196
X3
Category 3: Industrial Buildings and Plants
The project
This project concerns the construction of a steel
structure consisting of five spinning machines.
Spinning machines are machines that process plastic
granules into yarn.
This construction consists of three floors: the ground
floor, the first floor and the top floor.
The top floor, the extrusion floor, is the floor where the
extruders are located, together with the silo with the
granules and the spinning beams.
There are different configurations of the spinning
beams; for example, one spinning beam with three
extruders or one spinning beam with two extruders.
On the first floor there are cabinets which cool down the
wires.
On the ground floor the yarn is textured and here you
will find the final product.
The assignment
The assignment was to reconstruct the existing
installation identically at another location in a seismic
area.
The new structure cannot be an exact copy of the
existing structure because the existing structure was a
building with concrete elevations.
Because of the tight time schedule, the client chose a
steel structure instead of a concrete one.
The floor elevations are crucial for the construction and
setup of the machine.
The spinning beam, which is provided on the top floor, is
placed on a bottom flange of the steel beam.
The top floor has the heaviest load, with the spinning
beam, the extruders and the preheating furnace. All
floors are covered with checker plate.
Structural system
The design was based on Eurocode standards. The
static system of the structure is in the transverse and
longitudinal direction stabilised by bracing.
Design software
The static analysis was calculated using a 3D model in
Scia Engineer software with linear, non-linear and steel
modules.
Foundations
The structural design of the basements was made by a
local company based on the outputs of our analysis.
Equipment loads
The equipment load was given by the client.
Structural 3D modelling
The design of the process has been worked out in
Scia Engineer. The structure has been completely
modelled with 1D beam elements in 3D.
Live, dead and equipment loads have been applied to
the load-bearing structure.
The calculation included several steps:
1. A linear calculation using a 3D frame model for
the gravity loads (self-weight, dead load, live load,
equipment loads.
2. A non-linear calculation using a 3D frame model for
the bracings.
3. A check of steel elements using steel module EC 3.
The parameters of the structure were modified step by
step according to the technological demands.
The static system of the building is formed by frames
with diagonal bracing in transverse and longitudinal
bracing and horizontal bracings in the floors.
The system of bracing was active tension diagonal
bracings, in which the horizontal forces can be resisted
by the tension of diagonals only, neglecting the
compression ones.
Conclusion
The project has been successfully completed and will
become operational in June 2013.
Steel Extrusion Structure - Usak, Turkey
Software: Scia Engineer
