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CRANE GANTRY GIRDER DESIGN (BS5950-1:2000)

TEDDS calculation version 1.0.05

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); W crane = 100.0 kN
Self weight of crab; W crab = 25.0 kN
Crane safe working load (SWL); W swl = 250.0 kN
Span of crane bridge; Lc = 18000 mm
Minimum hook approach; ah = 785 mm
No. of wheels per end carriage; Nw = 2
End carriage wheel centres; aw1 = 4400 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 = 100 mm
Gantry girder details
Span of gantry girder; L = 6000 mm
Gantry girder section type; Composite with top channel
Gantry girder ‘I’ beam; UB 533x210x82
Top channel; PFC 300x90x41
Grade of steel; S 355
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
Beam, channel and crane rail self weight udl; wsw = [(Massbm + Massch)  gacc] + wr = 1.7 kN/m

Maximum unfactored static vertical wheel load

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From hook load; W h = W swl  (Lc - ah)/(Lc  Nw) = 119.5 kN

From crane self weight (incl. crab); W s = [W crane/2 + W crab  (Lc-ah)/Lc]/Nw = 37.0 kN
Total unfactored static vertical wheel load; W stat = W h + W s = 156.5 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; W sta = (Fsta  W h) + W s = 192.4 kN
Dynamic factor with crane moving; Fmov = 1.25;
Dynamic wheel load with crane moving; W mov = Fmov  W stat = 195.6 kN
Max unfactored dynamic vertical wheel load; W dyn = max(W sta,W mov) = 195.6 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; W sur = Fsur  (W crab + W swl)/(Nw  Nr) = 13.8 kN

Unfactored transverse crabbing wheel load

Unfactored transverse crabbing load per wheel; W cra = max(Lc  W dyn/(40  aw1),W dyn/20) = 20.0 kN

Unfactored longitudinal braking load

Proportion of static wheel load act’g as braking load; Fbra = 5 %
Unfactored longitudinal braking load per rail; W bra = Fbra  W stat  Nw = 15.7 kN

Ultimate loads
Loadcase 1 (1.4 Dead + 1.6 Vertical Crane)
Vertical wheel load; W vult1 = 1.6  W dyn = 313.0 kN
Gantry girder self weight udl; wswult = 1.4  wsw = 2.4 kN/m

Loadcase 2 (1.4 Dead + 1.4 Vertical Crane + 1.4 Horizontal Crane)

Vertical wheel load; W vult2 = 1.4  W dyn = 273.9 kN
Gantry girder self weight udl; wswult = 1.4  wsw = 2.4 kN/m
Horizontal wheel load (surge); W surult = 1.4  W sur = 19.3 kN
Horizontal wheel load (crabbing); W crault = 1.4  W cra = 28.0 kN

Maximum ultimate vertical shear force

From loadcase 1; Vv = W vult1  (2 - aw1/L) + wswult  L/2 = 403.7 kN

Ultimate horizontal shear forces (loadcase 2 only)

