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
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