STANDARD DESIGN

CRITERIA (StDC)
BASIC REQUIREMENTS

©Mannersdorf/Austria

EDITION MARCH 2022

Standard Design Criteria Edition March 2022
Basic Requirements 2/24

Change Index

Version Description Tool Owner

All Update March 2022 Corporate CEM/PME
Michael Weihrauch

Holcim Technology Ltd

Corporate CEM/PME

Document Number: LHSTX-PM&E-OS09-000000-001-02

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 3/24

TABLE OF CONTENT

Health & Safety ........................................................................................................................ 5

Introduction............................................................................................................................... 6
1. Plant Classification: Mechanical, Electrical Equipment, Civil and Structural Works ... 8
2. Equipment Standardization, Materials and Standards ............................................... 8
2.1 Equipment Standardization ........................................................................................ 8
2.2 Materials and Standards ............................................................................................ 8
3. Health and Safety and Maintenance Aspects ............................................................ 9
3.1 General ....................................................................................................................... 9
3.2 Health and Safety ....................................................................................................... 9
3.2.1 General ....................................................................................................................... 9
3.2.2 Potentially explosive atmospheres ............................................................................. 9
3.2.3 Warning signs ........................................................................................................... 10
3.2.4 Start-up alert systems .............................................................................................. 10
3.2.5 Emergency stop devices .......................................................................................... 10
3.2.6 Guards ...................................................................................................................... 10
3.2.7 Explosion Vents ........................................................................................................ 10
3.2.8 Isolation Valves ........................................................................................................ 10
3.2.9 Traffic Plan, Roads and Parking Areas .................................................................... 11
3.2.10 Pedestrian Walkways ............................................................................................... 11
3.2.11 Sub Surface Equipment Installation ......................................................................... 11
3.2.12 Permanent life lines and anchor points .................................................................... 11
3.2.13 Dust collecting hoppers ............................................................................................ 11
3.2.14 Piping ....................................................................................................................... 11
3.2.15 Forced ventilation ..................................................................................................... 12
3.2.16 Emergency Showers and Eye Wash Stations .......................................................... 12
3.2.17 Water ........................................................................................................................ 12
3.3 Maintenance ............................................................................................................. 12
3.3.1 Accessibility .............................................................................................................. 12
3.3.2 Supporting Structures, Maintenance Platforms, Accesses....................................... 12
3.3.3 Modularity of Equipment ........................................................................................... 13
3.3.4 Hoists ....................................................................................................................... 13
3.3.5 Lifting lugs ................................................................................................................ 13
3.3.6 Condition Based Maintenance ................................................................................. 13
3.3.7 Identification/Marking ............................................................................................... 14
3.3.8 Access, inspection and clean-out doors on equipment ............................................ 14
4. Quality and Operational Aspects .............................................................................. 14

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 4/24

4.1 Site Assembly ........................................................................................................... 14

4.2 Welding .................................................................................................................... 14
4.3 Corrosion protection, Painting, Galvanization .......................................................... 15
4.3.2 Examples of surface treatment ................................................................................. 15
4.3.3 Color Code for Finishing Painting ............................................................................. 17
4.4 Name Plates ............................................................................................................. 19
4.5 Special Tools ............................................................................................................ 19
4.6 Bolts, Holding-Down Bolts and Base Plates ............................................................. 19
4.7 Consumable Materials .............................................................................................. 19
4.8 Insulation and Cladding ............................................................................................ 19
4.9 Wear Parts and Wear Protection .............................................................................. 20
4.10 Vibration Prevention and Confinement ..................................................................... 20
4.11 Instrumentation tabs and mounting flange ............................................................... 20
5. Workplace and External Environmental Aspects...................................................... 20
5.1 Particulate Emissions and Controls .......................................................................... 20
5.1.1 Nuisance Dust Collection ......................................................................................... 20
5.1.2 Process Dust Collection ........................................................................................... 21
5.1.3 Particulate Emission Monitoring ............................................................................... 21
5.2 Gaseous Emissions and Control .............................................................................. 21
5.3 Noise Emission ......................................................................................................... 23
5.4 Liquid Effluents ......................................................................................................... 23

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 5/24

HEALTH & SAFETY

Health and Safety is our core value. At Holcim, we

want to do more than prevent accidents. We want to
create a healthy and safe environment for our
employees, contractors, communities and customers
based on a true safety culture.
Health and Safety is at the center of everything we do,
from the daily routines in our plants to our customers’
project worksites and our actions in our neighboring
communities. Our aspiration is to conduct our business
with zero harm to people. We believe in visible
leadership and personal accountability for Health and
Safety at all levels and throughout our organization.

