Economical Design of Bunkers

Volume 4, Issue 9, September 2014 ISSN: 2277 128X
International Journal of Advanced Research in

Computer Science and Software Engineering
Research Paper
Available online at: www.ijarcsse.com
Studies on Economical Design of Bunkers
N. Karthiga Shenbagam, Mahesh., Loganayagan. S, N. V. Manjunath, A. S. Ramesh
Assistant Professor Department of Civil Engineering Bannari Amman Institute of Technology, Sathamangalam,
Erode, Tamilnadu, India
Abstract: In order to study the most economical configuration of bunkers to store a given volume of a material, one
hundred and forty five bunkers have been designed by changing the ratio of height to lateral dimensions for storing a
given material, namely, bituminous coal. In this investigation, for each volume, i.e., for 100m 3 the length to breadth
ratio is taken constant as 1, 1.2, 1.4, 1.6, 1.8 and 2 and, for each length by breadth ratio, four bunkers having different
breadth by depth ratio have been designed and finally, the most economical size is found out. This method is carried
out for volumes of 120m3, 140m3, 160m3, 180m3, and 200m3also. A program has been developed using C-language
for the design of bunkers, columns and footings and all the bunkers have been designed using this program. All the
designs have been based on the recommendations of I.S 4995 -1974 and I.S 456 2000 codes. Based on these designs,
those dimensions of bunkers which will lead to least amount of concrete, steel and total cost to store a given amount of
material have been found out. These findings will be useful for the designers of bunkers.
Keywords: Bunkers, length to breadth ratio, lateral dimensions, bituminous coal, total cost, most economical.
I. INTRODUCTION
Bins are used by a wide range of industries to store bulk solids in quantities ranging from a few tonnes to over one
hundred thousand tones. A bin is an upright container for the storage of bulk granular materials. Shallow bins are usually
called as bunkers and deep bins are usually called as silos. If the depth and breadth of a bin are such that the plane of
rupture meets the surface of the material, before it strikes the opposite side of the bin, it is called a shallow bin or a
bunker. Hopper of bins is four sloping slabs. Bunkers are made from many different structural materials. They can be
constructed of steel or reinforced concrete and may discharge by gravity flow or by mechanical means. Steel bins range
from heavily stiffened flat plate structures to efficient unstiffened shell structures. They can be supported on columns,
load bearing skirts, or they may be hung from floors. Bins with flat bottom are usually supported directly on foundations.
Reinforced concrete is an ideal structural material for the building of permanent bulk-storage facilities for dry
granular like fillings. Initially concrete storage units are economical in design and reasonable in cost. Concrete can offer
the protection to the stored materials, requires little maintenance, is aesthetically pleasing, and is relatively free of certain
structural hazards (such as buckling or denting).
GENERAL CHARACTERISTICS:
Concrete storage units can be designed and built in any shape and size to fit the site or the process for which
they are required. They can be poured monolithically by the use of sliding forms when the walls are high, in single lifts
when they are low, and in rapidly following lifts of fixed forms when they are of moderate height.
OBJECTIVE OF THIS INVESTIGATION:

The main objective of the investigation reported herein is to identify the most economical size of bunkers to
store for a given volume of material.
SCOPE OF THE INVESTIGATION:

The volume of bunkers is varied from 100 m3 to 200 m3. The material to be stored is taken as bituminous coal,
having an angle of internal friction of 35o and unit weight of 8 kN/m3.For storing a given volume of material, the effect
of the ratio of height to lateral dimension on the total cost has been studied in depth. The provision of IS: 4995(Part1)-
1974 (Criteria for design of Reinforced Concrete Bins for Storage of Granular and Powdery Materials), IS: 4995(Part II)-
1974 (Criteria for design of Reinforced Concrete Bins for Storage of Granular and Powdery Materials), and IS: 456-2000
(Code of Practice for Plain and Reinforced Concrete) are made use of whenever required. Concrete grade of M20 and
steel of Fe 415 grade are used throughout the investigation for design of bunkers.
ETHODOLOGY:
A program has been developed using C-language for the design of bunkers, columns and footings and all the bunkers
have been designed using this program. All the designs have been based on the recommendations of I.S 4995 -1974 and
I.S 456 2000 codes. Estimation of cost of bunkers and its supporting structures are done by using Microsoft excel.
2014, IJARCSSE All Rights Reserved Page | 417
Shenbagam et al., International Journal of Advanced Research in Computer Science and Software Engineering 4(9),
September - 2014, pp. 417-429
II. DESIGN CONSIDERATION:
The design process for bunkers is of two types functional and structural, functional design must provide for adequate
volume, proper protection of the stored materials, and satisfactory methods for filling and discharge. Structural
considerations are stability, strength and control (minimizing) of crack width and deflection. Loads to be considered
include the following:
1. Dead load of the structure itself and items supported by the structure.
2. Live Load forces are taken based on the type of material stored.
Bin design procedures consist of four parts as follows:

i. Determine the strength and flow properties of the bulk solid.
ii. Determine the bin geometry to give the desired capacity, to provide a flow pattern with acceptable flow characteristics
and to ensure that discharge is reliable and predictable. Specialised mechanical feeder design may be required.
iii. Estimate the bin wall loads from the stored material and other loads such as wind, ancillary equipment, thermal, etc.
iv. Design and detail the bin structure.
Before the structural design can be carried out, the loads on the bin must be evaluated. Loads from the stored material are
dependent, amongst other things, on the flow pattern, the properties of the stored material and the bin geometry while the
methods of structural analysis and design depend upon the bin geometry and the flow pattern. The importance of Stages i
and ii of the design should not be underestimated. Simplified rules for the functional design of bins and for estimating
wall loads are given in IS 4995-1974.
Design Example:
Volume of bunker =100m3
Dimension of bunker:
Adopt a bunker size 5.35x5.35x2.5m with the depth of 1.2m hopper bottom.
Height of surcharge = =
=1.87m.
Check for volume:
Volume of surcharge =
V 1= =17.5m3.
Volume of cylindrical portion = a*b*h.
V2=5.35*5.35*2.5=71.42 m3.
Volume of hopper bottom portion, V3
V3 =
=
V3=11.35 m3.
V=100.27 m3. 100 m3.
As per IS 4995(part 1)-1974, table 1, the density of bituminous coal is 8kN/m3 and angle of repose is 35.
Design of Side walls:
Horizontal working pressure p= whcos2
p= 8*5.35 cos235=28.71 kN/m2
Assume the thickness of side wall =230mm.
Effective span =5.35+0.23=5.58m.
L=B
Maximum bending moment at corners is
M=p (L2+B2-LB)/12 =p (L2)/12 =(28.71*5.352)/12=68.47kNm.
Ultimate design moment, Mu=1.5*68.47
=102.72kNm.
Direct tension in wall,
T=pB/2 (for longer wall)
T=pL/2 (for shorter wall)
T=28.71*(5.35/2)=76.79kN.
Ultimate direct tension in wall, T u
Tu=1.5*76.79=115.18kN.
Providing a cover of 30mm,
Providing effecting depth=230-30=200mm.
Distance between reinforcement of slap, x=85mm.
Net design moment = Mu-Tu*x
=102.72-(115.18*0.085)=92.93kNm.

September - 2014, pp. 417-429
Based on limiting moment resistance, effective depth required is given by
D= =
=183.5mm <200mm.
Since the depth provided is more. The section is under reinforced. Hence the area of steel required is,
Mu=0.87fyAstd {1-Astfy/bdfck}
92.93*106=0.87*415*Ast*183.5{1-Ast*415/1000*183.5*20}
Ast=1748.18mm2.
Provide 12mm bars,
Ast= mm2.
Spacing S= =
Hence provide 12mm bars at 50mm c/c.

