Untitled

STANDARD SPECIFICATION NO.
KPC-C-01
REVISION 4 Sheet 1 of 50
STANDARD SPECIFICATION NO. KPC-C-01
STANDARD SPECIFICATION FOR

CIVIL AND STRUCTURAL DESIGN CRITERIA
FOR
P.T. KALTIM PRIMA COAL PROJECT

AT EAST KALIMANTAN, INDONESIA
Revision 1 2 3 4
D a t e 02/03/89 17/03/89 27/04/89 21/06/89
Prepared by S.S-J S.S-J S.S-J S.S-J
Checked by
Contracts
Approved
Approved by
Proj. Mgr.
TABLE OF CONTENTS
Page No.
SECTION 1 - GENERAL 4
1.1 Introduction 4
1.2 Definitions 4
[70/KPCCOAL2]
1.3 Abbreviations 4
1.4 Governing Codes, Standards, Regulations
and Reference Documents 4
1.5 Contractor's Obligation 5
1.6 Site Data 5
SECTION 2 - EARTHWORKS 6
2.1 General 6
2.2 Site Earthworks 6
2.3 Grassing and Slope Protection 6
2.4 Roadworks 6
SECTION 3 - DRAINAGE 8
3.1 General 8
3.2 Runoff Classification 8
3.3 Design Hydrology 8
3.4 Culvert Installation 9
3.5 Open Channel Drainage 9
3.6 Sedimentation Dams & Silt Traps 9
SECTION 4 - WATER 11
4.1 General 11
4.2 Raw Water 11
SECTION 5 - SEWERAGE 15
5.1 General 15
5.2 Sewer Lines 15
5.3 Sewage Treatment 16
SECTION 6 - STRUCTURAL - GENERAL 17
6.1 Design Loads 17

6.2 Structural Steelwork 21
6.3 Concrete Structures 25
6.4 Masonry/Blockwork 26
6.5 Foundations 26
6.6 Piles 26
6.7 Earth Pressure 28
SECTION 7 - BUILDINGS 29
7.1 Scope 29
7.2 General 29
7.3 Switch Rooms 30
7.4 Stockyard Control Room (SCR) 30
7.5 Portsite Amenities Building 30
7.6 Cribroom and Toilet at the Jetty Head 30
7.7 Pumphouse (Portsite) 31
7.8 Coal Washing Building 31
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7.9 Minesite Laboratory 31

7.10 Central Control Building (Minesite) 31
SECTION 8 - AIRCONDITIONING & VENTILATION 33
SECTION 9 - MARINE WORKS 34
9.1 General 34
9.2 Standards and Codes of Practice 34
9.3 Design Criteria 34
Fig. 9.3.4(ii)(a) 40
9.4 Design Load Combinations 47
Attachment A - List of Standards and

Reference Documents 45
Attachment B - Seismic Design Criteria for

(Revision 2) Civil Engineering Works
Attachment C - Design Flood Estimation Manual
Attachment D - Design Load Combinations for

Marine Structures
[70/KPCCOAL2]
SECTION 1 - GENERAL
1.1 INTRODUCTION
These criteria shall govern the design of the structures and

facilities included in the Scope of Work.
The metric system (SI) of measurement and calculation shall

be used throughout.
1.2 DEFINITIONS
"Submit", "submitted" and "submittal" shall mean written

submission to the Engineer requesting his approval.
"Approved" and "approval" shall mean approved by the

Engineer in writing.
"Instructed", "directed" and "ordered" shall mean ordered by

the Engineer in writing.
"Acceptable" shall mean acceptable to and approved by the

Engineer as advised by him in writing.
1.3 ABBREVIATIONS
The abbreviations listed below shall, where used in this

Specification, have the following meanings:
AS Australian Standard
SAA Standards Association of Australia
BS British Standard
KPC PT Kaltim Prima Coal
NAASRA National Association of Australian State Road
Authorities
ISO International Standards Organisation
NI Indonesian Code
1.4 GOVERNING CODES, STANDARDS, REGULATIONS AND REFERENCE

DOCUMENTS
Except as varied by this Specification or otherwise

specifically approved or ordered, the design of all
structures and facilities shall, as a minimum requirement,
be based on the codes, standards and reference documents
listed in Attachment A to this Specification as well as all
relevant Indonesian codes, standards and regulations and the
Site Data collected and listed in the Appendices.
In case of conflict between any of the listed codes,

standards, reference documents and regulations, the more
stringent requirement shall govern.
[70/KPCCOAL2]
1.5 CONTRACTOR'S OBLIGATION
In addition, the Contractor shall in every instance satisfy

himself as to the completeness and adequacy of the site data
presented, and where necessary for the proper design of the
facility or structure in question, carry out such further
investigations and determinations as he deems necessary.
The results of such further investigations and
determinations shall be made available to the Engineer.
All designs shall be carried out and checked by fully

qualified engineers experienced in the type of work being
undertaken, and all design computations shall be clearly and
methodically set out with all references noted.
1.6 SITE DATA
The available site data have been collected and are

available for perusal in KPC's offices in Jakarta. For
further details, including a listing of the available
reports, refer:
o Appendix I Meteorological, Oceanographic and

Hydrological Data
o Appendix J Geotechnical Data for the Pinang
Coal Mine Project
[70/KPCCOAL2]
SECTION 2 - EARTHWORKS
2.1 GENERAL
The design of earthworks, roads and accessways, embankments,

etc. shall generally be based upon the data collected in the
geotechnical investigations (Appendix J), the details
specified herein and any additional investigations and
determinations carried out by the Contractor to fully
satisfy himself of the site conditions pertaining to the
Works.
2.2 SITE EARTHWORKS
Maximum batter slopes shall generally be as follows:-
(a) In cut 2H:1V

(b) In fill 2H:1V for Terrain Units IV & V
2.5H:1V for Terrain Unit III
3H:1V for Terrain Unit II
Batter slopes may be steepened where it can be shown by

approved slope stability analyses for the particular soils,
that such slopes will be stable.
Flatter slopes may be necessary for slope stability of

particular in-situ batters or fill batters, depending on
Terrain Unit, depth of cut, dip and strength of soil strata
and height of fill. The Contractor shall assess the
appropriate stability requirements for all batters and shall
submit slope stability analyses as and when requested by the
Engineer.
2.3 GRASSING AND SLOPE PROTECTION
Grassing or other appropriate slope protection shall be

provided to all cut and fill batters and drainage channels,
and their design shall be submitted.
The types of grasses used shall be suitable for the region.
2.4 ROADWORKS
Access roads shall be provided to all areas of both the

minesite and portsite coal preparation and handling
facilities including all buildings, conveyors, stockpiles,
marine facilities, and to, as well as along, the overland
conveyor.
Minimum road dimensions shall be as follows:-
Single lane: - 3500mm minimum along overland conveyor

- 3700mm elsewhere
[70/KPCCOAL2]
Double lane: - 6000mm minimum along overland conveyor

- 8000mm elsewhere
Shoulders: - 1500mm minimum.
Pavement design shall be based upon the geotechnical

conditions at the particular locations, the available
pavement materials for base and sub-base courses, and the
traffic and vehicular loads imposed.
Painted marker posts shall be provided along all roads and

accessways, complete with reflectors at maximum spacings of
100m on straights, and and at spacings of 0.6R for curve
radius R to maximum 100m spacing.
Minimum 3% crossfalls shall be allowed on road surfaces.
Design speed of roads around the Site shall be 60km/hr.
Generally, the maximum grade shall be 10%. However, for

infrequently travelled roads the grade may exceed 10% for
limited stretches.
For the service road alongside the Overland Conveyor

