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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

6.4.a DESIGN OF CRANE GANTRY GIRDER 11M span All below


references are
a) INPUT DATA :- BS 5950,
(Refer Appendix-E, for EOT drawing) part-1, UNO

Crane Capacity = 1050 kN

Weight of Crab = 320 kN

Weight of Crane Bridge = 780 kN

Self weight of the Rail = 2 kN/m

Width of Walk way = 0.6 m

Dead Load of the Walkway = 1.5 kN/m


Live Load of the Walkway = 5 kN/m

Height of the Crane Rail = 65 mm

Span of the Crane Girder, Lg = 11 m

Centre to centre distance of , Lc = 32 m


Rail (i.e. Span of Crane Bridge)

Mini. approach of crane hook to the gantry = 1.800 m

No. of Wheels = 4
Wheel Spacing1 = 1.40 m
Wheel Spacing2 = 4.70 m
C.G of loading from left load = 3.75 m 1.40 4.70 1.40

Impact Factor : Vertical = 30 %

Horizontal = 10 %
(Transverse to rail)
Deflection Factor Vertical = 600 Table:5
Horizontal = 500

Load Factor : Imposed load vertical - 1.6


Imposed load Horiz.Ihf 1.6
Dead load df 1.4

Design strength of steel, py = 265.0 N/mm2 Table:6

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS
Maximum unsupported length Top Flange = 2.60 m

Depth of the surge girder = 0.60 m


Maximum unsupported length Bottom Flange = 2.60 m

1.80m (1050+320)kN 780 kN

Kicker
RL 32.00m RR

RL = (1370 x 30.20 + 780 x 32.00/2)/32.00= 1682.938 kN

Wheel Load by calculation 420.73 kN/wheel

b) LOAD CALCULATIONS:

b.1) Vertical Loads


b.1.a) Conc. Loads
Max. static Wheel Load say Wm = 421 kN
875.7 875.7
Load due to Impact = 0.30 x 421 = 126.3 kN

Total load = 547 kN


Factored Load W mf = 1.60 x 547. = 875.68 kN 1.40 4.70 1.40

b.1.b) Uniform Dirstributed Load


Self weight of rail = 2.00 kN/m
Walkway Dead Load = 0.45 kN/m
Walkway Live Load = 1.50 kN/m
Self weight of girder = 4.66 kN/m
8.61 kN/m
Factored load W df = 1.40 x 8.61 12.06 kN/m

b.2) Horizontal Loads

Maximum lateral load per wheel is equal to 10% Static vertical wheel load,
= 0.1 from Fig-1
Max. Lateral load W H
= 0.10(421*4) = 168.4 kN BS:2573,part-1

4 wheels are resisting the total lateral load

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS
Factored lateral load W df = 1.60 x 168.40 / 4 67.36 kN/wheel

c) MAXIMUM BENDING MOMENT AND SHEAR FORCE:

c.1) For vertical loads

c.1.a) Bending Moment :-

The maximum Bending moment under moving loads occurs when line of
action of one load and centre of gravity of the loads are at equal distance
from the centre of span.
CG. OF LOADS

875.68kN 875.68kN 875.68kN 875.68kN


12.06kN/m

= =
C
RA RB
11.00m Mid Span of Crane Girder

Reactions :-

Ra = 4x875.68x(11 - 11*0.5 - 0.25*4.7)/ = 1443.525 kN


+ 12.06 x 11 /2

Rb = 4x875.68+12.06x11- 1,443.525 = 2191.834 kN

Maximum Bending moment occurs at C. =

Mux1 = (1443.53 x 4.33) -875.68 x 1.4 - (12.06 x 4.33/2)


= 4904.517 kN.m
c.1.b) Shear Force:-

875.68kN 875.68kN 12.06kN/m

RA 11.00m
CG. OF GANTRY

Reactions:

RA = 4 x 875.7 x [11.0-3.8] /11+ (12.1 x 11.0/2) 2374.930 kN

RB = (4 x 875.7) + (12.1 x 11.0) - 2374.93 1260.428 kN

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

Max. Reaction = 2374.930 kN

c.2) For Horizontal loads :-

67.36kN

c.2.a) Local Bending Moment at C,

Crane Girder is laterally bending between Node points of surge Girder


Muy = 67.360 x 2.6 /4 43.784 kN.m

c.2.b) Axial Force:

Because of Lateral force, the Crane Girder is subjected to axial force.

