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CRANE GANTRY GIRDER DESIGN (BS5950-1:2000)
TEDDS calculation version 1.0.02
Crab
Crane Bridge
Gantry Girder
Safe Working Load, Wswl
Crab weight, Wcrab
Crane bridge weight, Wcrane
Minimum hook approach, ah
Span of crane bridge, L c
Elevation on Crane Bridge
Bogie wheel centres, aw2
= = aw1 - aw2
Wheel centres, aw1
Bogie centres, aw1
2 Wheel End Carriage
4 Wheel End Carriage
1. CRANE & GIRDER DETAILS
Crane details
Self weight of crane bridge (excl. crab);
Wcrane = 20.0 kN
Self weight of crab;
Wcrab = 25.0 kN
Crane safe working load (SWL);
Wswl = 150.0 kN
Span of crane bridge;
Lc = 6000 mm
Minimum hook approach;
ah = 2000 mm
No. of wheels per end carriage;
Nw = 2
End carriage wheel centres;
aw1 = 2000 mm
Class of crane;
Q3
No. of rails resisting crane surge force;
Nr = 1
Self weight of crane rail;
wr = 0.5 kN/m
Height of crane rail;
hr = 45 mm
Gantry girder details
Span of gantry girder;
L = 6000 mm
Gantry girder section type;
Composite with top channel
Gantry girder I beam;
IPE 360
Top channel;
UPN 220
Grade of steel;
S 275
Leg length of channel to beam flange fillet weld;
s = 6 mm
2. LOADING, SHEAR FORCES & BENDING MOMENTS
Unfactored self weight and crane rail UDL
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Beam, channel and crane rail self weight udl;
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wsw = [(Massbm + Massch) gacc] + wr = 1.3 kN/m
Maximum unfactored static vertical wheel load
From hook load;
Wh = Wswl (Lc - ah)/(Lc Nw) = 50.0 kN
From crane self weight (incl. crab);
Ws = [Wcrane/2 + Wcrab (Lc-ah)/Lc]/Nw = 13.3 kN
Total unfactored static vertical wheel load;
Wstat = Wh + Ws = 63.3 kN
Maximum unfactored dynamic vertical wheel load
From BS2573:Part 1:1983 - Table 4
Dynamic factor with crane stationary;
Fsta = 1.30;
Dynamic wheel load with crane stationary;
Wsta = (Fsta Wh) + Ws = 78.3 kN
Dynamic factor with crane moving;
Fmov = 1.25;
Dynamic wheel load with crane moving;
Wmov = Fmov Wstat = 79.2 kN
Max unfactored dynamic vertical wheel load;
Wdyn = max(Wsta,Wmov) = 79.2 kN
Unfactored transverse surge wheel load
Number of rails resisting surge;
Nr = 1
Proportion of crab and SWL acting as surge load; Fsur = 10 %
Unfactored transverse surge load per wheel;
Wsur = Fsur (Wcrab + Wswl)/(Nw Nr) = 8.8 kN
Unfactored transverse crabbing wheel load
Unfactored transverse crabbing load per wheel;
Wcra = max(Lc Wdyn/(40 aw1),Wdyn/20) = 5.9 kN
Unfactored longitudinal braking load
Proportion of static wheel load actg as braking load;
Unfactored longitudinal braking load per rail;
Fbra = 15 %
Wbra = Fbra Wstat Nw = 19.0 kN
Ultimate loads
Loadcase 1 (1.4 Dead + 1.6 Vertical Crane)
Vertical wheel load;
Wvult1 = 1.6 Wdyn = 126.7 kN
Gantry girder self weight udl;
wswult = 1.4 wsw = 1.9 kN/m
Loadcase 2 (1.4 Dead + 1.4 Vertical Crane + 1.4 Horizontal Crane)
Vertical wheel load;
Wvult2 = 1.4 Wdyn = 110.8 kN
Gantry girder self weight udl;
wswult = 1.4 wsw = 1.9 kN/m
Horizontal wheel load (surge);
Wsurult = 1.4 Wsur = 12.3 kN
Horizontal wheel load (crabbing);
Wcrault = 1.4 Wcra = 8.3 kN
Maximum ultimate vertical shear force
From loadcase 1;
Vv = Wvult1 (2 - aw1/L) + wswult L/2 = 216.8 kN
Ultimate horizontal shear forces (loadcase 2 only)
Shear due to surge;
Vsur = Wsurult (2 - aw1/L) = 20.4 kN
Shear due to crabbing;
