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Conservation of Derince Traverse Injection Factory and Power Station in the Context of Structural Behavior Emre Kishalı 1* 1* Department of Architecture, Faculty of Architecture and Design, Kocaeli University, Turkey ([email protected]) Abstract – The construction of industrial buildings in Istanbul commenced during Ottoman Empire in 19 th century and railway systems with the facilities were constructed in the scope of mobility of manufactures around the city afterwards spread into Anatolia. Railways, stations and subsidiary facilities were built by great significance during 19 th and 20 th century. In this research, Derince Traverse Injection Factory and Electric Power Building, the example of industrial heritage buildings are going to be analyzed in terms of structural safety for sustainability issues. These buildings have been abandoned due to economic developments, socio-politic influences, and health reasons. As a methodology, the damage assessment investigation done by direct investigations, infrared thermography and flat-jack test applications. Furthermore, the buildings Derince Traverse Injection Factory and Electric Power Building were analyzed with ISCARSAH principles by the help of SAP2000 analysis. Different load combinations including modal superposition (response spectrum analysis (RSA) and time history were defined in linear approach in order to analyze the structures globally in terms of deformation, internal stresses of structural elements and dynamic behavior. The program was used to assess the global dynamic behavior of the structures under the ground motions of Kocaeli earthquake occurred on 17 August 1999. The accelogram obtained from Strong Ground Motions Database of Turkey were introduced to the programs for the history – time analysis. The aim of this study is to find structural vulnerable parts of the structure considering preventive conservation approach. On the other hand, conservation issues are discussed under the integrated approach in post-earthquake damage assessment. The challenges for numeric analysis of historic buildings under strong ground motions and determination of mechanical properties are presented. 1. INTRODUCTION In 21 st century, charters for the preservation of industrial and railway heritage were constituted to promote cooperation in the decisions of the industrial heritage. The conservation of old structures and passing these values to next generations become more problematic matter where rapid manufacturing policies govern the global, national and even local economy. In Derince Railway case, conventional and scientific conservation notion is like wisely diffused since local development policies are shaped by dominantly macro economy. National and regional developments influences the surrounding of historical centers, their surroundings and contemporary industrial heritage zones with international initiatives. Contemporary conservation activities include scientific, planned conservation and constructive conservation approaches which were raised in order to define continuous maintenance, regular monitoring in long terms via integrated conservation approaches from the site scale to users scale in the context of current preservation tools [1]. The conservation of facilities needs to be analyzed in terms of two aspects both in urban context and in single building scale. Scientific conservation approaches are required for structural safety and damage assessment under the internal and external actions. Degradations, failures, structural behavior under seismic actions, material characteristics need to be analyzed. Most vulnerable parts of structure were identified via different load combinations to provide coherent information for possible interventions. In this paper, national, regional and city scale decisions are not mentioned – although these issues are directly related to conservation of architectural heritage - technical and structural analysis of Derince Traverse Injection Factory and Power Station were presented and discussed in the context of ICOMOS Charter – Principles for the Analysis, Conservation and Structural Restoration of Architectural Heritage (ISCARSAH Principles) principles [2]. Historical investigation, architectural – urban values, preliminary analysis and slightly and non-destructive tests were performed. Finally, global behavior of the buildings were simulated by SAP2000 with the data of 17 August 1999 earthquake logs. 2. METHODOLOGY Structural and conservation report was requested from Kocaeli University, Department of Architecture

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Page 1: Conservation of Derince Traverse Injection Factory and ...akademikpersonel.kocaeli.edu.tr/emre.kishali/bildiri/emre.kishali22.10... · last facility in Adana (1987) is one of the

Conservation of Derince Traverse Injection Factory and Power Station in the Context of Structural Behavior

Emre Kishalı1*

1* Department of Architecture, Faculty of Architecture and Design, Kocaeli University, Turkey ([email protected])

Abstract – The construction of industrial buildings in

Istanbul commenced during Ottoman Empire in 19th

century and railway systems with the facilities were

constructed in the scope of mobility of manufactures

around the city afterwards spread into Anatolia.

