PAN PAC PULPMILL TREATMENT TANK

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1 PAN PAC PULPMILL TREATMENT TANK B. PENG 1, M. ROMANES 2, P. GABY 1 1 Holmes Consulting Group 2 Concrete Structures (NZ) Ltd ABSTRACT The recently completed MBBR and AS tank is part of a multi-million dollar major development project for Pan Pac Forest Products Ltd, at Whirinaki, Napier. The tank was a sub-contract in a larger design-build contract. Concrete Structures Ltd was the constructor of the tank and Holmes Consulting Group and McManus Geotech Ltd were the design team. This paper describes the development of the unique design of this precast concrete tank and the construction methodology innovations required to complete this project in a tight program. Excellent collaboration between the contractor and designer delivered an innovative and quick-to-build design that was completed leak free and ahead of schedule. INTRODUCTION The MBBR and AS tank is part of a multi-million dollar major development project to upgrade existing pulp mill capacity for Pan Pac Forest Products Ltd, at Whirinaki, Napier. This project was a design-build contract with the main contractor Ovivo Ltd which includes the construction of a new pulp plant facility and three effluent treatment tanks; namely a circular Balance tank, a rectangular MBBR and AS tank and a circular Clarifier tank. The MBBR and AS tank was a design-build subcontract to Concrete Structures Ltd with the involvement of Holmes Consulting Group and McManus Geotech Ltd after Concrete Structures won the contract. The MBBR and AS tank is approximately 9m tall, 85m long and 30m wide which comprises four chambers separated by internal concrete walls. The tank walls are supported on concrete foundation beams incorporating post-tension tendons. The floor slab is reinforced concrete with added post tensioning. The precast walls are cantilevered off the foundation beams and tied transversely at the top of the wall at 7.3m centres with 310UC97 steel sections. The walls and cap beams were cast in 2.4m wide segments and stitched together onsite with cast-in-situ joints. The cap beams were post-tensioned to tie the top of the structure together.

2 Figure 1 below shows the general layout of the tank. MBBR AS MBBR AS (a) Plan Steel Tie 310UC97 MBBR AS (b) Longitudinal Section Post-tension tendons Figure 1. General Layout of the Tank PROJECT REQUIREMENTS The design brief for the project is outlined below: Tank to be designed for a 25 years design working life. 4 isolated chambers in the tank (2 MBBR and 2 AS s). The MBBR has an inner dimension of 13.4m by 19.7m by 9.3m high which can hold up to 2,455 cubic meters of liquid each. The AS is 63.9m by 13.4m by 8.5m high internally which can hold a maximum of 7,280 cubic meter of liquid each. The water level in each tank may be different. One could be empty while others are full. All possible loading cases need to be considered. Tank to be designed and built in a 9 months program. Tank to be leak free under Serviceability Limit State conditions. DESIGN METHODOLOGY The design loading was determined in accordance with NZS3106:2009 Design of Concrete Structures for the Storage of Liquids; noting that water level in each tank may be different at any one time as specified in the design brief. The seismic induced hydrodynamic pressure comprises two components: (i) the impulsive mass representing the portion of the contents accelerating with the tank and (ii) the convective mass representing the portion of the contents oscillating in the tank. Background on these actions is provided in NZSEE Seismic Design of Storage Tanks (2009). A 3D grillage model, as shown in Figure 2 below, was set up in Microstran to determine the maximum member design actions under various Ultimate Limit State (ULS) and Serviceability Limit State (SLS) load cases. Non-linear Winker soil springs were modelled underneath the foundation beams to limit maximum soil bearing pressure and to allow for

3 foundation uplift. Geotechnical information was provided by McManus Geotech Ltd. The transverse/horizontal grillage member properties of wall were calculated based on (Hambly 1991) assuming wall acts like a multi-cellular deck. Allowances for the reduction in member stiffness, due to the effect of concrete cracking at ULS, were included by adopting effective moment of inertia values as per the requirements of NZS3101:2006 Concrete Structures Standard. Figure 2. 3D Grillage Model in Microstran The analysis results show that in general the foundation beams and precast concrete walls were governed by ULS load combination with earthquake effect. However, the horizontal design actions in walls and in post tensioned cap beams were governed by SLS load combination with temperature effect. It was observed that the temperature effect is more prominent closer to the corners of the tank. This is because the level of restraint increases closer to the joints and therefore these locations attract larger secondary moments. INNOVATIVE DESIGN AND CONSTRUCTION SOLUTION The design and construction was completed 6 weeks ahead of a tight program. This was achieved by delivering the design on a week by week basis which enabled work to commence prior to the design being finalised. Excellent communication and strong collaboration between the contractor and designer were maintained throughout the design process to eliminate any surprises or complications which may otherwise arise. Structural Form Fully cast-in-situ cantilevered reinforced concrete walls were anticipated in the original tender document. It was apparent from the conceptual design stage that precast sections offered a better quality, more cost effective and quicker to build solution compared to a castin-situ system. Several precast wall alternatives, including double and triple tees, and double and triple hollow core sections, were considered during the preliminary design phase. Each design alternative was assessed by the contractor considering the criteria listed below to provide the optimal solution. Weight and size of individual precast units. By keeping each unit to 24 tonnes or less meant that no special transportation measures would be required. Quantity of reinforcing and concrete. Deeper sections mean less reinforcement. Void concrete sections results in less concrete. Less material means lower cost. Constructability. An easy quick build results in time and cost saving.