(CO-01), the design vehicular traffic shall be the same as
specified in section 9.3.4(ii) of this Specification. Other
roads, including any roads and overpasses within the
stockpile area, shall be designed for the following design
vehicles in addition to those specified in Section
9.3.4(ii):
(i) a 140t mobile crane,

(ii) the standards specified by the relevant Indonesian
regulations for that class of road,
(iii) the construction traffic generated by the
development and construction of KPC's mine and
facilities, including the transport by road of coal
to the interim stockpile at the portsite.
Transition slabs shall be designed and installed between any

bridge or overpass and the adjoining embankments, and shall
be minimum 3m long.
[70/KPCCOAL2]
SECTION 3 - DRAINAGE
3.1 GENERAL
Drainage design shall be based upon the site data listed in

Appendix I for meteorology, oceanography and hydrology, the
details specified herein and any additional investigations
and determinations carried out by the Contractor to fully
Works.
3.2 RUNOFF CLASSIFICATION
Runoff shall be collected in drainage facilities that

separates contaminated from uncontaminated water.
Contaminated water - from catchments disturbed by

mining operations, coal handling
facilities, and infrastructure
areas and roads.
Uncontaminated water - from natural, undisturbed or fully

vegetated catchments.
[70/KPCCOAL2]
3.3 DESIGN HYDROLOGY
All drainage collection facilities, water diversion

facilities, bridge structures, culverts and other hydraulic
structures shall be designed for flows appropriate to the
following requirements for probabilities of occurrence
expressed as "average recurrence intervals" (ARI) in years.
Description Design storm ARI (Years)
Major drainage works: 300

- bridges over rivers/streams
- floodways for overland
conveyor
- drainage where flooding may
disrupt production.
Open channels:
- normal flow with freeboard 25
- for overtopping where plant
facilities may be damaged 100
Culverts:
- flowing full 5
- 1 metre head at the inlet 10
- overtopping road 25
Peak flow calculations shall be computed using the

parameters recommended in Attachment C to this
Specification.
3.4 CULVERT INSTALLATION
The culverts shall be installed at slopes that will provide

self cleansing velocities of 0.6m/s minimum for 1/3 depth of
full flow. In areas where such grades cannot be achieved,
silt traps shall be provided at the culvert inlets.
The minimum culvert diameter shall be 375mm.
All culverts shall have reinforced concrete headwalls and

wingwalls with minimum concrete thickness of 150mm.
Guardrails or guide posts shall be provided at culvert

headwalls.
Culverts shall be designed for the maximum loading

configuration of plant and vehicles that will pass over
them.
[70/KPCCOAL2]
Culverts may be reinforced concrete pipes (RCP) of the

appropriate class or corrugated metal pipes (CMP) with
appropriate protection against corrosion.
Scour and erosion protection shall be provided at the inlets

and outlets to culverts.
Roughness coefficients for hydraulic flow calculations shall

be in accordance with Australian Standard AS2200.
3.5 OPEN CHANNEL DRAINAGE
All open channels shall have scour and erosion protection

facilities.
Manning's roughness coefficients for hydraulic calculations

shall be to the approval of the Engineer.
Batter slopes to drains shall be as appropriate to the soil

conditions such that erosion and undermining are minimised.
Minimum channel velocities at 0.08m depth shall be 0.2m/s.
[70/KPCCOAL2]
3.6 SEDIMENTATION DAMS AND SILT TRAPS
All contaminated runoff shall run through sedimenta-

tion storages, also referred to as "settlement ponds".
The design criteria for settlement ponds shall be as

follows:-
(i) particle sizes for settling during the 3 hours

design storm with ARI of 5 years:
. Coal particles: 0.07mm and larger
. Sand and silt particles: 0.03mm and larger
(ii) minimum storage volume equivalent to rainfall over a

24 hour period with an ARI of 5 years.
Silt traps shall be provided at locations adjacent to coal

handling facilities for collection of coal sediment before
entering drainage systems. Silt traps shall also be
provided at other locations where excessive silt can be
retained from runoff prior to entering major drainage
systems.
[70/KPCCOAL2]
SECTION 4 - WATER
4.1 GENERAL
Water for raw water and potable water will be reticulated by

KPC to a connection point within 100m of the eastern
boundary of the portsite stockpile area.
The Contractor shall base all design work on the details

specified herein and any additional investigations and
determinations carried out by the Contractor to fully
Works.
4.2 RAW WATER
Raw water shall be used for washdown, fire protection and

dust suppression facilities.
4.2.1 Reticulation Mains
Water reticulation mains and fittings shall be of

materials appropriate for buried or above ground
application as detailed in Standard Specifications
KPC-C-06 and KPC-M-16 respectively.
Hydraulic calculations shall be carried out with

appropriate roughness coefficients as detailed in
Australian Standard AS2200, or approved equivalent
for pipes in the "aged" condition, with checks for
higher flows for pipes in new condition.
Installation details for reticulation mains shall be

in accordance with the Standard Specifications
referred to in this Clause.
The minimum depth of cover over all buried pipes

shall be 600mm.
4.2.2 Washdown
Outlets for washdown hoses shall be provided at all

transfer stations, at regular intervals along
conveyors (not more than 100m apart), at truck
washdown facilities, and any other locations
requiring washdown facilities.
In addition, washdown connection points shall be
provided for the shiploader(s) and for the stockpile
machines (stackers and reclaimers). For the latter,
the connection points shall be maximum 100m apart.
4.2.3 Fire Protection

[70/KPCCOAL2]
Fire protection facilities shall be serviced from

either a separate reticulation supply or a joint
supply system with dust suppression and washdown
facilities, provided pressure and flow requirements
can be maintained.
Provision shall be made for augmenting the fire

water supply in cases of emergency and/or a major
fire, with sea water.
If it is proposed to use the same reticulation

system for both fresh water and sea water, then the
system shall be designed such that each and every
part of the system can be thoroughly flushed clean
with fresh water after each emergency, and the
flushing procedure, complete with diagrams, shall be
incorporated into an approved manual.
The pumps for the emergency fire water supply shall

be located off the trestle to the shiploader(s)
together with the pumps for the Power Station
cooling water intake. See also Section 7.7.
Each longitudinal row of stockpiles shall be

encircled by the fire watering main(s), which shall
not be less than 150mm diameter.
Fire service outlets shall be located adjacent to

all ground run conveyors, transfer stations, drive
heads, switchrooms, electric substations, oil
depots, amenities buildings, and the central control
room building.
Fire hydrants shall be located such that the

possibility of accidental damage from mobile
equipment is minimised.
Hydrant spacing along conveyor lengths and coal

stockpiles shall be a maximum of 100m.
Fire hydrant specification shall be as detailed in