Railways, stations and subsidiary facilities were built by

great significance during 19th and 20th century. In this

research, Derince Traverse Injection Factory and Electric

Power Building, the example of industrial heritage

buildings are going to be analyzed in terms of structural

safety for sustainability issues. These buildings have been

abandoned due to economic developments, socio-politic

influences, and health reasons. As a methodology, the

damage assessment investigation done by direct

investigations, infrared thermography and flat-jack test

applications. Furthermore, the buildings Derince

Traverse Injection Factory and Electric Power Building

were analyzed with ISCARSAH principles by the help of

SAP2000 analysis. Different load combinations including

modal superposition (response spectrum analysis (RSA)

and time history were defined in linear approach in order

to analyze the structures globally in terms of

deformation, internal stresses of structural elements and

dynamic behavior. The program was used to assess the

global dynamic behavior of the structures under the

ground motions of Kocaeli earthquake occurred on 17

August 1999. The accelogram obtained from Strong

Ground Motions Database of Turkey were introduced to

the programs for the history – time analysis. The aim of

this study is to find structural vulnerable parts of the

structure considering preventive conservation approach.

On the other hand, conservation issues are discussed

under the integrated approach in post-earthquake

damage assessment. The challenges for numeric analysis

of historic buildings under strong ground motions and

determination of mechanical properties are presented.

1. INTRODUCTION

In 21st century, charters for the preservation of

industrial and railway heritage were constituted to

promote cooperation in the decisions of the industrial

heritage. The conservation of old structures and passing

these values to next generations become more

problematic matter where rapid manufacturing policies

govern the global, national and even local economy. In

Derince Railway case, conventional and scientific

conservation notion is like wisely diffused since local

development policies are shaped by dominantly macro

economy.

National and regional developments influences the

surrounding of historical centers, their surroundings

and contemporary industrial heritage zones with

international initiatives. Contemporary conservation

activities include scientific, planned conservation and

constructive conservation approaches which were

raised in order to define continuous maintenance,

regular monitoring in long terms via integrated

conservation approaches from the site scale to users

scale in the context of current preservation tools [1].

The conservation of facilities needs to be analyzed

in terms of two aspects both in urban context and in

single building scale. Scientific conservation

approaches are required for structural safety and

damage assessment under the internal and external

actions. Degradations, failures, structural behavior

under seismic actions, material characteristics need to

be analyzed. Most vulnerable parts of structure were

identified via different load combinations to provide

coherent information for possible interventions.

In this paper, national, regional and city scale

decisions are not mentioned – although these issues are

directly related to conservation of architectural heritage

- technical and structural analysis of Derince Traverse

Injection Factory and Power Station were presented and

discussed in the context of ICOMOS Charter –

Principles for the Analysis, Conservation and Structural

Restoration of Architectural Heritage (ISCARSAH

Principles) principles [2]. Historical investigation,

architectural – urban values, preliminary analysis and

slightly and non-destructive tests were performed.

Finally, global behavior of the buildings were simulated

by SAP2000 with the data of 17 August 1999

earthquake logs.

2. METHODOLOGY

Structural and conservation report was requested

from Kocaeli University, Department of Architecture

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by TCDD and Bozdağ Architecture in the limited of

time. The structural analysis were executed to present

current situation of buildings and help restoration

project to be approved by Kocaeli Conservation Board.

ISCARSAH Principles were followed to conduct the

research; the necessary steps of restoration process of

old structure to perform conservation and structural

analysis of architectural heritage are defined as the

acquisition of data: information and investigation; the

structural behavior; diagnosis and safety evaluation;

structural damage, materials decay and remedial

measures [2].

The typical process adopted for analyzing the static

conditions of an existing structures involves

preliminary surveys which consist of a geometric and

photographic survey; a detailed survey of existing

cracks and damages related to structure during its

service life and an analysis of history of the monument

and its functions.

The second step, testing stage is executed to

determine the structural and mechanical characteristics

of the masonry structure. Flat – jack tests were applied

by KURAM lab of Fatih Sultan Mehmet Vakıf

University, Architecture Department staff to provide

realistic model for the analysis. Besides, the cases were

investigated whether they have pathological, structural

hidden anomalies or not. Therefore the buildings were

also analyzed by infrared thermography (IRT). Later,

the structures were analyzed under static and dynamic

forces. Dynamic analysis has been performed in three

different methods; equivalent static load, modal

superposition and time history analysis. Global

behavior of structure were aimed so elastic limit state

approach are used in the analytical models. Possible

failure mechanisms were detected by structural analysis

and existing cracks.