Max lateral bending Moment 4904.5 x 67.36 / 875.68 377.27 kN-m

F=Axial force in the surge girder 377.27 / 0.6 628.78 kN

c.2.c) Shear force :-

67.36kN 67.36kN

RA 3.75m 11.00m RB

Reactions :-

RA = 4x 67.4[11.0 - 3.8]11.00 = 177.585 kN

RB = 4 x 67.360 - 177.585 = 91.855 kN

Max. Horzontal reaction RH = 177.585 kN

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

d) DESIGN OF GANTRY GIRDER: y

Depth 1250 mm
Width 450 mm 20
t = 20 mm x x 1250

T = 40 mm
40

450

Properties :-
Depth of the section, D = 1250 mm
Width of the section, B = 450 mm
Thickness of web, t = 20 mm
Thickness of flange, T = 40 mm
Effective depth of web, d = 1170 mm
Second moment of inertia, Ixx = 1.59E+10 mm4
Second moment of inertia, Iyy = 6.08E+08 mm4
rmin = 101.19 mm
Section modulus, Zxx = 2.54E+07 mm3
Section modulus, Zyy = 2.70E+06 mm3
Plastic modulus, Sxx = 2.96E+07 mm3
Plastic modulus, Syy = 4.28E+06 mm3
Buckling parameter, u = 1 conservatively
Torsional index, x : D/T = 31.25 as per Cl.4.3.7.5
Sectional Area, A = 59400 mm2
Flange Area on one side, Ag = 18000 mm2
Out stand width of panel, b = 215 mm
Constant, sqrt(275/py) = 1.02

Outstand element of compression flange, b/T = 5.38 Plastic Cl.3.5.2 and


Web slenderness, d/t = 58.50 Plastic Table:7

d.1) Shear Capacity

Web slenderness, d/t = 58.50 < 63*1.02 Cl.4.4.4.1


Satisfactory
Shear area parallel to the web, Avx=t*d = 23400 mm2 Cl.4.2.3,

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

Critical Shear strength, qcr for t/d =58.50 = 159 N/mm2 Table:21,

Shear Capacity, Vcr=qcr*Avx = 3720.6 kN Cl.4.4.5.3


>2,374.93 kN Satisfactory

d.2) Moment capacity, Mb

d.2.a) Lateral-torsional buckling moment, Mb:


( as per clause 4.3.7.3 of BS 5950, part-1)

Effective length factor = 1.00 Table:9


( Destabilizing condition)
(As per table:9,BS 5950,part-1: Beam partial restrained against rotation)

Effective length, LE = 2.60 m


Slenderness, LE/rmin = 25.69
Equivalent slenderness, LT = nu Cl.4.3.7.5

Slenderness correction factor, n = 1.0 conservatively


Uniform moment factor, m = 1.0 conservatively
Buckling parameter, u = 1.000
x = 0.822
N = 0.50
Slenderness factor, = 1.00 Table:14

LT = 25.69
pb = 265.00 N/mm2 Table:12

Buckling resistance, Mb = pb*Sxx


= 7843.23 kN.m Satisfactory
>4904.52 kN.m Cl.4.3.7.2
> m*Mux1

e) CHECK FOR COMBINED BENDING COMPRESSIVE STRESS


IN EXTREME FIBRE (FOR VERTICAL PLUS LATERAL)

e.1) Compressive strength pc :-

Slenderness, LE/rmin = 25.69


Reduced design strength, py = 245.00 N/mm2 Cl.4.7.5
pc = 240.00 N/mm2 Table:27c

e.2) Overall buckling check

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS
(As per Clause 4.8.3.3.1, BS 5950: part-1)