To reach this aspiration, we are committed to:

• Maintain a global Health and Safety Management System designed to continuously
improve our performance and actively manage risk in our business
• Drive for operational discipline by instilling a mindset of safe execution and follow-up
• Communicate openly with all stakeholders on relevant health and safety issues

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 6/24

INTRODUCTION
Objectives of the Standard Design Criteria (StDC)

• Provide standard technical specifications to the Holcim community that is based on

proven technologies and practical experiences from constructing, maintaining and
operating plants.
• Achieve an optimized balance between high Overall Equipment Efficiency (OEE) and
Mean Time Between Failures (MTBF) during the expected lifetime of the assets
considering the lowest possible CAPEX.
• Ensure transparency and consistency among Supplier’s offers to Holcim projects.

Application and General instructions

• The Standard Design Criteria (StDC) covers all engineering projects including Cement
and Geocycle.
• The StDC is a reference guideline for designing new plants in Greenfield, Brownfield
replacement and revamping projects. This document is also equally applicable and
relevant for quarry & plant operation and maintenance teams for achieving efficient
operation & maintenance which will ultimately improve the overall plant performance.
• All statements and paragraphs marked with are design provisions for safe construction,
operation and maintenance of the plant. Deviations and exceptions are not allowed.
• For non-safety related design variations, justification of the alternative must be properly
recorded.
• The Basic Requirements document contains general specifications applicable for
Mechanical, Electrical and Civil design.
• The Mechanical Equipment, Electrical Equipment and Systems, and Civil and Structural
Works documents shall be used in conjunction with the Basic Requirements section.
• Specifications for Mechanical, Electrical and Civil components of the projects shall be
reflected in the Data Sheets (where available). They are intended to standardize the way
Suppliers present specifications to Holcim.
• The Standard Design Criteria lists certain codes and standards. In the event that any such
specified codes and standards are inconsistent with any codes or standards enforced by
law, the most stringent standard shall govern the Contractor’s performance as far as not in
conflict with local regulatory obligations.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 7/24

Contributors:
Michael Weihrauch CEM/PM&E (Tool Owner)
Ernst Bucher CEM/PM&E
Praveen Dubey Techport
Michel Sohet CEM/PM&E
Javier Alvarez HSE
Sajith Mohidee HSE
Dirk Wimmert CEM/PM&E
Parag Desai CEM/Maintenance
Rafael Menendez HSE
Paul Botha Geocycle
Werner Voramwald Geocycle
Beat Maier Geocycle

Sunil Gupta Techport

Marco Garello HSE
Dan Lewis Christensen HSE

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 8/24

1. PLANT CLASSIFICATION: MECHANICAL, ELECTRICAL EQUIPMENT, CIVIL

AND STRUCTURAL WORKS
Plant classification follows the specification as per Holcim Asset Coding (HAC) Manual. The
Contractor shall adopt the mentioned Plant classification thus ensuring proper identification
of all Equipment and the associated Cost of the Works. Also refer to paragraph 3.3.7
Identification/Marking.

2. EQUIPMENT STANDARDIZATION, MATERIALS AND STANDARDS

2.1 Equipment Standardization

The use of identical Equipment and components shall be maximized throughout the Project,
where practical, thus minimizing spare parts inventory while at the same time optimizing
maintenance procedures and parts interchangeability.
Equipment includes:
All Equipment or components performing similar functions at similar capacities shall be
identical in make, model and size and shall include identical components and parts such as
bearings, motors, seals, drives, control devices, etc.

2.2 Materials and Standards

a) The metric system (SI-units) applies exclusively for the design of the Plant including all
Equipment, provided that it is accepted for construction, fabrication, erection, safety
and environmental purposes in the country of project execution. This requirement is
extended to all documents, e.g. all specifications, drawings and operation- and
maintenance manuals.
The Contractor shall always include all metric equivalents on all drawings and
specifications, should the metric system not apply for any portion of the Plant.
b) Hazardous Substances need to be clearly labeled, identified, declared and reported
using the Globally Harmonized System (GHS) as well as any specific hazard
classification system regulatory requirements applicable to the country. All cargo,
carriers and containers etc. used for such substances shall meet this requirement,
declared in the respective forms i.e. Safety Data Sheet (SDS) and reported at all times.
An SDS must be obtained and kept at the site for all hazardous substances used to be
stored there. A hazardous substances risk assessment must be completed for all
intended uses of hazardous substances at the site.
Hazardous materials (inflammables, gases, corrosives, explosives, etc.) shall be stored
in suitable locations, to avoid pollution, fire and explosions.
Proper ventilation, accesses, containment, and security shall be provided according to
specific requirements or local regulations.
c) Prohibited and restricted substances as declared by International and Local
regulations and standards cannot be used.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 9/24

