December 1998
Process Industry Practices
Structural
PIP STC01015
Structural Design Criteria
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.
© Process Industry Practices (PIP), Construction Industry Institute,
The University of Texas at Austin, 3208 Red River Street, Suite 300,
Austin, Texas 78705. PIP member companies may copy this practice
for their internal use.
Not printed with State funds.
December 1998
Process Industry Practices
Structural
PIP STC01015
Structural Design Criteria
Table of Contents
1. Introduction ..................................2
4. Load Combinations ..................... 8
1.1 Purpose ................................................2
1.2 Scope ...................................................2
4.1 General ................................................8
4.2 Typical Load Combinations ..................8
4.3 Hydrotest Combinations .......................9
2. References....................................2
2.1 Process Industry Practices (PIP) .........2
2.2 Industry Codes and Standards.............2
2.3 Government Regulations .....................4
3. Design Loads................................4
3.1 Dead Loads (D) ....................................4
3.2 Live Loads (L).......................................4
3.3 Process Equipment Loads ...................5
3.4 Piperack Piping and Cable
Tray Loads...........................................6
3.5 Wind Loads (W) ...................................6
3.6 Earthquake Loads (E) ..........................6
3.7 Impact Loads........................................7
3.8 Thermal Loads .....................................7
3.9 Bundle Pull Load (Bp) ..........................7
3.10 Traffic Loads (Tl) ................................8
Process Industry Practices
5. Structural Design......................... 9
5.1 Steel .....................................................9
5.2 Concrete...............................................9
5.3 Masonry................................................9
5.4 Elevator Supports.................................9
5.5 Crane Supports ..................................10
5.6 Allowable Drift Limits ..........................11
5.7 Foundations .......................................11
5.8 Vibrating Machinery Supports ............11
5.9 Anchor Bolts .......................................12
Page 1 of 12
PIP STC01015
Structural Design Criteria
1.
December 1998
Introduction
1.1
Purpose
The purpose of this Practice is to provide the structural engineer with engineering
design criteria which harmonize the structural design requirements of process
industry companies and engineering/construction firms into a single document.
1.2
Scope
These general criteria define the minimum requirements for the structural design of
process industry facilities at onshore U.S. sites. This Practice is intended to be used
in conjunction with the PIP Architectural and Building Utilities Design Criteria
PIP ARC01015, Civil Design Criteria PIP CVC01015, Plant Site and Project Data
Sheets PIP CVC01016, and Building Data Sheets PIP ARC01016, as applicable.
2.
References
When adopted in these criteria, the latest edition of the following applicable codes,
standards, specifications, and references in effect on the date of contract award shall be used,
except as otherwise specified. Short titles will be used herein when appropriate.
2.1
2.2
Page 2 of 12
Process Industry Practices (PIP)
–
PIP ARC01015 - Architectural and Building Utilities Design
Criteria (In Process)
–
PIP ARC01016 - Building Data Sheets (In Process)
–
PIP CVC01015 - Civil Design Criteria
–
PIP CVC01016 - Plant Site and Project Data Sheets
–
PIP REIE686/API 686 - Recommended Practices for Machinery Installation
and Installation Design
Industry Codes and Standards
American Association of State Highway and Transportation
Officials (AASHTO)
AASHTO Standard Specifications for Highway Bridges
American Concrete Institute (ACI)
ANSI/ACI 318 - Building Code Requirements for Reinforced Concrete and
Commentary
ACI 350R - Environmental Engineering Concrete Structures
ACI 530/ASCE 5 - Building Code Requirements for Masonry Structures
Process Industry Practices
December 1998
PIP STC01015
Structural Design Criteria
American Institute of Steel Construction (AISC)
AISC Manual of Steel Construction - Allowable Stress Design (ASD)
