tm5 809 6
tm5 809 6
tm5 809 6
TECHNICAL MANUAL
This manual has been prepared by or for the Government and, except to the extent
indicated below, is public property and not subject to copyright.
Copyrighted material include din the manual has been used with the knowledge and
permission of the proprietors and is acknowledged as such at point of use. Anyone
wishing to make further use of any copyrighted material, by itself and apart from this text,
should seek necessary permission directly from the proprietors.
If the reprint of publication includes copyrighted material, the credit should also state:
“Anyone wishing to make further us of copyrighted material, by itself and apart from this text,
should seek necessary permission directly from the proprietor.”
*TM 5-809-6/AFM 88-3, Chap. 6
______________
* This manual supersedes TM 5-809-6, dated 16 January 1984 and AFM 88-3, Chapter 6, dated 14 May 1982
i
TM 5-809-6/AFM 88-3, Chap. 6
Paragraph Page
LIST OF TABLES
Table 2-1. Concrete strengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
7-1. Steel stack allowable stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ii
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 1
GENERAL
1-1. Purpose unusual structures, and other pertinent data. The approval
This manual establishes structural design criteria for struc- will apply to the specific project for which the special design
tures other than buildings, furnishes design guidance for use was requested and will not apply to other projects
various types of structures, and identifies special con- involving a similar application.
siderations with regard to certain materials in specific
applications. 1-5. Overseas construction
Where local material of grades other than those referenced
1-2. Scope herein are to be used, working stresses, yield strengths, and
Structures other than buildings which are covered by this details of construction will be modified as necessary to
manual include the following: bridges; dock and harbor reliably represent the performance of the local material.
facilities; drainage structures; bulk material structures; water Local material will be of equivalent or better grade than
and wastewater structures; and mechanical, electrical, and comparable materials referenced herein.
communication structures. Types of structures not covered
include dams and pavements for which guidance can be 1-6. Stability
found in other manuals. These criteria apply to all groups Unless noted otherwise, stability relates to sliding, over-
and agencies responsible for the design of military facilities. turning, buoyancy, and other sources of gross displacement
and not to stability as related to buckling. Except for
1-3. References foundation elements, a structure or any of its elements will
Appendix A contains a list of references used in this docu- be designed to provide a minimum safety factor of 2.0
ment. against failure by sliding, overturning, or uplift. This
required degree of stability will be provided solely by the
1-4. Special designs dead load plus any permanent anchorage. When load
combinations are specified in the design standards to
Prior approval for special designs will be obtained from the
maximize potential uplift, the specified load factor on dead
appropriate headquarters (HQUSACE (CEMP-ET) WASH,
load is less than 1.0 (usually + 0.9), and this load factor will
DC 20314-1000 for Army projects; and HO, USAF/CECE,
be used for stability calculations.
Boiling AFB, WASH, DC 20332-5000 for Air Force
projects). The request for approval will contain a complete
1-7. Basic design reference
statement of the reasons for using such a system, including
competitive costs, proposed special criteria and controls as TM 5-809-2/AFM 88-3, Chapter 2 will be the basic refer-
applicable, performance history or tests (if available), the use ence for design of structures other than buildings.
of a recognized structural consultant for the design of the
1-1
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 2
MATERIAL AND CRITERIA
Mass concrete not exposed to atmospheric conditions or other deteriorating agents 2000 psi
where mass rather than strength is the principal considerations.
Reinforced concrete structures over seawater which are sufficiently elevated so that 4000 psi
they are not ordinarily wetted by salt water.
Mass concrete exposed to seawater from 3 feet below low water to 3 feet above high 4000 psi
water or above normal wave action.