Standard Specification KPC-C-06.
Flow and pressure requirements shall be in
accordance with the requirements of Australian
Standard AS2419.1 and the requirements of KPC's
insurance policies for the Project.
In addition to hydrant installations, small bore

hose reels and fire extinguishers shall be used.
The former shall be 20mm solid bore hoses with
bayonet fittings to fit 25mm diameter outlet valves.
Portable hose reels shall be 36m long; and along
[70/KPCCOAL2]
each conveyor, fire hose outlets shall be spaced

maximum 100m apart.
Fire protection within buildings shall comply with

all relevant Codes, Standards and Regulations, as
well as the requirements of KPC's insurance
policies.
In addition, permanently connected hose reel units

shall be installed close to any fire hazardous
equipment and any storage area for fire hazardous
materials.
4.2.4 Dust Suppression
The design of all dust suppression systems,

including their associated water reticulation and
reagent injection systems, shall be submitted.
Where the Scope of Work calls only for the design

and installation of the associated reticulation
systems; the design shall still be submitted, and
shall be based on the criteria set out below for the
complete dust suppression system, such that the
future extension is limited to the simple addition
of the requisite monitors, nozzles, hoses and
instrumentation.
Water sprays shall be provided for all coal

stockpiles. The sprays shall consist of appropriate
spray nozzles along each side of the stockpiles such
that all the surface area of the stockpile will be
covered by the sprays.
Sprays shall be automatically activated when wind

velocity exceeds a set point, and shall also be
capable of being operated manually.
Provision shall also be made for spraying the coal

before stockpiling with water to which a surfactant
agent has been or can be added.
Manually operated dust suppression monitors shall be

spaced such that complete coverage of the coal
stockpiles is guaranteed, and located such that the
possibility of accidental damage from mobile
equipment is minimised.
In addition, fog sprays shall be installed in the

head chute of each conveyor.
[70/KPCCOAL2]
SECTION 5 - SEWERAGE
5.1 GENERAL
Sewerage collection, treatment and disposal facilities shall

be provided for all amenities included in the Scope of Work.
The Contractor shall determine the appropriate loadings

based upon the staffing requirements set by KPC.
5.2 SEWER LINES
All internal wastewater/sewerage collection facilities shall

be in accordance with Standard Specification KPC-A-10 for
Plumbing.
Buried sewer lines shall be vitrified clay or PVC for

nominal diameters of 150mm and under, and vitrified clay,
PVC, cast iron or ductile iron for diameters greater than
150mm. All jointing will be with rubber rings.
Minimum depth of cover over buried pipes shall be 750mm.

Pipe sections, other than cast or ductile iron, under
roadways shall be encased in concrete if cover is less than
[70/KPCCOAL2]
1200mm. Concrete encasing shall commence and finish at

flexible couplings in the pipelines.
Manholes shall be provided at all changes of direction,

changes of grade and at maximum distances of 100m on
straights. The fall across manholes shall be 30mm minimum.
Manhole covers in areas accessible to vehicular traffic

shall be cast iron of suitable load bearing capacity.
Manhole covers in areas not accessible to traffic shall be
light duty cast iron.
The design flows in reticulation pipelines shall be based

upon the fixture units connected to the sewers and the
population load on the sewers. In addition, an allowance
for infiltration shall be added to the above flows
equivalent to 100 cubic metres per day per kilometre per
metre diameter.
Minimum grades shall be such as to maintain adequate self

cleansing velocities without scouring the pipes.
5.3 SEWAGE TREATMENT
Sewerage treatment facilities shall comprise septic tank

systems or other approved disposal/treatment facilities.
It shall be the Contractor's responsibility to determine,

subject to approval, the appropriate treatment facilities
and disposal suitable for the Site conditions.
[70/KPCCOAL2]
SECTION 6 - STRUCTURAL
6.1 DESIGN LOADS
The design loads for all structures shall generally be as

detailed below. However, the Contractor shall be
responsible for assessing all specified loadings and load
combinations which may be applied to any particular
structure.
6.1.1 Dead Loads
The design dead load shall be in accordance with

AS1170 and shall include the weight of all
structural components and insulation, the empty
weight of equipment and piping, and all
miscellaneous permanent loads. For the maximum
loading condition, the total weight of the process
material or test fluid in the equipment and piping,
whichever is applicable, shall be included.
6.1.2 Live Loads
(a) General
Except where otherwise specified, live loads

shall comply with Section 3 of AS1170, Part
1. The provision for occasional loading on
roof trusses or frames shall be applied in
accordance with Clause 3.8.3 of AS1170, Part
1.
(b) Elevated Floors
[70/KPCCOAL2]
Except where equipment loads produce more

severe loading, the following live loads
shall be applied:
Operating Floors and

Light Storage 7.5kPa
Heavy Equipment
Lay Down Areas 12.0kPa
Plant Maintenance Walkways 5.0kPa
Stairs and Landings 5.0kPa
Office and Laboratory

Areas 3.0kPa
Walkways alongside Conveyors 2.5kPa
Storage Areas - to be calculated, but not

less than 2.4kPa per metre
of clear height.
In addition to the above a concentrated load

of 10kN shall be applied mid-span to all
major floor beams and girders, but these
loads shall not be cumulatively added to
supporting members.
(c) Ground Floor Slabs and Pavements
Ground floor slabs and pavements shall be

designed to support the equipment and live
loads specified for that particular area.
The minimum thickness shall be 150mm, unless
otherwise approved.
6.1.3 Wind Loads
(a) General
Wind loads shall be calculated in accordance

with AS1170, Part 2.
The design wind velocity shall be taken as

35m/s, in combination with:
o Terrain Category 1 for the coastal area,

including wharf and portsite stockpile
area, and the terminal transfer tower
for the Overland Conveyor, and
[70/KPCCOAL2]
o Terrain Category 2 for the mine area and

Overland Conveyor generally.
(b) Operating Conditions

For the limits of operating conditions a
maximum wind speed of 20m/sec shall be
adopted for design purposes.
6.1.4 Impact Loads
Static loads shall be increased by the following

percentages to allow for impact:
Reciprocating machinery,
crushers and pumps 100%
Rotating machinery 20%
Mobile equipment and Shiploaders 20%
Hangers supporting floors and

balconies 35%
6.1.5 Seismic Loads
For structures falling within the scope of volume 5:

Draft Code of Practice for Seismic Design of
Buildings in Indonesia, of the Indonesian Earthquake
Study, the design procedure, requirements and
assessment of earthquake forces shall be in
accordance with that Draft Code.
For civil engineering works the seismic design

criteria shall be as set forth in Attachment B to
this Specification and further elaborated in section
9.3.2(v).
For unusual buildings or other types of structures

the seismic design criteria shall be as submitted to
and approved by the Engineer.
6.1.6 Thermal Loads
Forces caused by expansion or contraction of

structures, pipes and/or equipment, shall be taken
into account.
The following coefficients of static friction shall

be used to determine forces at sliding surfaces:
Teflon on Stainless Steel 0.05

Steel on Steel 0.30
Steel on Concrete 0.45
[70/KPCCOAL2]
A minimum ambient temperature range of 20?C shall be

adopted for the design of all structures whether
enclosed and shielded from sunlight or not.
The effects of temperature gradients induced by the

sun and the cooling effects of either wind, shade or
wash down activities shall also be taken into
account.
6.1.7 Dynamic Loads
Dynamic loads, such as those resulting from

vibrating equipment and from surging fluids in
piping and equipment, shall be considered.
Design parameters and operating frequencies for

vibrating equipment shall be obtained from the
manufacturers for each piece of equipment.
6.1.8 Temporary Loads due to Construction
The method of construction and erection shall for

each facility be investigated and any possible extra
loadings applicable during the course of
construction ascertained.
If more severe than the normal operating loads, then

these shall be taken into account in the design of
that facility.
6.1.9 Vehicular Loads
These shall not be less than those specified in

section 9.3.4(ii) of this Specification, and shall
wherever specified and/or directed be combined with
any one or all of the following additional design
vehicles:
(i) a 140t mobile crane,
(ii) the standards specified by the relevant