AISC Manual of Steel Construction - Load and Resistance Factor
Design (LRFD)
American Iron and Steel Institute (AISI)
–
AISI SG 673, Part I - Specification for the Design for Cold-Formed Steel
Structural Members
AISI SG 673, Part II - Commentary on the Specification for the Design for
Cold-Formed Steel Structural Members
AISI SG 913, Part I - Load and Resistance Factor Design Specification for
Cold-Formed Steel Structural Members
–
AISI SG 913, Part II - Commentary on the Load and Resistance Factor
Design Specification for Cold-Formed Steel Structural Members
American Society of Civil Engineers (ASCE)
ASCE 7 - Minimum Design Loads for Buildings and Other Structures
ASCE Guidelines for Seismic Evaluation and Design of Petrochemical
Facilities
–
ASCE Wind Loads and Anchor Bolt Design for Petrochemical Facilities
American Society of Mechanical Engineers (ASME)
ASME A17.1 - Safety Code for Elevators and Escalators
American Society for Testing and Materials (ASTM)
–
ASTM A36 - Standard Specification for Carbon Structural Steel
–
ASTM A82 - Standard Specification for Steel Wire, Plain, for Concrete
Reinforcement
–
ASTM A185 - Standard Specification for Steel Welded Wire Fabric, Plain,
for Concrete Reinforcement
–
ASTM A193 - Standard Specification for Alloy-Steel and Stainless Steel
Bolting Materials for High-Temperature Service
–
ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs,
60,000 psi Tensile Strength
–
ASTM A325 - Standard Specification for Bolts, Steel, Heat Treated,
120/105 ksi Minimum Tensile Strength
–
ASTM A615 - Standard Specification for Deformed and Plain Billet-Steel
Bars for Concrete Reinforcement
–
ASTM A706 - Standard Specification for Low-Alloy Steel Deformed Bars
for Concrete Reinforcement
American Welding Society (AWS)
Process Industry Practices
AWS D1.1 - Structural Welding Code - Steel
Page 3 of 12
PIP STC01015
Structural Design Criteria
Crane Manufacturers Association of America (CMAA)
CMAA No. 70 - Specifications for Top Running Bridge and Gantry Type
Multiple Girder Overhead Electric Traveling Cranes
CMAA No. 74 - Specifications for Top Running and Under Running Single
Girder Overhead Overhead Electric Traveling Cranes Utilizing Under
Running Trolley Hoist
Precast/Prestressed Concrete Institute (PCI)
PCI MNL 120 - Design Handbook - Precast and Prestressed Concrete
Steel Joist Institute (SJI)
2.3
December 1998
SJI Standard Specifications and Load Tables
Government Regulations
Federal Standards and Instructions of the Occupational Safety and Health
Administration (OSHA), including any additional requirements by state or local
agencies that have jurisdiction in the state where the project is to be constructed,
shall apply.
US Department of Labor, Occupational Safety and Health
Administration (OSHA)
–
3.
OSHA 29 CFR 1910 - Industrial Safety and Regulatory Compliance
Design Loads
New facilities, buildings and other structures, including floor slabs and foundations, shall be
designed to resist the minimum loads defined in ASCE 7, local building codes, and this
Section. In addition to the loads in this Section, other loads which shall be considered, as
appropriate, include: snow, ice, rain, blast, hydrostatic, dynamic, upset conditions, earth
pressure, vehicles, buoyancy, erection, etc. Future loads shall be considered when specified
by the Owner.
For existing facilities, actual loads may be used in lieu of the minimum specified loads.
3.1
Dead Loads (D)
Dead loads are the actual weight of materials forming the building, structure,
foundation, and all permanently attached appurtenances (e.g., piping, valves,
lighting, electrical cable trays, instrumentation, HVAC, sprinkler and deluge
systems, fireproofing, insulation). Weight of fixed process equipment and machinery
are to be treated as dead loads and are covered in Section 3.3.
3.2
Live Loads (L)
3.2.1
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Live loads are gravity loads produced by the use and occupancy of the
building or structure. These include the weight of all movable loads,
including personnel, tools, miscellaneous equipment, movable partitions,
wheel loads, parts of dismantled equipment, stored material, etc.
Process Industry Practices
December 1998
PIP STC01015
Structural Design Criteria
3.2.2
Areas for maintenance use (e.g., heat exchanger tube bundle servicing) shall
be designed to support these loads.