Reinforced concrete decks of waterfront structures where the underside is frequently 4000 to
wetted by salt water. 5000 psi
c. Fiber-reinforced concrete. Concrete and cementitious (1) Corrosion-resistant steel. Use of corrosion-resis-
mortar can be reinforced with alkali-resistant, chopped-glass tant steel will be in accordance with the following. Steel
fibers, short steel fibers, or various organic plastic fibers to conforming to ASTM A 690 wilibe used asset forth in MIL-
obtain enhanced strength, ductility, and toughness when HDBK-1025/6. Use of corrosion-resistant steel conforming
compared to plan concrete and mortar. Fiber-reinforced to ASTM A 242 or A 588 is restricted. This type of steel
concrete will be used only if approved by the appropriate will not be used in areas where the atmosphere contains salt
headquarters. Design guidance and typical material spray and will not be used in a seawater environment. It
properties can be found in American Concrete Institute offers no benefit, and ASTM A 36 material is a better
(ACI) 544.1R, 544.2R, 544.3R, 544.4R, SP-81, and SP- choice. This type of steel will not be used in buried
105 and in Precast/Prestressed Concrete Institute (PCI) structures unless coated nor will it be used in locations where
MNL-128. rust staining of the supporting elements is objectionable.
d. Steel materials. Structural steel materials for typical (2) Stainless steel. Use of stainless steel conforming to
applications will conform to American Society for Testing ASTM A 666, Types 306 or 316 is restricted. This material
and Materials (ASTM) A 36, A 53, A 500, and A 572. will not be used in salt spray zones, in buried applications,
2-1
TM 5-809-6/AFM 88-3, Chap. 6
2-2
TM 5-809-6/AFM 88-3, Chap. 6
(d) Structural items like expansion plates, rocker densely mixed overlay, or both will be provided to prevent
joints, and surfaces intended to permit movement will be corrosion of reinforcing steel. Specific guidance should be
designed so they are protected against direct contact with obtained from local or state highway department officials.
water or condensation and will be detailed to readily drain Bridge decks subject to repeated applications of deicing salt
water. will require more than additional concrete cover for
(e) Surfaces and members will be designed so water reinforcing. Epoxy coated reinforcing bars and densely mixed
will drain from points where steel contacts or enters into concrete overlays are considered the most effective methods
masonry or concrete. and are approved by the Federal Highway Administration.
(2) Exposed conditions. (d) Vertical expansion and contraction joints for
(a) Wherever possible, contact between masonry and reinforced concrete retaining walls and similar structures will
wood or metal in exposed conditions will be prevented. be spaced sufficiently close to reduce or eliminate wall
Usually, the best way to drain masonry is to put weep holes cracking due to shrinkage and expansion.
where they will not adversely affect member strength. (e) In coastal areas, continuous concrete or masonry
(b) Where exposed and uncoated steel structures are foundation walls or grade beams will be extended 24 inches
used, an increased thickness of at least 1116 inch for above grade for wood or steel exterior walls so the junction
corrosion allowance will be used over the computed will be above the splash zone.
thickness required. No corrosion allowance for corrosion- (3) Buried or semi-buried structures. Structures of this
resistant or weathering steel is required. type will be designed to resist buoyant forces caused by the
(c) Exposed concrete structures will have enough presence of water. The safety factor will be at least 1.5 at
protective concrete cover to protect the reinforcement. The maximum water table using the dead weight of the structure
concrete mixture will be of maximum density and minimum without contents plus the weight of earth cover directly over
shrinkage, especially with regard to longtune shrinkage and the tank. A safety factor of 1.1 may be used when the
expansion which may be caused by alternate wetting and maximum water table or the maximum flood level is at or
drying. For bridges or structures exposed to corrosive above the top of the structure. Designers will consider the
chemicals or deicing salt, epoxy coated reinforcing bar, a possible hydrostatic uplift at various stages of construction.
2-3
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 3
TRANSPORTATION STRUCTURES
3-1. Bridges accordance with the CERC Shore Protection Manual. Site
a. Highway. Design of highway bridges will be in ac- wave studies will be performed to determine the effect of
cordance with the AASHTO Standard Specifications for wave action on structures.