F/Ag*pc + mMux1/Mb + mMuy/py*Zyy = 0.832 Satisfactory


< 1.000

f) CHECK FOR LONGITUDINAL STRESS:

Height of rail = 65 mm

5% of the static wheel load = 5/100 x4x 875.7 175.14 kN

Bending moment in the longitudinal direction is equal to Longitudinal Force into


Crane Rail Depth plus half of Crane Girder depth

Mux2 = 175136 x (65 + 625.0) 120.84 kN.m

CHECK FOR COMBINED BENDING COMPRESSIVE STRESS


IN EXTREME FIBRE (FOR VERTICAL PLUS LONGITUDINAL)

F/Ag*pc + m(Mux1+Mux2)/Mb = 0.681 Satisfactory

g) CHECK FOR DEFLECTION:


Allowable deflection for vertical loads
lim, v = Span / 600 =11,000.0 / 600.0 = 18.33 mm

Allowable deflection for horizontal loads


lim, h = Span / 500 = 11,000.0 /500 = 22.00 mm

Vertical Deflection:-

3.15 CG OF LOADS
1.75
547.3kN = = 547.3kN 8.61kN/m

c CG. OF GANTRY
RA 11.00 RB

[ ( )] [ ( )]
3 3 3 3
5 WL4 PL 3a1 a1 PL 3a2 4 a2
v = + 4 +
384 EI 48EI L L 48EI L L

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

= ((5/384)(8.61 x 11000^4)/( 205000 x 1.59E+10))+


{( 2 x 547300 x 11000)/( 48 x 205000 x 1.59E+10)} x
{[3 x 1.75/11 - 4 x (1.75/11)] + [3 x 3.15/11 - 4 x (3.15/11)]}
= 11.960 mm

CHECK v < Allowable Deflection 11.960 < 18.3 HENCE SAFE

h) Crane Girder Welding Calculation


Top Flange & Web is welded by full Penetration Butt weld.

Bottom Flange Weld.


Horizontal Shear = FAy/ Ixx
A- Area of the Bottom Flange = 18000 mm2

y - C.G of flange Plate from C.G of section = 605 mm

Ixx of the section = 1.59E+10 mm4

Maximum vertical shear = 2374.930 kN

Horizontal Shear 2,374.9 x 1000 x 18000x605 / 1585105 1631.626 N/mm

Size of the weld on each side 1,631.6/ ( 2 x 215x 0.707) 5.421 mm

Provide weld as = 12 mm

i) DESIGN OF BEARING STIFFENER

Bearing check:

Minimum area of stiffener in contact with the flange = 0.8*Fx/pys Cl.4.5.4.2


Fx = External reaction
pys = Design strength of stiffener

Minimum Area of stiffener required = 7169.60 mm2

Conside Thk. Of Stiffener , ts = 25.00 mm

Width of the stiffener, bs = 450.00 mm

Area of the stiffener = 11250.00 mm2 Satisfactory

Check for outstands

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

Outstand from the face of the web = bs/2-web thickness


= 215.00 mm

Outstand of web stiffeners, as per Cl.4.5.1.2 of BS5950: Limits:

19ts = 483.88 mm
13ts = 331.08 mm Satisfactory

Bearing resistance of the stiffener


Bearing Stress in member = 211.10 N/mm2
< 265 N/mm2 Satisfactory

Buckling resistance of the stiffner


(as per Cl.4.5.1.5 of BS5950,part-1)

Design strength of the stiffner in buckling = py-20 Cl.4.5.1.5


= 245.0 N/mm2

Buckling resistance check as a column:

Area of combined section 450 x25 + 20 x 20 x 20 19250.00 mm2

Ixx = 1.90E+08 mm4


Rmin= I / A = 99.38 mm

= l / Rmin =1250x 1000 / 99.4 = 12.58

Compressive strength, pc = 245.00 N/mm2 Tb.27c,

Buckling resistance of the stiffener = 4716.25 kN


> 2374.93 kN Satistactory

Weld between Stiffener & web

Vetical Height avilable for Welding = 1170.00 mm

Thk. of weld reqd =2,374.9 x1000/(1170x2x0.7*215) 6.74 mm

Provide weld thickness = 12.00 mm

j) Shear buckling of Web under Wheel load

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS
Web bearing under wheel load
(as per Cl.4.11.4,BS 5950, part-1)

Load dispersion under wheel,lw= 2(Height of the wheel + Thickness of the flange)
= 210 mm

Bearing Capacity = lw*py*t = 1113 kN


> 875.68 kN Satisfactory

Web buckling under wheel load


(as per Cl.4.5.2.1, BS 5950,part-1)

b1 = Stiff bearing length = 2(Height of the crane rail)


= 130.00 mm

n1 = Dispersion at 45degrees through half the depth of the section


= (depth of the web + 2*thickness of the flange)
= 1250 mm

d = Depth of the web


= 1170 mm

Web slenderness, = 2.5*depth of the web/thickness of the web Cl.4.5.2.1


= 146.25

Compressive resistance, pc = 70 N/mm2 Table 27c

Buckling resistance, Pw = (b1+n1)*t*pc


= 1932.00 kN
> 875.68 kN Satisfactory

k) Connection for Longitudinal Force

Longitudinal Force = 175.14 kN

Dia of bolt provided = 24.00 mm


No. of bolts provided = 4.00

Stress in Bolts = 96.78 N/mm2


< 160 N/mm2
l) Design of Surge Girder

Design of bracing members

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS
Maximum Horizontal force = 177.585 kN
Max Force in diagonal = 335.1 kN

Angles provided = 100X100X8 RSC


Area of the Section = 15.60 cm2
Rmin of the section = 3.07 cm
Length of diagonal = 1.50 m
Inclination of diagonal w.r.t Horizontal = 32.00

Stress in member = 214.82 N/mm2 (No.bays are


not to count in
the sketch)

Allowable Stress in member


48.86

Compressive stress, pc = 225.00 N/mm2 Table 27c


> 214.82 Satisfactory
Design of bottom chord member
(as surge may come on either direction, bottom chord members are designed
for compression)

Member size provided = 300X150X32 MS profile


Area of the Section = 40.80 cm2
Rmin of the section = 3.29 cm
Unsupported length = 2.60 m

Maximum axial force, F = 628.78 kN


Stress in member = 154.11 N/mm2

Allowable Stress in member


79.03
Compressive stress, pc = 161.00 N/mm2 Table 27c
> 154.11 Satisfactory

j) Design of Crane Girder Bracket

Depth of the bracket, Db = 1200 mm


Width of the flange plate, Wb = 600.00 mm
Thickness of the flange plate, Tb = 32.00 mm
Thickness of the web plate, tb = 25.00 mm
Eccetricity of Crane girder from grid = 1.00 m
Maximum Vertical force = 2374.93 kN

Design for Moment


Moment due to eccentricity, Me = 2374.93 kN.m

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SUMITOMO CORPORATION

PROJECT : SKS, Prai - 350MW CCGT Power Plant Checked By Page of


DOC.TITLE: Design of Super structure-Design of Crane-girder Area: Turbine build.
DOC. NO : CGPR1-100-5-011 Rev 0 Dept Structural

DESIGN CALCULATIONS REFERENCES /


REMARKS

Axial Force in Top flange, Ab=Me/Db = 1979.11 kN

Stress in top flange=Ab/Wb*Tb = 10.3078569 N/mm2


< 265.0 N/mm2 Satisfactory
Design for shear
Web slenderness = 45.44 < 63*1.02 Cl.4.4.4.1
Satisfactory
Shear area parallel to the web = 28400 mm2 Cl.4.2.3,
Critical Shear strength = 159 N/mm2 Cl.4.2.3