3. CASE STUDY: DERINCE RAILWAY

HERITAGE

3.1. General Introduction

In Istanbul, the construction of industrial buildings

was influenced by Industrial Revolution along with

industrialization process continued with rural life of

Ottoman Empire [3]. The developments also impacted

railway constructions in Ottoman Empire; the line

between Haydarpaşa – İzmit was completed in 1871 –

1873 [4]. After the establishment of Republic of

Turkey, railway construction policy was continued and

railway facilities were constructed for economic

development. Examples of such manufacturing

buildings, the impregnation facilities were established

in Denizli (1915), in Derince (1930) and in Bolu (1956).

After 1970s, private enterprises were established, the

last facility in Adana (1987) is one of the example of

private enterprise. Nowadays, concrete sleepers are

used in the railway constructions, especially for high-

speed train; thereby, recycle of timber sleepers and

conservation of the production and process facilities are

current issue [5].

3.2. Historical Investigation

Derince, located 8 km west of Izmit and 90 km east

of Istanbul, was established as a seaport at the end of

19th century which currently is the district of Kocaeli

Province. According to the researches, Derince Seaport

was constructed between 1894 – 1896 by Nagel Kaemp

A.G. and Philipp Holzman Construction Company

including railway facilities such as warehouse, storage

buildings, lodgings and hotel structures [4][6].

Railway construction line between Haydarpaşa –

İzmit was completed in 1871 – 1873. According to the

research conducted by Kösebay Erkan, Derince railway

facilities were completed in 1889 – 1892 [4]. In 1913,

the port was used as soldier deployment spot during

Balkan War. British troops reached the port, occupied

the area, including Ottoman armory in the warehouses,

in 1919 and then they invaded İzmit with its

surroundings.

In Republican era, private companies, operating the

railways, were nationalized in 1924 and General

Administration of Railways and Port was established in

order to integrate and centralize rail and sea

transportation operations in 1927. Until 1953, the

administration had functioned as supplementary

budgeted public enterprise which was converted into

Public Economic State Enterprise under the name of

Republic of Turkey General Directorate of State

Railways Administration (TCDD). In 1984, with a new

constitution, TCDD was counted as Public Economic

Enterprise performing economic activities by

governmental organizations [7].

Carpentry Workplace was constructed as dormitory

for 60 carriers, and Lodgings were constructed at the

end of 19th century whereas Timber Injection Factory

and Electric Power Building were established in 1930.

The national government promoted the timber sleepers

until 1940s. Afterwards, it was decreed that the

production of timber sleepers was not economic in turn

the production was highly influenced and the factory

completely and officially deactivated in 2001[5].

3.3. Urban and Architectural Features of Case

Studies

The area was free of built environment in late 1800s.

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Natural texture has been transformed by the scattered

constructions due to the industrialization. The area has

been becoming denser within the course of time, thus

nature and specific historic production facilities with

peculiar technology have not conserved well. The

sustainability of socio-economic life has been

disrupted. Furthermore, the projects are related to new

highway routes, transportation facilities, new

industries, technology and urban zones were planned.

Urban pressure on historical tissue are increasing along

with population and economic growth.

On the other hand, Derince Ports have been taken

into the scope of privatization. In this scope, the

operation rights of some enterprises have been

transferred for a period of 36 years but privatization

studies had been continued for Derince Port until 2014

due to objections from non-governmental organizations

[8]. Eventually, the tender for the privatization of the

Derince Port was started on December 12, 2004 and

completed on June 5, 2014 with a $543 million bid by

Safi Solid Fuel Industry and Trade for 39 years [9]. Safi

Port with the area of 396.382 m2 currently provides port

operation services with shore cranes and other

equipment; however isolated listed railway heritage

buildings stand without any active use and any

integrated - participatory conservation plan.

Historical railway buildings in the area can be

evaluated into two parts; first group buildings, located

north of railway, were transformed to other functions.

