.50

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1116 Kgs/sq. cm
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))
t =2.8 mm
Assume corrosion allowance 3 mm.
Total thickness reqd = 2.8+3 = 5.81 mm say 8.0 mm
Therefore Section is Safe

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Zone 5:

Thickness of Shell (cm.) =1.0 cm

Outside Diameter (OD) =91.6 cm
Inside Diameter (ID) =90 cm

Calculations:

Moment of Inertia I = (3.142/64) x (OD4 – ID4)

=0.049 x (91.64 – 904)
=234783.35 cm4

Modulus of Section Z =I x (2/OD)

=234783.35x (2/91.6)
=5126.27 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at 5 m. from Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. X
20% dia. of ladder x (sq of height of
zone) / 2] x 102
=[0.816 x 83.4 x 0.7 x (252/2)] +
[0.7 x 83.4 x 0.2 x 0.7 x (252/2)] x
102
=2382112.5

Self-Weight of Stack and Ladder P =6200 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (91.6) 2
=6590.78 sq. cm.

Stress at 11 m. from base (Kgs/cm2) =(M/Z) + (P/A)

=(2602126/5126.27)+
(6200/6590.78)
=465.62

Height to Dia. Ratio =Height/Mean Dia.

=2500/90.1
=27.74

Diameter to Thickness Ratio =Diameter (mean)/Thk.

=0.910/0.010
=90.10

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1116 Kgs/sq. cm..
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))
t =4.17 mm

Assume corrosion allowance 3 mm.

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Total thickness reqd = 4.17+3 = 7.17 mm say 8.0 mm
Therefore Section is Safe
Zone 6:
Thickness of Shell (cm.) =0.8 cm
Outside Diameter (OD) =111.6 cm
Inside Diameter (ID) =110 cm

Calculations:

Moment of Inertia I = (3.142/64) x (OD4 – ID4)

=0.049 x (111.64 – 1104)
=426597.17 cm4

Modulus of Section Z =I x (2/OD)

=426597.17 x (2/111.6)
=7645.11 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. X
20% dia. of ladder x (sq of height of
zone) / 2] x 102
=[1.116 x 83.4 x 0.7 x (302/2)] +
[0.7 x 83.4 x 0.2 x 0.7 x (302/2)] x
102
=3299637.6

Self Weight of Stack and Ladder P =8400 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (111.6)2
=9783.056 sq. cm.

Stress at base (Kgs/cm2) =(M/Z) + (P/A)

=(3299637.6/7645.11)+
(8400/9783.056)
=442.32

Height to Dia. Ratio =Height/Mean Dia.

=3000/111.6
=26.88

Diameter to Thickness Ratio =Diameter (mean)/Thk.

=1.108/0.008
=138.5

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1116 Kgs/sq. cm.
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))
t =3.96 mm

Assume corrosion allowance 3 mm.

8
Total thickness reqd = 3.96+3 = 6.96 mm say 10.0 mm
Therefore Section is Safe

Checking stress at 1m from bottom level.

Zone 7:
Thickness of Shell (cm.) =0.8 cm
Outside Diameter (OD) =111.6 cm
Inside Diameter (ID) =110 cm

Calculations:

Moment of Inertia I = (3.142/64) x (OD4 – ID4)

=0.049 x (111.64 – 1104)
=426597.17 cm4

Modulus of Section Z =I x (2/OD)

=426597.17 x (2/111.6)
=7645.11 cm3

For wind force on ladder, 20% of ladder dia. is considered for calculation and ladder dia. is
0.7 m.

Wind Moment at Base M =[OD x Design wind pr. x safe

factor x (sq of height of zone) / 2] +
[dia. of ladder x Design wind pr. X
20% dia. of ladder x (sq of height of
zone) / 2] x 102
=[1.116 x 83.4 x 0.7 x (292/2)] +
[0.7 x 83.4 x 0.2 x 0.7 x (292/2)] x
102
=3083328kg-m

Self Weight of Stack and Ladder P =8400 kg.

Cross Sectional Area of Chimney (sq. cm) A =(3.142/4) x OD2

=0.7855 x (111.6)2
=9783.056 sq. cm.

Stress at base (Kgs/cm2) =(M/Z) + (P/A)

=(3083328/7645.11)+
(8400/9783.056)
=404.16

Height to Dia. Ratio =Height/Mean Dia.

=3000/111.6
=26.88

Diameter to Thickness Ratio =Diameter (mean)/Thk.

=1.108/0.008
=138.5

Refer to table -3 of I.S 6533 (part-2 ).

Maximum Permissible Stress for steel = 1116 Kgs/sq. cm.
Maximum Permissible Stress for steel = 1/t x ((M/Z) + (P/A))

9
t =3.6 mm

Assume corrosion allowance 3 mm.

Total thickness reqd = 3.6+3 = 6.96 mm say 10.0 mm
Therefore Section is Safe

Total Horizontal Force at Base Plate Level

=0.5x10x83.4+0.55x5x83.4+0.65x83.4x5+0.8x6x83.4+1.0x6x83.4 = 1818.12 Kg

Design of Base Plate:

2
Max Compressive Force / unit length = F= (4M / π d1 ) + Ws / π d 1
2
F= (4 x 3299637 / π x 110 ) + 8400 / π x 110
F= 347.4 + 24.28 = 371.66 Kg / cm

Allowable Bearing stress for M20 grade Concrete = 5 N/mm2

Width of base Plate required = 371.66 / 1.25 x 5 =59.46 mm
There fore provide 2 ISA 100 x 100 x 10 are used to transmit the pressure @bottom of the
flared portion of the chimney.

The length of the base plate beyond angle section =1/2(250 – 2 x 100 -10) = 20 mm
Length of cantilever portion of the base plate up to the critical section xx as shown

20 +100-10 = 110 mm

The thickness is designed for allowable pressure instead of actual bearing pressure.
The total thickness @ the critical section xx

½
a = l (3 x σ c / σ cbc)
½
= 110 x (3x 1.25 x 5 / 1.33 x 185)
= 30.36- 10 = 20.36

Provide 24 mm plate thickness

Design of Anchor bolts: - F = (4M / π d12 ) – (Ws / π d 1t)

= ((4 x 3299637 x 1.5 / π x 1102) – (8400 / π x 110 ))
=496.7 Kg/cm

For 36 mm dia bolt.

Area = 452.16 mm2
Strength of anchor bolt = (10.178 x 1200 x 1.25) = 15267 Kg
Spacing of anchor bolt = (15267)/ 806.12 = 18.9 cm
Hence provide 24 nos of 36 mm dia bolt.

Tensile Capacity of each M36 Bolt = 10.178 cm2 x 1200 Kg/cm2

= 12219.6 Kg
As per IS 800 ([Link])
Permissible Shear stress =1000 Kg/cm2

Maximum Shear Capacity = 10.178 x 1000

= 10178 Kg

Maximum Tensile Force = T = = (4M / n D) – W / n

10
 = (4 x 1.5 x 5266759.2/24 x135) – 8400/24
= 9403.25Kg

Check for Combined Stress for Shear and tension

= (9403.25/12213.6) + (2308/10178) = 0.99<1
Hence, Design is Safe.

Bolt embedment length in concrete = Ld = Ø x σs / 4 x τbd

τbd = Permissible stress in bond 8 Kgs/Cm2

d = 3.6 cms

Ld = 135 cms

Hence provide a 36 mm dia anchor bolt of 135 cms embedded length in concrete.

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