DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

TABLE OF CONTENTS
PAGE
1.

SCOPE ..............................................................

2.

REFERENCES .........................................................

2.1
2.2
2.3

Purchaser Specifications .....................................

Purchaser Drawings ...........................................
Industry Codes and Standards .................................

3
3
4

3.

GENERAL CONDITIONS .................................................

4.

DESIGN LOADS .......................................................

4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15

Dead Load ....................................................

Live Load ....................................................
Product Load .................................................
Test Load ....................................................
Impact Load ..................................................
Dynamic Load .................................................
Thermal and Pressure Loads ...................................
Wind Load ....................................................
Seismic Load .................................................
Snow Load ....................................................
Blast Load ...................................................
Construction Loads ...........................................
Catalyst Load ................................................
Buoyant Load .................................................
Load Combinations ............................................

4
4
5
5
5
6
6
6
6
6
6
6
6
7
7

5.

SITE PREPARATION AND EARTHWORK DESIGN ..............................

6.

DESIGN OF CONCRETE FOUNDATIONS AND STRUCTURES ......................

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
7.

8.

General ......................................................
Foundations ..................................................
Floors .......................................................
Area Paving ..................................................
Precast Concrete Members .....................................
Concrete Trenches ............................................
Hot Equipment Considerations .................................
Construction Joints ..........................................
Electric Conduit .............................................
Construction .................................................

8
8
11
11
12
12
13
13
13
13

DESIGN OF PILE FOUNDATIONS .........................................

13

7.1
7.2

General ......................................................
Uplift Considerations ........................................

13
14

STEEL STRUCTURES ...................................................

14

8.1

14

General ......................................................
PAGE 1 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

8.2
9.

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

Galvanizing ..................................................

14

MAINTENANCE, ACCESS, AND STORAGE CONSIDERATIONS ....................

16

9.1
9.2
9.3
9.4
9.5
9.6
9.7

16
16
17
17
17
18
18

Platform for Exchanger Bundle Repair .........................

Platform for Horizontal Exchanger Maintenance ................
Vertical Exchanger Considerations ............................
Working Areas ................................................
Access Areas .................................................
Storage Areas ................................................
Roofs ........................................................

10. DATUMS AND RELATIVE ELEVATIONS FOR PAVING, STRUCTURES,

AND EQUIPMENT ......................................................

18

11. PLATFORMS, WALKS, STAIRS, LADDERS, AND FLOORS ......................

19

11.1
11.2
11.3
11.4

General ......................................................
Platforms ....................................................
Stairs and Ladders ...........................................
Steel Floors .................................................

19
19
19
20

12. LOADING PLATES .....................................................

20

PAGE 2 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

1.

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

SCOPE
This specification defines minimum general requirements for design of
concrete and pile foundations and steel and concrete structures.

2.

REFERENCES

2.1

Purchaser Specifications
This specification contains references to the following Purchaser
specifications:
1.

GEMS GC, General Conditions - General Equipment and Material

Specifications.

2.

GEMS A-1P, Construction of Concrete Structures (PIP STS03001).

3.

GEMS A-2P, Site Preparation (PIP CVS02100).

4.

GEMS B-1D, Design of Buildings.

5.

GEMS B-3D, Design of Blast Resistant Buildings.

6.

GEMS G-2D, Refinery Process Unit Layout.

7.

GEMS G-3D, Climatic Design Data.

8.

GEMS J-3D, Sewers, Drains, and Paving Arrangement.

9.

GEMS L-1D, Design of Electrical Systems and Equipment.

10. GEMS M-1D, Fireproofing.

11. GEMS S-1M, Fabrication and Erection of Structural Steel.
12. GEMS V-1P, Application of Industrial Coating Systems.
2.2

Purchaser Drawings
This specification contains references to the following Purchaser
drawings:
1.

3S-3459, Typical Refinery Process Unit Arrangement Illustrating

Clearances and Space Requirements.

2.

3S-3594, General Location Plan and Details - Unit Loading Plates

and Platform Loading Plates.

3.

4S-3615, Typical Details - Crushed Stone Ring Tank Foundation.

4.

4S-5134, Typical Details - Concrete Ring Tank Foundation.

5.

4S-5846, Standard Anchor Bolt Detail.

6.

4S-5848, Details - Construction and Expansion Joints - Concrete

Structures and Slabs.

7.

4S-5851, Details - Tower Skirt Drain.

8.

4S-5852, Details - Stair and Ladder Foundations.

9.

4S-6465, Typical Details - Foundation for Product Suction Sump.

10. 6S-6885, Standard Flooring Plate Platforms and Angle Handrailing.

11. 6S-6886, Standard Stair Tread Details.
12. 6S-6887, Minimum Platform Area Requirements for Horizontal
Vessels.

PAGE 3 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

13. 6S-6889, Intermediate Platforms for Vertical Vessels.