3. HEALTH AND SAFETY AND MAINTENANCE ASPECTS

3.1 General
a) The overall design shall be performed in a way to facilitate safe assembly and erection
at site and method statement shall be provided. The design shall allow for maximum
pre-assembly in order to minimize site fabrication and works.
b) Overall design shall ensure ease of maintenance and repair and result in facilities with
adequate provisions for safe operation, servicing and maintenance. Provisions shall be
made for proper maintenance and for the easy removal and replacement of
mechanical, electrical and other equipment.
c) The sizing of rooms and the location of equipment shall ensure adequate clear space
for equipment maneuvering and maintenance operations. The arrangement of valves,
control equipment and similar items shall ensure easy access and shall not be in
concealed areas.
d) In the selection of materials and equipment, due consideration shall be given to the
availability and cost of replacement parts and the need for special tools and
instructions in performing maintenance operations.
e) HAZID (Hazard Identification) study shall be carried out during the basic engineering of
the project, and any findings or recommendation shall be incorporated into the final
design.
f) HAZOP (Hazard and Operability) study shall be carried once the P&ID, functional
design specification (FDS) and other engineering specifications are ready, and any
findings or recommendation shall be incorporated into the final design. The HAZOP
study shall be chaired by an approved competent person who is independent of the
project or the contractor.
g) Precautions for plants and equipment operating in regions with very low ambient
temperatures to be obtained from the Holcim memo for precautions for the design of
mechanical equipment in cold climate conditions.

3.2 Health and Safety

3.2.1 General
The design must comply with Holcim Group Health and Safety standards as well as the
applicable Health and Safety regulations in the Country of project execution. The more
stringent Standard applies in case of conflict.

3.2.2 Potentially explosive atmospheres

Areas with potentially explosive atmospheres shall be classified into corresponding
Hazardous Areas as per ISO/IEC 60079-10 Part 1 and Part 2 and equipment located in
those areas (Ex zones) shall be designed according to the applicable international and local
standards defined for those areas (ATEX, IECEx or NEC/SEC certified). The demarcation of
all Ex zones shall be clearly documented by the Contractor and the Hazardous Area
Classification (HAC) drawings submitted for review by the Owner.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 10/24

The plant layout shall be designed such that to minimize the Ex equipment and prevent
unauthorized access (e.g. switchgears, control panels, electrical equipment, junction boxes
could be located away from the dusty area - none Ex).

3.2.3 Warning signs

Warning signs to warn personnel of workplace hazards and instruct employees on ways to
avoid injuries shall be as pictograms in English and local language(s).

3.2.4 Start-up alert systems

Every Plant Department shall be equipped with visible and audible start-up alert systems to
notify start of process equipment.
All moving machinery shall be equipped with warning devices being activated before and
during any movement.

3.2.5 Emergency stop devices

Every Plant Department shall be equipped with local manual and automatic emergency stop
devices, thus preventing injury to people or damage to Equipment.

3.2.6 Guards
Safety guards shall be installed in order to prevent, where necessary, any physical contact
with moving machinery or moving Components.
Guards shall be easy handable, colored and removable only with the aid of a tool or in
conjunction with an interlock.
Guards must be manufactured from good quality and durable materials to prevent access
and/or the ejection of material or objects.
Positioning of the guard must provide adequate clearance between the hazard and the reach
point of body parts being protected.
Guards must be designed to reduce manual handling risks when being removed or replaced
(e.g. lifting points or handles).
All machine safety guards shall be designed in accordance with local regulations or
International Standards.

3.2.7 Explosion Vents

The explosion vents shall be designed according to ISO/EN 14491 and be located in such a
way that the explosion waves propagate away from the building into open areas that are
made inaccessible to the workers during normal operation of the plant. Restricted access
and platform shall be provided to maintain the explosion vent.

3.2.8 Isolation Valves

Lockable isolation valves for compressed air, water and fuels shall be provided at each
diversion, building entrance and next to consumption points.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 11/24

3.2.9 Traffic Plan, Roads and Parking Areas

Access roads to Owner’s customer shipping areas, service(s) building(s), and raw material &
fuel storage areas shall be kept separate from access to production areas.
An alternative access to be considered in the layout as part of the rescue plan.
Pedestrian areas, roads (vehicle traffic routes) and parking areas shall be laid out and
designed to provide distinct separation from each other.
The design of roads and accesses shall be done in the way to facilitate
maneuverability of the equipment, minimizing the need of reversing, and by avoiding
interference between different equipment and vehicles that would operate at the area.
The extent of properly paved roadways and surfaces needs to be assessed for each
project based on the environmental impact and occupational exposure to dust.

3.2.10 Pedestrian Walkways

Pedestrian walkways shall be well marked with a clear separation from areas that are
intended for vehicle traffic. Roadway & railway crossings shall be well marked with
appropriate signage alerting operators and pedestrians of the danger. If the walkway passes
under a conveyor, overhead protection shall be provided to protect pedestrians from falling
objects.