Original uses as train station building and hotels were

adapted into municipality wedding ceremony hall and

police station respectively. Others which are named as

Derince Traverse Injection Factory, Electric Power

Building, Carpenter Workplace and Lodgings, are close

to Derince Port. Before privatization some important

railway lodgings were standing but they were

demolished in the consequence of the damages by

earthquake of 17 August 1999. Currently, there is only

one timber lodging standing in the area. The aforesaid

four structures were abandoned in 2000s and they were

listed by Conservation Board for Cultural and Natural

Assets of the Ministry at the same year (Fig. 1).

Furthermore, restoration projects were prepared for

these buildings considering physical degradations and

structural safety; possible uses of these buildings are

not defined. Due to devastating earthquake of 1999, the

buildings in the port were damaged in different scale;

major cracks were generated in the injection factory but

structural safety of the structure was not in the level of

high danger.

Fig. 1: Listed buildings in Derince located in the port and

neighborhood.

The building having the dimension of 43.5 x 22 m

includes pressure tanks for injection; compressor room;

raw material room; workplace and water tank.

Construction technique is mixed structure with stone –

brick masonry walls and reinforced concrete lentos; the

space is covered by timber trussed roof. The thickness

of stone masonry load bearing walls is 60 cm. and gable

walls with clay bricks stand on the stone load-bearing

walls. Five spaces with the original functions are the

entrance hall, it is possible to reach the large workplace

area (Z02) containing four pressure tanks for the

injection of timber sleepers (Z01). Compressor room

having vacuuming tank (Z04) and the workplace with

water tank (Z05) are located in north of Z02 (Fig. 2).

The four spaces are located in one volume whereas

extra impregnation facility erected in later time (Z03).

In Z02, two tanks having 2.2m diameter placed at the

elevation of – 1.24 m and the others are located at the

elevation of +3.07 m. Besides, the ground was filled

with water and the scent of creosote was still felt around

and inside the building (Fig 2).

The structure supply electricity for the injection of

creosote into timber sleepers. The building having the

dimension of 18.0 x 12.5 m. was designed as single

space. Construction technique is brick masonry walls

having 52 cm. covered by timber trussed roof. Vertical

timber elements of roof were supported by semi

heightened masonry columns so the thickness of wall is

increased in these areas (Fig. 3).

4. STRUCTURAL BEHAVIOUR

4.1. Direct Investigation

During the direct investigations, in the corners of

spaces Z05 and Z04 vertical cracks exist interior

surface building and at the connection of masonry

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walls. On the other hand, some structural cracks are

noticed in the masonry walls which can be also

observed from the outside facade.

Fig. 2: Traverse Injection Factory: Plan and Sections (Bahadır

Bozdağ Archive)

From the macro scale point of view, the building

has been affected by previous earthquake or ground

settlements since diagonal cracks are observed in the

part where Z03 is located. In this place, west and north

masonry walls behaved in a different way than the rest

of the structure; existing lengthwise cracks on the wall

display a failure mechanism, probably partial

overturning. Besides, vertical cracks are inspected in

the masonry walls, separating Z01 and Z05. The

vertical crack formation is due to the compression stress

from the timber trussed roof. Finally, shear cracks

pattern is noted in the connection of roof and masonry

wall in Z02. Additionally, plaster cracks, loss of

material, black crusts with decays due to moist and

vegetation are noted (Fig. 4).

In Electric Power structural cracks, degradations

and decay were not observed during direct

investigations. Hair cracks, vegetation and black stain

were noticed in the preliminary analysis of the

structure.

Fig. 3: Power Station: Plan and Sections (Bahadır Bozdağ

Archive)

4.2. Building Assessment: IRT and Flat Jack

Tests

Infrared Thermography which measures infrared

energy irradiated from the surface of building elements

is used to detect and quantify heat losses and

temperature variations through roofs and walls.

Infrared thermography is applied to buildings to collect

information for elements of structures, their shape, their

physical characteristics, existing cracks, recently

calculation of U-values and the state of decay in the

structures. Due to anomalies occurred in the structures

heat flux can be changed throughout the wall and IRT

analysis maps localized differences in surface

temperature by different heat flux from the surface

[10][11][12]. In Traverse Injection Factory, existing

cracks, stains due to the infiltration, rising damp, and

delamination were observed via IRT technique.

Flat-jack is carried out by introducing a thin flat-jack

into the mortar layer. After the test, the flat jack can

easily be removed and the mortar layer restored to its

original condition. The high reliability of the test is

related to the undisturbed conditions of the sample on

which masonry stress state, compression strength,

elastic modulus are determined.