14. 6S-6890, Cantilever Bracket Details for Vertical Vessels.
15. 6S-6891, Top Platform for Vertical Vessels Requiring Davits and all
PSV Vent Pipe Guides.
16. 6S-6892, General Platform Requirements - Vertical and Horizontal
Vessels.
17. 6S-7256, Davit Standard Details.
18. 6S-7257, Minimum Requirements for Top Tray Removal Platform for
Vessels Over 3 feet 0 inches Diameter.
19. 6S-7258, Ladder Standard Details - Sheet No. 1.
20. 6S-7259, Ladder Standard Details - Sheet No. 2.
21. 13S-181, Standard Fireproofing for Structural Steel.
2.3

Industry Codes and Standards

This specification contains references to the following industry codes
and standards:
2.3.1

American Concrete Institute (ACI)

STD 318, Building Code Requirements for Reinforced Concrete.

2.3.2

2.3.3

American Institute of Steel Construction (AISC)

1.

Specification for Structural Steel Buildings - Allowable

Stress Design and Plastic Design.

2.

Load and Resistance Factor Design Specification for

Structural Steel Buildings.

American Society of Civil Engineers (ASCE)

Standard 7, Minimum Design Loads for Buildings and Other
Structures.

3.

GENERAL CONDITIONS
General conditions shall comply with GEMS GC.

4.

DESIGN LOADS

4.1

Dead Load
Dead load is weight of steel and concrete structures, empty equipment
and piping, insulation, fireproofing, soil overburden, walls, etc., plus
net effect of prestressing.

4.2

Live Load
1.

Live loads are those produced by use of building or structure.

2.

Live loads do not include environmental loads, such as wind, snow,

rain, or earthquake, or dead loads.

3.

Live loads are those produced during:

a.

Maintenance by workers, equipment, and materials.

b.

Life of structure by movable objects.

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TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

4.3

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

4.

Typical live loads are weight of personnel, tools, equipment, etc.,

that may be temporarily placed on floors, roofs, walkways, and
platforms.

5.

Live loads may be uniformly distributed loads or concentrated loads.

6.

Live loads shall comply with ASCE Standard 7, Tables 2 and 3, and
Section 9 of this specification.

7.

Live loads shall be reduced in accordance with ASCE Standard 7.

8.

Design live loads for office buildings, etc., shall be determined in

accordance with ASCE Standard 7.

9.

Design live loads shall be shown on design drawings.

Product Load
Product load is weight of process fluid or material in equipment or
piping.

4.4

Test Load
Unless specified otherwise, test load is weight of hydrotest water in
equipment or piping.

4.5

Impact Load
4.5.1

General
Impact load caused by pulling of exchanger bundles, moving
trolleys or cranes, etc., shall be considered as applicable.

4.5.2

Bundle Pulling
Horizontal load for bundle pulling is 50% of bundle weight.
This includes allowance for impact.

4.5.3

Structures with Moving Loads

1.

Impact load for structures with moving loads, as a

percentage of lifted load, shall comply with the following
table:
Percentage of Lifted Load
Vertical
Lateral
Longitudinal
Trolley, Beams,
Lifting Eyes,
and Supporting
Structures

50

50

Davits

50

Traveling
Cranes

25

20(1)

10(2)

Notes:
1. 20% of lifted load plus weight of crane trolley.
2. 10% of maximum wheel load applied at top of rail.
2.

Lateral impact load shall not be applied to loads handled

by a chain hoist.

3.

Vertical load on structures handling moving loads by means

of remote hoisting units, such as tuggers or davits, shall
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TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

be lifted load plus hoisting line pull. Lateral impact

allowance shall be applied to sum of lifted load plus 25%
of hoisting line pull.
4.6

Dynamic Load
Load caused by pulsating and vibrating equipment, including overhead
bridge cranes, jib cranes, monorails and conveyor systems, and surging
fluids shall be considered, as applicable.

4.7

Thermal and Pressure Loads

Loads caused by thermal expansion and unbalanced pressure thrusts shall
be considered, as applicable.

4.8

4.9

4.10

4.11

Wind Load
1.

Wind load shall be determined in accordance with ASCE Standard 7,

GEMS G-3D, and this specification.

2.

Exposure C shall be used to determine wind load for all equipment

and structures, except as modified in paragraph 3.

3.

Exposure B shall be used to determine wind load on pipe racks inside

process unit limits.

4.

Except for control buildings, buildings and other structures shall

be classified in accordance with ASCE Standard 7, Table 1-1,
Category II.

5.

Control buildings shall be classified in accordance with ASCE

Standard 7, Table 1-1, Category IV.

Seismic Load
1.

Seismic load shall be determined in accordance with GEMS G-3D.

2.

Except for control buildings, buildings and other structures shall

be classified in accordance with ASCE Standard 7, Table 1-1,
Category II.

3.

Control buildings shall be classified in accordance with ASCE

Standard 7, Table 1-1, Category IV.

Snow Load
1.

Snow load shall be determined in accordance with GEMS G-3D.

