DESIGN OF GANTRY GIRDER-(VERSION-0)

SINGLE CRANE WITH TWO WHEELS PER END Refference

Type EOT or HOT
Data :- Crane Type EOT IS:800-1984
Self weight of crane bridge = w= 100 kN
Crane Lifting capacity = W1 = 75 kN
Wt. of trolley + hoist (crab weight) = W2 = 25 kN (Assume 0.3 W1 if not specified)
C/c distance of gantry rails (bridge span) = S= 9 m
Crane hook dist from girder (min. clearance) = x= 0.85 m
No. of crane wheels on each side = n= 2 wheels
C/c distance between cols (Girder span) = L= 6 m
C/c distance of crab wheels (base)= a= 3.8 m
Udl from weight of gantry = wg = 1.25 kN/m
Udl from weight of rails & platforms = wr = 0.5 kN/m
Yield stress for steel = sy = 250 N/mm2
Vertical Impact factor for gantry = i= 1.25 N/mm2 25% EOT / 10 % HOT
Unbraced Length of comp. flange of girder= Lub = 6m
Modulus of Elasticity of steel = E= 200000 N/mm2

Maximum Wheel Load with Impact (P)

Total Wt. of Moving Crane W = W 1+ W 2
= 100 kN
Reaction from Gantry when Wheel is at 'x' meter distance from edge
Ra = [W(S-x)]*(1/S) + (w/2)
Ra = 140.56 kN

Max wheel load with impact = 1  ; P = 87.85 kN

P i Ra
n
Maximum Bending moment due to wheel loads
Reaction at Right end = a/2 a/2

L a L 3 1 a/4
Rr P P a Rr = 60.03 kN
2 4 2 4 L
P P
1st Wheel
Reaction at Left end = R
l 2 P Rr Rl = 115.67 kN
Rl Rr
L/2 L/2

Moment under 1st wheel =

L a
Ma R r L Ma = 123.059 kN
2 4

Moment under 2nd wheel =

L 3
Mb R l L a Mb = 17.350 kN
2 4
2
L 3 L
R l due
M b BM L to
M self w r  and rails
aw gof gantry
wt
21 4 8
2
L
M1 wg wr  Ml = 7.875 kN-m
8

Total max bending moment = Mmax = 130.934 kN-m

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 DESIGN OF GANTRY GIRDER-(VERSION-0)

Maximum Shear Force

Max Shear force due to wheels at supp= Rl V = 120.06 kN

Total max Shear Force = V + (wg + wr) /2 Vmax = 125.31 kN

Lateral Forces :-
10% (Ks) of weight of crane and weight lifted by crane
Hence Lateral Force = Ks * W H = 10.00 kN
Lateral force per wheel = (H/n) Hw = 5.00 kN
H
MaxHBM
w due to lateral force =
N
Hw
My M a My = 7.00 kN-m
P
Hw Hw
VSF
M
Max M ato lateral force =
V
yy due
P P
Hw
V y V Vy = 6.83 kN
P

Longitudinal Forces :-
5% (Kl) of Static wheel load = Kl * Ra
LF = 7.03 kN
This force acts at the top of the rail
Ht of rail = h = 75 mm
Eccentricity of lateral load =e=h+Yt e = 214.37 mm
Bending moment in comp. Flange =
LF x e = BML = 1.51 kN-m

Design of Section :-
Assume bending stress = sbc = 125 N/mm2
s bc section
Required 125 modulus =
M max 10 1
6

Zr 
Zr = 1047.4745 x 103mm3
s bc 10
3

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G001 R0

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DESIGN OF GANTRY GIRDER-(VERSION-0)

Use Section :- ISMB400 ISMC300

Yc

Cyy twc

yt

x x
y
Di D
x x
yb

Properties of Section :-
Total Area = A(total) = 12470 mm2
Area of channel = Ac = 4630 mm2
Thickness of web of I section = tw = 8.9 mm
Thickness of web of channel = twc = 7.8 mm
Moment of Inertia about x-axis = Ixx = 30700.381 x104mm4
Moment of Inertia about y-axis = Iyys = 7042 x104mm4
(Whole section)
Moment of Inertia about y-axis = Iyyc = 6731 x104mm4
(Comp. flange)
Max distance from NA to = Yt = 139.37 mm
compression flange
Max distance from NA to = Yb = 268.43 mm
tension flange
C.g.of channel section from back = Cyy = 23.5 mm
Section modulus at top = Zxt = 2202.78 x103mm3
Section modulus at bottom = Zxb = 1143.71 x103mm3
Section modulus at Comp.Flange = Zyc = 448.73 x103mm3
Least radius of gyration = ryy(min) = 94.42 mm
Mean thickness of compression = T= 10.41 mm
flange
Mean thickness of tension flange = tt = 16 mm
Depth of the section = D= 407.8 mm
Width of the section = Yc = 300 mm
Height of MB = Di = 400 mm
Web Fillet Height = h2 = 32.8 mm
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; DESIGN OF GANTRY GIRDER-(VERSION-0)