Highway Bridges and American Institute of Steel Con- b. Piers and wharves.
struction (AISC) Highway Structures Design Handbook. (1) Main structure. Design of main pier or wharf
Loading for military vehicles will be in accordance with TM structures will consider conditions of exposure and loadings
5-312 and FM 5-36. applicable to the location and service for which the structure
b. Railroad. Design of railroad bridges will be in ac- is intended. A discussion of appropriate design loads can be
cordance with the American Railway Engineering As- found in MIL-HDBK-1025/1. Design loads will include
sociation (AREA) Manual for Railway Engineering. considerations of vertical live load, berthing forces, mooring
c. Pedestrian. Design of pedestrian bridges will consider loads, wave loadings, ice forces, as well as seismic and other
a minimum live load of 85 psf and possible loads by forces as appropriate.
maintenance vehicles as set forth in the AASHTO standard (2) Dolphins. Dolphins will be designed as described
specifications. Such loads will be considered in conjunction in the MIL-HDBK-1025 series and will be provided where
with wind, snow, and other loads to which the structure may required to resist ship berthing, mooring, and/or turning
be subjected. forces. Guidance regarding the determination of berthing,
d. Other. Bridges for other specialized applications, such mooring, and turning forces is also provided in the MIL-
as pipeline supports, transit systems, etc., will meet HDBK-1025 series.
requirements unique to such applications for the service (3) Fendering. Fender systems will be designed to
involved and the materials used. For example, bridges protect the pier or wharf structure, as well as the berthing
constructed of aluminum will be designed in accordance with vessel itself, from forces which can result from the impact of
the Aluminum Association Specifications for Aluminum the vessel against the structure. Design of fender systems
Structures using allowable stresses for bridges and similar will be in accordance with MIL-HDBK-1025/1 for vessel
type structures. For additional guidelines for concrete bridge sizes appropriate for the structure and for the recommended
structures, see ACI 343R. approach velocity and angle.
c. Offshore platforms. Offshore platforms will be
3-2. Tunnels designed considering requirements and loadings set forth in
the MIL-HDBK-1025 series and the CERC Shore Protection
Analysis and design for tunneling and tunnel structures will
Manual and will be designed in conformance with applicable
be based on the information and references provided in
portions of the American Petroleum Institute (API) RP 2A.
NAVFAC DM-7.3 and American Society of Civil Engineers
For additional design guidance, see ACI 357R, 357.1R, and
(ASCE) 402. Structural strength and stability will be
357.2R.
considered, as well as the need for ventilation and other
d. Offshore POL unloading facilities. Design of
services.
offshore POL unloading systems will be in accordance with
NAVFAC DM-22. Wave studies will be made for the design
3-3. Docks and harbors
of the mooring system and platforms. Submarine pipelines
a. Design. Design of docks and harbors will, in general, will be properly designed and anchored against undersea
be in accordance with the MIL-HDBK- 1025 series which current and underwater tow.
addresses waterfront operational facilities. Additional
guidance may also be found in the NAVFAC DM-26 series 3-4. Pipelines and supports
and the Coastal Engineering Research Center (CERC) Shore
Design requirements for pipelines and their supports will
Protection Manual, Volumes I through m. Specific
depend on the nature of the material being transported and
requirements applicable to particular types of dock and
the materials used for construction. Among the standards
harbor structures will be established from references spe-
which should be consulted when undertaking design of
cially suited to those types of structures such as MIL-
pipeline systems are the following:
HDBK-1025/3 and MIL-HDBK-1025/5. Particular
a. American Society of Mechanical Engineers (ASME)
consideration will be given to corrosion-resistant design in
B31.8.
seawater environments. For guidance in this regard, refer to
b. American Petroleum Institute (API) Standard 1104
MIL-HDBK-1025/6. Wave forces on vertical walls, piles,
and Recommended Practices 1102 and 1110.
and other exposed structures will be determined in
3-1
TM 5-809-6/AFM 88-3, Chap. 6
c. American Society of Civil Engineers (ASCE) Publica- e. American Concrete Institute (ACI) 346 and 346R.
tions 368, 418, and 428. When necessary, reference may be made to appropriate
d. American Water Works Association (AWWA) Publi- publications of specialty associations such as the American
cations M9 and M11. Concrete Pipe Association (ACPA) and the American
Concrete Pressure Pipe Association (ACPPA).