Vcra = Wcrault = 8.3 kN
Maximum horizontal shear force;
Vh = max(Vsur,Vcra) = 20.4 kN
Ultimate vertical bending moments and co-existing shear forces
Bending moment loadcase 1;
Mv1 = (Wvult1/L) (L-aw1/2) (L/2-aw1/4) + wswult L2/8 = 272.4 kNm
Co-existing shear force;
Vv1 = Wvult1 [1 - aw1/(2L)] = 105.6 kN
Bending moment loadcase 2;
Mv2 = (Wvult2/L) (L-aw1/2) (L/2-aw1/4) + wswult L2/8 = 239.4 kNm
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Co-existing shear force;
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Vv2 = Wvult2 [1 - aw1/(2L)]= 92.4 kN
Ultimate horizontal bending moments (loadcase 2 only)
Surge moment;
Msur = (Wsurult/L) (L - aw1/2) (L/2 - aw1/4) = 25.5 kNm
Crabbing moment;
Mcra = Wcrault (aw1/L) (L - aw1) = 11.1 kNm
Maximum horizontal moment;
Mh = max(Msur, Mcra) = 25.5 kNm
3. SECTION PROPERTIES
Beam section properties
Area;
Abm = 72.7 cm2
Second moment of area about major axis;
Second moment of area about minor axis;
Ixxbm = 16266 cm4
Iyybm = 1043 cm4
Torsion constant;
Jbm = 37.4 cm4
Channel section properties
Area;
Ach = 37.4 cm2
Second moment of area about channel major axis; Ixxch = 2691 cm4
Second moment of area about channel minor axis; Iyych = 196 cm4
Torsion constant;
Jch = 16.2 cm4
Composite elastic section properties
Position of neutral axis above bottom flange;
yna = [(Abm Dbm/2) + Ach (Dbm + tch - Cych)]/(Abm + Ach) = 236.9 mm
Second moment of area about major axis;
Ixx = Ixxbm+Abm(yna-Dbm/2)2+Iyych+Ach(Dbm+tch-Cych-yna)2 = 23401 cm4
Second moment of area about minor axis;
Iyy = Iyybm + Ixxch = 3735 cm4
Elastic modulus about major axis (top);
Zxxtop = Ixx/(Dbm tch - yna) = 1772 cm3
Elastic modulus about major axis (bottom);
Zxxbtm = Ixx/yna = 988 cm3
Elastic modulus about minor axis;
Zyy = Iyy/(Dch/2) = 340 cm3
Radius of gyration about minor axis;
ry = [Iyy/( Abm + Ach)]1/2 = 5.82 cm
Composite plastic section properties
Plastic modulus
Area of one flange of beam;
Afl = Tbm Bbm = 2159 mm2
Position of equal area axis below top of channel;
yea=tch+Tbm+[(Abm+Ach)/2-tchDch-(Bbm+2Tch)Tbm]/(2Tch+tbm)=53.6 mm
Plastic modulus about major axis
Channel web component above equal area axis;
Suchw = Dch tch( yea- tch/2) = 97.2 cm3;
Channel web component below equal area axis;
Slchw = 0.0 cm3;
Channel flange component above equal area axis; Suchfl = 2 Tch (yea- tch)2/2 = 24.8 cm3;
Channel flange component below equal area axis; Slchfl = 2Tch( Bch- yea)2/2 = 8.7 cm3;
Beam top flange component above eq area axis;
Submtfl = Afl( yea- tch- Tbm/2)) = 82.5 cm3;
Beam top flange component below eq area axis;
Slbmtfl = 0.0 cm3;
Beam web component above equal area axis;
Submw = tbm( yea- (tch+ Tbm))2/2 = 4.1 cm3;
Beam web component below equal area axis;
Slbmw = tbm(tch+ Dbm- Tbm- yea)2/2) = 366.5 cm3;
Beam bottom flange component;
Sbmbfl = Afl (tch + Dbm - Tbm/2 - yea) = 667.3 cm3
Plastic modulus about major axis;
Sx=Suchw+Slchw+Suchfl+Slchfl+Submtfl+Slbmtfl+Submw+Slbmw+Sbmbfl= 1251 cm3
Torsion constant, J
Torsion constant;
J = Jbm + Jch = 53.6 cm4
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Torsional index, x (Annex B.2.4.1)
Position of top shear centre from top of section;
sct = [(Dch tch2/2) + Afl (tch + Tbm/2)]/[(Dch tch) + Afl] = 10.2 mm
Distance between flange shear centres;
hs = Dbm + tch - Tbm/2 - sct = 352.5 mm
Torsional index;