Shear due to surge; Vsur = W surult  (2 - aw1/L) = 24.4 kN
Shear due to crabbing; Vcra = W crault = 28.0 kN
Maximum horizontal shear force; Vh = max(Vsur,Vcra) = 28.0 kN
Ultimate vertical bending moments and co-existing shear forces
Bending moment loadcase 1; Mv1 = W vult1  L/4 + wswult  L2/8 = 480.3 kNm
Co-existing shear force; Vv1 = W vult1/2 = 156.5 kN
Bending moment loadcase 2; Mv2 = W vult2  L/4 + wswult  L2/8 = 421.6 kNm
Co-existing shear force; Vv2 = W vult2/2 = 136.9 kN
Ultimate horizontal bending moments (loadcase 2 only)
Surge moment; Msur = W surult  L/4 = 28.9 kNm
Crabbing moment; Mcra = W crault  L/4 = 42.0 kNm
Maximum horizontal moment; Mh = max(Msur, Mcra) = 42.0 kNm
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3. SECTION PROPERTIES
Beam section properties
Area; Abm = 104.7 cm2
Second moment of area about major axis; Ixxbm = 47539 cm4
Second moment of area about minor axis; Iyybm = 2007 cm4
Torsion constant; Jbm = 51.5 cm4
Channel section properties
Area; Ach = 52.7 cm2
Second moment of area about channel major axis; Ixxch = 7218 cm4
Second moment of area about channel minor axis; Iyych = 404 cm4
Torsion constant; Jch = 28.5 cm4
Composite elastic section properties
Position of neutral axis above bottom flange; yna = [(Abm  Dbm/2) + Ach  (Dbm + tch - Cych)]/(Abm + Ach) = 346.9 mm
Second moment of area about major axis; Ixx = Ixxbm+Abm(yna-Dbm/2)2+Iyych+Ach(Dbm+tch-Cych-yna)2 = 69360 cm4
Second moment of area about minor axis; Iyy = Iyybm + Ixxch = 9226 cm4
Elastic modulus about major axis (top); Zxxtop = Ixx/(Dbm  tch - yna) = 3643 cm3
Elastic modulus about major axis (bottom); Zxxbtm = Ixx/yna = 1999 cm3
Elastic modulus about minor axis; Zyy = Iyy/(Dch/2) = 615 cm3
Radius of gyration about minor axis; ry = [Iyy/( Abm + Ach)]1/2 = 7.66 cm
Composite plastic section properties
Plastic modulus
Area of one flange of beam; Afl = Tbm  Bbm = 2756 mm2
Position of equal area axis below top of channel; yea=tch+Tbm+[(Abm+Ach)/2-tchDch-(Bbm+2Tch)Tbm]/(2Tch+tbm)=71.6 mm
Plastic modulus about major axis
Channel web component above equal area axis; Suchw = Dch tch( yea- tch/2) = 181.2 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 = 60.7 cm3;
Channel flange component below equal area axis; Slchfl = 2Tch( Bch- yea)2/2 = 5.2 cm3;
Beam top flange component above eq area axis; Submtfl = Afl( yea- tch- Tbm/2)) = 154.3 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 = 11.7 cm3;
Beam web component below equal area axis; Slbmw = tbm(tch+ Dbm- Tbm- yea)2/2) = 982.8 cm3;
Beam bottom flange component; Sbmbfl = Afl  (tch + Dbm - Tbm/2 - yea) = 1265.4 cm3
Plastic modulus about major axis; Sx=Suchw+Slchw+Suchfl+Slchfl+Submtfl+Slbmtfl+Submw+Slbmw+Sbmbfl= 2661 cm3
Torsion constant, J
Torsion constant; J = Jbm + Jch = 80.0 cm4
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] = 10.1 mm
Distance between flange shear centres; hs = Dbm + tch - Tbm/2 - sct = 520.6 mm
Torsional index; x = 0.566  hs  [(Abm + Ach)/J]1/2 = 41.3

Buckling parameter, u (Annex B.2.3)

Buckling parameter; u = [4  Sx2  (1 - Iyy/Ixx)/((Abm + Ach)2  hs2)]1/4 = 0.778;

Flange ratio/monosymmetry index, /(sagging moment) cl. 4.3.6.7

2nd moment of area of top flange about minor axis; Itf = Ixxch + TbmBbm3/12 = 8219.8 cm4
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2nd moment of area of btm flange about minor axis; Ibf = TbmBbm3/12 = 1001.3 cm4
Flange ratio (sagging moment); sag = Itf/(Itf + Ibf) = 0.891
Monosymmetry index (sagging moment); sag = 0.8  ((2  sag) - 1)  (1 + 0.5  Bch/(Dbm + tch)) = 0.679

Section properties of top flange only

Elastic modulus; Ztf = Itf/(Dch/2) = 548.0 cm3
Plastic modulus; Stf = Sxxch + Tbm  Bbm2/4 = 711.7 cm3

Steel design strength

Maximum steel thickness; T = max(Tbm,Tch) = 15.5 mm
From BS5950-1:2000 - Table 9
Steel design strength; py = 355 N/mm2
Section classification (cl. 3.5.3)
Parameter epsilon; = (275 N/mm2/py)1/2 = 0.880;
Channel flange (outstand element of comp. flange); ratio1 = Bch/Tch = 5.806;
Channel web (internal element of comp. flange); ratio2 = Bbm/tch = 23.200;
Channel web (internal element of comp. flange); ratio3 = (Dch/2 - Bbm/2 - Tch)/ tch = 3.344;
Beam flange (outstand element of comp. flange); ratio4 = (Dch/2 - Tch)/Tbm = 10.189;
Beam web (conservatively assume n.a is middepth); ratio5 = dbm/tbm = 49.635;
Flange classification; Class 3 semi-compact
Web classification; Class 1 plastic
Overall section classification; Class 3 semi-compact
Shear buckling check (cl. 4.2.3)
Ratio d upon t; d_upon_t = dbm/tbm = 49.635;
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 = 1080.3 kN
PASS - Vv <= Pvv - Vertical shear capacity adequate (UF1 = 0.374)
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 = 528.4 kN
Horizontal shear capacity of channel web; Pvhch = 0.6  py  tch  Dch = 575.1 kN
Combined horizontal shear capacity; Pvh = Pvhbm + Pvhch= 1103.5 kN
PASS - Vh <= Pvh - Horizontal shear capacity adequate (UF2 = 0.025 - low shear)
Vertical bending capacity (cl. 4.2.5)
Vertical bending capacity of composite section; Mcx = py  min(Zxxtop,Zxxbtm) = 709.7 kNm
PASS - Mv1 <= Mcx - Vertical moment capacity adequate (UF3 = 0.677)
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)