Shear Capacity, = 4515.6 kN


>2,374.93 kN Satisfactory

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erences are

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:2573,part-1

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04/14/2017 07:22:14

Name Depth Breadth wt/m Tf Tw Cyy G Ixx Iyy Rxx Ryy Zxx Zyy Area
mm mm kN/m mm mm mm mm mm4 mm4 mm mm mm3 mm3 mm2
ISMC 75 75 40 0.0681 7.30 4.40 13.10 21 760000 126000 29.60 12.10 20300 4700 867
ISMC 100 100 50 0.0918 7.50 4.70 15.30 28 1867000 259000 40.00 14.90 37300 7500 1170
ISMC 125 125 65 0.1271 8.10 5.00 19.40 35 4164000 599000 50.70 19.20 66600 13100 1619
ISMC 150 150 75 0.1639 9.00 5.40 22.20 40 7794000 1023000 61.10 22.10 103900 19400 2088
ISMC 175 175 75 0.1914 10.20 5.70 22.00 40 12233000 1210000 70.80 22.30 139800 22800 2438
ISMC 200 200 75 0.2214 11.40 6.10 21.70 40 18193000 1404000 80.30 22.30 181900 26300 2821
ISMC 225 225 80 0.2591 12.40 6.40 23.00 45 26946000 1872000 90.30 23.80 239500 32800 3301
ISMC 250 250 80 0.3036 14.10 7.10 23.00 45 38168000 2191000 99.40 23.80 305300 38400 3867
ISMC 300 300 90 0.3583 13.00 7.60 23.60 50 63626000 3108000 118.10 26.10 424200 46800 4564
ISMC 350 350 100 0.4212 13.50 8.10 24.40 60 100080000 4306000 136.60 28.30 571900 57000 5366
ISMC 400 400 100 0.4940 15.30 8.60 24.20 60 150828000 5048000 154.80 28.30 754100 66600 6293

351622061.xls Page 25 of 31 ISMC


04/14/2017 07:22:14

Section H B wt/m A Tf Tw R1 R2 H1 H2 G Ixx Iyy Rxx Ryy Zxx Zyy


mm mm kN/m mm2 mm mm mm mm mm mm mm mm4 mm4 mm mm mm3 mm3
ISMB100 100 75 0.115 1460 7.2 4.0 9.0 4.5 65.0 17.50 35 2575000 408000 42.0 16.7 51500 10880
ISMB125 125 75 0.130 1660 7.6 4.4 9.0 4.5 89.2 17.90 35 4490000 437000 52.0 16.2 71840 11653
ISMB150 150 80 0.149 1900 7.6 4.8 9.0 4.5 113.9 18.05 40 7264000 526000 61.8 16.6 96853 13150
ISMB175 175 90 0.193 2462 8.6 5.5 10.0 5.0 134.5 20.25 50 12720000 850000 71.9 18.6 145371 18889
ISMB200 200 100 0.254 3233 10.8 5.7 11.0 5.5 152.7 23.65 55 22354000 1500000 83.2 21.5 223540 30000
ISMB225 225 110 0.312 3972 11.8 6.5 12.0 6.0 173.3 25.85 60 34418000 2183000 93.1 23.4 305938 39691
ISMB250 250 125 0.373 4755 12.5 6.9 13.0 6.5 194.1 27.95 65 51314000 3345000 103.9 26.5 410512 53520
ISMB300 300 140 0.442 5626 12.4 7.5 14.0 7.0 241.6 29.25 80 86034000 4539000 123.7 28.4 573560 64843
ISMB350 350 140 0.524 6671 14.2 8.1 14.0 7.0 288.0 31.00 80 136303000 5377000 142.9 28.4 778874 76814
ISMB400 400 140 0.616 7846 16.0 8.9 14.0 7.0 334.4 32.80 80 204584000 6221000 161.5 28.2 1022920 88871
ISMB450 450 150 0.724 9227 17.4 9.4 15.0 7.5 379.2 35.40 90 303908000 8340000 181.5 30.1 1350702 111200
ISMB500 500 180 0.869 11074 17.2 10.2 17.0 8.5 424.1 37.95 100 452183000 13698000 202.1 35.2 1808732 152200
ISMB600 600 210 1.226 15621 20.8 12.0 20.0 10.0 509.7 45.15 140 918130000 26510000 242.4 41.2 3060433 252476

