The project involved designing a steel pipe rack / pipe bridge for an oil and gas plant. This rack serves as the backbone for routing multiple process pipelines, cable trays, coolers, and equipment platforms. The structure had to ensure safe operation, optimized material usage, and future flexibility, while accommodating maintenance access and equipment clearances.

This blog highlights the design approach, obstacles, and resolutions involved in creating this complex structure.

Project Overview

Structure Type:
Multi-bay steel framing system with rolled and built-up sections.

Scope of Work

• Analysis and Design:
  Global structural analysis and design of both superstructure and foundation using advanced software, considering seismic response spectrum and wind actions.

• Connection Design:
  Structural connections, including base plates and member-to-member joints, were meticulously designed to ensure the safe and efficient transfer of forces.

• Modelling:
  Creation of a 3D structural model coordinated with piping and equipment layouts.

• Drawings:
  Preparation of detailed structural drawings.

Primary Challenge

The main challenge was to design a safe yet optimized structure capable of withstanding high seismic and wind forces, while supporting multiple pipes and equipment without excessive material usage.

Design Challenges

Seismic and Wind Effects

• High lateral forces demanded stringent drift control and ductile detailing.

• Wind-induced sway and uplift required strong anchorage and bracing.

Load Complexity

• Multiple pipe sizes, coolers, and trays created eccentric loads and torsional effects.

• Future load provisions added uncertainty to the design.

Optimization vs Safety

• Balancing material economy with structural strength under extreme load combinations.

Foundation Design

• Uplift and overturning moments under seismic and wind combinations.

• Settlement control to maintain piping alignment.

Constructability and Access

• Dense piping and equipment required clear walkways and safe margins.

Engineering Strategy & Structural Design

Structural System Selection

• Adoption of a robust yet efficient framing system to carry gravity loads and resist lateral forces.

• Combination of moment frames and braced frames to ensure stability while minimizing interference with piping and equipment layouts.

• Provision of expansion bays to accommodate thermal movements and future modifications.

Load Identification & Distribution

Consideration of all relevant loads:

• Permanent loads (self-weight, grating, equipment)

• Variable loads (maintenance live load, pipe operating and test loads)

• Environmental loads (wind and seismic forces)

Loads were distributed realistically, accounting for eccentricities from pipe clusters and equipment.

Analysis Approach

• Development of a 3D structural model using advanced analysis software.

• Global analysis for overall stability and local checks for individual members.

• Inclusion of dynamic effects such as seismic response and wind-induced vibration.

Member Design

• Beams, columns, and bracing designed for combined axial, bending, and shear forces.

• Lateral stability ensured through adequate bracing and restraints.

• Serviceability checks for deflection, drift, and vibration to ensure operational safety.

Connection Detailing

• Connections designed to transfer forces effectively between members.

• Ductility and strength ensured for reversible and cyclic loading conditions.

• Simple, inspectable detailing adopted for ease of fabrication and maintenance.

Foundation Design

• Foundations designed to resist vertical loads, lateral forces, and overturning moments.

• Uplift and settlement control addressed to maintain alignment of piping and equipment.

• Foundation type selection based on soil conditions and load intensity.

BIM Integration

• BIM coordination used for clash detection between structural elements, piping, equipment, and foundations.

• Enabled real-time interdisciplinary collaboration, improving constructability.

Safety & Access

• Integration of walkways, guardrails, kick plates, and safe margins around openings.

• Adequate space ensured for maintenance and future expansion.

Design Outcome Summary

• Excellent structural stability achieved through anchor bays and braced frames.

• Seismic and wind effects, lateral drift, and vibration maintained within safe limits.

• Optimized material usage without compromising safety or reliability.

• Expansion bays and future load provisions integrated into the design.

• Clear walkways and access points ensured ease of construction and maintenance.

(3D model and wireframe view generated in STAAD for analysis)

Conclusion

This project demonstrates Paradigm’s capability to deliver strong, reliable infrastructure for the oil and gas industry under demanding conditions. By combining rigorous seismic and wind-resistant design principles with cost-effective engineering solutions and BIM-driven coordination, the steel pipe rack was designed to be safe, durable, and future-ready.

The final structure integrates seamlessly with plant operations and meets the evolving demands of modern industrial facilities.

About Author

Ashly Paul is an experienced structural engineer with 6+ years of experience in structural design, analysis, and management of diverse structural projects. She has worked on refinery and power plant structures, with a strong focus on innovative and sustainable design solutions. With expertise in structural analysis software, construction practices, and project coordination, she brings both technical knowledge and practical insight to every project.

The post Paradigm Designs a High-Performance Steel Pipe Rack for an Oil and Gas Plant appeared first on Paradigm.

We take pride in delivering engineering solutions that push the boundaries of conventional design. One of our most technically ambitious and rewarding undertakings involved the design and analysis of a multi-level warehouse, incorporating crane systems and all modeled and validated using advanced 3D tools.

This wasn’t just a theoretical exercise, it was a real-world design challenge, executed with precision by coordinating with MEP, and aimed at maximizing usable space without compromising structural integrity.

Project Overview

• Structure Type: Multi-level warehouse with integrated storage and logistics zones

• Design Scope:

• Superstructure:

  • Steel or RCC frame system based on span and load requirements

  • Roof trusses or portal frames for large clear spans

• Foundations:

  • Deep foundations (bored piles or raft) based on soil conditions

  • Pile caps and grade beams to distribute loads from columns and crane supports

• Crane System Integration

  • Overhead Gantry Cranes:

    • Design runway beams and brackets for EOT (Electric Overhead Travelling) cranes

    • Include crane columns and bracing for lateral stability

  • Monorail or Jib Cranes:

    • Localized support systems for workstation-level lifting

• Primary Challenge: Design a warehouse with cranes and other lifting mediums for storage of different hazardous substances.