Positive bending moment at centre of span
=
=34.23kNm.
Design ultimate moment=1.5*34.23=51.35kNm.
Mu-Tu*x
=51.35-(115.18*0.085)=41.597kNm
Hence the area of steel required to resist the moment is
41.597*106=0.87*415*Ast*183.5{1-Ast*415/1000*183.5*20}
Ast=680.15mm2.
Provide 12mm bars,
Ast= mm2.
Spacing S= = 0
Provide 12mm bars at 150mm c/c

Distribution reinforcement = 0.12%bD
=0.0012*1000*210 =252mm2.
Use 8mm bars,
ast= mm2.
Spacing S= =
Hence provide 8mm bars at 175mmc/c

Design of hopper bottom:
Weight of bituminous coal = W=wV
=8*100=800kN.
Weight of sloping hopper bottom (210mm) thick is computed as
Wh=(5.35+0.5/2)(2.4252+1.52)*(4*0.21*25
=287.16kN.
Total load on 4 walls
=800+287.16=1087.16kN
Total load on one wall
=1087.16/4=271.79kN.
Then tan =1.5/2.425
=tan-1 (1.5/2.425)=31.74 and cosec=1.9
Direct tension in sloping wall = Wtcosec
= 340.711.9
= 565.58 58 KN
Working tension per meter run = 647.349 /5.35
=120.9 KN/m run
Design of ultimate tension = 1.5 120.9
= 181.499 KN
Area of reinforcement for resisting direct tension is,

September - 2014, pp. 417-429
Ast = (181.499103 ) / (0.87 415)
= 502.69mm2
Spacing S, = ast / Ast 100
= (120.9/502.69) 1000
= 240.45 mm
Provide 12mm bars @ 225 mm c/c in the direction of sloping faces
Ast = ast / s 1000
Ast = (120.9 / 225) 1000
= 537.3.2mm2
Normal component of coal pressure @ centre of slab is,
Pn = w.hp [cos2 + cos2 . Sin2 ]
Where,
W = 8 KN/m2
hp = [5.35 + (0.5 1.5 ) + (0.5 1.87) ]
hp = 6.95 m
= 37.07 & = 35
Pn = 8 6.95 [cos 2 37.07 + cos 2 35. Sin2 37.07]
= 48.78 KN/ m2
Working pressure = Pn = 848.78 KN/ m2
Normal component due to weight of sloping slab,
= wd. cos
= 0.21 25 cos 37.07
= 4.19 KN / m2
Total normal pressure P = Pn + wd. Cos
P = 48.78 + 4.19
P = 52.97 KN / m2
Effective Design moment, L1 = ((5+0.5) / 2) + 0.21 = 2.96m

Maximum negative bending moment, M
= P. (L1 2 + B12 -L1B1)/12
=pL12/12=52.97*2.962/12=38.67kNm
Ultimate design moment=1.5*38.67
=58kNm.
Limiting moment of resistance, Mu limit
=0.138fckbd2=0.138*20*1000*176.652.
=86.13kNm>58kNm.
Since Mu<Mulimit
The section is under reinforced section.
58*106=0.87*415*Ast*183.5{1-Ast*415/1000*183.5*20}
Ast=985.15mm2.
Provide 12mm bars,
Ast= mm2.
Spacing S= = 0

Maximum positive bending moment at centre is = P. (L1 2 +-2B12 +2L1B1)/12
= (52.97*2.7252)/12=32.77kNm
Ultimate bending moment = 1.5*32.77
=49.17kNm.
Area of reinforcement steel required is
49.17*106=0.87*415*Ast*183.5{1-Ast*415/1000*183.5*20}
Ast=810.6mm2.
Provide 12mm bars,
Ast= mm2.
Spacing S= = 0

