Reinforced Concrete Chimneys IP 4-5-2
INTERNATIONAL Page 1 of 4
PRACTICE
Rev. 1 March 1998
Changes shown by
SCOPE
I 1.1 This practice covers the design, construction and inspection of reinforced concrete chimneys.
I 1.2 An asterisk () indicates that a decision by the Owner is required or that additional information is furnished
by the Owner.
SUMMARY OF ADDITIONAL REQUIREMENTS
I 2.1 Table 1 lists the practices and standards which shall be used with this practice as specified.
TABLE 1
PRACTICES
IP 4-1-1 Concrete Design and Construction
IP 4-6-1 Reinforced Concrete Foundations and Anchor Bolts
STANDARDS
ACI Standards
211.1 Recommended Practice for Selecting Proportions for Normal and Heavyweight Concrete
301 Specifications for Structural Concrete for Buildings
307 Specification for the Design and Construction of Reinforced Concrete Chimneys
ANSI Standards
A14.3 Safety Code for Fixed Ladders
C5.1 Lightning Protection Code
I 2.2 Table 2 lists the practices, standards and publication which shall be used with this practice as applicable.
TABLE 2
PRACTICES
IP 4-7-1 Piles and Sheet Piling
IP 14-1-1 External Insulation
IP 19-3-3 Linings for Fired Heaters
STANDARDS AND PUBLICATION
ASTM Standards
C64 Refractories for Incinerators and Boilers
CICIND (International Committee on Industrial Chimneys) Publication
Model Code for Concrete Chimneys
Part B Brickwork Linings
Part C Steel Liners
I 2.3 If local codes or standards exist for the materials, design, and test methods covered in Table 1 and
Table 2 which yield comparable quality, they may be substituted if approved by Owner's Engineer.
DOCUMENTATION
PROPOSAL INFORMATION
I
3.1 An outline drawing shall be provided, showing the chimney and foundation diameters, height, taper, flue
arrangement, location and size of openings. The drawing shall also include a data sheet listing anticipated
concentration of sulphur in the fuel burned and maximum and minimum gas exit velocities; gas
temperatures at each duct entry and gas exit temperatures. This data shall relate to both normal and
abnormal operating conditions.
I 3.2 Complete material specifications shall be provided for the shell, flue, insulation, accessories, and the
foundation.
THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY
EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
IP 4-5-2 Reinforced Concrete Chimneys
Page 2 of 4 INTERNATIONAL
PRACTICE
Rev. 1 March 1998
CONSTRUCTION DRAWINGS AND CALCULATIONS
I 3.3 Copies of all computations on which design drawings are based shall be furnished. Construction
drawings shall show details of the shell, flue, insulation accessories, and foundation. The minimum and
maximum temperatures for which the various components are designed shall also be shown.
MATERIALS
I
4.1 Proposals to use concrete admixtures shall be submitted for approval by the Owner's Engineer.
R 4.2 Materials for use in acid resisting brickwork shall comply with the requirements of the CICIND Model
Code for concrete chimneys, Part B - Brickwork Linings. When acid resistant coatings are required for the
inner surfaces of steel liners, hydraulic setting castable containing a catalyzed sodium silicate cement
(Sauerseisen No. 33, 54, or 72 cements) or demonstrated equal shall be used.
R 4.3 Hastalloy, Type 316L stainless steel, silicon bronze, or lead-sheathed carbon steel shall be used for the
following applications:
a. Anchor bolts for ladders, platforms and scaffold supports exposed to flue gases.
b. All external hardware which may be in contact with flue gases (e.g., within 5 diameters of the top
of the chimney).
DESIGN
R 5.1 Cast-in-place reinforced concrete chimneys shall be designed and constructed per ACI 307 unless
otherwise specified.
R
5.2 The seismic risk zone for earthquake loads will be specified. The specified design wind speed or 80 mph
(36 m/s), whichever is greater, with an Importance Factor, I, of 1.0 shall be used for wind loads.
I 5.3 Thermal stresses shall be determined for the shell and the flue, using the largest anticipated temperature
differential, including startup, shutdown, normal and abnormal operating conditions.
I 5.4 Stresses shall be determined at the base, at levels of openings, and at 10 or more regular intervals
along the height of the chimney.
I 5.5 Foundation design shall be per IP 4-6-1. The relevant “Design overturning moment" relates to unfactored
loads. For chimneys taller than 300 ft (90 m), the entire chimney foundation must remain in compression
when the completed chimney is subjected to the design overturning moment, regardless of soil type.
I 5.6 Foundations and elevated floors which support the flue shall not be directly exposed to hot flue gases.
Sufficient insulation, vents, drains, coatings and flashing shall be provided to control concrete temperatures
and minimize corrosion.
R 5.7 Minimum airspace width for chimneys with free-standing brickwork flues shall be 8 in. (200 mm) for
chimneys of heights up to 200 ft (60 m). An additional 3 in. (75 mm) clearance shall be provided for each
additional 100 ft (30 m) height. A 30 in. (750 mm) minimum clearance shall be provided when inspection
capability is specified.
I 5.8 Lightning protection shall be provided per ANSI C5.1.
R 5.9 Special care shall be taken to ensure the long term integrity of all items attached externally to the shell
or to exposed parts of the flue. Such items include insulation protection, rainshields, lightning
conductor rods, aircraft warning lights, ladders and platforms. In their design and the design of their
attachments, the effects of stress corrosion and fatigue damage, due to wind “Flutter," shall be considered.