x = 0.566 hs [(Abm + Ach)/J]1/2 = 28.6
Buckling parameter, u (Annex B.2.3)
u = [4 Sx2 (1 - Iyy/Ixx)/((Abm + Ach)2 hs2)]1/4 = 0.769;
Buckling parameter;
Flange ratio/monosymmetry index, /(sagging moment) cl. 4.3.6.7
2nd moment of area of top flange about minor axis; Itf = Ixxch + TbmBbm3/12 = 3211.1 cm4
2nd moment of area of btm flange about minor axis;Ibf = TbmBbm3/12 = 520.0 cm4
Flange ratio (sagging moment);
sag = Itf/(Itf + Ibf) = 0.861
Monosymmetry index (sagging moment);
sag = 0.8 ((2 sag) - 1) (1 + 0.5 Bch/(Dbm + tch)) = 0.640
Section properties of top flange only
Elastic modulus;
Ztf = Itf/(Dch/2) = 291.9 cm3
Plastic modulus;
Stf = Sxxch + Tbm Bbm2/4 = 383.2 cm3
Steel design strength
Maximum steel thickness;
From BS5950-1:2000 - Table 9
T = max(Tbm,Tch) = 12.7 mm
Steel design strength;
py = 275 N/mm2
Section classification (cl. 3.5.3)
= (275 N/mm2/py)1/2 = 1.000;
Parameter epsilon;
ratio1 = Bch/Tch = 6.400;
Channel flange (outstand element of comp. flange);
Channel web (internal element of comp. flange);
ratio2 = Bbm/tch = 18.889;
Channel web (internal element of comp. flange);
ratio3 = (Dch/2 - Bbm/2 - Tch)/ tch = 1.389;
Beam flange (outstand element of comp. flange); ratio4 = (Dch/2 - Tch)/Tbm = 7.677;
ratio5 = dbm/tbm = 37.325;
Beam web (conservatively assume n.a is middepth);
Flange classification;
Class 1 plastic
Web classification;
Class 1 plastic
Overall section classification;
Class 1 plastic
Shear buckling check (cl. 4.2.3)
Ratio d upon t;
d_upon_t = dbm/tbm = 37.325;
PASS - d/t <= 70 - The web is not susceptible to shear buckling
4. DESIGN CHECKS
Vertical shear capacity (cl. 4.2.3)
Vertical shear capacity of beam web;
Pvv = 0.6 py tbm Dbm = 475.2 kN
PASS - Vv <= Pvv - Vertical shear capacity adequate (UF1 = 0.456)
Loadcase 1 - Vv1 <= 0.6Pvv - Beam is in low shear at position of max moment
Loadcase 2 - Vv2 <= 0.6Pvv - Beam is in low shear at position of max moment
Horizontal shear capacity (cl. 4.2.3)
Horizontal shear capacity of beam flange;
Pvhbm = 0.6 py 0.9 Tbm Bbm = 320.6 kN
Horizontal shear capacity of channel web;
Pvhch = 0.6 py tch Dch = 326.7 kN
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Pvh = Pvhbm + Pvhch= 647.3 kN
Combined horizontal shear capacity;
PASS - Vh <= Pvh - Horizontal shear capacity adequate (UF2 = 0.032 - low shear)
Vertical bending capacity (cl. 4.2.5)
Vertical bending capacity of composite section;
Mcxz = 1.2 py min(Zxxtop,Zxxbtm) = 325.9 kNm
Mcxs = py Sx = 344.1 kNm
Mcx = min(Mcxz,Mcxs) = 325.9 kNm
PASS - Mv1 <= Mcx - Vertical moment capacity adequate (UF3 = 0.836)
Effective length for buckling moment (Table 13)
Length factor for end 1;
KL1 = 1.00
Length factor for end 2;
KL2 = 1.00
Depth factor for end 1;
KD1 = 0.00
Depth factor for end 2;
KD2 = 0.00
Effective length;
Le = L (KL1 + KL2)/2 + (Dbm + tch) (KD1 + KD2)/2 = 6000 mm
Lateral torsional buckling capacity (Annex B.2.1, 2.2 & 2.4)
Slenderness ratio;
= Le/ry = ;
Slenderness factor;
v = 1/[(4 sag (1 - sag) + 0.05 (/x)2 + sag2)0.5 + sag]0.5 = 0.729;
Section is class 1 plastic therefore;
w = 1.0
Equivalent slenderness;
LT = u v (w) = 57.8;
Robertson constant;
LT = 7.0
Limiting equivalent slenderness;
L0 = 0.4 (2 ES5950/py)0.5 = 34.3;
Perry factor;
LT= 2 LT (LT - L0)/1000 = 0.328;
Euler buckling stress;
pE = 2 ES5950/LT2 = 606.2 N/mm2
Factor phi;
LT = [py + (LT + 1) pE]/2 = 540.2 N/mm2