2.

Except for control buildings, buildings and other structures shall

be classified in accordance with ASCE Standard 7, Table 1-1,
Category II.

3.

Control buildings shall be classified in accordance with ASCE

Standard 7, Table 1-1, Category IV.

Blast Load
Blast load for buildings shall be determined in accordance with GEMS
B-3D.

4.12

Construction Loads
Loads caused by construction shall be considered, as applicable.

4.13

Catalyst Load
Catalyst load is load caused by buildup of catalyst in short term
operational upset.

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TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

4.14

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

Buoyant Load
Buoyant load is uplift load caused by weight of volume of water
displaced by foundation.

4.15

Load Combinations
Structures and foundations shall be designed to resist effects of load
combinations defined in this section.
4.15.1

General
All possible combinations of dead and live loads shall be
considered to determine maximum design condition, except:

4.15.2

1.

If wind and snow loads are combined, individual members

shall be proportioned for full wind plus one-half snow or
full snow plus one-half wind, whichever is more severe.

2.

Maintenance loads shall not be combined with wind, snow,

or earthquake loads.

3.

Hydrostatic test loads shall not be combined with snow or

earthquake loads.

4.

Earthquake loads shall not be combined with wind loads.

5.

Hydrostatic test loads shall be combined with 25% of wind

loads.

Erection
Erection load combinations shall include loads experienced
during construction and effects of climatic or seismic loads on
lightly loaded erected equipment.

4.15.3

4.15.4

Unit Turnaround
1.

Unit turnaround (I and T) load combinations shall include

maintenance loadings combined with full hydrostatic test
of pipelines and equipment.

2.

Unit turnaround load combinations shall also include

partial loadings that occur if vessels, exchanger bundles,
vessel linings, internal parts, and other equipment are
removed for maintenance.

Normal Operations
Normal operations load combinations shall include loads
experienced during operations and effects of coincident
climatic or seismic loads.
NOTE: In combining platform live loads under normal operations,
all platforms, except permanent storage areas, shall be
considered to have access area live loads.

4.15.5

Short Term Operational Upset

Load combinations for short term operational upset shall
include loads for normal operation plus weight of catalyst that
can build up inside towers, vessels, or piping by stopping flow
at any point in system.

5.

SITE PREPARATION AND EARTHWORK DESIGN

1.

Site preparation design shall be developed by engineering

constructor in accordance with recommendations of geotechnical
consultant.
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TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

2.

3.

DESIGN OF FOUNDATIONS AND STRUCTURES

Results of this design shall be included on a construction drawing

that shows the following as a minimum:
a.

Requirements for excavation, filling, and backfill.

b.

Soil treatment (lime, geotextile materials, etc.).

Design shall be based on premise that site preparation and earthwork

have been performed in accordance with GEMS A-2P.

6.

DESIGN OF CONCRETE FOUNDATIONS AND STRUCTURES

6.1

General
1.

Unless specified otherwise, concrete foundations and structures

shall be designed in accordance with ACI 318.

2.

If strength method of ACI 318 is used, load factors shall comply

with ACI 318, except that load factors on members and connections
may be decreased in accordance with the following table, provided
resultant section is not less than section required for other
applicable load combinations:
Load Combination

6.2

GEMS A-1D21

Load Factor Reduction

Combination w/Wind or Seismic

Loads

25%

Test

16-2/3%

Test w/Wind

25%

Short Term Operational Upset

16-2/3%

3.

Unless specified otherwise, minimum compressive strength of concrete

shall be 3000 psi.

4.

Concrete with minimum compressive strength greater than 3000 psi

shall be used if more economical but shall require Purchaser
approval.

5.

Mass concrete and concrete around underground electrical ducts shall

have minimum compressive strength of 2000 psi. Mass concrete is
concrete required for geometric or weight considerations.

6.

Unless specified otherwise, minimum yield strength of reinforcing

steel shall be 60,000 psi.

7.

Design shall take into consideration constructability of structures,

including use of cubing, circular shapes, precast members, and
standardized shapes.

8.

Allowable tensile stress on carbon steel structural anchor bolts

shall comply with Drawing 4S-5846.

Foundations
6.2.1

General
1.

Minimum stability ratio of soil bearing foundations shall

be 1.5 during construction and 2.0 during operation.

2.

Allowable bearing load on soil may be increased 33-1/3%

for load combinations that include wind, seismic,
hydrotest, or catalyst load.

PAGE 8 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

6.2.2

6.2.3

6.2.4

6.2.5

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

3.

Unless specified otherwise, bottoms of soil bearing

foundations shall extend to good soil below frost line and
below expansive soil in region of wetting and drying.

4.

Bottoms of equipment foundations inside enclosed buildings

do not need to extend below frost line.

5.

Bottoms of grade beams that span between column footings

may be located above frost line and in expansive soils.

6.

Grade beams shall be designed for wall load plus load of

any equipment to be handled across grade beam or for 2000
pounds at center, whichever is greater.

