IPRO Industrieprojekt GmbH - sugar silo at the Çumra Sugar Factory

Case Study

The engineers produced more than 100 drawings for the whole project.
The application of the new standard DIN 1045-1 led to a need for more wall tendons than with comparable silos dimensioned to the former standard.
In view of the new stringent building standards, the structural engineers depended on precise calculations.

brief

IPRO Industrieprojekt is one of Germany's leading independent engineering consultants. Based in Braunschweig, the privately-owned company has more than 40 years of experience in the design of industrial plants around the world, specialising in the food industry.

The company employs around 60 engineers, technicians and designers and has additional offices in Poland and Brazil.

IPRO has successfully completed more than 100 projects, including the world's largest reinforced concrete sugar silos at the Clauen and Uelzen sugar factories in the north of Germany.

Then Turkey's largest private sugar producer Konya Seker selected IPRO to design the country's first sugar silo at the Çumra Sugar Factory, the project demanded extensive planning and knowledge of the sugar industry.

Çumra Sugar Factory, situated in the highlands of Central Anatolia 300km south of Ankara, is the most modern sugar factory in Europe and the largest plant in Turkey with a processing capacity of 12,000 tonnes per day.

IPRO selected TRIMAS, RIB Software's powerful finite element analysis and design programme, to meet the many structural engineering challenges on the project, including the need to comply with new design standards and conform to Turkey's earthquake standard as the site is situated in an earthquake zone.

solution

During the design process for Turkey's first sugar silo, which used 2,000 tonnes of concrete and 200 tonnes of reinforcing and pre-stressing structural steel in the silo form alone, many new standards had to be taken into account. With the aid of TRIMAS, IPRO's structural engineers were able to perform exact stress calculations, verifications and dimensioning to meet the stringent new building standards.

Another challenge for IPRO was the incorporation of German structural standards, as some of the DIN standards were still being updated during the design phase. The structural engineers had to decide whether to take these into consideration or to rely on existing guidelines. This also applied to the new silo load standard which was still being drafted during the design phase of the silo.

RIB Software's finite element modelling (FEM) system, TRIMAS, verified the calculations according to both the old and the proposed new standards. All the results of the calculations can be immediately visualised which is particularly helpful for demanding engineering projects that have to meet even tougher specifications than those imposed by German standards.

To achieve the required capacity of 40,000 tonnes of sugar and to meet the economic needs of the plant, IPRO's engineers designed a pre-stressed concrete silo with a diameter of 38 metres and a height of 40 metres to bear the pressure of the sugar masses inside. The material used for the outer wall had to have extremely high load bearing capacity.

More than 100 engineering drawings were produced during the course of the project, the majority of which related to the planning of the structural framework. Many of the reinforcement drawings were produced with RIB's proprietary CAD programme, ZEICON, which enables fast and exact generation of formwork and reinforcement plans.

result

"As some of the previous standards were no longer state-of-the-art, we chose the new DIN as the basic load standard. The reliability of the calculations was particularly important with this difficult project."

"With TRIMAS it was easy to optimise the number of pre-stressed tendons as the verification of both the performance capability and the load bearing capacity could be checked graphically."

"The programme's interactive, graphical, user-friendly interface and its ability to exchange and transfer CAD data with alphanumeric data, helped us to perform fast and reliable dimensioning and to process complex 2D and 3D finite element models."

Dr Regine Timmers
Structural Engineer, IPRO Industrieprojekt GmbH



Industries>Manufacturing>High-Tech>Ipro Industrieprojekt

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