Bending strength;
pb = pE py/[LT + (LT2 - pE py)0.5] = 186.5 N/mm2
Buckling resistance moment;
Mb = pb Sx = 233.4 kNm
Equivalent uniform moment factor;
mLT = 1.0
Allowable buckling moment;
Mballow = Mb/mLT = 233.4 kNm
FAIL - Mv1 > Mballow - Buckling moment capacity exceeded (UF4 = 1.167)
Horizontal bending capacity (loadcase 2 only) cl. 4.2.5
Horizontal moment capacity of top flange;
Mctf = min(py Stf,1.2 py Ztf) = 96.3 kNm
PASS - Mh <= Mctf - Horizontal moment capacity adequate (UF5 = 0.265)
Combined vertical and horizontal bending (loadcase 2 only)
Cross section capacity (cl. 4.8.3.2)
Section utilisation;
UF6 = Mv2/Mcx + Mh/Mctf = 0.999;
PASS - Section capacity adequate (UF6 = 0.999)
Member buckling resistance (cl. 4.8.3.3.1)
Uniform moment factors;
mx = 1.0
my = 1.0
Case 1;
UF7 = mx Mv2/(py Zxxbtm) + my Mh/(py Ztf) = 1.199;
Case 2;
UF8 = mLT Mv2/Mb + my Mh/(py Ztf) = 1.344;
FAIL - Buckling capacity exceeded (UF7&8 = 1.344)
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Check beam web bearing under concentrated wheel loads (cl. 4.5.2.1)
End location
Maximum ultimate wheel load;
Wvult1 = 126.7 kN
Stiff bearing length (dispersal through rail);
b1 = hr + tch = 54 mm
Bearing capacity of unstiffened web;
Pbw = [b1 + 2 (Tbm + rbm)] tbm py = 253.9 kN
PASS - Wvult1 <= Pbw - Web bearing capacity adequate (UF9 = 0.499)
Check beam web buckling under concentrated wheel loads (cl. 4.5.3.1)
End location - top flange not effectively restrained rotationally or laterally
Maximum ultimate wheel load;
Wvult1 = 126.7 kN
Stiff bearing length (dispersal through rail);
b1 = hr + tch = 54 mm
Effective length of web;
LEweb = 1.2 dbm = 358 mm
Buckling capacity of unstiffened web;
Pxr=1/225tbm/[(b1+2(Tbm+rbm))dbm]1/20.7dbm/LEwebPbw
Pxr = 79.8 kN
FAIL - Wvult1 > Pxr - Web buckling capacity exceeded (UF10 = 1.588)
Check channel to beam flange weld
Maximum vertical shear force;
Vv = 216.8 kN
Shear stress on weld;
vw = Vv Ach (Dbm + tch - Cych - yna)/(2 0.7 s Ixx) = 45.7 N/mm2
From BS8110-1:2000 Table 37
pw = 220 N/mm2
Allowable weld stress for grade S275 steel;
PASS - vw <= pw - 6 mm continuous fillet welds are adequate (UF11 = 0.208)
Allowable deflections
Allowable vertical deflection = span/800;
vallow = L/limitv = 7.5 mm
Allowable horizontal deflection = span/800;
hallow = L/limith = 7.5 mm
Calculated vertical deflections
Modulus of elasticity;
E = ES5950 = 205 kN/mm2
Due to self weight;
sw = 5 wsw L4/(384 E Ixx) = 0.5 mm
Due to wheels at position of maximum moment
First wheel;
v1 = Wstat(L/2-aw1/4)[3L2-4(L/2-aw1/4)2]/(48EIxx) = 5.7 mm
Second wheel;
v2 = Wstat (L/2-3aw1/4) [3L2-4(L/2-3aw1/4)2]/(48EIxx)
v2 = 4.1 mm
v = sw + v1 + v2 = 10.3 mm
Total vertical deflection;
FAIL - v > vallow - Allowable vertical deflection exceeded (Actual deflection = span/584)
Calculated horizontal deflection
Due to surge (wheels at position of max moment)
First wheel;
h1 = Wsur(L/2-aw1/4)[3L2-4(L/2-aw1/4)2]/(48EItf) = 5.7 mm
Second wheel;
h2 = Wsur (L/2-3aw1/4) [3L2-4(L/2-3aw1/4)2]/(48E Itf)
h2 = 4.1 mm
Total horizontal surge deflection;
hs = h1 + h2 = 9.9 mm
Horizontal crabbing deflection;
hc = Wcra aw1 (L2 - aw12)3/2/(15.588 L E Itf) = 3.5 mm
Maximum horizontal deflection;
h = max(hs,hc) = 9.9 mm
FAIL - h > hallow - Allowable horizontal deflection exceeded (Actual deflection = span/609)