3.2.3
Minimum live loads shall be in accordance with ASCE 7, applicable codes
and standards, and, unless otherwise specified, the following:
Uniform
Concentrated
Stairs and exitways
100 psf (4.8 kPa)
1,000 lbs (4.5 kN)
Walkways; operating and
access platforms
75 psf (3.6 kPa)
1,000 lbs (4.5 kN)
Control, I/O, HVAC room floors
100 psf (4.8 kPa)
1,000 lbs (4.5 kN)
Light
125 psf (6.0 kPa)
2,000 lbs (9.0 kN)
Heavy
250 psf (12.0 kPa)*
3,000 lbs (13.5 kN)
Process manufacturing floors
and storage areas:
* This 250 psf (12.0 kPa) live load is considered to include smaller
equipment.
3.3
3.2.4
Uniform and concentrated live loads listed in the table above shall not be
applied simultaneously.
3.2.5
Per ASCE 7, concentrated loads equal to or greater than 1,000 pounds (4.5
kN) may be assumed to be uniformly distributed over an area of 2.5 feet (762
mm) by 2.5 feet (762 mm), and shall be located so as to produce the
maximum load effects in the structural members. However, stair treads shall
be designed per OSHA regulations or building code as applicable.
3.2.6
Live load reductions shall be as permitted in ASCE 7. In addition, for process
manufacturing floor areas not used for storage, the live load reduction
permitted by ASCE 7 for lower live loads may be used.
3.2.7
The loadings on handrail and guardrail for process equipment structures
shall be per OSHA 1910. The loadings on handrail and guardrail for
buildings and structures under the jurisdiction of a building code shall be per
the building code.
Process Equipment Loads
3.3.1
Empty Load (Pe) - Empty weight of process equipment or vessel, including
all attachments, trays, internals, insulation, packing, agitators, piping,
ladders, platforms, etc. Empty Load also includes weight of machinery (e.g.,
pumps, compressors, turbines, and packaged units).
3.3.2
Operating Load (Po) - Empty Load plus the maximum weight of contents
during normal operation.
3.3.3
Test Load (Pt) - Empty Load plus the weight of test medium contained in the
system. Test medium shall be as specified in the contract documents or by
the Owner. Equipment and pipes which may be simultaneously tested shall
be included. Cleaning load may be higher than hydrotest load (e.g., cleaning
fluid is heavier than water).
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PIP STC01015
Structural Design Criteria
3.3.4
3.4
December 1998
Process equipment empty, operating, and test loads shall be considered as
dead loads (i.e., 1.4 load factor).
Piperack Piping and Cable Tray Loads
3.4.1
Piping and cable tray loads on piperacks shall be considered dead loads and
may be estimated as follows:
a. A uniformly distributed load of 40 psf (1.9 kPa) for piping, product,
and insulation. This is equivalent to 8 inch (203 mm) diameter,
Schedule 40 pipes, full of water, at 15 inch (381 mm) spacing.
b. A uniformly distributed dead load of 20 psf (1.0 kPa) for a single level
of cable trays and 40 psf (1.9 kPa) for a double level of cable trays.
3.5
3.4.2
For any pipe larger than 12 inches (304 mm) nominal diameter, use a
concentrated load, including the weight of piping, product, valves, fittings,
and insulation, in lieu of the above 40 psf (1.9 kPa) over its associated area.
3.4.3
For checking uplift and components controlled by minimum loadings, use
60 percent of the estimated piping loads when combining with wind or
earthquake.
3.4.4
Piperacks and their foundations shall be designed to support loads associated
with full utilization of the available rack space, and any specified future
expansion.
Wind Loads (W)
Unless otherwise specified, wind loads shall be computed and applied in accordance
with ASCE 7 and the recommended guidelines for open frame structures, pressure
vessels, and piperacks in ASCE Guidelines for Wind Loads and Anchor Bolt Design
for Petrochemical Facilities.
Category II (formerly Category I in editions prior to ASCE 7-95) has been the
industry standard; however, in some cases it may be appropriate to select the current
Category III or IV.