Indonesian regulations for that class of road
and/or bridge,
(iii) the construction traffic generated by the

development and construction of KPC's mine
and facilities, including the transport by
road of coal to the interim stockpile at the
portsite.
[70/KPCCOAL2]
Any road, accessway, bridge and overpass forming

part, or likely to be part, of the main transport
route between the port area and the mine shall be
designed for all of the additional design vehicles
listed above; while any road, accessway, parking
area and overpass leading to and being part of the
maintenance area for the stacker and the
stacker/reclaimer shall be designed also for the
140t mobile crane.
6.1.10 Bin and Silo Pressures
These shall be determined based on the properties

and characteristics, including flow characteristics,
of the material to be stored, as evidenced by actual
tests performed at an approved laboratory.
Any effect due to the shape and size of the bin or

silo proposed, including the proposed reclaim
arrangements and equipment, shall also be taken into
account.
6.1.11 Load Combinations
Any or all of the following loads shall be combined

to produce the most severe stresses in the
structure:
. Dead loads
. Roof and floor live loads
. Equipment loads
. Crane loads
. Material loads
. Wind loads
. Temperature effects
. Seismic effects
. Wave loads
. Current loads
. Buoyancy effects
. Accident loads
In each combination of loads considered, the various

classes of loads and/or effects shall be combined
using the relevant combination factors.
6.2 STRUCTURAL STEELWORK
6.2.1 General
The design shall generally conform to AS1250 or

AS1538 and the referenced standards, unless
otherwise approved.
[70/KPCCOAL2]
For any specific structure, reference should also be

made to the relevant Project Specification for any
particular requirements.
6.2.2 Design and Stresses
Load combinations examined shall generally, as a

minimum, include those listed in Clause 3.3.1 of
AS1250.
In addition, and where relevant, the load

combinations examined shall include those listed in
Attachment D and in ISO5049, Part 1. For the latter
load combinations the permissible stresses shall be
as specified for the equipment in question.
For conveyor trusses see subsection 6.2.2(a)

following.
Particular attention shall be paid to steelwork that

is supporting dynamic loads or vibrating machinery.
It shall be checked for fatigue as per the
requirements of the referenced codes and it shall be
ensured that resonance does not occur.
All bolted connections of members subject to dynamic

loads or reversal of stresses shall be bolted with
grade 8.8 high strength bolts and be fully tensioned
conforming to AS1511 to form a friction type joint.
Load indicating washers or bolts designed for
special tightening procedures shall not be used
unless otherwise approved.
The minimum bolt diameter for primary structural

members shall be 20mm and each individual member
shall be connected with at least two bolts per
connection.
Connections for purlins, girts, door and window

frames, handrails, ladders, stairs and other minor
members may be designed using commercial class mild
steel bolts. Commercial class bolts shall be
minimum 16mm in diameter unless otherwise approved.
All connection plates shall be minimum 10mm thick,

with small cleats etc. being minimum 6mm thick
plates.
Where purlins and girts are used to provide lateral

restraint to supporting members, the adequacy of
such support shall be proven to the satisfaction of
the Engineer.
[70/KPCCOAL2]
Roof and wall cladding shall not be considered as

effectively restraining the supporting members.
Walkway grids shall minimum be "Forgeline" type

FA325, Series 2, with a mass of 35.4 kg/m2, by Johns
Perry Industries Pty. Ltd., or approved equivalent.
(a) Conveyor Trusses and Supporting Trestles
The load combinations examined for conveyor

trusses and their supporting trestles shall
include the following, each with maximum
stresses not greater than the permissible
stresses to AS1250.
(i) Conveyor Trusses with Two Walkways
. (SW+ID+BL)+LL+PL+MN
. (SW+ID+BL)+LL+PL+MN+WS
. (SW+ID+BL)+0.5(LL)+PL+MF
. (SW+ID+BL)+0.5(WS)+PL+MF
. (SW+ID+BL)+LL*+LL*+PL+EL+MN [* live
load on both walkways]
. (SW+ID+BL)+PL+WD
. [(SW+ID+BL)+PL+EQ+MN]0.75
. [(SW+ID+BL)+PL+WD+MN]0.75
Longitudinal wind drag on rising

conveyors shall be considered in the
appropriate load combinations as
applicable.
(ii) Conveyor Trusses with one Walkway
The following load combinations shall be

considered in the design of conveyor
trusses with only one side walkway.
. (SW+ID+BL)+LL+PL+EL+MN
. (SW+ID+BL)+LL+PL+EL+MN+WS
. (SW+ID+BL)+0.5(LL)+PL+EL+MF
. (SW+ID+BL)+0.5(WS)+PL+EL+MF
[70/KPCCOAL2]
. (SW+ID+BL)+PL+EL+WD
. [(SW+ID+BL)+PL+EL+EQ+MN]x0.75
. [(SW+ID+BL)+PL+EL+WD+MN]x0.75
Longitudinal wind drag on rising

conveyors shall be considered in the
appropriate load combinations as
applicable.
(iii) Conveyor Trestles
The load combinations shall be the

same as for the supported trusses.
In the preceding load case definitions the

following notation has been used:
SW Self Weight of Steelwork

ID Idlers Load
BL Belt Loads
LL Live Load on Walkway per Walkway
WS Wind Load at Shutdown (20m/sec)
WD Wind Load at Maximum Design Wind
MN Normal Operating Material Weight
MF Flooded Belt Material Weight
EL Electrical Cable Design Load
PL Piping Load
EQ Earthquake Load
The vertical and horizontal deflections of

conveyor trusses shall not exceed SPAN/500
for any load combination except those
including WD or EQ, in which case deflection
shall not exceed SPAN/250.
The horizontal lateral deflection at the top

of a conveyor trestle shall be limited to the
following:
(a) For WS: HEIGHT OR 50mm maximum

500
(b) For WD or EQ: HEIGHT

250
Conveyor trusses shall be given a vertical

precamber equal to the deflection caused by
SW+ID+BL+PL+EL.
Belt clearances from steelwork shall be 175mm
[70/KPCCOAL2]
6.2.3 Materials
All structural steel shall be Grade 250 unless

otherwise approved.
All bolted structural steelwork connections shall be

made with hot dipped galvanised bolts.
For cladding to conveyors refer section 2.1(b) of

Standard Specification KPC-A-07.
For cladding and roofing of buildings, including

conveyor transfer towers, refer sections 2.1(a) and
2.3 respectively of Standard Specification KPC-A-07.
6.2.4 Welding
Welding shall conform to the requirements of AS1554.
Minimum welds shall be 6mm fillet welds.
All hollow sections shall be sealed to prevent

corrosion.
6.2.5 Fabrication and Erection
Fabrication and erection procedures shall comply

with AS1250 and the SAA Manual on Steel Structures,
Sections MA1.8 and MA1.9 respectively. Where the
approved design is based on a specific or
specialised fabrication or erection technique, full
details shall appear on the drawings.
6.2.6 Corrosion Protection
Generally, no specific allowances for corrosion

shall be made in the selection of structural member
sizes. However, where erected steelwork is
inaccessible and also subject to corrosive
atmosphere, such steelwork shall be protected by one
of the specified surface protection systems, or the
members selected shall be subject to reduced
allowable stresses, or additional thickness
provided, all as agreed with the Engineer.
6.2.7 Wear Protection
Structural members exposed to wear due to the motion

of coal or reject material, shall be protected by
wear plates or similar devises.
6.3 CONCRETE STRUCTURES
The design shall generally conform to AS3600 - 1988 and