351622061.xls Page 26 of 31 ISMB


DESIGN OF CRANE GANTRY GIRDER

Project : PRAI POWER 350 MW CCGT POWER PLANT PROJECT


Building : CW PUMPHOUSE ( INTERNAL)
Girder Type : EXISTING CRANE BEAM - DESIGN CHECK

1) INPUT DATA
(Refer Appendix-A, for EOT drawing) All below
references are
Crane Capacity = 200 kN BS 5950,
part-1,
Weight of Crab = 50 kN

Weight of Crane Bridge = 0 kN

Self weight of the Rail = 0.8 kN/m

Height of the Crane Rail = 0 mm

Span of the Crane Girder, Lg = 18 m

Mini. approach of crane hook to the gantry = 1.100 m

No. of Wheels = 2
Wheel Spacing1 = 4.00 m
C.G of loading from left load = 2.00 m

Impact Factor : Vertical = 25 %

Horizontal = 10 %
(Transverse to rail)
On Stopper = 16 kN

Deflection Factor Vertical = 1000 Table:5


Horizontal = 1000

Load Factor : Imposed load vertical -Ivf 1


Imposed load Horiz.Ihf 1
Dead load df 1

Design strength of steel, py = 250 N/mm2 Table:6

Maximum unsupported length Top Flange = 8.70 m

Maximum unsupported length Bottom Flange = 8.70 m

2) LOAD CALCULATIONS

Wheel load calculation

RL = (250 x 999998.90 + 0 x 1000000.00/2)/1000000.00 250.000 kN

Max wheel Load by calculation = 125.00 kN/wheel

Wheel Load by Vendor = 50.00 kN/wheel

2.a) Vertical Loads


i) Conc. Loads
Average static Wheel Load say Wm = 125.0 kN
156.2 156.2
Load due to Impact = 0.25 x 125 = 31.25 kN

Total load = 156 kN


Factored Load W mf = 1.00 x 156.25 = 156.25 kN 4.00 ### 4.00

ii) Uniform Dirstributed Load


Self weight of rail = 0.80 kN/m
Self weight of girder = 1.49 kN/m
2.29 kN/m
Factored load W df = 1.00 x 2.29 = 2.29 kN/m

2.b) Horizontal Loads


Maximum lateral load per wheel is equal to 10% Static vertical wheel load,
= 0.1 from Fig-1
Max. Lateral load W H = 0.10(125*2) = 25.0 kN BS:2573,part-1

2 wheels are resisting the total lateral load

Factored lateral load W df = 1.00 x 25.00 / 2 = 12.50 kN/wheel

2.c) Stopper Loads

Factored lateral load Wsp = 1.00 x 16.00 = 16 kN/stopper

3) MAXIMUM BENDING MOMENT AND SHEAR FORCE

3.a) For vertical loads

i) Bending Moment
The maximum Bending moment under moving loads occurs when line of
action of one load and centre of gravity of the loads are at equal distance
from the centre of span. ( refer diagram at deflection check)

Reactions :-

Ra = 156.249828125x(1 + 4.00/2/18) +2.29x1 = 194.23 kN

Rb = 2x156.249828125+2.29x18- 194.234 = 159.51 kN

Maximum Bending Moment

Mux1 = (194.23 x 9.00) -156.249828125 x 3 - (2.29 x 9.00/2)


= 908.14 kN.m
ii) Shear Force:-

Reactions:

RA = 2 x 156.2 x [18.0-2.0] /18+ (2.3 x 18.0/2) = 298.40 kN

RB = (2 x 156.2) + (2.3 x 18.0) - 298.40 = 55.35 kN

Max. Reaction = 298.40 kN

3.b) For Horizontal loads

i) Local Bending Moment at C,

Crane Girder is laterally bending between points of restrained at support


Muy = 12.500 x 8.7 /4 = 27.19 kN.m

ii) Shear force

Reactions :-

RA = 2x 12.5[18.0 - 2.0]18.00 = 22.222 kN

RB = 2 x 12.500 - 22.222 = 2.778 kN

Max. Horzontal reaction RH = 22.222 kN

4) DESIGN OF GANTRY BEAM

Properties :-
Depth of the section, D = 609.9 mm UB610X305X149kg/m
Width of the section, B = 304.8 mm
Thickness of web, t = 11.9 mm
Thickness of flange, T = 19.7 mm
Effective depth of web, d = 537.2 mm
Second moment of inertia, I xx = 1.25E+09 mm4
Second moment of inertia, I yy = 9.30E+07 mm4
rmin = 69.90 mm
Section modulus, Zxx = 4.09E+06 mm3
Section modulus, Zyy = 6.10E+05 mm3
Plastic modulus, Sxx = 4.57E+06 mm3
Plastic modulus, Syy = 9.37E+05 mm3
Buckling parameter, u = 0.886
Torsional index, x : D/T = 32.5
Sectional Area, A = 19000 mm2
Flange Area on one side, Ag = 6005 mm2
Out stand width of panel, b = 146.45 mm
Constant, sqrt(275/py) = 1.05

Outstand element of compression flange, b/T = 7.43 Plastic Cl.3.5.2 and


Web slenderness, d/t = 45.14 Plastic Table:7

4.a) Shear Capacity

Web slenderness, d/t = 45.14 < 63*1.05 Cl.4.4.4.1


Satisfactory
Shear area parallel to the web, Avx=t*d = 6392.68 mm2 Cl.4.2.3,

Critical Shear strength, qcr for d/t =45.14 = 165 N/mm2 Table:21,

Shear Capacity, Vcr=qcr*Avx = 1054.79 kN Cl.4.4.5.3


> 298 kN Satisfactory

4.b) Moment capacity, Mb

i) Lateral-torsional buckling moment, Mb:


( as per clause 4.3.7.3 of BS 5950, part-1)

Effective length factor = 1.20 Table:9


( Destabilizing condition)
(As per table:9,BS 5950,part-1: Beam partial restrained against rotation)

Effective length, LE = 10.44 m


Slenderness, LE/rmin = 149.36
Equivalent slenderness, LT = nu Cl.4.3.7.5

Slenderness correction factor, n = 1.0 conservatively


Uniform moment factor, m = 1.0 conservatively
Buckling parameter, u = 0.886
x = 4.596
N = 0.50
Slenderness factor, = 0.82 Table:14

LT = 108.51
pb = 109.00 N/mm2 Table:11

Buckling resistance, Mb = pb*Sxx


= 498.13 kN.m Unsafe
<908.14 kN.m Cl.4.3.7.2
> m*Mux1

5) CHECK FOR COMBINED BENDING COMPRESSIVE STRESS


IN EXTREME FIBRE (FOR VERTICAL PLUS LATERAL)

5.a) Compressive strength pc

Slenderness, LE/rmin = 149.36

pc = 81 N/mm2 Table 27c

5.b) Overall buckling check


(As per Clause 4.8.3.3.1, BS 5950: part-1)

mMux1/Mb + mMuy/py*Zyy = 2.001 Unsafe


< 1.000

6) CHECK FOR LONGITUDINAL STRESS

Height of rail = 0 mm

5% of the static wheel load = 5/100 x2x 156.2 15.62 kN

Bending moment in the longitudinal direction is equal to Longitudinal Force into


Crane Rail Depth plus half of Crane Girder depth

Mux2 = 15625 x (0 + 305.0) = 4.76 kN.m

CHECK FOR COMBINED BENDING COMPRESSIVE STRESS


IN EXTREME FIBRE (FOR VERTICAL PLUS LONGITUDINAL)