Rainshields protecting the annular airspace shall not be attached to the flue.
I 5.10 When a Flue Gas Desulfurization (FGD) or energy conservation system involves cooling flue gas
below its acid dew point, followed by reheat, achieved by mixing with by-passed flue gas, the mixing shall
be accomplished upstream of the stack.
BRICK FLUES
R 5.11 Acid-resisting brickwork flues shall be used in stacks serving units equipped with Flue Gas
Desulfurization systems, or if the sulfur content of the fuel fired exceeds 0.5 mass % (flue gas sulfur
concentrations 17 grains per 100 scf or 400 mg/m 3 are considered equivalent for this purpose) and the hot
face temperature of any part of the flue is less than 350F (175C).
I 5.12 Independent brick flues shall have a minimum thickness of 8 in. (200 mm).
THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY
EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
Reinforced Concrete Chimneys IP 4-5-2
INTERNATIONAL Page 3 of 4
PRACTICE
Rev. 1 March 1998
R 5.13 Stresses in the brickwork shall comply with the requirements of the CICIND Model Code for Concrete
Chimneys, Part B - Brickwork Linings. Where test data on the relevant brickwork properties are not
available, the following may be assumed:
Characteristic compressive strength = 900 psi (6.3 MPa) or 15% of the minimum
crushing strength of the bricks used
Modulus of elasticity (Eb) = 3.0 x 106 psi (2.1 x 104 MPa)
Admissible thermal stress (b,adm) = 300 psi (2.1 MPa)
R 5.14 Independent brick flues shall be externally reinforced with flat steel bands for their full height. These
bands shall be protected against acid condensate corrosion.
I
5.15 The dryout procedure for brick flues shall be submitted for approval by Owner’s Engineer.
STEEL FLUES
I 5.16 Steel flues shall conform to CICIND Model Code for Concrete Chimneys, Part C - Steel Liners, except that
application of insulation shall be per IP 14-1-1.
R 5.17 The length of flue exposed to flue gas, below the lowest duct entry, shall be no more than 1 m.
LININGS AND COATINGS
R 5.18 When a steel liner is used to carry gases from a sulfur incinerator or a unit in which hydrocarbon is
heated, a 3 in. (75 mm) thick refractory fireproofing lining shall be applied to its inner face. The refractory
may be medium weight castable, per IP 19-3-3 if:
a. Sulfur content of the fuel is less than 0.5 mass % (17 grains per 100 scf or 400 mg/m 3 of the flue
gas are considered equivalent for this purpose), or
b. Sulfur content of fuel exceeds 0.5 mass %, but the hot face temperature of the refractory exceeds
350F (175C).
R 5.19 An acid resistant lining shall be applied to the inside surface of steel flues if the sulfur content of the fuel
fired exceeds 0.5 mass % and the hot face temperature of any portion of the flue is less than 350 F
(175C).
R 5.20 An acid resistant coating shall be applied to the inside surface of the concrete shell, including any
corbels and support beams or slabs, for chimneys with brick flues and an air space less than 30 in. (750
mm) wide if the sulfur content of the fuel fired exceeds 0.5 mass %. Provision shall also be made to drain
the flue support system. Packing at flue expansion joints shall be of a flexible acid resistant material such
as Viton “A."
I 5.21 Acid resistant linings and coatings shall have proven long term integrity and acid resistance under wet
conditions at their anticipated service temperature.
R 5.22 Acid resistant coatings for external shell application shall be applied to all chimneys and meet the
following criteria:
a. The top 25 ft (7.5 m) of the external surface of the concrete chimney shall be coated with coal tar
epoxy or other acid resistant coating having a demonstrated history in similar service.
b. Coating manufacturer shall supply a written procedure for surface preparation, application and
required thickness subject to the Owner's approval. Linings and coatings shall be applied in
accordance with the manufacturer's instructions.
THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY
EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
IP 4-5-2 Reinforced Concrete Chimneys
Page 4 of 4 INTERNATIONAL
PRACTICE
Rev. 1 March 1998
CONSTRUCTION REQUIREMENTS
I 6.1 Erection tolerances for concrete and brickwork shall be as follows:
ITEM TOLERANCE
Variation of the vertical axis from plumb:
in any 10 ft (3 m) of height 1/4 in. (6 mm)
Maximum for entire height 0.1% of height
Variation of minimum measured inside diameter 1% of nominal inside diameter at cross-section
from that specified at any cross-section under consideration
Out-of-roundness, measured as the difference 2% of nominal inside diameter at cross-section
between maximum and minimum inside under consideration
diameters at any cross-section
Variation in cross-sectional dimensions or
thickness of shelf, slab, beams or columns:
Minus 1/4 in. (6 mm)
Plus 1/2 in. (13 mm)
I 6.2 The pile cap or foundation mat shall be constructed in one continuous concrete placement.
Revision Memo
1/72 Original Issue of Basic Practice
1/75 Revision 1
1/76 Revision 2
12/90 Revision 3
6/96 Revision 0 - Original Issue of International Practice
3/98 Revision 1
Practice subjected to rationalization process. Added New Par. 5.1 for clarification of applicable design code. Old Par.
5.1 deleted since covered in Code. Par. 5.3 combined into Par. 5.2. Par. 3.4 combined into Par. 3.3.
Old Par. No. New Par. No.
5.3 - 5.23 5.2 - 5.22
Exxon Research and Engineering Company, 1996, 1998
THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY
EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