3.6
Earthquake Loads (E)
Earthquake loads shall be computed and applied in accordance with ASCE 7, unless
otherwise specified. The earthquake loads in ASCE 7 are limit state seismic loads
and this should be taken into account when using allowable stress design methods
and applying load factors from other codes, etc.
ASCE Guidelines for Seismic Evaluation and Design of Petrochemical Facilities
may also be used for seismic design. The Rw factors in ASCE Seismic Guidelines
Tables 4.4 and 4.5 may be converted to R factors for use with ASCE 7 by dividing by
1.4.
Category II (formerly Category I in editions prior to ASCE 7-95) has been the
industry standard; however, in some cases it may be appropriate to select the current
Category III or IV.
Page 6 of 12
Process Industry Practices
December 1998
3.7
PIP STC01015
Structural Design Criteria
Impact Loads
Impact loads shall be per ASCE 7. Impact loads for davits shall be the same as those
for monorail cranes (powered).
3.8
3.9
Thermal Loads
3.8.1
All support structures and elements thereof shall be designed to
accommodate the loads or effects produced by thermal expansion and
contraction of equipment and piping.
3.8.2
Thermal loads shall be considered as a dead load and included with process
equipment operating loads in the appropriate load combinations.
3.8.3
Thermal loads and displacements shall be based on the difference between
ambient or equipment design temperature and installed temperature.
3.8.4
Friction loads caused by thermal expansion shall be determined using the
appropriate static coefficient of friction. Some commonly used coefficients
shall be taken as follows:
Steel to Steel
0.4
Steel to Concrete
0.6
Proprietary Sliding Surfaces
or Coatings (i.e., “Teflon”)
Per Manufacturer’s
Instructions
3.8.5
For piperacks supporting multiple pipes, 10 percent of the total piping
weight shall be taken as an estimated horizontal friction load applied only to
local supporting beams. However, an estimated friction load equal to 5
percent of the total piping weight shall be accumulated and carried into
piperack struts, columns, braced anchor frames, and foundations. Under
certain circumstances, engineering judgement should be used to determine if
a higher friction load should be used.
3.8.6
Pipe anchor and guide loads produced from thermal expansion, internal
pressure, and surge shall be considered as dead loads. Piperack beams, struts,
columns, braced anchor frames, and foundations shall be designed to resist
actual pipe anchor and guide loads. For local beam design, consider only the
top flange as acting in horizontal bending unless the pipe anchor engages
both flanges of the beam.
3.8.7
Estimated pipe friction loads (per Section 3.8.5) shall not be combined with
wind or seismic loads for the design of piperack struts, columns, braced
anchor frames, and foundations, when there are multiple frames. However,
anchor and guide loads (excluding their friction component) shall be
combined with wind or seismic loads.
Bundle Pull Load (Bp)
3.9.1
Process Industry Practices
Structures and foundations supporting heat exchangers subject to bundle
pulling shall be designed for a horizontal load equal to 1.5 times the weight
of the removable tube bundle, but not less than the smaller of 2,000 pounds
(9.0 kN) or the total weight of the exchanger, applied at the center of the
Page 7 of 12
PIP STC01015
Structural Design Criteria
December 1998
bundle.
3.10
3.9.2
Bundle pull load shall have the same load factors as a live load. Due to the
short duration of bundle pull loading and ductility requirements of codes,
allowable stresses may be increased by 1/3, or load factors may be reduced
by a factor of 0.75 for load combination including bundle pull.
3.9.3
The portion of the bundle pull load at the sliding end support shall equal the
friction force or 1/2 the total bundle pull load, whichever is less. The
remainder of the bundle pull load shall be resisted at the anchor end support.
Traffic Loads (Tl)
Buildings, trenches and underground installations accesible to truck loading shall be
designed to withstand HS20 load as defined by AASHTO Standard Specifications for
Highway Bridges. Maintenance or construction crane loads shall also be considered
where applicable. Truck or crane loads shall have the same load factor as live load.
4.
Load Combinations
4.1
General
Buildings, structures, equipment, and foundations shall be designed for the
appropriate load combinations from ASCE 7, local building codes, any other
applicable design codes and standards, and any other probable and realistic
combination of loads.