F/Ag*pc + m(Mux1+Mux2)/Mb = 1.865 Unsafe

7) CHECK FOR DEFLECTION


Allowable deflection for vertical loads
lim, v = Span / 1000 =18,000.0 / 1,000.0 = 18.00 mm

Allowable deflection for horizontal loads


lim, h = Span / 1000 = 18,000.0 /1,000 = 18.00 mm

Vertical Deflection:-

10 8

6.00 CG OF LOADS
156.249828125kN 156.24982 2.29kN/m
= =

c
RA 18.00 RB
CG. OF GANTRY

[ ( )] [ ( )]
3 3 3
v = 5 WL4 PL 3a1 a1 PL3 3a2 4 a2
+ 4 +
384 EI 48EI L L 48EI L L

v = ((5/384)(2.29 x 18000^4)/( 205000 x 1.25E+09))+


{( 156250 x 18000)/( 48 x 205000 x 1.25E+09)} x
{[3 x 6.00/18 - 4 x (6.00/18)] + [3 x 8.00/18 - 4 x (8.00/18)]}
= 148.097 mm

CHECK v < Allowable Deflection 148.097 > 18.0


NOT SAFE, FAILS IN DEFLECTION

8) SHEAR BUCKING OF WEB UNDER WHEEL LOAD

8.a) Web bearing under wheel load


(as per Cl.4.11.4,BS 5950, part-1)

Load dispersion under wheel,lw= 2(Height of the wheel + Thickness of the flange)
= 39.4 mm

Bearing Capacity = lw*py*t = 117.215 kN


< 156.25 kN Redesign

8.b) Web buckling under wheel load


(as per Cl.4.5.2.1, BS 5950,part-1)

b1 = Stiff bearing length = 2(Height of the crane rail)


= 0.00 mm
n1 = Dispersion at 45degrees through half the depth of the section
= (depth of the web + 2*thickness of the flange)
= 609.9 mm

d = Depth of the web = 570.5 mm

Web slenderness, = 2.5*depth of the web/thickness of the web Cl.4.5.2.1


= 119.85

Compressive resistance, pc = 97 N/mm2 Table 27c

Buckling resistance, Pw = (b1+n1)*t*pc= 704.01 kN


= > 156.25 kN Satisfactory

9) CONNECTION FOR LONGITUDINAL LOAD

Longitudinal Force = 15.62 kN

Dia of bolt provided = 16 mm


No. of bolts provided = 2

Stress in Bolts = 38.86 N/mm2


< 160 N/mm2

10) DESIGN OF STOPPER BRACKET

Depth of the bracket, Dsp = 250 mm


Width of the bracket, Wsp = 102 mm
Thickness of the bracket plate, Tsp = 6 mm
Thickness of stiffener plate, Ts = 6 mm
No of stiffener plate, Ns = 1 nos
Distance between Stopper and flange of Crane girder = 0.20 m
Maximum Stopper force = 16.0 kN
Maximum ultimate Stopper force, S = 16.0 kN

10.a) Design for Moment


Moment due to eccentricity, Mc = 3.20 kN.m

Combined plate C.G., x = 91.2 mm

Combined plate Ixx = 1.40E+07 mm4

Distance of compression edge = 158.8 mm

Combined plate Zxx = 88189 mm3

Moment capacity, Mc = PypZxx = 22.05 kNm Cl.4.13.2.4


> 3.20 kNm Satisfactory

10.b) Weld between Bracket and flange of Crane Girder

Design strength of fillet weld, pw = 215 N/mm2 Tb.36, BS5950

Weld thickness = 6 mm

Effective length of flange weld = 400 mm

Max.bending tension in bracket, T = M/x = 35.1 kN

Capacity of bracket weld under tension = 361.2 kN


> 35.1 kN Satisfactory O.K.

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