Foundations on Pavement Floors

1.

Small pipe supports (jackscrew type), stairs, ladders, and

light structural columns may be supported on concrete
paving or concrete floors, provided differential
settlement does not cause harmful effects.

2.

Flooring/paving that supports foundations shall be

adequately reinforced.

3.

In absence of adequate soil data, maximum soil pressure

under floors/paving shall not exceed 500 psf.

4.

Foundations on pavement/floors shall not be used over or

near underground lines that will require excavation for
inspection and maintenance.

5.

Foundations for electrical switchracks shall be

independent and shall not be supported on pavement/floors.

6.

Design of equipment foundations that are supported by

pavement/floors shall consider soil conditions.

Adjacent Foundation Considerations

1.

Foundations shall be designed such that allowable soil

pressure under adjacent lower foundation is not exceeded.

2.

In absence of adequate soil data, pressure underneath

foundation shall be assumed to spread at a 45 degree angle
down and away from its lower edge.

3.

Depth of foundations shall be established such that soil

within 45 degree envelope is not disturbed due to
excavation required for adjacent underground
piping/sewers.

Vessel Foundations
1.

Foundation piers that support fixed cradles on horizontal

vessels shall be designed for all lateral load developed
by vessel.

2.

Foundation piers that support cradles with slotted bolt

holes shall be designed for friction load between cradle
and pier.

3.

Lateral load on piers shall not be resisted by pavement

around piers.

4.

Tower skirt drains shall comply with Drawing 4S-5851.

Heavy Machinery Foundations

1.

Heavy machinery includes:

PAGE 9 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

2.

GEMS A-1D21

a.

Reciprocating compressors.

b.

Rotating compressors.

c.

Horizontal reciprocating pumps.

d.

Contactors.

e.

Engines and turbines with combined weight of more than

5000 pounds.

Foundations for heavy machinery shall:

a.

Have sufficient mass to prevent excessive vibration or

displacement.

b.

Be designed such that none of its parts are in

resonance with exciting forces.

c.

Not be attached to adjacent foundations without prior

Purchaser approval.

3.

Eccentricity, in any direction, between centroids of mass

of foundation and machine base contact area shall be kept
to a minimum.

4.

Foundation slabs shall have minimum thickness of 2 feet

plus L/30, where L is longest horizontal dimension (in
feet) of foundation slab.

5.

Foundations shall have minimum reinforcement of 84 pounds

per cubic yard of concrete, except for foundation slab,
which shall have minimum reinforcement of 50 pounds per
cubic yard.

6.

Unless specifically approved otherwise by Purchaser,

foundations for groups of reciprocating machinery shall be
supported on common slab.

7.

Foundations for reciprocating machinery shall have the

following characteristics:

8.

a.

Rectangular slab, if possible, with larger dimension

resisting largest of unbalanced forces.

b.

Distance from bottom of slab to action point of

unbalanced forces shall be kept to a minimum.

c.

Distance from center of gravity of foundation to line

of action of resultant of unbalanced forces shall be
kept to a minimum.

d.

Soil bearing pressure underneath foundations shall not

exceed 25% of net allowable static load. Pile
foundations require no reduction in allowable pile
capacity.

e.

Foundations for compressors shall have integral

supports for pulsation bottles.

f.

Deflection (double amplitude) measured at any point on

foundation shall be maximum of 0.003 inch or as
suggested by equipment manufacturer, whichever is
smaller.

Design of foundations for reciprocating machinery shall

include dynamic analysis. Analysis report shall be subject
to Purchaser approval and shall include the following:
a.

Vibration prognosis.

PAGE 10 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

9.

6.2.6

6.3

6.4

GEMS A-1D21

b.

Calculations.

c.

Outline drawing of machine assembly.

d.

Weight of machine(s).

e.

Location of vertical and horizontal centers of gravity

of major machine components.

f.

Frequencies or speed ranges of machine(s).

g.

Magnitudes, directions, and locations of unbalanced

forces and couples.

h.

Dynamic soil shear modulus, soil unit weight, and soil

Poisson's ratio.

i.

Moments of inertia and spring and damping coefficients

of foundation for main modes of vibrations.

j.

For piling, elasticity moduli of piles and surrounding

soil media, coefficient of lateral soil reaction,
effective (equivalent cantilever) pile length in
bending and compression, and other pertinent pile
foundation data.

k.

Analysis of in-phase condition(s) if there is more

than one machine.

Foundations for rotary machinery shall have the following

characteristics:
a.

Rotary machinery may be supported either on rigid

foundation or integral elevated structure.

b.

Soil bearing pressure shall not exceed 75% of net

allowable value for static load. For pile foundations,
no reduction in allowable pile capacity is required.

c.

Foundation slabs for rotary machinery on elevated

structures shall not weigh less than combined weight
of upper table, columns, walls, and machines. Upper
table and foundation slab shall be as rigid as
possible. Machine loads shall be directly over
vertical supports if possible.

d.

