The document provides design details for foundations and retaining walls for a conveyor system and storage area at Suez Cement Company. General design notes specify the design standards, loads, foundation conditions, and material specifications to be used. Foundations are designed for individual conveyor components using Excel, MathCAD, and SAP2000 for analysis and reinforcement detailing. Retaining wall and strap footing design is conducted in SAP2000, applying earth pressures, uniform loads, and determining moments and reinforcement. Design drawings including plans, sections and reinforcement details are provided.

1. Calculation Note
SUEZ CEMENT COMPANY-SCC
FOUNDATIONS AND RETAINING WALLS

2. Page1
Table of Content: PAGE
I- Introduction and General Design Notes---------------------------------------------------2
 Introduction--------------------------------------------------------------------------------------3
 1-General Design Notes-----------------------------------------------------------------------3
1.1-Design Method and Standards----------------------------------------------------------3
1.2 –Loads----------------------------------------------------------------------------------------3
1.3-foundation conditions--------------------------------------------------------------------4
1.4 -Specifications of Materials--------------------------------------------------------------4
II-Mechanical Drawings---------------------------------------------------------------------------5
III-Conveyor Foundation Design---------------------------------------------------------------12
IV- Retaining Wall and strap footing Design------------------------------------------------29
VI-Design Drawings--------------------------------------------------------------------------------49

3. Page2
Introduction and General Design Notes

4. Page3
 Introduction
 This report has been prepared for structural design of conveyor and storage area foundations, retaining walls and slab on grad ,its popose to briefly describe the the structural system, names of various applicable codes of structural engineering practice are mentioned, the design criteria are described in detail including all types of gravity loads to be considered in design, Methods of structural analysis and design to be followed are explained with reference to the use of personal computer in organizing all calculations, The types of structural materials and their corresponding strengths are mentioned briefly.
 All the design procedures were done by taking into account the Egyptian code Specifications
 Foundation type is selected as single and combined footing for conveyor and as strap footing for retaining walls.
 Plan dimensions of foundations are determined by taking into consideration the soil bearing capacity which is defined by geotechnical site research.
 This structural system has been designed by using Excel sheets , MathCad and static analyze programs SAP2000 and SafeV.12
 1-General Design Notes
1.1 Design Method and Standards:
The design and works shall comply with:
Loading
 If no higher loads will be requested by the Client or by the Supplier, the loads shall be applied based on the Egyptian Code for 'Computation of Loads and Structural Forces & Building.
Reinforced Concrete
 The design method to be taken into consideration is the limit state design method, covering the Egyptian Code of Practice for the design of reinforced concrete as well as the load specifications.
Foundation
 The design of the foundation concerning safety against overturning, uplift and sliding has to be established according to the Egyptian Code Volume 3 'Shallow Foundations'
1.2 Loads
Load categories
1.2.1-Dead load (permanent loads)
 Dead load of deck, equipment, lining and other well-defined installations (in terms of both load and location).
1.2.1.1 Dead loads / weights
 Working values of dead loads:
o Concrete, un-reinforced 24 kN/m3
o Concrete, reinforced 25 kN/m3
o Soil, for soil pressure 20 kN/m3
o Soil, for stability 18 kN/m3
1.2.2 -Live loads, normal (variable loads)
 Normally occurring loads from e.g. plant operators, furniture and equipment, traffic, material (stored, transported, occasional accumulations,dust, fillings, etc.).
 When a dynamic load is approximated to an additional static load, this additional load, which stems from normally occurring conditions of impacts and vibrations, is included in this load category.

5. Page4
1.2.3 -Loads from meachinery and equipment(variable loads)
 The working loads as shown on mechanical drawings, these loads include nature loads like wind and seismic loads.
1.3-foundation conditions
 The soil condition and foundation recommendations are spcified in the geotechnical investigation report
 the allowable net soil pressure are recommended as 250 kN/m2
 In case of design due to permeanent and probabilistic/dynamic Loads of either wind or earthquake the maximum net soil pressure can be increased by 20% either on Serviceability Limeit States/allowable or on Ultimate Limit State/design whenever is more economical for the foundation design.
1.4 Specifications of Materials
1.4.1 Reinforced concrete
Material properties of concrete:
 The concrete grades for foundations and structures have to be as follows:
Concrete class
Concrete designation
28days standard compresseve strength cube 150*150*150 mm
Application
A
Fcu 350
350 kg/cm3
Grouting
B
Fcu 300
300 kg/cm3
Reinforcement concrete
C
Fcu 200
200 kg/cm3
Plan concrete
Thermal expansion coefficient = 10-5 per ° C.
Poisson's ratio of concrete = 0.2
Material properties for reinforcement:
 Rebars complying with the requirements of Egyptian Standard 262 (steel bars for concrete reinforcement) can be used, provided, that its characteristics shall be considered in design. The following indicates the characteristics of the Egyptian steel.
Type of steel
Yield stresses
(fy N/mm2)
Ultimate design strength
(Fu N/mm2)
Min elongation
Deformed bars 400/600
(ribbed high grade steel)
400
600
12%
smooth bars 240/350 (normal mild steel)
240
350
20%
Elastic modulus: ES = 200'000 N/mm2
 Following diameters of deformed bars shall be used for the design: Y 10, 12, 16, 18, 22, 25.

6. Page5
II-Mechanical Drawings

8. Page7

9. Page8

10. Page9

11. Page10

12. Page11

13. Page12
III-Conveyor Foundation Design

14. Page13
3.1 Design of Conveyor Foundation

15. Page14
 Design using Excel Sheets

16. Page15

17.  Check Design using MathCAD Sheet

18. Page17

19. Page18

20. Page19

21. Page20

22. Page21
 Design Combined footing F4 using Safe program
 Loads input
Check Stresses under Foundation in each Load combination

23. Page22

24. Page23

25. Page24

26. Page25

27. Page26
 F4- Rienforcement

28. Page27
 Design F6 using Safe program
 Loads input
Check Stresses under Foundation

29. Page28
 F6- Rienforcement

30. Page29
IV- Retaining Wall and strap footing Design

31. 4.1 Retaining Wall Design using Sap 2000 program
 3D View

32.  Steel Columns and moving Floor Loads

33. Page32
 Earth pressure Loads

34. Page33
 Uniform Loads

35. Page34
 Deformed Shape

36.  Check stresses Under Strap Footing

37. Page36
 Check stresses Under Strap Footing

38. Page37
 Check stresses Under Strap Footing

39.  Strap Footing Rienforcement using Y12@150mm in X direction

40. Page39
 Strap Footing Rienforcement using Y12@150mm in Y direction

41. Page40
 Wall horizontal Rienforcement using Y12@150mm

42. Page41
 Wall vertical Rienforcement using Y12@150mm
 For the structure model, the program SAP v. 14.1 was used, which is based on the finite element method.
 The finite element model consists of a main truss carrying the conveyor supported on truss towers
 The main truss modeled as continuous top and bottom chords members with bracing members have pinned ends.
 The truss towers modeled as continuous columns with bracing members have pinned ends.
 The loads are introduced in the model using nodal, frame and shells loads.

43. Page42
 Wall 4 horizontal Max moment

44. Page43
 Wall 4 vertical Max moment

45. Page44
 Wall 4 top Beam Max moment

46. Page45
 Design of Wall 4 top Beam
 Design of Wall 4 vertical and horizontal rienforcement

47. Page46
VI-Design Drawings

48. Page47

49. Page48

50. Page49

51. Page50