4 The selected precast section is shown in Figure 3 below. Each unit is approximately 2.4m wide, 9.3m long and 0.8m deep and weigh about 23 tonnes. The proposed section is thick but hollow with 160mm flange thickness which provides superior strength to weight ratio. The size and weight of the precast unit was carefully configured such that it can be transported using standard truck. The units could also be picked up and placed at 50m radius by Concrete Structures 450 tonne tracked crane which came free at the right time for this scheme. The precast wall units complete with cap beam and wall-foundation joint were cast together in one piece at Concrete Structure s Hastings precast factory. Three custom made re-usable steel moulds were fabricated for this task which reduced formwork cost and turnover time. The ends of precast unit were grooved to provide support for formwork of cast-in-situ joints and hence cut down material cost. Voids at the bottom of precast unit allowed foundation reinforcement to pass through and foundation beam to be cast onsite. (b) Section of Precast Cap Beam (c) Section of Precast Wall (d) Section of Precast Foundation (a) Elevation of Typical Precast Wall (e) Cast-in-situ Wall Joint Figure 3. Precast Wall Panel Unit

5 Tied Cantilever Walls A value engineering analysis was carried out during the preliminary design phase to examine the cost savings associated with providing steel ties at the top of cantilevered walls. The advantage of tied cantilever walls over the pure cantilever walls is that the maximum moment demand at the base of the wall reduces and the moment along the height of the wall is more evenly distributed. Significant efficiencies resulted. Post Tensioned Cap Beams As discussed previously, SLS temperature effect governs the design actions of cap beams. The maximum design actions occur at the intersection of 4 s. To minimise the size of cap beams and the reinforcing content, post-tension tendons were utilised. Each cap beam has six 7 number 12.7mm strand tendons. The need for a wider cap beam (as would have been required with a conventionally reinforced cap) was eliminated because of the efficiency of the post-tensioning. The net result was a constant depth precast element which was simpler and cheaper to make. Prestressed loss due to friction, creep and relaxation along the length was considered. Spread of prestressed force into the concrete walls along the length was also considered. The cap beams were designed in accordance with prestressed concrete requirements in NZS3101:2006 and NZS3106:2009 ensuring allowable stress fluctuation in prestressed tendon, crack widths and maximum stress in non-prestressed reinforcement were kept within the allowable limits. Post tensioned tendons were also incorporated into the foundation beams and slab on grade to minimise cracking and tie the base together under SLS hydrostatic loading. The post tensioning also reduces the amount of normal reinforcement required in the foundation resulted with a net cost saving. CONSTRUCTION SEQUENCE The main construction sequence is outlined below. 1. The foundation beams and slabs were excavated and prepared. Site concrete was poured on the exposed ground under the foundation beams and on compacted granular material under the slabs. The 150mm thick slab with 662 mesh was then cast in place (see Figure 4 below). Control joints with waterstop were added every 7.2m along the slab to permit shrinkage movements. Figure 4. Concrete Slab Ready to Pour 2. Precast walls were fabricated in the precast yards (see Figure 5 below). A total of 138 precast units were completed in less than 7 weeks.

6 (a) Top View (b) Side View Figure 5. Precast Unit Ready to Pour 3. The units were transported to site and lifted into position using a Manitowac 450 tonne crane which has a 25 tonne lifting capacity at a 50m operating radius. Units were propped with purpose made shoring anchored to the new slab. Reinforcement in the precast wall joints, the corner columns and foundation beams was tied subsequently (see Figure 6 below). Figure 6. Precast Walls Tilted Up and Foundation Reinforcement in Place 4. Once all the precast wall units were lifted in place and steel beams installed, the foundation beams were poured followed by the precast joints and the corner columns. 5. Post-tension tendons in the foundation and cap beams were stressed up. 6. Water tightness test was carried out prior to installation of mechanical services. An aerial shot of the completed tank is shown in Figure 7.

7 Figure 7. Completed Tank SUMMARY The MBBR and AS tank was completed in October 2011, 6 weeks ahead of schedule. Excellent collaboration between contractor and engineer meant that construction was able to proceed while the design was carrying out. The choice of design solution (precast tied cantilever wall with post-tension beam system), proposed jointly by the contractor and the designer, proved to be the best solution with considerable cost and time savings. REFERENCES Hambly, E.C., (1991), Bridge Deck Behaviour, Second Edition, E & FN Spon. NZSEE, (2009), Seismic Design of Storage Tanks: Recommendations of a NZSEE Study Group on Seismic Design of Storage Tanks, New Zealand Society of Earthquake Engineering. SNZ, (2006), NZS3101:2006 Concrete Structures Standard, Standards New Zealand. SNZ, (2009), NZS3106:2009 Design of Concrete Structures for the Storage of Liquids, Standards New Zealand.

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