referred standards, unless otherwise approved.
[70/KPCCOAL2]
For any specific structure, reference should also be made to

the relevant Project Specification for any particular
requirements.
Characteristic concrete strength shall be minimum 30MPa for

the overland conveyor and minesite and minimum 35MPa for the
portsite and marine works.
Reinforcing bars shall be deformed bars either Grade 400Y or
Grade 250S to AS3600 unless otherwise specified or approved,
except that 10mm diameter plain round bar Grade 250R may be
used for ties and ligatures.
Except where otherwise specified, the minimum cover to

reinforcement shall be :-
Pad Footings 60mm

Columns 50mm
Elevated Beams and Slabs 40mm
Retaining Walls 50mm
Structures in Contact with
Ground Water 60mm
Precast Slabs and Wall Panels 40mm
Marine Structures See Section 9.3.9
Elsewhere 50mm
6.4 MASONRY/BLOCKWORK
Design shall generally conform to AS1475.
6.5 FOUNDATIONS
All foundations shall be founded on undisturbed soil unless

otherwise approved.
All foundation designs shall take cognizance of all of the

site data, and geotechnical and other reports that provide
the requisite information on geotechnical structure, soil
type, bearing capacity etc.
Adjacent foundations at different levels shall be designed

and built in such a way that the vertical angle between the
two adjacent foundations edges is not steeper than 45?.
Under operating conditions (excluding earthquake and

erection conditions) the maximum eccentricity of the
resultant shall be: e max = B/6, where e max is measured
from the centre of the underside of the foundation in
question.
For earthquake loading and erection conditions the maximum

eccentricity of the resultant shall be: e max = B/3.
[70/KPCCOAL2]
All foundations supporting vibrating machines shall be

checked for resonance and amplitude of vibration.
6.6 PILES
6.6.1 General
The design shall generally conform to AS2159 unless

otherwise approved.
For piles forming part of the Marine Works see also

section 9.0 following as well as Standard
Specification KPC-C-10 and Project Specification
KPC-MA1.
6.6.2 Design Pile Capacities
Unless otherwise determined by the detailed design,

the estimated ultimate load capacity to be used in
the design of tubular steel piles shall be taken
from the following table:
Description Ultimate Resistance Diameter

of Pile
----------------------------------------------------
Onshore piles 1000kN 610mm
----------------------------------------------------
Marine piles:
Trestle 0-12m
water depth 1500kN 762mm
Trestle 12m-17m
water depth 1500kN 914mm
Jetty head
vertical piles 3500kN 914mm
Jetty head
raking piles 4000kN 914mm
___________________________________________________
Notes:
(a) Depth of water is measured below LAT.
(b) The above tabulated design values shall be

proven by tests as specified in Specification
KPC-C-10.
[70/KPCCOAL2]
(c) The design capacity of steel piles not listed

in the above table and of piles of other
materials, eg. timber piles, shall be as
approved.
(d) The factor of safety on the working loads of

piles shall be not less than two (2). This
factor of safety shall be maintained
notwithstanding the ultimate load capacities
quoted in the table above.
6.7 EARTH PRESSURE
Lateral earth pressures shall be calculated using the soil

data established in the geotechnical reports plus any
additional investigations deemed necessary and shall be done
in conformity with best available and accepted international
practice as agreed with the Engineer.
Seismic effects and "overpressures" due to any applied

compactive effort shall all be taken into account.
SECTION 7 - BUILDINGS
7.1 SCOPE
The buildings covered by this specification are the:
o Electrical substations with switchrooms
o Stockyard Control Room (SCR)

[70/KPCCOAL2]
o Portsite Amenities Building
o Cribroom and Toilet at the Jetty Head.
o Pumphouse (Portsite)
o Coal Washing Building
o Minesite Laboratory
o Central Control Building (Minesite)
o Conveyor Transfer Towers
7.2 GENERAL
All buildings shall be designed to comply with all relevant

Indonesian regulations as well as the criteria set forth in
this specification.
Except as otherwise specified or approved, all onshore

buildings shall be of concrete blockwork type construction,
reinforced as and if necessary, with steel roof and steel
roof sheeting and R.C. floors; while Conveyor Transfer
Towers and any buildings on the Trestle and Jetty Head shall
be of steel frame construction with steel cladding and roof.
The Coal Washing Building shall be an open steel framed
building with steel roof sheeting.
For further details regarding roofing and cladding materials

refer Sections 2.1, 2.2 and 2.3 of Standard Specification
KPC-A-07.
All buildings including transfer towers shall have an R.C

floor at ground level. Floors above ground level shall
generally be reinforced concrete except that for conveyor
transfer towers and the Coal Washing Building open steel
floor grids may, subject to approval, be used as and where
appropriate.
All air conditioned buildings and/or rooms shall have foil

insulation between roofing and purlins, batt insulation over
suspended ceilings, and, where necessary, perimeter wall
insulation with vapour barrier.
For further particular requirements refer the standard

architectural specifications nos. KPC-A-07 and KPC-A-10.
7.3 SWITCH ROOMS
These shall be pressurised to 25mm w.g. static pressure and

provided with adequate ventilation, and insulation as
[70/KPCCOAL2]
necessary, to offset internal heat gain. Exhaust air shall

be released by barometric type dampers.
For further requirements refer the relevant project

specifications: ie. KPC-CP for minesite and KPC-CO1 for
portsite.
7.4 STOCKYARD CONTROL ROOM (SCR)
This shall be airconditioned as well as pressurised to 25mm

w.g. static pressure, and shall contain toilet and wash
facilities for the operators stationed in that building.
For further requirements refer project specification

KPC-CO1.
7.5 PORTSITE AMENITIES BUILDING
This building shall provide:
o change room, toilet and shower facilities for

25 people plus lockers for 40 people.
o airconditioned lunchroom facilities for 25

people.
o an airconditioned prayer room
7.6 CRIBROOM AND TOILET AT THE JETTY HEAD
This building shall provide lunchroom and toilet facilities

for up to 8 people. The lunchroom shall be airconditioned.
7.7 PUMPHOUSE (PORTSITE)
It is anticipated that this will house the pumps, including

standby pumps and associated control gear, for both the
Power Station cooling water and the emergency fire water
supply and that the water depth at the pump intakes will be
approx. 6m.
It is further anticipated that:
(i) the platforms supporting this equipment and its

shelter will be a concrete slab not less than
2
approximately 55m in area and supported on not less
than 4 nos. 762mm diameter steel piles.
[70/KPCCOAL2]
(ii) the platform will be integral with one of the

passing bays along the trestle.
The pumphouse shall be so designed as to permit the removal

of any of the pumps and their intake pipes; and the
forecourt or roadway in front of the pumphouse, or the
platform supporting the pumps and pumphouse as the case may
be, shall be designed to withstand the loads imposed by the
15 tonne mobile crane being used to both place and remove
any of this equipment.
The pumphouse shall be pressurised and ventilated similar to

the switch rooms, see Section 7.3.
7.8 COAL WASHING BUILDING
For detailed requirements refer project specification

KPC-CP.
7.9 MINESITE LABORATORY
For detailed requirements refer project specification

KPC-CP.
7.10 CENTRAL CONTROL BUILDING (MINESITE)
This shall be separate from the Coal Washing Plant, but

connected to the latter with a walkway at first floor level.
The building shall contain all electrical switchgear and

controls, with the transformers housed in suitable "pens"
integral with the building.
In addition, the building shall also contain the control

room for the minesite coal preparation and handling
facilities as well as change rooms, crib room, prayer room,
toilets and management offices for the nominated number of
people. These latter facilities shall all be located on the
first floor, unless otherwise approved.
The cribroom, prayer room and management offices shall all

be airconditioned.
For further requirements refer project specification KPC-CP.
SECTION 8 - AIRCONDITIONING AND VENTILATION
The buildings and/or rooms designated to be