Calculation for Permissible Stress :-

Permissible bending stress in compression

Y= 1 k1 = 1 Table 6.3
w = 0.96 k2 = 0.46 Table 6.4
Inc = 1.2 {fcb is increased by 20% when T/tw is < = 2.0 & d1/tw < = 1344/sqrt(fy)} Cl. 6.2.4.1
X = 698.11 Y = 656.28 Table 6.5
c2
f cb k 1 X k 2 Y   Inc
c1 fcb = 2311.21 N/mm2 Cl. 6.2.4

Major Direction
0.66  f cb  s y
s bc s bcx = 160.45 N/mm2 Cl. 6.2.3
1
1.4
1.4 1.4
f cb s y

Minor Direction 0.66*sy s bcy = 165.00 N/mm2

Permissible bending stress in tension

s btp = 0.66*sy s bt = 165.00 N/mm2

Permissible shear stress

tp = 0.4*sy t= 100.00 N/mm2

Permissible Axial stress

sacp = 0.6 x fcc x fy lmax = 79.8

[(fcc) + (fy) ]
n n 1/n
n= 1.4
fcc = p2x E = 309.64
lmax2 s ac = 100.94 N/mm2

Permissible bearing stress (required for web crippling check)

s bp = 0.75*sy s bp = 187.5 N/mm2

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 ESSAR ENGINEERING CENTRE

G001 R0 DESIGN OF GANTRY GIRDER-(VERSION-0)

MUMBAI
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G001 R0

DESIGN OF GANTRY GIRDER-(VERSION-0)

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Stress Calculations :- Cl. 6.2

Actual Bending Compressive Stress in x-direction in Top Flange due to vertical loads-
M max 10
6

s bc.x s bc.x cal = 59.44 N/mm2

Z x.t  10
3
< 16045 Hence OK

Actual Bending tensile Stress in x-direction in Bottom Flange due to vertical loads-
M max 10
6

s bt.x s bt.x cal = 114.48 N/mm2

Z x.b  10
3
6 < 16500 Hence OK
M max 10
s bt.x
Z x.b Compressive
3
Actual Bending 10 Stress in y-direction in Top Flange due to Lateral loads-
M y  10
6
Yc
s bc.y 
s bc.y cal = 15.61 N/mm2
I yyc  10
4 2
< 16500 Hence OK

Actual Bending Compressive Stress in x-direction in Top Flange due to longitudinal loads-
sbc.xL = BML / Zx.t = s bc.xl cal = 0.68 N/mm2

Actual Bending tensile Stress in x-direction in Bottom Flange due to longitudinal loads-
sbt.xL = BML / Zx.b = s bc.xl cal = 1.32 N/mm2

Axial Stress due to longitudinal loads

sac = LF /A (total) s ac cal = 0.56 N/mm2

Check for Combined Stresses :-

Vertical + Lateral loads

(sbc.x cal / sbc.x)+(sbc.y cal / sbc.y) = 0.47 < 1.1, Hence O.K

Vertical + Longitudinal loads

(sac cal / sac)+[(sbc.x cal + sbc.xL cal) / sbc.x] = 0.38 < 1.1, Hence O.K

Check for Shear :-

Average shear stress =
V max 10
3

t c ty = 35.20 N/mm2
D i t w 3
V max 3 10 < 100.00 Hence OK
t c V y  10
Shear
t stress
D i t w to lateral load =
due
Y c t wc3
V y  10
t tx = 2.92 N/mm2
Y c  t wc
< 100.00 Hence OK

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DESIGN OF GANTRY GIRDER-(VERSION-0)

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Check for Deflection :-

Total U.D.L on the girder = wg + wr = DUDL = 1.75 kN/m

Vertical Deflection
Deflection @ center due to total U. D.L = dUDL =
5*DUDL*L4 = dUDL = 0.48 mm
b a b
384*E*IXX
Deflection @ center due to static wheel load (dWC)
Ps Ps
Ps * b * (3L2 - 4b2), Where, Ps = Static wheel load = P/i
24*E*IXX Ps = 70.28 kN Rl Rr
L/2 L/2
b= 1.1 m
Hence, dWC
= 5.41 mm
Permissible Vertical Deflection dVP = L / 750 dVP = 8.00 mm
Total Vertical Deflection = dV = dUDL + dWC dV = 5.89 mm
< 8.00 Hence OK
Horizontal Deflection
Deflection @ center due to surge loads (dSL)
Hw * b * (3L2 - 4b2), Where, Hw = Lateral Force per wheel
24*E*IYY Hw = 5.00 kN
b= 1.1 m
Hence, dSL = 1.68 mm
Permissible Horizontal Deflection dHP = L / 400 dHP = 15.00 mm
> 1.68 Hence OK