September - 2014, pp. 417-429
Edge beams:
Provide edge beams of 300x300mm connecting the corner columns as the top and the junction of vertical walls and
sloping slab with 4 numbers of 12mm bars.
TABLE 1
volume h a/b ratio h/b ratio a b
100 2.5 1.0 0.5 5.35 5.35
100 4.3 1.0 1.0 4.40 4.40
100 5.8 1.0 1.5 3.86 3.86
100 7.1 1.0 2.0 3.54 3.54
TABLE 2
100 2.3 1.2 0.5 6.00 4.90
100 4.0 1.2 1.0 4.90 4.10
100 5.4 1.2 1.5 4.30 3.70
100 6.6 1.2 2.0 4.00 3.30
TABLE 3
100 2.4 1.4 0.5 6.20 4.50
100 4.0 1.4 1.0 5.20 3.80
100 5.1 1.4 1.5 4.80 3.40
100 6.30 1.4 2.0 4.35 3.12
TABLE 4
100 2.2 1.6 0.5 6.80 4.20
100 3.5 1.6 1 5.80 3.70
100 4.9 1.6 1.5 5.20 3.20
100 5.90 1.6 2.0 4.75 3.00
TABLE 5
100 1.89 1.8 0.5 7.45 4.10
100 3.5 1.8 1.0 6.20 3.40
100 4.6 1.8 1.5 5.60 3.10
100 5.8 1.8 2.0 5.00 2.85
TABLE 6
100 2.05 2.0 0.5 7.60 3.80
100 3.3 2.0 1.0 6.60 3.30
100 4.4 2.0 1.5 5.90 3.00
100 5.5 2.0 2.0 5.50 2.70
September - 2014, pp. 417-429
TABLE 7
120 2.9 1.0 0.5 5.50 5.50
120 4.4 1.0 1.0 4.40 4.40
120 6.1 1.0 1.5 4.15 4.15
120 7.42 1.0 2.0 3.80 3.80
TABLE 8
120 2.75 1.2 0.5 6.00 5.20
120 4.4 1.2 1.0 5.20 4.25
120 5.7 1.2 1.5 4.72 3.80
120 7.0 1.2 2.0 4.20 3.58
TABLE 9
120 2.5 1.4 0.5 6.70 4.80
120 3.9 1.4 1.0 5.80 4.10
120 5.4 1.4 1.5 5.10 3.60
120 6.5 1.4 2.0 4.76 3.30
TABLE 10
120 2.4 1.6 0.5 7.20 4.50
120 3.8 1.6 1.0 6.20 3.90
120 5.1 1.6 1.5 5.60 3.40
120 6.3 1.6 2.0 5.05 3.20
TABLE 11
120 2.3 1.8 0.5 7.60 4.30
120 3.8 1.8 1.0 6.50 3.66
120 4.9 1.8 1.5 6.00 3.25
120 6.1 1.8 2.0 5.50 3.00
TABLE 12
120 2.1 2.0 0.5 8.20 4.10
120 3.6 2.0 1.0 6.90 3.50
120 4.7 2.0 1.5 6.32 3.20
120 5.9 2.0 2.0 5.75 2.90
September - 2014, pp. 417-429
TABLE 13
140 2.8 1.0 0.5 6.00 6.00
140 4.9 1.0 1.0 4.90 4.90
140 6.6 1.0 1.5 4.30 4.30
140 7.8 1.0 2.0 4.00 4.00
TABLE 14
140 2.8 1.2 0.5 6.50 5.40
140 4.6 1.2 1.0 5.50 4.50
140 6.0 1.2 1.5 4.99 4.00
140 7.4 1.2 2.0 4.40 3.80
TABLE 15
140 2.8 1.4 0.5 6.90 5.10
140 4.4 1.4 1.0 6.00 4.20
140 5.6 1.4 1.5 5.50 3.80
140 7.0 1.4 2.00 4.94 3.50
TABLE 16
140 2.4 1.6 0.5 7.80 4.80
140 4.2 1.6 1.0 6.50 4.00
140 5.5 1.6 1.5 5.80 3.60
140 6.9 1.6 2 5.35 3.25
TABLE 17
140 2.4 1.8 0.5 8.18 4.43
140 4.0 1.8 1.0 6.84 3.85
140 5.2 1.8 1.5 6.20 3.50
140 6.4 1.8 2.0 5.75 3.20
TABLE 18
140 2.3 2.0 0.5 8.60 4.25
140 3.6 2.0 1.0 7.50 3.70
140 5.0 2.0 1.5 6.70 3.30
140 6.1 2.0 2.0 6.10 3.10
September - 2014, pp. 417-429
TABLE 19
160 3.2 1.0 0.5 6.10 6.10
160 5.2 1.0 1.0 5.10 5.10
