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1- Introduction
2- Using CRANEgirder
3- Crane Classes
5- Impact Factor
6- Crane Girder Section
25- References
1
5
Crane Girder Design to BS 5950-1: 2000
User Notes
An Excel Template for the Design of Crane Girders to BS5950-1:2000 by
Dr Shaiq U.R. Khan
BEng (Civil), MEng, PhD, PE, CEng, FIStructE
November 2004
Techno Consultants Ltd
www.technouk.com
Contents
Introduction
Using CRANEgirder
Crane Classes
Single or Double Flange Wheels in the End Carriage
Impact Factor
Crane Girder Section
Calculated Weight of the Crane Girder
Plastic Modulus of the Section
Section Classification of the Compound Girder Section
Structural Deployment of Various Section Parts
Horizontal Wheel Loads
Crabbing Force of Trolley
Partial Factors for Loads
Load Combinations
Vertical Wheel Loads
Vertical and Horizontal Deflection
Shear Resistance at Supports Fv < Pv
Vertical Moment Resistance x-x
Horizontal Moment Resistance y-y
Web Bearing & Buckling at Support
Local Compression under the Wheel
UB-Flange to Top Section Weld
Reactions on to the Support Structure
Cautions & Limitations of Use
References
1- Introduction
This Template helps design simply supported crane girders comprising a UB section at its bottom and a
PFC, RSC or a Plate section at its top. By omitting the top section, the girder can also be a UB section
alone.
The compound section of a girder can be Class 1 Plastic, Class 2 Compact or Class 3 Semi-compact
sections.
Class 4 slender sections as crane girders are outside the scope of this template. BS5950-1: 2000
appear ambiguous for calculating the necessary Zx effective values and it may not be a good idea to use
such sections as crane girders.
The crane class can be Q1, Q2, Q3 or Q4 as defined in BS 2573-1:1983. The steel grades can be S275,
S355 or S460.
The Template allows storing data for up to 100 Crane girders. Any girder data can be recalled, amended
and re-stored later to suit design needs.
The method of design used is generally based on the Steelwork Design Guide 2. However there is a
difference when it comes to deploying section parts for resisting lateral loads.
Whereas the Guide ignores the top flange of UB to resist horizontal bending and deflection, this template
optionally allows including it in line with a conventional design practice of the past 5.
2- Using CRANEgirder
"Home" worksheet allows navigation to all worksheets through its command buttons. To design a Crane
Girder, the data input and output is via "Cranegirder" worksheet.
All data input is via green colour cells. The user is responsible for values in these cells to make an
engineering sense. The result output is via rest of the non-green colour cells
At top of the screen, four command buttons allow storing, retrieving and navigating through the stored
information. For example using the NEXT and PREVIOUS buttons, data can be viewed in girder
sequence numbers.
During its use, CRANEgirder keeps an eye on 7 adequacy checks. It reports the outcome at top left
corner of the screen in Cell A2.
When a girder passes all 7 checks, "All Checks OK" message is displayed. When it is not so, failing
check numbers are displayed and the background colour of the cell changes to red.
To improve structural usage of the crane girder, eight usage ratios are calculated and a maximum value
displayed in upper part of the worksheet. This ratio represents the actual to permitted values on
deflection and strength for the chosen girder.
3- Crane Classes
The descriptions as per BS2573-1 are:
Q1 - Light - hoisting SWL very rarely and, normally light loads
Q2 - Moderate - hoisting SWL fairly frequently and, normally moderate loads
Q3 - Heavy - hoisting SWL very fairly frequently and, normally heavy loads
Q4 - Very heavy - normally hoisting loads close to SWL
4- Single or Double Flange Wheels in the End Carriage
Single or double flange wheels can be specified in the end-carriages via a drop down menu.
In the case of single flange wheels, the transverse surge is shared by two wheels in one end-carriage of
the crane bridge.
In the case of double flange wheels (i.e. one flange on each side of the rails), the transverse surge is
shared by four wheels in two end-carriages of the crane bridge.
Generally, double flanged wheels are assumed in a routine design.
5- Impact Factor
For overhead travelling cranes, Cl 2.2.3 of BS 5950-1:2000 states that the impact effects and the vertical
and horizontal dynamic loads should be determined in accordance with BS 2573-1.
As stated in Cl 3.1.4 of BS2573-1, the impact factor applies to the motion of the hook load in a vertical
direction and covers inertia forces including shock.
In order to calculate dynamic wheel loads for Crane girder design, the hook load is multiplied by an
impact factor. For example, Table 4 of BS2573-1 gives a value of 1.3 for medium and heavy
workshop/warehouse duty cranes.
This Template permits using various impact factors. The values that can be selected from a drop down
menu are 1.1, 1.25, 1.3, 1.4, 1.5 and 2.
The values of 1.1, 1.3, 1.4, 1.5 and 2 are from Table 4 of BS 2573-1. The value of 1.25 is for a traditional
design with dynamic effects based on BS 449.
The plate section dimensions can be specified by amending h & b dimensions in worksheet PFC. The
cells for these dimensions are shown in green colour.
To select a Nil section, scroll to very bottom of the drop down list and select Nil.
7- Calculated Weight of the Crane Girder
This weight is obtained by multiplying span length and mass/m of the combined section i.e. = L M. It is
calculated for information only as the user may need to include the weight of various attachments e.g.
crane rails, packing plates, etc.
Starting from top, the width of these areas are Dc, (Bb+2Tfc), (Twb+2Tfc), Twb & Bb. The corresponding
heights of these strips are Twc, Tfb, (Bc-Twc-Tfb)>=0, (D-Bc-Tfb) & Tfb.