4.2
Typical Load Combinations
The following non-comprehensive list of typical, non-factored load combinations
shall be considered and used as applicable. Engineering judgment shall be used in
establishing all appropriate load combinations.
Page 8 of 12
D + Po + L
Maximum Operating
D + Po + L + (W or E)
Max. Oper. + Wind or Seismic
D + Po + E
Earthquake Uplift
D + Pe + W
Wind Uplift
D + Pt + 0.5L
Hydrotest
D + Pt + 0.5L + W (50 mph, 3-sec. gust)
Hydrotest + Partial Wind
D + Pe + Bp
Bundle Pull
Process Industry Practices
December 1998
4.3
PIP STC01015
Structural Design Criteria
Hydrotest Combinations
Full live, wind, and earthquake loads do not need to be combined with hydrotest
loads. For allowable stress design, a 20 percent allowable stress increase is permitted
for any hydrotest load combination. However, for ultimate strength/limit states
design, no load factor reduction is permitted for any hydrotest load combination.
5.
Structural Design
5.1
5.2
5.3
Steel
5.1.1
Steel design shall be in accordance with AISC ASD or AISC LRFD and AISI
specifications for cold-formed shapes. Bar joists shall be designed per SJI
specifications.
5.1.2
All bolted structural connections shall be ASTM A325-N, unless otherwise
required.
5.1.3
All welded structural connections shall use weld filler material conforming
to AWS D 1.1 Section 3.3 (including Table 3.1) with an electrode strength of
58 ksi (400 MPa) minimum yield strength and 70 ksi (480 MPa) tensile
strength, unless otherwise required.
Concrete
5.2.1
Concrete design shall be in accordance with ANSI/ACI 318 and ACI 350R
for liquid containing structures.
5.2.2
All reinforcing steel shall be per ASTM A615, Grade 60, deformed. ASTM
A706 material shall be permitted for reinforcing bars resisting earthquake or
blast induced forces. Plain wire conforming to ASTM A82 may be used for
spiral reinforcement. Welded wire fabric shall be per ASTM A185.
5.2.3
Precast and prestressed concrete shall be in accordance with the PCI Design
Handbook.
Masonry
Masonry design shall be in accordance with ACI 530/ASCE 5.
5.4
Elevator Supports
Elevator support design shall be per ASME A17.1.
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Page 9 of 12
PIP STC01015
Structural Design Criteria
5.5
December 1998
Crane Supports
5.5.1
Vertical deflection of support runway girders shall not exceed the folowing
limits due to maximum wheel load(s), without impact (where L = the span
length):
Top running CMAA Class A, B and C cranes
L/600
Top running CMAA Class D cranes
L/800
Top running CMAA Class E and F cranes
L/1000
Under running CMAA Class A, B and C cranes
L/450
Monorails
L/450
5.5.2
Vertical deflection of jib cranes shall not exceed L/225 (where L = the
maximum distance from the support column to load location along the length
of the jib beam) due to the maximum lifted plus hoist load(s), without
impact.
5.5.3
Lateral deflection of support runway girders for cranes with lateral moving
trolleys shall not exceed L/400 (where L = the span length) based on a total
crane lateral force not less than 20 percent of the sum of the weights of the
lifted load (without impact) and the crane trolley. The lateral force shall be
distributed to each runway girder with due regard for the lateral stiffness of
the runway girders and structure supporting the runway girders.
5.5.4
Crane stops shall be designed per Manufacturer’s requirements, or if not
specified, the following load:
2
F = WV /(2gTn)
where:
F
Page 10 of 12
=
Design force on crane stop, kips (kN)
W =
50% of bridge weight + 90% of trolley weight,
excluding the lifted load, kips (kN)
V
=
Rated crane speed, ft/sec (m/s)
g
=
Acceleration of gravity, 32.2 ft/sec (9.8 m/sec )
T
=
Length of travel, (ft) of spring or plunger required to
stop crane, from crane Manufacturer (usually 0.15 ft
(50 mm))
n
=
Bumper efficiency factor (0.5 for helical springs; see
Manufacturer for hydraulic plunger)
2
2
Process Industry Practices
December 1998
5.6
5.7
5.8
PIP STC01015
Structural Design Criteria
Allowable Drift Limits
5.6.1
Allowable wind drift limits for pipe racks shall not exceed H/150 (where
H = pipe rack height).
