Date: 29-Jan-19

DESIGN CALCULATION REPORT: STEEL

RUNWAY BEAMS FOR 4T TROLLEY

DESIGN BY:
Damodharan J

CHECKED BY:
Hashim Al Amidi

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Contents
1 Introduction .......................................................................................................................................... 3

2 Design Assumptions .............................................................................................................................. 3

2.1 Reference ...................................................................................................................................... 3

2.2 Design Codes ................................................................................................................................. 3
2.3 Design Methodology ..................................................................................................................... 3
3 Material Properties ............................................................................................................................... 3

4 Loads ..................................................................................................................................................... 3

5 References Documents ......................................................................................................................... 3

5.1 Drawings ....................................................................................................................................... 3

6 Design of Runway beam UB 305X165X46 ............................................................................................. 4

7 Suspended post design SHS 120X120X8mm......................................................................................... 8

8 Design Check for the Built up section at curved portion .................................................................... 12

9 Design Check for the Built up section bending stress ......................................................................... 18

10 Splice Design check ............................................................................................................................. 22

11 Connection between UB 305X165X46 and SHS 120X120X8 ............................................................... 23

12 Base connection .................................................................................................................................. 24

13 Conclusion ........................................................................................................................................... 24

14 Appendix-1 .......................................................................................................................................... 26

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1 Introduction
Objective of this report is to design the Mono rail beam for a capacity of 40kN (4000kg).

2 Design Assumptions

2.1 Reference
QCS 2014 has adopted as a reference code

2.2 Design Codes

 BS 2853:1957 & BS 449-2:1969 have been adopted in the calculation of steel sections Capacity.
 Steel Design Guide to BS 5950-1:2000 Volume 01 (Blue Book) section properties and Member
Capacities, is referred for the weld strength.

2.3 Design Methodology

 Beam capacity is checked using SCALE, and connection capacity is checked using Hilti PROFIS
Anchor.
 The beams are suspended by 1500mm from the slab soffit.

3 Material Properties
 Steel Density : 78 kN/m3
 Steel plate yield stress σ y : 355 N/mm2

4 Loads
 Dead load self-weight of the beam and trolley (300kg)
 Vertical load on the beam = 4000kg = 40kN
 Horizontal load transverse to the beam = 10% of the combined weight = 43 kN X 0.1 = 4.3 kN (as
per BS 449-2:1969)
 Horizontal load acting along the beam = 5 % of the combined weight = 43 kN X 0.05 = 2.15 kN (as
per BS 449-2:1969)

5 References Documents

5.1 Drawings
 D18-5932-00-02-01 Rev.0 – 4T hoist GA drawings

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6 Design of Runway beam UB 305X165X46

To check the capacity of the beam it is assumed the load is acting at the centre.

43 kN

1500 mm
 Max. Span L = 1.5m
 The beams are suspended from slab soffit by 1500mm.
 Factored Self-weight of the beam Pd = 0.46 kN/m
 Trolley capacity = 40 kN
 Trolley Self weight = 300kg =3 kN

The capacity of the beam is checked using SCALE.

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7 Suspended post design SHS 120X120X8mm

 The Horizontal force shall be taken into account when considering the lateral rigidity of the rails
and their Fastenings (as per BS 449-2:1969).
 Max. Tension load = 54 kN * 2 = 108 kN (to be in saferside)
 Transverse load Vx = 4.3 kN * 1.6 = 6.68 kN
 Longitudinal horizontal load Vy = 2.15 kN * 1.6 = 3.44 kN
 Max. height of the post l = 1.5m
 Moment Mx = 6.68 kN * 1.5m = 10.02 kNm
 Moment My = 3.44* 1.5 m = 5.10 kNm

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8 Design Check for the Built up section at curved portion

While designing the curved runway beam, we have to consider both torsional and bending effect. The
torsional effect causes additional bending stress.so, the effect of torsional moment is considered by
evaluating the value of minor axis bending stress due to torsion.

The vertical load is same as calculated in case of design of straight runway beam. The centrifugal force is
added to the lateral load.

Radial force / centifugal force Fa = 20.72 kN

SCALE Software has been adopted to check the effects on the plate girder
depth = 306mm; Width=166; flange thickness = 12mm; web thickness = 10mm

Stiffner plate 6mm @ 250mm C/C both side only on the curved portion.

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9 Design Check for the Built up section bending stress

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10 Splice Design check

 Max. Moment at mid span = 20 kN.m

 We recommend to provide splice at l/3 of the span,
 Max. Moment at l/3 m = 15 kN.m
 Max. Shear at l/3 = 50 kN
 Tension force due to moment on the top flange = 20kN.m/0.20m = 67kN
 Using 10mm fillet welding, with 8mm connection plate in top flange and web.
 Transverse capacity = 1.925 kN/mm
 Longitudinal capacity = 1.540 kN/mm
 Minimum length of weld required for flange = 67kN/ 1.54 kN/mm = 43.5 mm , Provide > 100
mm balanced weld

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11 Connection between UB 305X165X46 and SHS 120X120X8

 The Horizontal force shall be taken into account when considering the lateral rigidity of the rails
and their Fastenings (as per BS 449-2:1969).
 Max. Tension load = 54 kN * 2 = 108 kN ~ 110kN
 Transverse load Vx = 4.3 kN * 1.6 = 6.68 kN
 Longitudinal horizontal load Vy = 2.15 kN * 1.6 = 3.44 kN
 Max. height of the beam l = 0.3m
 Moment Mx = 6.68 kN * 0.3m = 2.00 kNm
 Moment My = 3.44* 0.3 m = 1.032 kNm

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 Use connection plate 165mmX250X 16mm, Using 4 nos. M20 grade 8.8 Bolt
 Tension load due to moment = 2 kNm /0.07m = 29 KN
 Total tension load = 29 kN +110 kN = 139 kN
 Tension load on each bolt = 139 kN/4 = 34.75 kN~ 35 kN
 Tension capacity of M 20 grade 8.8 bolt = 110 kN > 35 kN (safe)
 Shear Capacity of M 20 grade 8.8 bolt = 91.9 kN > 6.68 kN (safe)
 Combined Shear and Tension
 35 kN / 110 kN + 6.68 kN / 91.9 kN ≤ 1.4
 0.38 ≤ 1.4 (safe)

12 Base connection
 Baseplates are designed on the assumption that the horizontal forces (longitudinal and
transvers) are alternatives which do not act at the same time but that each of them may act at
the same time as the vertical load. (BS 449-2:1969)
 For the base plate connection, the safety factor for vertical load = 1.5, therefore P = 43 kN x 1.5
= 64 kN (refer appendix-1 for detailed Hilti report)

13 Conclusion
 For 4T capacity Trolley use UB 305X165X54 runway beam with suspended post SHS
120X120X8mm@ 1500mm C/C spacing, for heights above 800mm provide bracing EA
100X100X8mm for stability.

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14 Appendix-1

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