When the crane girder has no top element (FFC, RSC or Plate), however, CRANEgirder always includes
the UB flange to resist lateral bending and deflection; the Yes/No input is ignored when the UB section
alone is acting as the crane girder.
11- Horizontal Wheel Loads
These loads act transverse and longitudinal to the crane rails and stem from surge or crabbing.
Due to surge or inertia, the horizontal loads are taken as:
Transverse load of 10% of the combined weight of the crab & the lifted load
Longitudinal load of 5% of the static vertical reactions (i.e. crab + crane + lifted-load)
When the cranes are Class Q1 or Q2, the crabbing forces are not considered. For Class Q3 & Q4
cranes, the transverse crabbing forces are obtained from Cl 4.11.2 of BS 5950-1:2000.
The critical position of this force is at mid span of the Crane girder. As per Cl 4.11.2, the magnitude of
FR is:
FR = Lc Ww / (40 s) but >= Ww/20
When the crane is class Q1 or Q2, the crabbing force FR is assumed to be zero and the Crane girder is
designed for the surge forces only.
When calculating maximum moment and deflection in the horizontal direction, the surge or crabbing
load, whichever causes the maximum effect, is used.
The formula for vertical deflection due to Crane girder self weight is:
5 Wg L^3 / (384 E Ix)
The formula for vertical (and similarly horizontal) deflections due to two equal point loads acting at
distances a & c from the supports is:
Wus L^3 [ 3(a+c)/L - 4(a^3 + c^3)/L^3 ] / [48 E Ix]
The formula for horizontal deflection due to a single crabbing load FR at mid span is:
FR L^3 / (48 E Iyfc)
When calculating deflections, full combined section is used for the vertical loading & part combined
section (comprising PFC/RSC/Plate and optionally top UB flange) for the horizontal loading.
When a girder section happens to be slender, Mb calculations become outside the scope of this template
and the value of Mb is made equal to zero.
Mb= pb Zx for Class 3 Semi-compact Sections, using the lesser of Zx top and Zx bottom values.
In the above, pb =f(py, LamdaLT) and is obtained from Table 17 of BS 5950-1:2000 and by using Cl
4.3.6.7 to calculate various factors as below:
LamdaLT= u v Lamda (Bw)^0.5
Lamda=Le/ry
u = [4 Sx^2 (1-Iy/Ix)/{A^2 hs^2}]
v = 1 / [{4N(1-N) + 0.5 (Lamda/x)^2 + sai^2}^0.5 + sai ]^0.5
x = 0.566 hs(A/J)^0.5
hs = Db +Twc/2 -Tfb
sai =kn (2N-1) (1 + 0.5 DL/D) where kn=0.8 when N>0.5 and kn=1 when n<0.5
The buckling resistance is checked by using the following two interaction expressions:
mx Mx / py Zx + my My / py zy <=1 and
mLT MLT / Mb + my My / py Zy <=1
As per Cl 4.11.3, the lateral torsional factor buckling factor mLT is taken as 1. The equivalent uniform
moment factors mx and my for flexural buckling are also taken as 1 for simplicity, i.e. the moment
gradient is ignored.
However, it calculates the magnitudes of both the longitudinal and the transverse shears and also their
resultants. Using these values, welds can be sized by the user.
The horizontal shear in each of the two welds due to vertical reaction is:
Rb Ac (Ytop -Cy)/(2Ix)
This force acts in longitudinal direction of the Crane girder.
In addition, the surge and crabbing actions also cause shear in these welds.
Whereas the shear due to surge occurs in both the longitudinal and the transverse direction, the shear
due to crabbing is assumed to occur in the transverse direction only.
The weld length XR for transferring the surge and crabbing forces from the top-section to the UB-flange
is given by:
XR= 2(HR+Twc)
Two sets of values are calculated for crane reactions. One set is for crabbing and the other for crane
surge. To design the support structure, critical set values need to be used.
The maximum reaction due to crane crabbing occurs when one carriage wheel is at the support and the
other within the girder span at distance s.
The maximum reaction due to crane surge occurs when the two carriage wheels are symmetrically
placed at equal distance from a middle support.
A static 3D diagram shows the position of crane bridge causing maximum crabbing and surge reactions
together with the direction and position of induced reactions.
CRANEgirder allows changing of plate sizes towards bottom of the PFC data sheet. Any section change
made here applies also to all stored crane girders being recalled later and using the changed section.
CRANEgirder allows selecting bottom and top section parts to make a compound crane girder. However,
it makes no detailing checks to ensure a logical section. It is therefore the user's responsibility to specify
a feasible compound section.
As mentioned in the introduction section, CRANEgirder allows inclusion of the top flange of UB to resist
lateral bending and displacements. Although a past design practice, this aspect differs from the
Steelwork Design Guide2 and gives less conservative results.
Storing crane girder data does not save the Excel file to the hard disk. It merely writes information of a
crane girder into the Store worksheet. When finishing the use of CRANEgirder, save the Excel file in the
usual windows manner.
Do not delete contents of cells O1, O2 & O3 as being unprotected for Excel use purposes. They house
bottom & top section numbers and crane numbers.
25- References
BS 5950: Structural use of steelwork in building
BS 5950-1:2000: Code of practice for design - Rolled and welded sections, 2001
Steelwork Design Guide to BS 5950-1:2000, Volume 2, Worked Examples, SCI Publication P326, The
Steel Construction Institute, 2003
BS 2573: Rules for the design of cranes
BS 2573-1: 1983: Specification, for classification, stress calculations and design criteria for structures,
British Standards Institution, 1983
BS 449: The use of structural steel in buildings
BS 449-2: 1969: Metric Units
British Standards Institution, 1969
Structural Steelwork, Design to Limit State Theory, 2nd Edition, T J MacGinley & T C Ang, Butterworth-
Heinemann, 1992