3.2.11 Sub Surface Equipment Installation

Equipment installations below ground level shall be justified and if required properly designed
(escape routes, space for maintenance, water drainage…).

3.2.12 Permanent life lines and anchor points

Anchor Points must be suitable for the conditions prevailing in the workplace (e.g. weather,
salt water spray or other corrosives, extremes of temperature).
Anchor points must be designed, manufactured and installed to ensure a static load capacity.
Anchors must be able to support 22kN per worker attached.
Anchors must be tagged with their rating.
Anchorages for specific purposes must be tagged as such, e.g. “Work position only”, or
“Rope access only”, etc.
Doors and manholes to vertically access confined spaces shall be provided with double
anchoring point and need to be compatible for access and rescue requirements.

3.2.13 Dust collecting hoppers

Dust collection hoppers shall be designed for being 110% full of material.

3.2.14 Piping
For fixed pipe work, the pipes shall be routed as much as possible away from any vehicle
traffic road (to avoid collision damage). If routed alongside a road, protection shall be
provided (ex: road railing). Piping shall be marked with color and/or label.
Pipes shall be tested against leakage by pressure test or equivalent.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 12/24

The route of underground pipe work shall be adequately protected from physical damage
such as excessive surface loading, ground movement or ground disturbance and clearly
marked (with warnings provided by standard colored plastic mesh). If mechanical joints used,
they shall be installed in a closed inspection pit, which is readily accessible for inspection.

3.2.15 Forced ventilation

A forced ventilation system shall be provided whenever ventilation is required for regular
operation activities.

3.2.16 Emergency Showers and Eye Wash Stations

A risk assessment must reveal where Emergency showers and eye wash stations with non-
contaminated water at suitable temperature must be provided including:
a) Each of the three lowest stages of the preheater
b) Main burner platform
c) Chemical storages
d) Wet-chemistry laboratory
e) Plant control room
f) Other relevant areas with the risk of exposure incidents due to hazardous substances
(i.e. water treatment, ammonia storage etc.)

3.2.17 Water
Source of water accumulation around the site must be avoided to prevent associated health
risks (e.g. in malaria areas to reduce mosquitos for vector control, prevent water sources that
can be contaminated with rodent borne diseases such as leptospirosis etc.).
Reject flow to the natural environment shall be regulated.
Adequate filtration devices shall be provided to avoid the transport of oil/grease and solids
(oils/sand traps) prior to any discharge to external networks and/or bodies of water.

3.3 Maintenance

3.3.1 Accessibility
All Equipment that require periodic inspection, lubrication, cleaning, adjustment, repair or
replacement, or that are designed for manual operation or cleaning, shall be easily
accessible by virtue of their location or by means of stairs, galleries, fixed ladders or
platforms.

3.3.2 Supporting Structures, Maintenance Platforms, Accesses

a) The design and specifications of platforms and walkways must follow the requirements
of ISO 14122 as a minimum.
b) Anchor points shall be provided to permit the safe use of harnessed access to roofs and
sides of buildings.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 13/24

c) All supporting structures, maintenance platforms and access facilities to Equipment shall
be designed as required to provide the proper and safe access to the Equipment for the
purpose of inspection and maintenance.
d) Concrete silo outlet equipment shall be accessible without ladders and equipped with
two sides platform made of grates.
e) Steel silos outlet equipment might be accessible with ladders conditional to safety
engineering provisions.
f) Distance between floor or platform (fixed or movable) to equipment and instrumentation
shall not exceed 1.6m, unless otherwise approved by the Owner.
g) Platforms have to be dimensioned to provide lay-down areas for spare parts and
consumables.

3.3.3 Modularity of Equipment

Components of Equipment shall be modular in design thus facilitating easy and fast
maintenance, exchange or repair with minimal interference with other components. Quick
connectors, plug & socket systems, etc. shall be used to ease maintenance, replacement
and repair.

3.3.4 Hoists
a) Hoists, monorail trolleys and hooks shall be included to enable safe maintenance and
repair service.
b) Unless maintenance with a mobile crane has been considered in the layout, all hoists,
monorail trolleys and hooks shall be designed for the safe lifting and transfer of the
heaviest and the biggest component of the Equipment.
c) The appropriate installation of support beams shall be included for Equipment which is
moved once a year or less.
d) Permanently installed hoists shall be included or design shall enable usage of mobile
cranes for more frequently moved Equipment.
e) Safe access and/or platform shall be provided for the maintenance or operation of
hoists.

3.3.5 Lifting lugs

Equipment to be dismantled for regular maintenance shall be equipped with lifting lugs (or
equivalent) and lifting procedure shall be clearly described in the equipment user manual.