3-2
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 4
SITE STRUCTURES
4-1
TM 5-809-6/AFM 88-3, Chap. 6
4-3. Other site structures regarding impact factors appropriate for the speed at which
a. Canopies and shelters. the structures are to be moved. Additional consideration will
(1) Open canopies. Open canopies include unenclosed be given to possible load increases which can result from
roofed areas and one-, two-, and three-sided enclosures. irregularities in alignment of the support system over which
Design of such structures will be based on the specialized the structures will be moved, e.g., enforced displacements or
loading considerations set forth in TM 5-809-1/AFM 88-3, variable support conditions.
Chapter 1 or MIL-HDBK-1002/2 and American National b. Light poles, flag poles, and sign supports. Design of
Standards Institute (ANSI) A58.1. light poles, flag poles, and sign supports will be in accord-
(2) Mobile. Mobile canopies and shelters will be ance with the special provisions for such structures set forth
designed for the loads which would otherwise apply to in ANSI A58.1.
stationary structures of that type with additional provisions
4-2
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 5
STRUCTURES FOR BULK MATERIALS
5-1
TM 5-809-6/AFM 88-3, Chap. 6
Protection Agency and local agencies who would have and 15072.01D. Other acceptable standard design methods
jurisdiction for privately developed projects. or concepts may also be used.
(a) Earth cover. Earth cover will be provided over (b) Prestressed concrete tanks. Design of prestressed
the top of tanks in accordance with frost penetration concrete tanks will be in accordance with ACT 344R. Other
requirements (considering concrete distribution slab current acceptable methods may also be used.
thickness) but will be not less than 2 feet 6 inches. (5) Petroleum, oil and lubricant (POL) tanks and
(b) Backfill material. Backfill for underground tanks facilities. Design of POL tanks will be in accordance with
will include a &inch course of inert sand or fine gravel API 650.
placed against exposed exterior surfaces. (6) Water storage tanks. Design of water storage tanks
(4) Concrete tanks and reservoirs. Tanks and reser- will be in accordance with applicable American Water
voirs designed to contain fresh water and other non- Works Association publications but subject to specific
deteriorating substances will have a clear cover over the design restrictions as set forth above.
reinforcement of not less than 1-1/2 inches for slabs and 2 (7) Tanks for other than oil or water. The basis for
inches for beams and girders or shall be constructed using design of steel tanks will be API 650, but special considera-
conventional depth of cover but with surface sealants or tions related to the product stored in the tank must be
coated reinforcing or both. A minimum temperature dif- accounted for. Steel tanks to store liquefied gases at or near
ferential of 40 degrees F will be assumed to exist between atmospheric pressures will be designed in accordance with
inside and outside faces of tank walls. API 620. Storage of corrosive solutions and the effects of
(a) Reinforced concrete tanks. Design of reinforced temperature in conjunction with corrosive solutions will be
concrete tanks will be in accordance with PCA 15003.02D considerations in selecting tank materials.
5-2
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 6
WATER RELATED STRUCTURES EXCEPT STORAGE TANKS
6-1
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 7
MECHANICAL SYSTEM STRUCTURES
7-1
TM 5-809-6/AFM 88-3, Chap. 6
Handbook by Gaylord & Gaylord for circular steel stacks. conveying a gas of different specific gravity than atmospheric
Components will be proportioned so that resonance due to conditions and to temperature differential stresses caused by
vortex shedding at low wind velocities is avoided. For duct an uneven temperature distribution within the stack. See also
of rectangular cross section, structural design will be in ASCE Design and Construction of Steel Chimney Liners.
accordance with the AISI Design of Plate Structures, Design (1) Reinforced concrete stacks. Reinforced concrete
of Welded Structures by Blodgett, and applicable portions of stacks will be designed in accordance with ACI 307.
the American Institute of Steel Construction (AISC) (2) Aluminum stacks. If constructed of aluminum,
Specification for Structural Steel Buildings Allowable Stress design of stacks will follow similar design guidance and
Design and Plastic Design that relates to plate girders. general references given for design of steel stacks.