Design of Welds :-

Connection of Channel to ISMB, using staggered welds on both sides of flange

Limiting Weld size = rlim = 12 mm
Weld size = r= 6 mm
Shear strength of weld = f= 108 N/mm2
Length of weld = lw = 40 mm
Weld strength = R 0.707  a  f  l 2 R = 36650.88 N
Shear per unit length =
V max 10  A c  10  y t c yy  10
3 2

S c yy 10 S = 218.97 N/mm
3 2
V max 4 10 A c 10 yt

S I xx 10
R 4
p I xx 10
S R
Pitch of weld = p p= 167.38 mm
S

Maximum Pitch of weld = minimum (200 mm or 12 times of thickness of the thinnest part joined) + lw

Hence provide 6 mm and 40 mm long intermittent weld on both sides of flange @ 130 mm c/c

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G001 R0
DESIGN OF GANTRY GIRDER-(VERSION-0)
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G001 R0

DESIGN OF GANTRY GIRDER-(VERSION-0)

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Check for Web Buckling :-

Slenderness ratio for web =

d 1 3
l l= 65.08 Cl. 5.1.1
tw
s ac = 116.88 N/mm2 Table 5.1
Taking stiff portion of bearing of girder on crane column
b= 100 mm with load dispersion at 450 (b = bearing plate length)
Total bearing =
Di
B b B= 300 mm
2

Load carrying capacity

s ac  B t w  10
3
P P= 312.06 kN
> Vmax(125.3 kN)
Hence Vertical Stiffner not required

Check for Web Crippling :-

The effective bearing length of web at end support point = B = b + h2*cot 30 0

B= 156.8 mm
Allowable bearing Stress = sbp = s bp = 187.5 N/mm2

Hence, Load bearing capacity of web = sbp *tw* B = 261.68 kN

> Vmax(125.3 kN)
Hence Vertical Stiffner not required

Structural Steel MTO:-

Wt/m
Section Length (m) Total (t)
(kg/m)
ISMB400 61.5 6.0 0.37
ISMC300 36.3 6.0 0.22
Total Weight = 0.59

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G001 R0
DESIGN OF GANTRY GIRDER-(VERSION-0)
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 ISMB400 ISMC300
A= 7840 mm2 A= 4630 mm2
Ixx = 20500 x10 mm 4 4
Ixx = 6420 x104mm4
Iyy = 622 x104mm4 Iyy = 313 x104mm4
Zxx = 1020 x10 mm 3 3
Zxx = 428 x103mm3
Zyy = 88.9 x10 mm
3 3
Zyy = 47.1 x103mm3
rxx = 162 mm rxx = 118 mm
ryy = 28.2 mm ryy = 26 mm
Di = 400 mm Di = 300 mm
tw = 8.9 mm tw = 7.8 mm
tf = 16 mm tf = 13.6 mm
h2= 32.8 mm Cyy= 23.5 mm
b= 140 mm wt= 36.3 kg/m
wt= 61.5 kg/m

A(total) = 12470 mm2

Y' = 68.43 mm
Moment of Inertia of Gantry Girder-
Ix = 30700.381 x104mm4
Iy = 7042 x104mm4
rx = 157 mm lx = (L / rx) = 38.24
ry= 75 mm ly = (Lub / ry) = 79.84
Moment of Inertia of Compression Flange-
Iyc = 6731 x104mm4
Ayc = 7898.58 mm2
d1 = 334.4 mm
D= 407.8 mm
T= 10.41 mm
Lub = 6 m
ryy = 94.42 mm
Yt = 139.37 mm
Yb = 268.43 mm
Zxt = 2202.78 x103mm3
Zxb = 1143.71 x103mm3

w = Iyyc / Iyys = 0.96

C1 = 139.37 mm
C2 = 268.43 mm
C2/C1 = 1.93
Yt/Yb = 0.52
T/tw = 1.17
d1/tw = 37.57 z= 2
1344/Ösy = 85.00
D/T = 39.18
leff/ryy = 63.54 ----- leff = kL
k= 1
Y= 656.28
X= 698.11