Deflection (double amplitude) measured at any point on

foundation shall be maximum of 0.002 inch.

Tank Foundations
1.

Crushed stone ring tank foundations shall comply with

Drawing 4S-3615.

2.

Concrete ring tank foundations shall comply with Drawing

4S-5134.

3.

Foundations for product suction sumps shall comply with

Drawing 4S-6465.

Floors
1.

Concrete floors shall be at least 4 inches thick.

2.

Soil bearing floors in buildings shall be water proofed in

accordance with GEMS B-1D.

Area Paving
1.

Area paving is paving that is provided around or beneath equipment

or that which is used as work area or storage area.
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TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

2.

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

Area paving shall as a minimum be provided for:

a.

Access or work space around equipment.

b.

Collection of contaminated water or other sewer liquids.

3.

Area paving for open area shall be paved with flexible asphalt.

4.

Congested areas and areas subject to drips or spills harmful to

asphalt shall be paved with concrete.

5.

Concrete paving shall be at least 4 inches thick.

6.

Paving in trucking areas and areas where live loads exceed 200 psf
shall be 6 inches thick. Paving shall as a minimum be reinforced
with 6 x 6 x 6 gage welded wire fabric placed at centerline of slab
cross section.

7.

Adequate paving thickness, reinforcement, and construction and

expansion joints shall be provided where yard cranes and mobile
equipment are required to handle such equipment as exchanger
bundles, air cooler sections, heater tubes, and reactor catalyst.

8.

Joints shall comply with Drawing 4S-5848.

9.

Surfaces of concrete paving subject to acid spillage shall be acid

proofed with materials and procedures approved by Purchaser.

10. Where more than one pipeline and/or sewer is installed under
concrete paved areas, concrete surface shall be permanently scored
with lines to define strip boundaries over such lines.
11. Additional paving requirements shall comply with GEMS J-3D.
6.5

6.6

Precast Concrete Members

1.

Column joints on precast columns shall be located above paving.

2.

Connections between precast columns and their foundation shall be

subject to Purchaser approval.

3.

Precast concrete beams that support piping shall have steel plate or
structural shape as slide plate. Beams shall comply with Drawing
13S-181, Detail B.

4.

Inserts, such as 'Unistrut' may be used in precast members to

support miscellaneous small members, such as knee braces and
hangers.

5.

End connections of struts between precast pipe bents shall be

designed to minimize fireproofing requirements and shall be subject
to Purchaser approval.

Concrete Trenches
1.

Unless specified otherwise, walls and floors for concrete trenches

up to 24 inches deep shall be 4 inches thick. Walls for trenches
over 24 inches deep shall be 6 inches thick.

2.

Walls and floors of trenches shall be reinforced with minimum of 6 x

6 x 6 gage welded wire fabric.

3.

Trenches inside buildings shall be covered with removable steel

grating sections designed for 150 psf.

4.

Trenches outside buildings shall be covered with removable checkered

plate sections or removable concrete slabs where heavy loads are
anticipated.

5.

For deep trench pipe lines for special conditions (except for acid
lines), trenches may be filled with sand and covered with 2 inches
PAGE 12 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

of grout suitably scored to define limits of the grout covering.

Such special conditions shall be subject to specific Purchaser
approval.

6.7

6.8

6.9

6.10

6.

Surface drainage to trenches with pipelines shall be avoided.

7.

Trenches with lines subject to vibration shall not be tied to

building columns or grade beams.

8.

Exposed surfaces of concrete trenches for acid lines shall be acid

proofed.

Hot Equipment Considerations

1.

Concrete foundations/structures shall be isolated from hot equipment

with spacers, lugs, rings, or heat resistant concrete such that
temperature of concrete does not exceed 250F.

2.

Heat resistant concrete shall have compressive strength equal to

that of structural concrete it protects.

Construction Joints
1.

Construction joints shall comply with Drawing 4S-5848 and ACI 318.

2.

If it is uneconomical or impractical to pour concrete continuously,

required construction joints shall be shown on drawings.

Electric Conduit
1.

Below grade electrical conduit, including conduit below concrete

floors and paving, shall be encased with 3 inch minimum thickness of
red colored concrete.

2.

Red color shall be obtained in accordance with GEMS A-1P.

Construction
Concrete foundations and structures shall be constructed in accordance
with GEMS A-1P.

7.

DESIGN OF PILE FOUNDATIONS

7.1

General
1.

Piles shall be designed in accordance with recommendations of

geotechnical report and local experience.

2.

Spacing and cutoff elevations of piles shall be subject to Purchaser

approval.

3.

Top of piles shall penetrate 2 inches into bottom of large slab

foundations, such as those for cooling towers, cooling boxes, and
oil-water separators.

4.

Top of piles shall penetrate 4 inches into bottom of foundations for

all other major equipment.

5.

Reinforcing bars in bottom of footings and slabs shall be minimum of

3 inches above pile cutoff.