[70/KPCCOAL2]
air-conditioned shall be cooled and ventilated by mechanical means

designed to maintain 24?C Dry Bulb Temperature and 55% relative
humidity in the designated areas as well as providing an adequate
rate of air change.
Change rooms, toilets and showers shall be provided with natural

ventilation plus a primary mechanical exhaust system giving 10 air
changes per hour.
SECTION 9 - MARINE WORKS
9.1 GENERAL
This section sets out the particular design criteria to be

used for the marine facilities defined in Project
Specification No. KPC-MA1: Marine Works.
9.2 STANDARDS AND CODES OF PRACTICE
Design of the marine facilities shall be carried out in

accordance with the latest editions of the codes of practice
and design standards referenced in this Specification.
The abbreviated titles for codes, standards and design

practices have been used for convenience.
The principal design codes shall be:
AS1170, Part 1 Dead and Live Loads

Part 2 Wind Loads
AS1250 SAA Steel Structures Code
AS1554 SAA Structural Steel Welding Code
AS1720 SAA Timber Engineering Code
AS2159 SAA Piling Code
AS3600-1988 SAA Concrete Structures Code
BS6349 Draft Code of Practice for Maritime

Structures
Where there is no applicable Code nominated herein, the

design shall be carried out in accordance with the
[70/KPCCOAL2]
applicable Australian, British or United States Code of

Practice or Standard as agreed with the Engineer.
9.3 DESIGN CRITERIA
9.3.1 General
The depth of water at the berthing line shall be

17.8 below LAT. LAT is defined as 1.21m below mean
sea level (MSL), and MSL is 2.42m below bench mark
DAS 6010.
The structures and embankments shall be designed to

resist design loads derived from the criteria given
in this Specification unless otherwise approved.
Structures shall be checked for both service and

ultimate limit states.
Where alternative maximum and minimum factors are
given for imposed loads, the ultimate limit state
shall be checked separately for each alternative.
For further details see Section 9.4 and Attachment
D.
The various loadings are summarised in the
following.
9.3.2 Environmental Loads
Environmental Loads are those imposed upon the

structure by thermal, wind, sea, seismic or other
natural effects. The effect of these loads upon
ships moored to and vehicles and equipment parked on
the structures shall be included.
Loads imposed by the sea include those resulting

from waves, currents and buoyancy effects.
Environmental loads other than seismic shall be

separately computed for extreme and normal
conditions.
Concrete structures shall also be designed to resist

forces and effects caused by their own creep and
shrinkage.
(i) Deformation
The structures shall be designed to resist

all forces and effects caused by their own
thermal expansion and contraction and that of
pipelines, equipment and buildings supported
by the structures.
[70/KPCCOAL2]
Coefficients of thermal expansion shall be

taken as:
-5
o Steel 1.15 x 10 /?C
-5
o Concrete 1.1 x 10 /?C
-5
o Timber 0.6 x 10 /?C
A minimum ambient temperature range of 20?C

shall be adopted for design purposes.
The effect of temperature gradient induced by

the sun and the cooling effects of sea spray
shall be included in the loading cases
considered. It is noted that under specific
circumstances the effects of temperature
gradients will be superimposed on to gravity
and other loads.
(ii) Wind
Refer Section 6.1.3 of this specification.
(iii) Wave
Extreme wave loads for design purposes shall

be quasi-static loads imposed by a maximum
single occurrence wave (H max) of 7 seconds
period.
The design wave shall be:
Hsig. = 2.5m Hmax. = 4.0m
The design wave shall be assumed concurrent

with a tide level of
RL + 2.5 metres.
Waves shall be assumed to approach the

structures from any direction between
north-east and south.
(iv) Current
The structures shall be designed to resist

forces imposed by currents with velocities
evaluated by the Contractor.
However, for the purposes of this Contract

said velocities shall not be taken into
account at values less than the following:
o All structures (both extreme and normal

conditions):
[70/KPCCOAL2]
- parallel to berth 0.30m/sec

- perpendicular to berth 0.15m/sec
o On tubular structural members, current

forces shall be calculated using the
following formulae:
FL = 0.5 CLSV A and FD =0.5 CDSV A
Where FL and FD = lift and drag force per

unit length,
S = mass density of
seawater,
CL = lift coefficient = 1.2
CD = drag coefficient = 1.0
Allowances made for protruding fins, etc.

shall be stated in the design submission. In
addition, 50mm of marine growth shall be
allowed for in the design (ie. D nom > D +
100mm).
=
No allowance shall be made for variation in

current forces with depth.
Non-circular members shall be designed using

the above formulae with revised CL and CD
(which shall be stated).
Lift and drag forces due to currents shall be

assumed to act simultaneously, shall be added
vectorially, and shall be added to the wave
forces.
(v) Seismic
Structures shall be designed to resist all

lateral and vertical seismic forces, which
shall be assessed in accordance with
Attachment B.
For piled marine structures the value of

EQ(=KCD) shall be increased by 50% as
required for bridge type structures founded
in weak deep soils, and shall be a minimum of
0.07D.
The structures shall be designed to be

ductile in accordance with AS2121 Appendix
4(a), 4(b) or 4(c) as appropriate.
[70/KPCCOAL2]
Should a value of K less than 1.0 (minimum

0.67) be proposed for the design, then the
adoption of that K-value for design purposes
shall be contingent upon the required
ductility of the proposed design being proven
to the satisfaction of the Engineer.
The design forces for the vertical direction

shall be taken as 50% of the horizontal
design forces, and shall be applied
simultaneously with the horizontal forces.
Lateral seismic design of the piles shall

include consideration of the likely movement
of any reclamation or embankment as a result
of earthquakes.
The wharf and trestle structures as a whole

shall be designed to withstand without
distortion or damage the forces likely to be
generated by earth movements caused by the
code level earthquake. Prediction as to the
likely behaviour of these structures in a
more severe event is required.
(vi) Buoyancy
Structures shall be designed to accommodate

the uplifts due to submergence in seawater.
For the purposes of calculation of uplift
forces the specific gravity of seawater may
be take as 1.025.
(vii) Tidal Variations
For available data refer Appendix I.
9.3.3 Dead Load of Structures
The dead loads of the structures shall include the

weights of all structural components, using the
following material densities:
3
o Structural steel 7850kg/m
o Normal weight reinforced
concrete including
3
reinforcement 2600kg/m
o Lightweight reinforced
concrete including
reinforcement 2100kg/m3
3
o Cement grout 1900kg/m
[70/KPCCOAL2]
Where necessary, values for other components shall

be taken from AS1170 Part 1.
9.3.4 Other Imposed Loads on Structures
(i) General
Imposed loads are those due to equipment

which can be removed, conveyed materials,
traffic and equipment live loads,
construction loads, mooring and berthing
loads, and loads imposed by the shiploader,
jetty conveyor, transfer tower, and crib room
and other buildings.
(ii) Vehicular Loads
Apart from any construction loads, the

causeway, approach trestle and loading
platform deck structures shall also be
designed to accommodate the following design
vehicles:
o 15 tonne mobile crane
o NAASRA H20 - 44 truck
o 1 tonne light passenger vehicle
The plan arrangement of axles and wheel