Design will include a determination of plate thickness (3) Steel stacks.
required to resist flexural loading, the size and spacing of (a) Design of steel stacks will be in accordance with
stiffeners, the size and location of internal bracing, and the AISC Specification for Structural Steel Buildings
additional plate thickness and features which may be Allowable Stress Design and Plastic Design; Structural
required if the duct is designed as a spanning box girder. Engineering Handbook by Gaylord & Gaylord; SMACNA
b. Stacks. In addition to maximum loadings, stacks will Guide for Steel Stack Design and Construction; and ASME
be designed to resist the effects of vortex shedding or STS-1. Allowable stresses will be in accordance with table
fluttering caused by steady wind. Stack designs will consider 7-1. The allowable stress is for a design condition of dead
pressure differential stresses caused by virtue of the stack*s load combined with either seismic or wind loads.
(b) Shell thickness will be at least 1/4 inch for lined bolt hole areas) will be used to determine actual stresses.
stacks and 5/16 inch for unlined stacks. The computed shell Allowable stresses for parts other than the shell plate will be
thickness will be increased by 1/16th inch to allow for in accordance with AISC Specification for Structural Steel
possible corrosion. The net section area (gross area minus Buildings Allowable Stress Design and Plastic Design.
7-2
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 8
ELECTRICAL AND COMMUNICATION STRUCTURES
8-1
TM 5-809-6/AFM 88-3, Chap. 6
CHAPTER 9
SPECIALTY STRUCTURES
9-1
TM 5-809-6/AFM 88-3, Chap. 6
APPENDIX A
REFERENCES
Government Publications
Department of Defense
MIL-HDBK-1002/2 Loads.
MIL-HDBK-1002/3 Structural Engineering Steel Structures.
MIL-HDBK-100216 Aluminum Structures, Composite Structures, Structural Plastics, and Fiber-
Reinforced Composites.
MIL-HDBK-1008A Fire Protection for Facilities, Engineering, Design, and Construction.
MIL-HDBK-1025/1 Piers and Wharves.
MIL-HDBK-1025/2 Dockside Utilities for Ship Service.
MIL-HDBK-1025/3 Cargo Handling Facilities.
MIL-HDBK-1025/4 Seawalls, Bulkheads, and Quaywalls.
MIL-HDBK-1025/5 Ferry Terminals and Small Craft.
MIL-HDBK-1025/6 General Criteria for Waterfront Construction.
A-1
TM 5-809-6/AFM 88-3, Chap. 6
Corps of Engineers, Coastal Engineering Research Center, (CERC), Kingman Building, Fort Belvoir, VA 22060
Shore Protection Manual, Volumes I, II, and m.
Nongovernment Publications
Aluminum Association, 900 19th Street, NW, Suite 300, Washington, DC 20006
American Association of State Highway and Transportation Officials (AASHTO), 444 North Capitol Street, NW, Suite
225, Washington, DC 20001
American Concrete Institute (ACI), P.O. Box 19150, Redford Station, Detroit, MI 48219-0150
A-2
TM 5-809-6/AFM 88-3, Chap. 6
American Institute of Steel Construction (AISC), 400 North Michigan Avenue, Chicago, IL 60611-4185
American Institute of Timber Construction (AITC), 11818 SE Mill Plain Boulevard, Suite 415,
Vancouver, WA 98684
American Iron and Steel Institute (AISI), 1000 16th Street, NW, Washington, DC 20036
American National Standards Institute (ANSI), 1430 Broadway, New York, NY 10018
American Railway Engineering Association (AREA), 50 F Street, NW, Suite 7702, Washington, DC 20001
Manual for Railway Engineering (Fixed Properties), Volumes I and II, (1988-89).