The reference field of displacements is first

determined by measuring distances between gauge

points fixed to the surface of the masonry. Then, a slot

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is cut in a plane normal to the direction of measured

stresses. Cutting the slot causes partial stress relief in

masonry above and below. Afterwards, a thin flat jack

is introduced into the slot. With the aid of this device,

pressure (compressive stress) is applied to the masonry.

In masonry, double flat jack can be applied by a second

cutting, parallel to the first one, and a second jack is

inserted, at a distance of about 50 cm from the other.

The two jacks apply a uniaxial compression stress and

deformability [13][14].

In the building three different points in various

facades, close to ground level, were selected for both

Traverse Injection Factory and Electric Power Station

in order to perform double flat – jack tests and obtain

in-situ Elastic Modulus and Poisson Ratio. ASTM

C1197-14a Standard Test Method for In Situ

Measurement of Masonry Deformability Properties

Using the Flat jack Method was applied by KURAM

Fatih Sultan Mehmet Vakıf University. As a result,

average value of Elastic Modulus and Poisson ratio is

found as 9520 MPa and 0.20 for rubble stone masonry

of Traverse Injection Factory; 6822 MPa and 0.30 for

brick masonry bounded with cement mortar of Electric

Power Station [15]. The results displayed elastic regime

in the stress – strain diagram.

4.3. Structural Modelling

Structural analysis is an important part of scientific

and preventive conservation carried out with chemical,

physical analysis and monitoring. Furthermore, global

behaviors of structures under seismic actions are sought

then they will be compared with the assessment results

done during direct investigations. Despite the fact that

technology enables the conservation experts to make

realistic estimations about masonry, composition of

structure, anomalies and even the chemical

composition of building materials, one-to-one model

which is supposed to reflect exact behavior of historical

building is a complicated task. Therefore, it is necessary

to generate more realistic models and make correct

assumptions with specialized research questions.

Realistic models are defined by exact geometry,

material properties, soil conditions, connections of

structural elements and current degradations. The aim

of this study is to find vulnerable parts of the structures

via global behavior and slightly or non-destructive

methods considering preventive conservation

approach. Post-earthquake damage assessment and

numeric analysis under strong ground motions and

mechanical properties are integrated.

Fig. 4: Structural cracks during preliminary analysis (Figures:

Personal archive)

In the elastic analysis of masonry structures, it is

assumed that masonry units and mortar behave as a

single material having unique mechanical properties.

The deformations are fully recovered when the applied

actions are removed [2][16]. Elastic analysis is the

simplest method for the analysis and gives general

information about the behavior of the structure.

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Therefore the aforesaid structures were analyzed by

SAP2000 program using finite element model

approaches. The masonry units and mortar are

considered as homogeneous material. In these study,

macro – modelling, homogeneous and continuous

material are assumed in models to see the global

response of case studies under static and dynamic loads.

Fig. 5: Structural investigation via IRT.

Complex buildings can be preliminary analyzed by

linear analysis to allow first assessment of load

distribution and overall results [17]. In literature, the

reliability of elastic analysis was compared to the crack

pattern; it was found that two investigation display

good agreement when overall behavior is sought [18].

The model for the factory generated with 191 shell

(thick) and 255 frame elements; that of power station

includes 103 shell (thick) and 119 frames for the roof.

Building and ground relation were modelled as fixed

restraints for both structures.

The most essential aspect of the numeric analysis is

that flat jack tests are applied on the structures for the

input of material during simulation processes. Density,

the property of material, Young’s Modulus and Poisson

ratio is used for the definition in model. They are

obtained from flat-jack tests so that model becomes

more realistic. It is aimed to determine the most

vulnerable parts of structures by calculating direct

stress (force per unit area) and out of plane shears

stresses acting on the positive and negative faces in

each direction. The values were compared to the

allowable ones obtained from literature considering

limestone masonry behavior as a result vulnerable parts

of structure can be interpreted.