Key Design Challenges

• Managing high live loads from forklifts and storage racks
• Foundation design complexity due to heavy point loads from crane columns and differential settlement risk because of uneven loading from cranes
• Navigating variable soil strata and groundwater conditions
• MEP Routing conflicts like overhead space constraints, service accessibility etc.

Engineering Strategy & Structural Design

To meet the design goals, we adopted a top-down structural approach, supported by detailed 3D modelling.

Core Design Elements:
• Crane Load accommodation by using high-strength steel beams and precast concrete girders
• Design for dynamic loads, including impact, acceleration, braking, and lateral sway
• Foundations are considered as isolated or pile foundations
• Early-stage BIM Integration: Use Building Information Modelling (BIM) from the conceptual stage to coordinate crane supports, structural elements, and MEP systems
• Dedicated Crane Pathways: Reserve overhead zones exclusively for crane runways and lifting operations, with MEP routed around or beneath these paths

3D Modelling & BIM Integration

• The entire structure was modeled using Building Information Modelling (BIM) tools
• Clash detection and tolerance checks were performed to ensure constructability
• Underground MEP utilities are integrated into the BIM model, and clash detection is performed to ensure coordination with structural elements and avoid interference during construction

Design Outcome Summary

• A structurally sound warehouse was designed with integrated crane systems for storage and services
• Crane-supporting beams and columns were optimized for dynamic loads, deflection control, and vibration resistance
• Crane-supporting beams and columns were optimized for dynamic loads, deflection control, and vibration resistance
• Structural elements were validated for seismic, wind, and operational loads using advanced analysis tools
• The design complies with IS, BS EN, and OSHA standards, ensuring safety, durability, and operational efficiency

Conclusion

This warehouse design demonstrates the integration of structural innovation and operational efficiency. Using detailed analysis, 3D modeling, and adaptive engineering, we developed a high-performance facility that meets modern industrial needs while ensuring safety and functionality.

About Author

The author Ashly Paul is an experienced structural engineer having 6+ years of experience in structural design, analyzing, and managing diverse structural projects. Skilled in applying engineering principles to ensure safety, functionality, and cost-effectiveness. She has worked on refinery and power plant structures, with a strong focus on innovative and sustainable design solutions. With expertise in structural analysis software, construction practices, and project coordination, she brings both technical knowledge and practical insight to every project.

The post Structural Analysis and Design of Warehouses with Integrated 3D Modelling by Paradigm Engineering appeared first on Paradigm.

Introduction

Circular platforms are an integral part of refinery structures. They are used to support heavy equipment, pipelines, and access systems, while also ensuring safety and stability for operational needs. Preparing accurate designs and detailed drawings for such platforms requires a blend of engineering expertise and advanced modelling tools.

Project Overview

In our company, we have successfully executed many refinery projects involving circular platforms and their foundations. Each project required close coordination with process, piping, and mechanical departments to meet the complex functional requirements.

Snaps from Model and drawings

Structural Analysis and Design

The process begins with a thorough structural analysis. Circular platforms often need to carry eccentric loads from pipelines, vessels, and rotating equipment. Our engineering team carefully evaluates:

• Load combinations (dead, live, equipment, wind, seismic, piping, snow, etc.).

• Foundation interaction, considering soil conditions.

• Dynamic effects, especially where rotating machinery is involved.

We ensure that the design complies with industry standards and project-specific guidelines. The outcome is a safe, efficient structure capable of long-term performance.

Foundations are critical for refinery platforms, especially since they support concentrated loads. Our detailing covers:

• Raft and isolated footing design.

• Anchor bolt layouts and embedment details.

• Reinforcement schedules for concrete works.

• Special detailing for vibration and heavy equipment loads.

Modelling and Detailing

Once the design is finalized, we will be converting concepts into highly detailed 3D models.

• Model primary and secondary steel members with precision.

• Generate detailed connections suitable for fabrication.

• Prepare general drawings showing anchor bolts, pedestals, and reinforcements.

• Create clash-free models by coordinating with piping and equipment layouts.

The 3D model ensures better visualization, quick revisions, and high-quality deliverables for both fabrication and erection.

Deliverables & Results

Upon completion, the following engineering outputs are generated:

• Analysis and Design results

• 3D Model

• 2D general arrangement drawings

• Erection and fabrication drawings

• Design calculation report

Conclusion

Over the years, we have successfully completed many refinery projects involving circular platforms. Each project presented unique challenges, from congested layouts to strict safety requirements. Our combination of structural analysis, design expertise, and Tekla modelling has helped us deliver accurate, constructible, and cost-effective solutions.

By integrating advanced analysis with Tekla modelling, we provide end-to-end solutions that ensure structural safety, fabrication accuracy, and ease of construction on-site.

About Author

Rinshadul Haque K P is a Structural Engineer specializing in design, Tekla modelling, and structural drawing preparation. With hands-on involvement in various industrial projects, including power plants and refineries, the author brings a practical understanding of BIM-based workflows and detailing standards. Passionate about precision and coordination, they focus on delivering efficient, high-quality structural solutions using modern tools and technologies.

Related Services

Explore More Of Our Expertise:

• • Structural Design
  • Geotechnical Consulting Firm
  • Structural Steel Detailing Services
  • Reinforcement Detailing
  • BIM Services
  • Preconstruction CAD Services
  • As Built Services

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