T d1 1344
Inc if  2  if   1.2 1  1
tw tw
s y
Inc = 1.2

Check for web buckling

sac = 0.6 x fcc x fy = 116.88
[(fcc)n + (fy)n]1/n

sy = 250 Mpa
scc = pxE=
2
466.07517
 l2
E = 200000 Mpa
n = 1.4
1/n = 0.7142857
DESIGNATION Wt AREA DEPTH WIDTH OF THK OF THK OF MOMENT OF RADII OF GYRATION MODULI OF SECTION
FLANGE FLANGE WEB INERTIA
A D b tf tw Ixx Iyy rxx ryy zxx zyy h2

kg/m mm2 mm mm mm mm cm4 cm4 mm mm cm3 cm3 mm

ISMB100 8.9 1140 100 50 7.0 4.7 183.0 12.9 40.0 10.5 36.6 5.2 17.50
ISMB125 13.3 1700 125 70 8.0 5.0 445.0 38.5 51.6 15.1 71.2 11.0 17.90
ISMB150 15.0 1910 150 75 8.0 5.0 718.0 46.8 61.3 15.7 95.7 12.5 18.05
ISMB175 19.6 2500 175 85 9.0 5.8 1260.0 76.7 71.3 17.6 144.0 18.0 20.25
ISMB200 24.2 3080 200 100 10.0 5.7 2120.0 137.0 82.9 21.1 212.0 27.4 23.65
ISMB225 31.1 3970 225 110 11.8 6.5 3440.0 218.0 93.1 23.4 306.0 39.7 25.85
ISMB250 37.3 4750 250 125 12.5 6.9 5130.0 335.0 104.0 26.5 410.0 53.5 27.95
ISMB300 46.0 5860 300 140 13.1 7.7 8990.0 486.0 124.0 28.6 599.0 69.5 29.25
ISMB350 52.4 6670 350 140 14.2 8.1 13600.0 538.0 143.0 28.4 779.0 76.8 31.00
ISMB400 61.5 7840 400 140 16.0 8.9 20500.0 622.0 162.0 28.2 1020.0 88.9 32.80
ISMB450 72.4 9220 450 150 17.4 9.4 30400.0 834.0 182.0 30.1 1350.0 111.0 35.40
ISMB500 86.9 11100 500 180 17.2 10.2 45200.0 1370.0 202.0 35.2 1810.0 152.0 37.95
ISMB550 104.0 13200 550 190 19.3 11.2 64900.0 1830.0 222.0 37.3 2360.0 193.0 41.25
ISMB600 123.0 15600 600 210 20.8 12.0 91800.0 2650.0 242.0 41.2 3060.0 252.0 45.15
SECTION Wt AREA DEPTH WIDTH OF THK OF THK OF CENTER OF MOMENT OF RADII OF MODULI OF
FLANGE FLANGE WEB GRAVITY INERTIA GYRATION SECTION
(a) (h) (b) (tf) (tw) (Cyy) (Ixx) (Iyy) (rxx) (ryy) (zxx) (zyy)
kg/m mm2 mm mm mm mm mm cm4 cm4 mm mm cm3 cm3

ISMC200 22.3 2850 200 75 11.4 6.2 22.0 1830.0 141.0 80.20 22.2 181.0 26.4
ISMC250 30.6 3900 250 80 14.1 7.2 23.0 3880.0 211.0 99.20 23.7 307.0 38.5
ISMC300 36.3 4630 300 90 13.6 7.8 23.5 6420.0 313.0 118.00 26.0 428.0 47.1
ISMC350 42.7 5440 350 100 13.5 8.3 24.4 10000.0 434.0 136.00 28.2 576.0 57.3
ISMC400 50.1 6380 400 100 15.3 8.8 24.2 15200.0 508.0 154.00 28.2 760.0 67.0
ISMB100 1460 100 75 7.2 4.0 257.5 40.8 42.00 16.7 51.5 10.9
ISMB125 1660 125 75 7.6 4.4 449.0 43.7 52.00 16.2 71.8 11.7
ISMB150 1900 150 80 7.6 4.8 726.4 52.7 61.80 16.6 96.9 13.1
ISMB175 2462 175 90 8.6 5.5 1272.0 85.0 71.90 18.6 145.4 18.9
ISMB200 3233 200 100 10.8 5.7 2235.4 150.0 83.20 21.5 223.5 30.0
ISMB225 3972 225 110 11.8 6.5 3441.8 218.3 93.10 23.4 305.9 39.7
ISMB250 4755 250 125 12.5 6.9 5131.6 334.5 103.90 26.5 410.5 53.5
ISMB300 5626 300 140 12.4 7.5 8603.6 453.9 123.70 28.4 573.6 64.8
ISMB350 6671 350 140 14.2 8.1 13630.3 537.7 142.90 28.4 778.9 76.8
ISMB400 7846 400 140 16.0 8.9 20458.4 622.1 161.50 28.2 1022.9 88.9
ISMB450 9227 450 150 17.4 9.4 30390.8 834.0 181.50 30.1 1350.7 111.2
ISMB500 11074 500 180 17.2 10.2 45218.3 1369.8 202.10 35.2 1808.7 152.2
ISMB550 13211 550 190 19.3 11.2 64893.6 1833.8 221.60 37.3 2359.8 193.0
ISMB600 15621 600 210 20.8 12.0 91813.0 2651.0 242.40 41.2 3060.4 252.5