3.3.6 Condition Based Maintenance

The drives of raw mills, kilns, cement- and coal mills and main process fans shall be
equipped for state-of-the art online and/or offline data collection for condition monitoring.
Refer to StDC part Mechanical Equipment.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 14/24

3.3.7 Identification/Marking
All Equipment, sub-assemblies, components, units, instruments, pipes and electric cables
shall have unmistakable Holcim Asset Coding (HAC) identification. HAC codes shall be
appropriately extended where necessary. All markings shall be both in Contract Language as
well as in the Project Owner's preferred language. Markings shall correspond with the data,
symbols and instructions used in the Operating- and Maintenance Manuals.
Signs shall be provided to indicate the risks on:
a) Personal protective equipment (PPE) requirement in each area.
b) On equipment and installations, i.e. accessible equipment with surfaces temperature
above 60°C.

3.3.8 Access, inspection and clean-out doors on equipment

All equipment shall incorporate access, inspection and clean-out doors as required to assist
in daily maintenance of equipment, locating potential problems, verifying the proper operation
of the equipment and related instrumentation and control devices.
Access manholes, Inspection and clean-out doors shall:
a) Be provided with suitable platforms and accesses
b) Be located where the worker will not be exposed to danger (e.g. projections)
c) Require a tool for opening
d) Be of hinged design
e) If potential to swing open, a measure shall be provided to limit the opening or swinging
f) Access manholes shall be designed to allow passage, minimum dimensions shall be as
per the applicable regulations, but not smaller than 610 mm diameter
g) Be insulated when installed on insulated equipment

4. QUALITY AND OPERATIONAL ASPECTS

4.1 Site Assembly

Equipment shipped to the Site shall be pre-assembled to the considering restrictions for
shipping and handling. All Equipment shall be properly prepared for the Site assembly with
appropriate alignment holes, match markings and all required temporary bracings. Special
devices, parts and tools necessary for proper Site assembly shall be identified and provided
with the Equipment.

4.2 Welding
All welding materials required for on-site assembly shall be supplied in the required quality
and in sufficient quantity including spares. It shall be properly packed and marked according
to its intended use. Welding instructions shall be included. The Equipment shall be properly
prepared for welding.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 15/24

4.3 Corrosion protection, Painting, Galvanization

a) All steel and cast surfaces of equipment and its supporting steel structures shall have
surface preparation and corrosion protection (painting or galvanizing) treatment
according to the corrosive categories C1 to C5 of ISO 12944-2.
The required category for the project is defined in the respective Contract document.
b) The quality of surface treatment systems for equipment shall be equal or superior to
the criteria in Paragraph 4.3.1 (Examples of surface treatment).
c) The color-coding shall meet the requirements of the table in Paragraph 4.3.2 (Color
Code for Finish Painting).
d) Original equipment manufacturer (OEM) standard color is acceptable.
e) The Contractor shall design its surface treatment systems according to duration class
“Medium” (5 to 15 years) or superior as specified in ISO 12944-5, § 5.5.
f) If there is no seaworthy packing provided, the painting shall give a protection against
corrosion during sea transport.
g) The paint required for touch-up painting work during and after erection of the
equipment shall not deviate from the initial paint as per specification.
h) The following procedures shall be strictly followed for all site-painting work:
• Touch-up painting work shall recover all damages on the painted surface of the
Equipment caused during sea and land transportation, erection and commissioning).
• Surface treatment shall be satisfactorily carried out prior to commencement of
painting. In particular welding spatters and slag shall be removed prior to painting.
• The addition of any other dilution (thinners) than requested by paint Supplier is not
allowed.

4.3.2 Examples of surface treatment

a) For each relevant ISO 12944 class examples of surface treatment systems of two
different corrosion protection and paint specialists are listed in the table below.
b) The table also lists examples of surface treatment systems which are not covered by
ISO 12944 for Equipment operated above 120°C.
c) Qualities equal or superior to the examples listed in the table below are requested.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
 Standard Design Criteria Edition March 2022
Basic Requirements 16/24

WORKSHOP ERECTION AT SITE

ISO 12944 EQUIPMENT OPERATING PRE- PRIME COAT DFT TOUCH-UP CLEANING FINISH COAT DFT
CLASS TEMPERATURE TREATMENT & REPAIR
Range EXAMPLES EXAMPLES

C2 In- & Ambient up to 120 Surface Tolerant 100 Aliphatic 50

Outdoor C High Solid Epoxy micron Polyurethane micron
AMERLOCK 400C AMERCOAT
450-Series

Surface Tolerant 80 Polyurethane 50

High Solid Epoxy micron SF 11/SF 12 micron
NEOPLAST SF 30

C3 In- & Ambient up to Surface Tolerant 150 Aliphatic 50

Outdoor 120 C High Solid micron Polyurethane micron
Epoxy AMERCOAT
AMERLOCK 450-Series
400C

Surface Tolerant 100 Polyurethane 80

High Solid Epoxy micron SF 11/SF 12 micron
NEOPLAST SF 30
Steel
In- & Structures,
C4 Sheet Metal, Ambient up to Zinc Rich Epoxy 75 High Solid 100
Outdoor 120 C micron Aliphatic micron
General
AMERCOAT 68- Polyurethane
Equipment
SERIES AMERSHIELD

High Solid 160 Polyurethane 80

Epoxy micron micron
Cleaning Remove rust SF 11/ SF 12
according to NEOPLAST to at least St
ISO 8501-1 SG 31 2.