6.

Allowable design loads on piles subject to lateral loads shall be

subject to Purchaser approval.

7.

Timber piles shall not be spliced.

8.

Unless approved otherwise by Purchaser, foundations that use

combination of piles and soil bearing shall not be used.

PAGE 13 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

9.

DESIGN OF FOUNDATIONS AND STRUCTURES

GEMS A-1D21

Pile foundations shall be designed such that load on piles does not
exceed their capacity.

10. Top of pile caps shall be at elevation such that there is nominal
clearance between top of caps and bottom of pavement, underground
piping, electrical conduit envelopes, etc.
11. Pile capacity may be increased 33-1/3% for load combinations that
include wind, seismic, hydrotest, or catalyst load.
7.2

Uplift Considerations
1.

Special details required for piles subject to uplift shall be shown

on design drawings.

2.

Unless specified otherwise by Purchaser, uplift connections shall

consist of hooks embedded in pile cap.

3.

Details of uplift hooks shall be subject to Purchaser approval prior

to installation.

4.

All uplift forces shall be taken by hook. Uplift forces shall not be
taken by bond between pile and pile cap.

5.

Hooks for timber piles shall be bolted through pile butt.

6.

Hooks and bolts for timber piles shall be hot dipped galvanized.
Portions of hooks and bolts exposed below bottom of pile cap shall
be doped with coal tar and encased in concrete with minimum cover of
4 inches.

7.

Reinforcing bars in concrete piles connected to uplift hook shall be

extended to pile tip.

8.

Pile foundations shall be designed such that uplift on any part of

foundation does not exceed uplift capacity of piles.

8.

STEEL STRUCTURES

8.1

General

8.2

1.

Steel structures shall be designed in accordance with AISC

Specification for Structural Buildings - Allowable Stress Design
and Plastic Design or AISC Load and Resistance Factor Design
Specification for Structural Steel Buildings.

2.

Clearances for steel structures shall comply with GEMS G-2D.

3.

Design of steel structures shall consider vat sizes of hot dip

galvanizing facilities that may be economically used by fabricator.

4.

Structural steel members shall be fireproofed in accordance with

GEMS M-1D.

5.

Structural steel shall be fabricated and erected in accordance with

GEMS S-1M.

6.

Back to back structural steel surfaces that are painted but not
galvanized or seal welded shall not be permitted in locations
subject to atmospheric corrosion, as it would be impossible to
perform maintenance painting on surfaces that face each other.

Galvanizing
8.2.1

General
1.

Galvanizing requirements will be specified by Purchaser.

PAGE 14 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

2.
8.2.2

GEMS A-1D21

Structures or parts to be galvanized will be specified on

design drawings and/or purchase order.

Light Structural Framing

If galvanizing is specified as light structural framing, the
following items shall be galvanized:
1.

Platform stringers, stair stringers, walkway stringers,

columns, cross members, and bracing, provided nominal size
of such members does not exceed 10 inches. Size of member
normally required shall not be increased to avoid
galvanizing requirements.

2.

Platform support brackets and clips welded to vessels,

heaters, and storage tanks (excluding reinforcing plates
applied to the wall).

3.

Handrailing, toe plates, ladders, ladder cages, and their

support clips.

4.

Floor plates, stair treads, and supporting angles or lugs.

Nosing on stair treads shall be galvanized along with
stair treads.

5.

Trolley beam structures, davits, and their supports

provided on vessels for handling trays, manways, and
safety valves.

6.

Rods, clevises, clamps, spring hanger assemblies

(excluding springs which shall be neoprene coated), bolts,
nuts, and other manufactured standard items for pipe
supports and guides.

7.

Structural bolting.

8.

Anchor bolts and nuts for bolting galvanized members to

concrete.

9.

Members with faces bolted against concrete or which are

close enough to concrete to make it impractical to
maintain metal surface protection by other means.

10. Pipe supports, shoes, anchors, and guides, including shoes

and anchors, to be welded to lines.
11. Excluded from galvanizing requirements are:

8.2.3

a.

Any materials in paragraphs 1. through 10. that are

inside of buildings and shielded from weather by roof
and siding.

b.

Trolley beam structures other than those described in

paragraph 5.

c.

Structural members to be completely fireproofed. If

partially fireproofed, members specified in paragraph
9. shall require galvanizing.

All Structural Steel

If galvanizing is specified as all structural steel, the
following items shall be galvanized:
1.

Items specified under light structural framing,

regardless of inside location. Materials located inside of
totally enclosed buildings that are air conditioned need
not be galvanized.

PAGE 15 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

2.

Anchor bolts and nuts for bolting structures and equipment

to concrete.

3.

Structural steel, regardless of size, including

connections, trolley structures and davits, and members
inside of buildings, shall be galvanized. Materials
located inside of totally enclosed buildings with air
conditioning need not be galvanized.

4.

Flare towers shall be 100% galvanized.

5.