spacings is shown in Figure 9.3.4(ii)(a).
For impact allowances see Section 6.1.4.
The following vehicle live load combinations

for the approach trestle shall be adopted for
design:
(a) A single mobile crane or NAASRA truck

plus up to one (1) full span of light
passenger vehicles, with vehicles either
on same span or on two (2) adjacent
spans.
Note: If the inclusion of the light

passenger vehicles produces a
more severe loading situation,
then that situation shall be
treated as an exceptional or
extreme load case; while the
loading situation formed by
excluding the light passenger
vehicles shall be treated as a
normal load case.
[70/KPCCOAL2]
(b) Mobile crane and NAASRA truck on

adjacent spans or within the same span.
(c) One (1) span of light passenger vehicles

only.
In addition, the approach trestle including

the superstructure and roadway shall also be
designed for the loads imposed by using the
15 tonne mobile crane for maintenance and
repairs of the trestle conveyor, CT-04. For
these operations the maximum lift is expected
to be no more than 5 (five) kN.
(iii) Other Live Loads
In addition to the vehicle loads given above,

and combined therewith where appropriate, the
structures shall be designed to also
withstand the following loads:
o Walkways 2.5kPa
o Dolphin Decks 5kPa
o Service Areas
(a) Service Deck at Transfer Tower:
10kPa and/or a 200kN point load on a

bearing area of 0.4m x 0.4m
(b) Shiploader Repair and Storage Area:
12kPa and/or a 200kN point load on a

bearing area of 0.4m x 0.4m
(c) Service Deck at Conveyor Return Unit:
10kPa or a 200kN point load on a bearing

area of 0.4m x 0.4m
(iv) Construction Loads
Where construction equipment is supported on

the permanent works, any loads and effects,
including dynamic effects, imposed on any
part of the permanent works, whether fully
assembled or in parts, as a result of the
chosen method(s) of construction and erection
shall be examined and allowed for in the
design. The combined effect of various wind,
wave, and other loads on the equipment, and
on the structures shall also be allowed for.
[70/KPCCOAL2]
(v) Berthing Dolphins
Breasting and berthing dolphins shall be

designed to safely absorb the berthing energy
from the following vessels under normal
serviceability conditions:
180,000 DWT 25,000 DWT

VESSEL VESSEL
______________________________________________
Ballast Displacement
(Tonnes) 60,000 10,000
Maximum Displacement
(Tonnes) at Berthing 200,000 35,000
Length Overall (m) 300 175

Beam (m) 50 25
Length Overall on
Hatches (cm) 220 130
Width of Hatches (m) 22 12
Berthing Velocity
(m/sec) 0.15 0.19
Point of Impact 1/4 Point 1/4 Point
Angle of Vessel to
Fender Face up to 10? up to 10?
_______________________________________________
The lateral forces on the structures,

imparted at right angles to the berthing
line, shall be calculated from the above data
and the characteristics of the fender system.
The longitudinal and vertical berthing loads

shall be taken as 30% of the lateral load.
(vi) Mooring Dolphins
Mooring bollards for the vessels listed in

sub-section (v) preceding have been nominated
in Project Specification No. KPC-MA1. The
Contractor shall calculate the loads on
mooring points imposed by moored vessels
under the action of wind, waves and currents
and compare these with the nominated bollard
capacities. If the calculated bollard
capacity is greater than that nominated,
then, subject to approval, a mooring bollard
of the required greater capacity shall be
substituted.
[70/KPCCOAL2]
Mooring bollards and support structures shall

be designed for a bollard pull which can act
in any direction within an arc of 150
degrees, the centreline of which is
perpendicular to the berthing face of the
loading platform. The bollard pull shall
also be assumed to act at an inclination to
the horizontal of up to 30 degrees to produce
the maximum effects on the bollard and/or
support structures.
(vii) Accident Loads
In addition to the normal serviceability

loads, the structures shall be checked for
the effects of accidental loads as defined
below.
(a) Approach Trestle
An accidental point blow of 50kN at

water level arising from the collision
of a barge or tug with either of the
piles in the trestle. The blow may be
absorbed by plastic deformation but the
trestle should remain in place.
(b) Berthing Dolphins
An accidental point blow transversely to

the dolphin of 7,500kN with damage or
destruction of fenders and buckling and
distortion of dolphin above MSL but pile
loads not exceeding ultimate.
(c) Mooring Dolphins
The maximum accident limit for mooring

dolphins shall be taken as breakage of
ships mooring ropes imposing a load of
2,500kN in any of the directions defined
in Clause 9.3.4(v).
(viii) Operational Loads due Shiploader and Feed

Conveyors
The support structures including running

rails for the shiploader, shall be designed
for the operational loads. These loads
include:
[70/KPCCOAL2]
o Dead load of shiploader, feed conveyors

and coal.
o Live load on the walkways.
o Inertial loads of shiploader, shiploader

boom and boom carriage.
o Inertial loads of belt conveyors.
o Start up and braking loads for

shiploader and conveyors.
o Skewing loads during rotation of

shiploader, and travelling of boom
carriage.
o Loads due to luffing of shiploader boom.
The environmental effects of wind and seismic

loadings on the shiploader structure reacting
against the trestle support structure shall
also be designed for.
(ix) Loads from Service Pipes
The gravity loads from the cooling water

intake pipes, when full, shall be taken as
5.2kN/m per pipe.
In addition, the design of the trestle

structure(s) shall take into account the
expansion and contraction of all the service
pipe supported by the trestle(s).
9.3.5 Deformation of Structures
The differential lateral deflection between, on the

one hand the shiploader support structure(s) or the
trestle from shore, and on the other hand the
structure supporting the transfer tower TT-03, shall
be checked and shown to be within acceptable limits
for the satisfactory operation of the respective
conveyors.
The deflection of the dolphins, particularly the

berthing dolphins, shall likewise be checked, also
in the extreme load cases, and shown to be less than
the clear distance to any adjacent structure by an
acceptable margin.
9.3.6 Causeway
[70/KPCCOAL2]
(i) Imposed Loads
In addition to the dead load of the

structures and conveyed materials, the
causeway shall be designed for the
following loads:
o The environmental loads specified in
section 9.3.2 of this specification.
o The live loads specified in section

9.3.4(ii) of this specification.
(ii) Stability
While the causeway alignment is given, the

longitudinal position of the causeway head is
not. The actual location of the causeway
head shall be determined by the Contractor
having regard to the requirements for
stability and his responsibilities under the
Contract.
The available geotechnical data indicate that

the soil conditions at the site are weak and
compressible. Therefore, particular care
shall be taken in the stability analyses and
in developing the requisite construction
techniques, the latter of which may need
inclusion of one or more methods for
improving the strength of the in-situ soils.
In addition to the Site Data, the Contractor

shall also study the records of the 1987
slippage failure of the existing reclamation
at the nearby service wharf, to assist in
deriving suitable parameters for the design
of the proposed causeway.
Stability design shall as a minimum include

analyses of both the total stress state for
short term considerations, and the effective
stress state for long term considerations.
The stability analyses shall furthermore take

into account:
o any layering of the subsoils, and
o the pore pressures and their variation

during construction,
and define the potential failure surface with

minimum margin of safety.
[70/KPCCOAL2]
The factors of safety to be achieved when

considering short term loading using total
stress parameters shall not be less than 1.3.
Limiting pore pressures shall be established

based on effective stress analyses.
The long term factor of safety shall not be

less than 1.5 under the most adverse tidal
conditions and maximum live loading, while
for earthquake with one third of live load in
place the factor of safety shall not be less
than 1.1.
(iii) Settlement
In designing the causeway works, the