160 7.0 1.0 1.5 4.50 4.50
160 8.2 1.0 2.0 4.19 4.19
TABLE 20
160 3.0 1.2 0.5 6.70 5.80
160 4.8 1.2 1.0 5.60 4.86
160 6.3 1.2 1.5 5.20 4.20
160 7.8 1.2 2.0 4.60 4.00
TABLE 21
160 2.9 1.4 0.5 7.28 5.30
160 4.4 1.4 1.0 6.45 4.45
160 5.8 1.4 1.5 5.75 4.00
160 7.3 1.4 2.0 5.15 3.70
TABLE 22
160 2.5 1.6 0.5 7.90 5.20
160 4.4 1.6 1.0 6.75 4.20
160 5.8 1.6 1.5 6.00 3.80
160 6.8 1.6 2.0 5.75 3.49
TABLE 23
160 2.5 1.8 0.5 8.60 4.70
160 4.1 1.8 1.0 7.20 4.10
160 5.4 1.8 1.5 6.50 3.70
160 6.7 1.8 2.0 5.95 3.40
TABLE 24
160 2.3 2.0 0.5 9.00 4.60
160 4.0 2.0 1.0 7.78 3.80
160 5.2 2.0 1.5 7.00 3.50
160 6.3 2.0 2.0 6.55 3.20
September - 2014, pp. 417-429
TABLE 25
180 3.3 1.0 0.5 6.40 6.40
180 5.4 1.0 1.0 5.30 5.30
180 7.0 1.0 1.5 4.75 4.75
180 8.8 1.0 2.0 4.30 4.30
TABLE 26
180 3.1 1.2 0.5 7.00 6.00
180 5.0 1.2 1.0 5.90 5.02
180 6.5 1.2 1.5 5.40 4.40
180 8.2 1.2 2.0 4.90 4.00
TABLE 27
180 2.8 1.4 0.5 7.70 5.70
180 4.8 1.4 1.0 6.45 4.70
180 6.1 1.4 1.5 5.90 4.20
180 7.8 1.4 2.0 5.35 3.80
TABLE 28
180 2.8 1.6 0.5 8.20 5.20
180 4.4 1.6 1.0 7.20 4.40
180 6.0 1.6 1.5 6.25 4.00
180 7.2 1.6 2 5.80 3.70
TABLE 29
180 2.6 1.8 0.5 8.90 4.90
180 4.4 1.8 1.0 7.50 4.20
180 5.7 1.8 1.5 6.80 3.80
180 7.1 1.8 2.0 6.20 3.50
TABLE 30
180 2.5 1.9 0.5 9.20 4.80
180 4.1 2.0 1.0 8.10 4.00
180 5.5 2.0 1.5 7.20 3.62
180 6.7 2.0 2.0 6.75 3.30
September - 2014, pp. 417-429
TABLE 31
200 3.5 1.0 0.5 6.55 6.55
200 5.6 1.0 1.0 5.50 5.50
200 7.4 1.0 1.5 4.90 4.90
200 9.0 1.0 2.0 4.50 4.50
TABLE 32
200 3.3 1.2 0.5 7.40 6.00
200 5.0 1.2 1.0 6.40 5.20
200 7.1 1.2 1.5 5.40 4.60
200 8.5 1.2 2.0 5.00 4.20
TABLE 33
200 3.0 1.4 0.5 7.90 5.85
200 4.9 1.4 1.0 6.80 4.80
200 6.3 1.4 1.5 6.20 4.30
200 8.0 1.4 2.0 5.50 4.00
TABLE 34
200 2.9 1.6 0.5 8.50 5.40
200 4.7 1.6 1.0 7.40 4.50
200 6.2 1.6 1.5 6.57 4.10
200 7.5 1.6 2.0 6.10 3.79
TABLE 35
200 7.8 1.8 2.2 6.30 3.50
200 8.6 1.8 2.5 6.00 3.40
200 8.9 1.8 2.7 6.00 3.30
200 9.6 1.8 3.0 5.80 3.20
TABLE 36
200 7.4 2.0 2.2 6.72 3.40
200 7.9 2.0 2.4 6.60 3.30
200 8.5 2.0 2.6 6.40 3.20
200 9.1 2.0 2.9 6.20 3.10
September - 2014, pp. 417-429
III. COST COMPARISON OF R.C.C BUNKERS WITH VARIOUS H/B RATIO
For the purpose of cost comparison, the rates are adopted as per the prevailing rates at Sathyamangalam during the period
of October 2011 and the rates are given below
Rate of concrete: Rs.5000 per m3.
Rate of Steel: RS.50 per kgf.
Rate of Formwork: Rs. 150 per m2.