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Slenderness ratio;  = Le/ry = 78.4;

Slenderness factor; v = 1/[(4  sag  (1 - sag) + 0.05  (/x)2 + sag2)0.5 + sag]0.5 = 0.769;
Section is class 3 semi-compact therefore; w = min(Zxxtop,Zxxbtm)/Sx = 0.751;
Equivalent slenderness; LT = u  v    (w) = 40.6;
Robertson constant; LT = 7.0
Limiting equivalent slenderness; L0 = 0.4  (2  ES5950/py)0.5 = 30.2;
Perry factor; LT= 2  LT  (LT - L0)/1000 = 0.146;
Euler buckling stress; pE = 2  ES5950/LT2 = 1227.0 N/mm2
Factor phi; LT = [py + (LT + 1)  pE]/2 = 880.4 N/mm2
Bending strength; pb = pE  py/[LT + (LT2 - pE  py)0.5] = 297.7 N/mm2
Buckling resistance moment; Mb = pb  min(Zxxtop,Zxxbtm) = 595.2 kNm
Equivalent uniform moment factor; mLT = 1.0
Allowable buckling moment; Mballow = Mb/mLT = 595.2 kNm
PASS - Mv1 <= Mballow - Buckling moment capacity adequate (UF4 = 0.807)
Horizontal bending capacity (loadcase 2 only) cl. 4.2.5
Horizontal moment capacity of top flange; Mctf = py  Ztf = 194.5 kNm
PASS - Mh <= Mctf - Horizontal moment capacity adequate (UF5 = 0.216)
Combined vertical and horizontal bending (loadcase 2 only)
Cross section capacity (cl. 4.8.3.2)
Section utilisation; UF6 = Mv2/Mcx + Mh/Mctf = 0.810;
PASS - Section capacity adequate (UF6 = 0.810)
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) = 0.810;
Case 2; UF8 = mLT  Mv2/Mb + my  Mh/(py  Ztf) = 0.924;
PASS - Buckling capacity adequate (UF7&8 = 0.924)
Check beam web bearing under concentrated wheel loads (cl. 4.5.2.1)
Internal location
Maximum ultimate wheel load; W vult1 = 313.0 kN
Stiff bearing length (dispersal through rail)); b1 = 2  (hr + tch) = 218 mm
Bearing capacity of unstiffened web; Pbw = [b1 + 5  (Tbm + rbm)]  tbm  py = 1184.3 kN
PASS - Wvult1 <= Pbw - Web bearing capacity adequate (UF9 = 0.264)
Check beam web buckling under concentrated wheel loads (cl. 4.5.3.1)
Internal location - top flange not effectively restrained rotationally or laterally
Maximum ultimate wheel load; W vult1 = 313.0 kN
Stiff bearing length (dispersal through rail); b1 = 2  (hr + tch) = 218 mm
Effective length of web; LEweb = 1.2  dbm = 572 mm
Buckling capacity of unstiffened web; Pxr=25tbm/[(b1+5(Tbm+rbm))dbm]1/20.7dbm/LEwebPbw
Pxr = 358.6 kN
PASS - Wvult1 <= Pxr - Web buckling capacity adequate (UF10 = 0.873)
Check plate to beam flange weld
Maximum vertical shear force; Vv = 403.7 kN
Shear stress on weld; vw=VvAch(Dbm+tch-Cych-yna)/(20.7sIxx)((lon+loff)/lon)=120.1 N/mm2
From BS8110-1:2000 Table 37
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Allowable weld stress for grade S355 steel; pw = 250 N/mm2

PASS - vw <= pw - 6 mm 300 mm on 300 mm off fillet welds are adequate (UF11 = 0.480)
Allowable deflections
Allowable vertical deflection = span/600; vallow = L/limitv = 10.0 mm
Allowable horizontal deflection = span/500; hallow = L/limith = 12.0 mm

Calculated vertical deflections

Modulus of elasticity; E = ES5950 = 205 kN/mm2
Due to self weight; sw = 5  wsw  L4/(384  E  Ixx) = 0.2 mm
Due to wheels at position of maximum moment; v1 = W stat  L3/(48  E  Ixx) = 5.0 mm
Total vertical deflection; v = sw + v1 = 5.2 mm
PASS - v <= vallow - Vertical deflection acceptable (Actual deflection = span/1164)

Calculated horizontal deflection

Due to surge (wheels at position of max moment); hs = W sur L3/(48  E  Itf) = 3.7 mm
Horizontal crabbing deflection; hc = W cra  L3/(48  E  Itf) = 5.3 mm
Maximum horizontal deflection; h = max(hs,hc) = 5.3 mm
PASS - h <= hallow - Horizontal deflection acceptable (Actual deflection = span/1123)