SIS 05 59 00 Cleaning of
total surface
C5-I & M In- & Ambient up to DIN 12944 p.4 Zinc Rich Epoxy 75 Touch-up before High Solid 125
Outdoor 120 C micron any trans- application of Aliphatic micron
AMERCOAT 68- Polyurethane
port or the finish
SERIES AMERSHIELD
erection coat.
damages on
the coating
Blasting High Solid Epoxy 160 Polyurethane 80
and feather
according to: micron micron
surrounding
NEOPLAST SF 11/SF 12
edges.
Sa 2.5 SG 31

(40 - 60 micron
Not Outdoor Hot going < 200 C anchor profile) Inorganic Zinc 65 Inorganic Silica 125
Applicable (visible equipment with Amercoat 741 or micron
surface) or w/o DIMETCOTE 9 micron
refractories, Silicon Acryl 2* 25
e.g. cyclones, Amercoat 891 3) micron
ducts max.

Hot going 200 up to 400 C Inorganic Zinc 65 Inorganic Silica 125

equipment with micron Amercoat 741 or micron
or w/o DIMETCOTE 9
refractories, Silicone 1) 2* 25
e.g. cyclones, Amercoat 878 micron
ducts max.

Not Outdoor Parts at cold < 200 C Modified Epoxy 150 not required -
Applicable (non-visible end micron
surface) AMERCOAT 90S
e.g. Filters &
ducts

Insulated
from outside

Parts applied 200 up to 400 C Inorganic Zinc 65 not required 2) -

micron
before waste DIMETCOTE 9 see footnote
heat utilization,
e.g. cyclones,
ducts
Insulated
from outside

Not Not Machined Blank surface Tectyl 846 - Cleaning not required -
Applicable Applicable surfaces which
cannot be or equivalent
coated due to
operation

Table 1: Surface Treatment Examples

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 17/24

DFT: Dry film thickness, Sa2.5: Sand blasting according to ISO 8501-1, St.2: Rust removal
according to ISO 8501-1.
Footnotes
1) Curing temperature of Silicone is above 200°C.
2) To be prevented: rain water or condensation of water vapor, otherwise finish coat to be
applied on visible surfaces
3) Amercoat 891 and 741 of Comp. Ameron (NL) are not suitable with Amercoat 90S,
hence Dimetcote 9 required

4.3.3 Color Code for Finishing Painting

Object to be coated Color RAL No.

Steel structures, conveyor bridge Squirrel grey 7000

Machinery platforms, landings Squirrel grey 7000

Portal frames of buildings, doors, window frames Squirrel grey 7000

Stairs, ladders, walk ways, platforms Squirrel grey 7000

Piping supports, cable rack supports Squirrel grey 7000

Duct supports Squirrel grey 7000

Tunnel-and manhole-lid, trenches Squirrel grey 7000

Hoist rails, maintenance beams Squirrel grey 7000

Silos, feed bins, hoppers, chutes Squirrel grey 7000

Pneumatic transport pipelines Squirrel grey 7000

Hoists, cranes Pastel yellow 1034

Maintenance devices Pastel yellow 1034

Nuisance filters, fans, ducts Squirrel grey/light ivory 7000/1015

Firefighting Equipment Tomato red 3013

Handrails, guards, buffer Pastel yellow 1034

Belt conveyors, apron conveyors, weigh bridges, Squirrel grey 7000

apron feeders, drag chains, elevators

Motors, geared motors, gears Squirrel grey 7000

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 18/24

Object to be coated Color RAL No.