September - 2014, pp. 417-429
275
8 nos of 32
mm dia @
125mm c/c
275
Dwg 1: Column details.
180
16 mm dia bars
@200 mm c/c
4000
16 mm dia bars
@100 mm c/c
16 mm dia bars
@150 mm c/c
16 mm dia bars
@200 mm c/c
300
Dwg 2: Bunker reinforcement details
275
425
500
3000 32 mmm dia bars

@250 mm c/c
Dwg 3: Foundation details.

September - 2014, pp. 417-429
IV. CONCLUSION
From the above Figures it is concluded that for storing Bituminous coal for various volumes from 100m3 t 200m3 the
most economical h/b ratio of 0.5 and l/b ratio of 1 is found to be economical. As the ratio of h/b ratio increases the total
cost of construction of the storage structure also increases.
ACKNOWLEDGEMENT
The authors thank the Management and the Principal, and the HOD of Bannari Amman Institute of Technology,
Sathyamangalam.
REFERENCES
[1] N.Krishna Raju, Advanced Reinforced Concrete Structures.
[2] Bhavikatti.V, Advanced Reinforced Concrete Structures.
[3] O.P Jain and Jai Krishna Plain and reinforced Concrete Volume-II.
[4] IS: 4995(Part1)-1974 (Criteria for design of Reinforced Concrete Bins for Storage of Granular and Powdery
Materials),
[5] IS: 4995(Part II)-1974 (Criteria for design of Reinforced Concrete Bins for Storage of Granular and Powdery
Materials).
[6] IS: 456-2000 (Code of Practice for Plain and Reinforced Concrete)

Economical Design of Bunkers

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Volume 4, Issue 9, September 2014 ISSN: 2277 128X

International Journal of Advanced Research in

OBJECTIVE OF THIS INVESTIGATION:

SCOPE OF THE INVESTIGATION:

Bin design procedures consist of four parts as follows:

2014, IJARCSSE All Rights Reserved Page | 418

Hence provide 12mm bars at 50mm c/c.

Provide 12mm bars at 150mm c/c

Hence provide 8mm bars at 175mmc/c

2014, IJARCSSE All Rights Reserved Page | 419

Effective Design moment, L1 = ((5+0.5) / 2) + 0.21 = 2.96m

Provide 12mm bars at 100mm c/c

Provide 12mm bars at 100mm c/c

2014, IJARCSSE All Rights Reserved Page | 420

2014, IJARCSSE All Rights Reserved Page | 427

Dwg 1: Column details.

Dwg 2: Bunker reinforcement details

3000 32 mmm dia bars

Dwg 3: Foundation details.

2014, IJARCSSE All Rights Reserved Page | 429

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