Contractor shall:
o calculate the settlement which will

occur in the short term (1-3 months), at
1, 2 and 5 years, and the total
settlement expected;
o assess the pore pressures likely to be

generated and determine a method of
controlling these pore pressures such
that the specified minimum factors of
safety are maintained at all times.
The Contractor shall design and install a

minimum 3m long transition slab between the
trestle and the head of the causeway to
maintain traffic access. The slab shall be
constructed of reinforced concrete and
provided with lifting eyes to allow
readjustment.
9.3.7 Fenders
Fenders, their frontal frames, and appurtenances,

shall be designed to safely withstand and absorb at
least the forces and berthing energies defined in
Section 9.3.4(vi), as well as the effects of:
o angular approach of vessels,
o variations in vessel size and tidal levels at

time of berthing,
o shear distortion of fenders, and
[70/KPCCOAL2]
o variation in the nominal design properties of

fender material.
In addition, the frontal frame of the fenders shall

project below the deck of a laden ship of 25,000 DWT
berthing at lowest astronomical tide.
9.3.8 Navigation Beacons and Buoys
The type, number and locations of navigational aids,

including beacons, buoys, leading lights, channel
markers, daymarks and land fall mark shall be in
accordance with Project Specification MA1.
These navigational aids, their fittings and

attachments shall be designed to safely withstand
the environmental loads given in section 9.3.2, the
dead load arising from batteries, solar cell arrays,
lamps, daymarks and ladders, and, for navigational
aids located at sea: the berthing loads from a 50
tonne displacement vessel berthing at 0.3m/second
against the structure in normal environmental
conditions.
9.3.9 Cover to Reinforcement
The cover to steel reinforcement for all marine

concrete structures shall be as follows:
- In-situ beams, soffit and sides 75mm

- In-situ slabs, top 60mm
- In-situ slabs, sides and soffit 65mm
- Precast slabs 65mm
- Pile caps 75mm
- Elsewhere 75mm
9.4 DESIGN LOAD COMBINATIONS AND FACTORS
Combinations of loads calculated in accordance with Section

9.3 shall be multiplied by the load factor stated in
Attachment D.
Structures shall be checked for both service and ultimate

limit states.
Where alternative maximum and minimum factors are given for

imposed loads, the ultimate limit state shall be checked for
each alternative - ie. all minimum factors in combination
and all maximum factors in combination. The minimum factors
generally will relate to ultimate loads in tension piles and
similar effects.
[70/KPCCOAL2]
ATTACHMENT A
LIST OF STANDARDS
AND REFERENCE DOCUMENTS
[70/KPCCOAL2]
CODES AND STANDARDS
NI 2 Indonesian Reinforced Concrete Code
NI 18 Indonesian Loading Code, Chapters 1 to 4 inclusive

and Chapter 6.
AS1170 SAA Loading Code
AS1221 Fire Hose Reels
AS1250 SAA Steel Structures Code
AS1302 Steel Reinforcing Bars for Concrete
AS1418 SAA Crane Code
AS1475 SAA Blockwork Code
AS1504 SAA Formwork Code
AS1511 SAA High Strength Structural Bolting Code
AS1523 Elastomeric Bearings for use in Structures
AS1538 SAA Cold-formed Steel Structures Code
AS1554 SAA Structural Steel Welding Code
AS1657 SAA Code for Fixed Platforms, Walkways, Stairways

and Ladders
AS1720 SAA Timber Engineering Code
AS2121 SAA Earthquake Code
AS2159 SAA Piling Code
AS2200 Design Charts for Water Supply and Sewerage
AS2419 Installation of Fire Hydrants
AS3600-1988 SAA Concrete Structures Code
MA1 SAA Manual on Steel Structures

Section MA1.8: Fabrication
Section MA1.9: Erection
BS5337 Code of Practice for the Structural Use of Concrete

for Retaining Aqueous Liquids
BS6349 Code of Practice for Maritime Structures
[70/KPCCOAL2]
Part 1: General Criteria

Part 4: Design of Fendering and Mooring Systems
BS8004 Code of Practice for Foundations
ISO5049 Mobile Continuous Bulk Handling Equipment

Part 1: Rules for the Calculation of Frameworks
REFERENCE DOCUMENTS
1. Indonesian Earthquake Study, by Beca Carter, Hollings &

Ferner Ltd. and the Indonesian Counterpart Team
Volume 5: Draff Code of Practice for Seismic Design of

Building in Indonesia.
2. NAASRA: Bridge Design Specification
[70/KPCCOAL2]

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STANDARD SPECIFICATION NO.

STANDARD SPECIFICATION NO. KPC-C-01

STANDARD SPECIFICATION FOR

P.T. KALTIM PRIMA COAL PROJECT

D a t e 02/03/89 17/03/89 27/04/89 21/06/89

Prepared by S.S-J S.S-J S.S-J S.S-J

SECTION 6 - STRUCTURAL - GENERAL 17

6.1 Design Loads 17

7.9 Minesite Laboratory 31

SECTION 8 - AIRCONDITIONING & VENTILATION 33

SECTION 9 - MARINE WORKS 34

Attachment A - List of Standards and

Attachment B - Seismic Design Criteria for

Attachment C - Design Flood Estimation Manual

Attachment D - Design Load Combinations for

These criteria shall govern the design of the structures and

The metric system (SI) of measurement and calculation shall

"Submit", "submitted" and "submittal" shall mean written

"Approved" and "approval" shall mean approved by the

"Instructed", "directed" and "ordered" shall mean ordered by

"Acceptable" shall mean acceptable to and approved by the

The abbreviations listed below shall, where used in this

1.4 GOVERNING CODES, STANDARDS, REGULATIONS AND REFERENCE

Except as varied by this Specification or otherwise

In case of conflict between any of the listed codes,

1.5 CONTRACTOR'S OBLIGATION

In addition, the Contractor shall in every instance satisfy

All designs shall be carried out and checked by fully

1.6 SITE DATA

The available site data have been collected and are

o Appendix I Meteorological, Oceanographic and

The design of earthworks, roads and accessways, embankments,

2.2 SITE EARTHWORKS

Maximum batter slopes shall generally be as follows:-

(a) In cut 2H:1V

Batter slopes may be steepened where it can be shown by

Flatter slopes may be necessary for slope stability of

2.3 GRASSING AND SLOPE PROTECTION

Grassing or other appropriate slope protection shall be

The types of grasses used shall be suitable for the region.

Access roads shall be provided to all areas of both the

Minimum road dimensions shall be as follows:-

Single lane: - 3500mm minimum along overland conveyor

Double lane: - 6000mm minimum along overland conveyor

Shoulders: - 1500mm minimum.

Pavement design shall be based upon the geotechnical

Painted marker posts shall be provided along all roads and

Minimum 3% crossfalls shall be allowed on road surfaces.

Design speed of roads around the Site shall be 60km/hr.

Generally, the maximum grade shall be 10%. However, for

For the service road alongside the Overland Conveyor

(i) a 140t mobile crane,

Transition slabs shall be designed and installed between any

Drainage design shall be based upon the site data listed in

3.2 RUNOFF CLASSIFICATION

Runoff shall be collected in drainage facilities that

Contaminated water - from catchments disturbed by

Uncontaminated water - from natural, undisturbed or fully

3.3 DESIGN HYDROLOGY