American Society of Civil Engineers (ASCE), 345 East 47th Street, New York, NY 10017
A-3
TM 5-809-6/AFM 88-3, Chap. 6
American Society of Mechanical Engineers (ASME), 345 East 47th Street, New York, NY 10017
B31.8-86 Gas Transmission and Distribution Piping Systems.
STS-1-1986 Steel Stacks.
American Society for Testing and Materials (ASTM), 1916 Race Street, Philadelphia, PA 19103
American Water Works Association (AWWA), 6666 West Quincy Avenue, Denver, CO 80235
Conveyor Equipment Manufacturers Association (CEMA), 932 Hungerford Drive, Suite 36, Rockville, MD 20850
Electronic Industries Association (EIA), 2001 Eye Street, NW, Washington, DC 20006
Institute of Electrical and Electronics Engineers (IEEE), 345 East 47th Street, New York, NY, 10017
A-4
TM 5-809-6/AFM 88-3, Chap. 6
National Electrical Manufacturers Association (NEMA), 2101 L Street, NW, Washington, DC 20037
National Fire Protection Association (NFPA), Publications Department, Batterymarch Park, Quincy, MA 02269
211-88 Standard for Chimneys, Fireplaces, Vents and Solid Fuel Burning
Appliances.
National Forest Products Association, 1250 Connecticut Avenue, NW, Suite 200, Washington, DC 20036
Portland Cement Association (PCA), 5420 Old Orchard Road, Skokie, IL 60077-1083
Precast/Prestressed Concrete Institute (PCI), 175 West Jackson Boulevard, Chicago, IL 60604
Sheet Metal and Air Conditioning Contractors* National Association (SMACNA), P.O. Box 70, Merrifield VA 22116
Steel Tank Institute (STI), 728 Anthony Trail, P.O.Box 4020, Northbrook, IL 60065
Water Pollution Control Federation (WPCF), 2626 Pennsylvania Avenue, NW, Washington, DC 20035
Suresh C. Arya, Michael W. O*Neill, and George Pincus, Design of Structures and Foundations for Vibrating Machines,
Gulf Publishing Company, Houston, TX, 1979.
Omer W. Blodgett, Design of Welded Structures, The lames F. Lincoln Arc Welding Foundation,
Cleveland, OH, 1966.
A-5
TM 5-809-6/AFM 88-3, Chap. 6
Joseph E. Bowles, Foundation Analysis and Design, Second Edition, McGraw-Hill Book Company,
New York, NY, 1977.
Braja M. Das, Principles of Foundation Engineering, Wadsworth, Inc., Belmont, CA, 1984.
Mark Fintel, Handbook of Concrete Engineering, Second Edition, Van Nostrand Reinhold Company,
New York, NY, 1985.
Edwin H. Gaylord & Charles N. Gaylord, Structural Engineering Handbook, Second Edition, McGraw-Hill
Book Company, New York, 1979.
M. Reimbert & A. Reimbert, Silos: Theory & Practice, (Bulk Materials Handling Ser: Vol. 1, No. 3),
Trans Tech, Germany, 1976.
A-6
TM 5-809-6/AFM 88-3, Chap. 6
The proponent agency of this publication is the Office of the Chief of Engineers, United States
Army. Uses are invited to send comments and suggested improvements on DA Form 2028
(Recommended Changes to Publications and Blank Forms) to HQUSACE, (CEMP-ET),
WASH DC 20314-1000.
GORDON R. SULLIVAN
General, United States Army
Official: Chief of Staff
MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
Distribution:
Army: To be distributed in accordance with DA Form 12-34-E, requirements for nonequipment technical
manuals.
Air Force: F