Allowable compression strength, allowable tensile

strength and shear strength are obtained as 18 MPa, 2

MPa and 6 MPa respectively [19]. The values for

timber structural elements are obtained from UNI

11119 as 7.5 MPa for allowable compressive strength

and 6 MPa for allowable tensile strength. Main load

bearing material is taken as oak for timber-framed walls

as shell elements and selected as 3rd class. They are the

lowest timber class in order to address the worst

scenario [20].

Live loads for snow in the roof (0.47 KN/m2) are

calculated from Turkish Standards 498 [21]. Load

combinations are defined to analyze the response of

structures under different possible loads. In the

SAP2000 analysis, different load combinations

including modal superposition (response spectrum

analysis (RSA) and time history are defined in order to

analyze the structures in terms of deformation, internal

stresses of structural elements and dynamic actions. In

this study two combinations are represented to assess

the dynamic behavior of the structures under the ground

motions of Kocaeli earthquake occurred on 17 August

1999. The accelogram data of the earthquake, obtained

from Strong Ground Motions Database of Turkey, are

introduced to the programs for the history – time

analysis. Load combinations defined in model are;

• 1,0G + 1,0Q + 1,0Tx (COMB1)

• 1,0G + 1,0Q + 1,0Ty (COMB2)

Where G, Q and E are dead load, live load and time

– history earthquake loads respectively.

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Fig. 6: Structural analysis of Traverse Injection Factory.

4.4. Explanatory Results

According to the simulations, the most vulnerable

parts are the connections of roof construction and load

bearing masonry walls in Derince Traverse Injection

Factory. Compression and tensile stresses are higher

than the assumed allowable strengths in southwest

façade and in the partition wall which is perpendicular

to it. Direct investigation with damage assessment

results match the results deduced from the simulation.

On the other hand, structural cracks in Z03 are not

detected in the numerical model. It can be explained

that these cracks are caused by previous soil settlements

and/or seismic actions. Moreover, the connection of

stone masonry walls with partition walls are found as

vulnerable zones as indicated during direct

investigations (Fig 6.)

Considering Electric Power Building, the weak

points are listed as the connection between vertical

elements of roof and short masonry columns in the

corners and along the façades considering allowable

compression and shear strength and the calculated ones.

These values do not exceed the assumed allowable

stresses but they are close to these values. Tensile

stresses may create critical areas only in northeast

façade.

5. CONCLUSION

The railway heritage structures were faced

privatization, abandonment and lack of conservation

maintenance in Derince. The macro impacts on

buildings are complicated to provide consistent

maintenance and preservation program. Furthermore,

the buildings display structural problems that need to be

investigated in the context of scientific conservation

approach. In this research, ISCARSAH

recommendations were followed to find the structural

anomalies, degradations, global structural behaviors

and remedial measure if needed.

The historical, architectural, geometrical and

contextual analysis of structures were carried out.

Linear analysis was performed via SAP2000 program

to reveal the global behavior of structure and

vulnerability under seismic data of 17 August 1999.

The load distribution schemes and high values show

good agreements with the detected failure analysis.

Especially in the north and west façade of Injection

Factory existing cracks were not detected. Structures

have gone through strong earthquake and still standing

with some structural cracks; no partial and heavy

damage observed. Therefore, these structures can be

rehabilitated by minimum interventions. Furthermore,

nonlinear behavior of material is not considered which

means structural modeling and analysis need further

investigations. More detailed analysis nonlinear

pushover and detailed micro modeling for vulnerable

areas are suggested. In the model, connection of timber

roof with structure was assumed as fully connected,

these situation should be checked by in-situ

investigations. Furthermore, the structures should be

inspected by other non-destructive tests such as

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ultrasonic velocity tests, Schmidt hammer, georadar,

and metal detector etc. and laboratory chemical tests for

more data. They also need to be monitored in order to

support conservation acts and structural behavior.

Last but not least, regional and national conservation

vision is very essential for the protection of the assets.

Demolishment and reconstruction issues are discussed

for these buildings; unplanned conservation plan

creates uncertain conditions for the sustainability.

Therefore, macro and micro conservation activities

should be consistent to have holistic approach.

ACKNOWLEDGEMENTS

The author is grateful to Arch. Bahadır Bozdağ and

Arch. Elisabetta Rosina for their valuable contributions.

REFERENCES

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[2] Paolo B. Lourenço, Proceedings of Historical

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[3] Donald Quataert, Ottoman Manufacturing in the Age

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