5.6.2
Allowable wind drift limits for process structures, pre-engineered metal
buildings, and personnel access platforms shall not exceed H/200 (where
H = structure height).
5.6.3
Allowable wind drift limits for buildings with bridge cranes shall not exceed
H/200 or 2 inches, whichever is less (where H = the height from the base of
the crane support structure to the top of the runway girder).
5.6.4
Allowable wind story drift limits for occupied buildings that may suffer
damage from excessive drift shall not exceed H/400 (where H = building
story height).
5.6.5
Allowable seismic drift limits shall be in accordance with ASCE 7. Process
structures and piperacks shall be considered as buildings.
Foundations
5.7.1
Foundation design shall be based on the results of a geotechnical engineering
investigation.
5.7.2
The minimum factor of safety for overturning due to loads other than seismic
shall be 1.5.
5.7.3
The minimum factor of safety against sliding due to loads other than seismic
shall be 1.5. Friction and passive soil resistance, per the geotechnical report,
may both be considered as resisting sliding.
5.7.4
The minimum factor of safety against overturning and sliding due to seismic
loads shall be 1.0. For additional guidance, see Chapter 5 of ASCE Seismic
Guidelines.
5.7.5
The minimum factor of safety against buoyancy shall be 1.2.
5.7.6
Long term and differential settlement shall be considered when designing
foundations supporting interconnected, settlement-sensitive equipment or
piping systems.
Vibrating Machinery Supports
5.8.1
Machinery foundations shall be designed in accordance with PIP REIE686
Chapter 4, equipment Manufacturer’s recommendations, and published
design procedures and criteria for dynamic analysis. If Manufacturer’s
vibration criteria is not available, the maximum velocity of movement during
steady-state normal operation shall be limited to 0.12 inch per second for
centrifugal machines and 0.15 inches per second for reciprocating machines.
5.8.2
Support structures or foundations for centrifugal rotating machinery greater
than 500 horsepower shall be designed for the expected dynamic forces
using dynamic analysis procedures. For units less than 500 horsepower, in
the absence of a detailed dynamic analysis, the foundation weight shall be
designed to be at least three times the total machinery weight, unless
Process Industry Practices
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PIP STC01015
Structural Design Criteria
December 1998
specified otherwise by the Manufacturer.
5.9
Page 12 of 12
5.8.3
For reciprocating machinery less than 200 horsepower, in the absence of a
detailed dynamic analysis, the foundation weight shall be designed to be at
least five times the total machinery weight, unless specified otherwise by the
Manufacturer.
5.8.4
The allowable soil bearing or allowable pile capacity for foundations for
equipment designed for dynamic loads shall be a maximun of 1/2 of the
normal allowable for static loads.
5.8.5
The maximum eccentricity between the center of gravity of the combined
weight of the foundation and machinery and the bearing surface shall be 5
percent in each direction.
Anchor Bolts
5.9.1
Anchor bolts shall be headed type or threaded rods with compatible nuts
using ASTM A36, A307, or A193 Grade B7 material.
5.9.2
ASTM A36 or A307 anchor bolts shall be designed using an allowable
tension stress of 19 ksi (131 MPa) and an allowable shear stress of 10 ksi (69
MPa) on the gross (nominal) area of the bolt or using ultimate strength
methods with the appropriate load factors.
5.9.3
ASTM A193 Grade B7 anchor bolts shall be designed using an allowable
tension stress of 38 ksi (262 MPa) and an allowable shear stress of 20 ksi
(138 MPa) on the gross (nominal) area of the bolt or using ultimate strength
methods with the appropriate load factors.
5.9.4
Allowable tension and shear stresses in the anchor bolt material may be
increased 1/3 when considering wind or earthquake loads.
5.9.5
Shear and tension interaction shall be considered.
5.9.6
All ASTM A36 and A307 anchor bolts shall be galvanized, unless otherwise
noted.
Process Industry Practices