Process filters w/o insulation Squirrel grey 7000

Main process fans w/o insulation Squirrel grey 7000

Kiln burners Squirrel grey/brilliant 7000/5007

blue

Process filters, dedusting cyclones, fans, w/o Squirrel grey/white 7000/9006

insulation aluminum

Waste gas ducts, stacks White aluminum 9006

Preheater, precalciner Squirrel grey/white 7000/9006

aluminum

Fresh water pipelines Light green 6027

Treated water pipelines Emerald green 6001

Industrial water tank White aluminum 9006

Pumps, piping, armatures Grass green 6010

Waste water: piping, armatures Bottle green 6007

Sewage treatment plant water Gray blue with black 5008 +

bands black
bands

Compressor, receivers and piping for pressurized Brilliant blue 5007

air

Control air pipelines Pastel blue 5024

Fuel oil (diesel) tank White aluminum 9006

Pumps, piping, armature (ocher brown) Brown 8001

SNCR ammonia piping Canary yellow with dark 1016 +

violet bands violet
bands

Danger zones (striped) Black/yellow 9005/1003

Table 2: Color Code for Finish Painting

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 19/24

4.4 Name Plates

All name plates shall be made of corrosion resistant metal or Resopal®-type materials (min.
1.6 mm thickness). It shall be securely fitted to Equipment and it shall be clearly visible and
easily readable. The following name plates are required:
a) Instruction plates, to the extent necessary for safe operation, shall be in English
Language and the preferred language(s) of the Project Owner
b) Manufacturer's labels with typical technical data
c) Plate containing machine code (HAC) engraved according to the Plant Classification
(refer to Paragraph 3.3.7 (Identification/Marking))

4.5 Special Tools

a) Special tools are uncommon tools and devices that cannot be purchased by the Project
Owner as "normal" tools. Such tools are tailor-made- and supplied by the Contractor for
special tasks required on- or operation and maintenance of any piece of Equipment.
b) Special tools are considered part of Equipment and hence shall be supplied with
Equipment. A list shall be provided with the Equipment and identified to the Project
Owner in writing. Such tools may be used during the erection of the Equipment,
provided that these tools are handed over to the Project Owner undamaged after
erection. Damaged tools shall be replaced immediately and free of charge to the
Owner.

4.6 Bolts, Holding-Down Bolts and Base Plates

All bolts, nuts, washers and securing devices shall be made of galvanized steel. Such items
along with base plates, frames, anchoring-, fastening- and shimming materials as required
for proper assembly and installation of Equipment shall be included and part of the relevant
Equipment. This also refers to all foundation bolts and fastening devices required for the
attachment of Equipment to steel structures or concrete foundations.

4.7 Consumable Materials

a) First fill consumables (i.e. lubricants, hydraulic fluids) for flushing or for initial filling shall
be included with the equipment supply.
b) The Project Owner will specify or approve in writing, the brands and types of
consumable materials.

4.8 Insulation and Cladding

a) The design of fixing, overlapping and sealing is subject to the Project Owner’s written
approval.
b) The type and layer thickness of insulating material for Equipment and ductwork depend
on the application (refer to StDC part Mechanical Equipment).
c) Cladding of insulating layers shall be made of aluminum or galvanized steel sheets of
minimum thickness of respectively 0.75 mm or 0.63 mm. Profiled sheets may be used
on large process filters and large ductwork.
d) The use of asbestos containing materials is not permitted e.g. roofing, paneling,
insulation or asbestos cement.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 20/24

4.9 Wear Parts and Wear Protection

a) All Equipment exposed to wear shall be protected by high wear resistant materials of
bolted replaceable design. Bolt heads to be protected.
b) Chutes handling abrasive material can be made of direct wear resistance material or
base material with wear resistant liners as described in paragraph a).
c) Special attention is needed for access to- and handling of replaceable liners. The
maximum weight and size for manual handling, as governed in the country of project
execution, strictly applies, however, it shall not exceed 25 kg per piece.

4.10 Vibration Prevention and Confinement

a) Machine vibrations are to be limited to acceptable levels by means of decoupling of
foundations (where necessary) and adequate design of building structures with due
consideration of frequency/excitation aspects.
b) Drive trains of main machinery (i.e. kiln, mills, process fans and blowers) shall be
analyzed to ensure that operational speed does not coincide with natural frequency.
c) Vibration sensors shall be provided critical equipment such as gearboxes for vertical
mills and process fans etc.

4.11 Instrumentation tabs and mounting flange

Instrumentation tabs and mounting flanges as well as associated check and calibration tabs
for process control Equipment shall be installed latest during erection in order to avoid
damage to insulation and cladding after erection of the Plant.

5. WORKPLACE AND EXTERNAL ENVIRONMENTAL ASPECTS

5.1 Particulate Emissions and Controls

5.1.1 Nuisance Dust Collection

a) Dust collectors or dust suppression Equipment shall be provided wherever needed so
that the Plant is visibly dust-free during operation in order to ensure limitation of dust
exposure of workers of max. 1 mg/m3 respirable (8h time weighted average) according
to Holcim Hazardous Substances Standard. Related ductwork and chutes shall be
skillfully designed and executed, with provisions for adjustment and fine-tuning.
Particular attention shall be paid to the dedusting of:
• Transfer points of conveying Equipment
• Hoppers, bins, silos
• Dust producing machinery
b) The dust collector and suppression Equipment shall be designed to a clean air dust
load of less than 30 mg/Nm3 dry or according to Permits and local regulations,
whichever is more stringent. Venting ducts shall always be routed to the outside of
buildings.
c) More detailed requirements are outlined in the Mechanical Standard Design Criteria.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 21/24

5.1.2 Process Dust Collection

The process dust collectors shall include the dust collectors for the kiln, the partial kiln gas
extraction (bypass), the clinker cooler and all mills, and shall be designed to have a clean
gas dust load less than 30 mg/Nm3 dry or according to Permits and local regulations,
whichever is more stringent.

