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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)