Excluded from galvanizing requirements are:

a.

Structural members that are integral parts of heater

metal shells if composite unit is of such size or
shape to render galvanizing impractical. All other
structural attachments shall be galvanized.

b.

Insulation support members welded to vessels.

c.

Vessel skirts, exchanger saddles, and horizontal

vessel saddles.

d.

Structural members to be completely fireproofed. If

partially fireproofed, members with face bolted
against concrete or which are close enough to concrete
to make it impractical to maintain metal surface
protection by other means, shall require galvanizing.
If less costly, galvanizing may be provided in lieu of
paint requirement (GEMS V-1P).

9.

MAINTENANCE, ACCESS, AND STORAGE CONSIDERATIONS

9.1

Platform for Exchanger Bundle Repair

9.2

GEMS A-1D21

1.

Platforms shall be designed for all bundles that may be placed on

them at one time. Number of bundles will be confirmed by Purchaser.

2.

Areas of platforms that do not directly support bundles shall be

designed for live load of 75 psf.

Platform for Horizontal Exchanger Maintenance

9.2.1

9.2.2

General
1.

Elevated horizontal exchangers shall have platform around

them for maintenance.

2.

Platforms shall be divided into:

a.

Channel area.

b.

Shell cover area.

c.

Shell area.

Channel Area
1.

Channel area shall be defined as area that extends

longitudinally from exchanger support nearest channel to
edge of platform in front of channel.

2.

Channel area shall be full width of platform or 5 feet on

each side of rim of channel flange, whichever is smaller.

PAGE 16 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

DESIGN OF FOUNDATIONS AND STRUCTURES

9.2.3

9.2.4

GEMS A-1D21

Shell Cover Area

1.

Shell cover area shall be defined as area that extends

longitudinally from exchanger support nearest shell cover
end to edge of platform in back of shell cover end.

2.

Shell cover area shall be full width of platform or 5 feet

on each side of rim of shell cover flange, whichever is
smaller.

Shell Area
Shell area shall be defined as area on each side of exchanger
between channel area and shell cover area.

9.2.5

Handling Facilities
1.

2.

9.3

9.4

a.

For channel area, design live load shall be weight of

all channels and channel covers of exchangers placed
singly within limits of channel area or 150 psf,
whichever is greater.

b.

For shell cover area, design live load shall be weight

of all shell covers of exchangers with floating heads
placed in shell covers and shell covers placed singly
(not stacked) within limits of shell cover area or 75
psf, whichever is greater.

c.

For shell area, design live load shall be 75 psf.

Structures that have yard crane to handle exchanger bundle

parts shall be classified as Mobile Handling Facility
Structure. Live loads are:
a.

Channel area - 75 psf.

b.

Shell cover area - same as permanent handling facility

structures.

c.

Shell area - 75 psf.

Vertical Exchanger Considerations

1.

Areas around elevated vertical exchangers require special

consideration on an individual basis.

2.

Design live loads shall be defined by Purchaser.

Working Areas
1.

2.
9.5

Structures with fixed trolley beams, davits, or lifting

lugs that handle exchanger bundle, channel, channel cover,
shell cover, and floating head shall be classified as a
Permanent Handling Structure Facility. Live loads are:

Working areas shall be defined as:

a.

All platforms provided at vessels and other equipment where

maintenance work involving workmen, air tools, dismantled
equipment valves, etc., is anticipated, except platforms used
for bundle repair or exchanger maintenance.

b.

All platforms (including tower tray handling platforms) inside

process unit limits, except platforms listed above.

Working areas shall be designed for live load of 75 psf.

Access Areas
1.

Access areas shall be defined as areas used only for access for
inspection and observation.
PAGE 17 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

2.
9.6

2.

10.

GEMS A-1D21

Access areas shall be designed for live load of 30 psf.

Storage Areas
1.

9.7

DESIGN OF FOUNDATIONS AND STRUCTURES

Storage areas shall be defined as:

a.

Areas designated for permanent storage.

b.

Areas for storing vessel internal lining materials during

maintenance.

c.

Areas used to store dismantled fired heater fittings.

Storage areas shall be designed for anticipated storage load or live

load of 75 psf plus snow load, whichever is greater.

Roofs
1.

Flat or pitched roofs that cannot be classified as Storage,

Exchanger Bundle Repair Deck, Exchanger Maintenance, Working
Areas, or Access Areas shall be designed in accordance with ASCE
Standard 7.

2.

Roofs that support banks of pipe above roof shall be designed for
live load of 20 psf plus piping load or live load of 75 psf,
whichever is greater.

3.

Roofs that support banks of pipe above roof shall have 3 foot wide
working area adjacent and parallel to each side of each piping
bank where there is space.

4.

Live loads on pitched roofs shall be assumed to act on horizontal

projection of roof area.

DATUMS AND RELATIVE ELEVATIONS FOR PAVING, STRUCTURES, AND EQUIPMENT

Unless specified otherwise by Purchaser, paving, structures, and
equipment within plant shall be located in accordance with the following
datums and relative elevations:
1.