5.1.3 Particulate Emission Monitoring

In accordance with the Permits, the stacks of process dust collectors shall have continuous
monitoring. Such stacks are equipped with correctly located and dimensioned platforms.

Particulate Design Value Comments

Emission [mg/Nm3, dry gas at 10% O2]

Dust 10* and Bag filters exclusively for kiln/raw mill/kiln

Permit bypass gas dedusting
Stacks of process dust collectors shall
include continuous monitoring
* 97% of the daily average values shall be within the Design Value

Table 3: Particulate Emission Monitoring

5.2 Gaseous Emissions and Control

The proposed kiln system shall be designed to be in compliance with the design values in the
following table, or as imposed by the Permits or local regulations, whichever is more
stringent.
SO2, NOx and VOC emissions from the main stack are continuously measured and
recorded. The stack is equipped with a correctly located and dimensioned platform. Values
apply also to the weighted average of both stacks in case of a separate bypass stack.

Gaseous Design Value Comments

Emission [mg/Nm3 dry gas at 10%
O2]

SO2 <200* and Primary measures target < 200 mg/Nm3

<Permit (Primary measures - raw material selection)

• Hydrated lime injection

• Wet sulfur scrubbing
• Other methods
In difficult cases exceptional <400

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 22/24

Gaseous Design Value Comments

Emission [mg/Nm3 dry gas at 10%
O2]

NOx (as NO2) <450* and Target < 450 mg/Nm3 (< 200 mg/Nm3 as future
target and for EU installations):
<Permit
• Primary NOx reduction measures, and
• SNCR or SCR
• Other
Preheater/precalciner design shall allow future
target < 200 mg/Nm3 in all cases

VOC <30* and Primary measures target 30 mg/Nm3

(as organic C) <Permit (Primary measures - raw material selection)
In difficult cases exceptional 50 mg/Nm3

CO <1000* and
<Permit

Benzene <5 and Primary measures target << 5 mg/Nm3

<Permit (Primary measures - raw material selection)

HCl <10 and

<Permit

NH3 <30 and Primary measures target < 30 mg/Nm3

<Permit Primary measures - raw material selection
Avoid excessive SNCR-NH3 slip
Avoid detached plumes

Hg <0.025 and Target < 0.025 mg Hg/Nm3

< Permit Primary measures (raw mat./fuel selection)
Secondary measures
Low exhaust gas temperatures and dust-to cement
mill during direct operation
Activated carbon injection

Tl, Cd <0.03 (each)

and <Permit

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 23/24

Gaseous Design Value Comments

Emission [mg/Nm3 dry gas at 10%
O2]

Other 9 HM of <0.5 (sum) “Other nine” include: As, Co, Cr, Cu, Mn, Ni, Pb,
European IED Sb, V
and <Permit

PCDD/DF <0.1 (ng TEQ/Nm3)

and <Permit

* for the daily average

Table 4: Gaseous Emission Monitoring

5.3 Noise Emission

Noise emissions are to be kept to a minimum. Local and international limits shall not be
exceeded. The following applies:
The maximum noise level shall be 85 dB(A) at one meter from the emitting machine.
a) Operating noise level for workers shall not exceed 80 dB(A) in 8 h time weighted
average (TWA).
b) Unless differently specified in the permit, at the closest point of the nearest living area
outside the Plant the maximum level is 40 dB(A) at night and 55 dB(A) during the day
(06:00 - 22:00h).
c) Where possible, noise emission levels shall be in accordance with ISO standards 3744,
3746, 4871, 11201.

5.4 Liquid Effluents

The amount of liquid effluents shall be minimized by recycling and reusing waste water as
much as possible. Unavoidable liquid effluents shall be treated in order to comply with local
and international regulations, e.g. “Clear Water ACt” of USA-EPA or similar.

©2022 Document and all Appendices III-5-1-1 StDC Basic Requirem March 2022.docx
Holcim Ltd
Standard Design Criteria Edition March 2022
Basic Requirements 24/24

Holcim Technology Ltd

Corporate CEM-Project Management & Engineering Michael Weihrauch/Tool Owner

pme.admin-hts@holcim.com michael.weihrauch@holcim.com