Paving design and layout shall comply with GEMS J-3D, GEMS G-2D, and
Drawing 3S-3459.

2.

High point of finished concrete paving shall be used as datum and

shall be set at an elevation of 100.0 feet.

3.

Plant bench mark corresponding to reference elevation of 100.0 feet

shall comply with GEMS G-3D.

4.

Low point of finished paving shall not be less than 99.25 feet.

5.

Totally enclosed buildings (except control houses, which shall

comply with GEMS L-1D):

6.

a.

Base of columns, top of grade beams, and high point of floor

shall be set at 100.5 feet.

b.

Top of foundations for pumps, compressors (unless required

otherwise by complementary equipment), vessels, and other
equipment shall be set at 101.0 feet.

Open Sided Buildings

a.

Base of columns, top of foundations for pumps, compressors

(unless required otherwise by complementary equipment),
vessels, and other equipment shall be set at 100.5 feet.

b.

High point of floor at building perimeter shall be 100.0 feet.

PAGE 18 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

7.

DESIGN OF FOUNDATIONS AND STRUCTURES

Structures Other Than Buildings and Equipment Outside of Buildings

a.

Base of columns and top of foundations for pumps and vessels

shall be set at 100.5 feet.

b.

Elevation of top of foundation for heat exchangers (varies)

shall not be less than 100.5 feet. Heat exchanger foundations
shall be set as low as possible with necessary clearance for
piping.

11.

PLATFORMS, WALKS, STAIRS, LADDERS, AND FLOORS

11.1

General
1.

2.

11.2

11.3

GEMS A-1D21

Layout and location of platforms, walks, and stairs and ladders

shall comply with GEMS G-2D and the following drawings:
a.

Vertical Vessels: Drawings 6S-6889, 6S-6890, 6S-6891, 6S-6892,

and 6S-7257.

b.

Horizontal Vessels: Drawings 6S-6887 and 6S-6892.

c.

Miscellaneous: Drawings 6S-6885, 6S-6886, 6S-7256, 6S-7258,

6S-7259, 3S-3594, and 4S-5852.

If shop assembly is required, ladders, stairways, and platforms

shall be designed for shop assembly in largest sections practical.
Size of sections shall comply with handling, shipping, and
galvanizing facility requirements.

Platforms
1.

Except for top platform on vessels over 3 feet 0 inch in diameter,

platforms on vertical vessels shall be circular.

2.

Platforms shall be self supporting. Ladders shall not be used to

support platforms.

3.

Platforms for access to inspection manways on side of vertical

vessels shall have minimum clearance of 2 feet 6 inches from face of
manway to edge of platform.

4.

Platforms for access to manways through which vessel internals are

removed shall have minimum clearance of 4 feet 6 inches from face of
manway to edge of platform. If tower is less than 4 feet 6 inches in
diameter, minimum clearance shall 2 feet 6 inches or diameter of
tower, whichever is greater.

Stairs and Ladders

1.

Stairs shall have slope of 7.75 inches vertical to 9 inches

horizontal, if possible.

2.

Stairs shall be designed for load equal to five times anticipated

live load or moving concentrated load of 1000 pounds, whichever is
greater.

3.

Bottoms of stair and ladder footings may be located 18 inches below

high point of grade in unpaved areas.

4.

Stairs that extend to grade in paved areas or buildings shall

terminate at high point of pavement or building floor.

5.

Ladders shall terminate minimum of 3 inches above high point of

paving or building floor (refer to Drawing 6S-7259).

6.

Stairs and ladders shall not be terminated above catch basins or dry
boxes.

PAGE 19 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT

DEC 98

7.

11.4

GEMS A-1D21

Ladders attached to equipment operating above 150F shall be

supported from top, with sliding connections at all lower
attachments in accordance with Drawing 6S-7258, Note 3.

Steel Floors
1.

2.

12.

DESIGN OF FOUNDATIONS AND STRUCTURES

Hatchways or chute floor openings with smallest dimension of 12

inches or more shall have one of the following safety guard systems:
a.

Hinged cover for floor opening with fixed standard

handrailing. Cover shall have one side exposed if in use. If
not in use, cover shall be closed and/or its exposed side
shall have removable handrail.

b.

Removable railing with toeplate. Cover shall have removable

railing with toeplate on maximum of two sides and shall have
fixed standard railing with toeplate on all other exposed
sides.

Except where flooring is removable, floor plate or grating may be

designed as integral part of supporting member.

LOADING PLATES
1.

Loading plates (in accordance with Drawing 3S-3594, Detail 2) that

show approved uniform live load shall be provided on all platforms,
decks, and floors.

2.

Reusable templates shall be fabricated of durable material, such as

light gage steel, aluminum, or fiberglass.

PAGE 20 OF 20
TEXACO GENERAL ENGINEERING DEPARTMENT