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CHAPTER-1
INTRODUCTION
1.1 Introduction to industrial workshop
A one storey building having most of the enclosed area used for an
industry is known as an industrial building. An industrial building is a structure
with a self supporting steel frame with a light weight covering. The frame work of
a steel frame industrial building consists of series of transverse bents, which carry
the purlins on the top of the trusses, and grits on the sides of the columns to carry
covering. The frame work is braced by diagonal bracings in the planes of roof and
the sides of the building.
The functions of the industrial buildings are to store the raw materials or
manufactured products of the industry or to support and house a manufacturing
process for the industry.
Industrial buildings in the first category are shed type buildings. These are
common for short span layouts. These consist of frames composed of continuous or
double cantilever girders over columns in one direction with simple span bar joists
to the other direction. These are simple roof structures on open frames. These
structures provide some protected areas. These used to house the industries,
workshops and ware houses etc.
For the proper design of the industrial building, the designer should have
knowledge manufacturing process and the purpose for which the industrial building
is installed. Economy is always a primary factor for design industrial buildings. In
a real sense the cost of manufacturing products depend upon the initial cost of
construction, maintenance and operating cost of industrial building. The designer
should be able to provide optimum balance view the industrial building should be
properly related aesthetically to the community and its natural environment.
The internal Architecture of the industrial building should provide for the
development of design so as to satisfy the requirements of the occupants. The total
area and volume requirements are determined for proper planning and layout of the
industrial building. The exterior dimensions of the structure surrounding the
manufacturing process are then developed by the designer .These type of buildings
may require extra large spans ,extra large heights and may involve very heavy
loads.
Gantry girder:
The travelling over head cranes are commonly used in factories and work
shop to lift and move heavy materials and assembled parts from one point to other.
The crane system consists of a bridge over which a crab (trolley), hoist and cabin
which houses the control and operator move. The crane bridge itself is provided
with wheels to move over the rails provided over gantry girder. Thus gantry girder
supports crane girder, the gantry girder supported on columns with bracket.
Crane girder:
The crane consist of a bridge made up of truss girders. The Bridge is termed
as a crane bridge, crane girder or crab girder. It spans the bay of the shop and
moves in a longitudinal direction, wheels are attached to ends of a crane girder
these wheels moves over rails placed centrally over the girders which are called
Roof truss:
Large column free areas are required for auditoriums, assembly halls,
workshops etc. to get such column free area on of the commonly used roofing
system is steel roof trusses, interconnected with purlins which in turn support
G.I(galvanized iron) or A.C(asbestos cement)sheets. The roof trusses are supported
on walls or a series of columns.
Beams:
Beams are structural elements carrying transverse external loads that cause
bending moment and shear force along their span. These are generally supported on
bearing walls or columns and are subjected to roof or floors loads and are
reinforced to take up stresses.
Columns:
Lintel:
A lintel is a structural member used for carrying the wall loads and they do
not transfer the loads on to the doors and windows.
Foundation:
2. Sub structure
The sub structure transmits the loads of the super structure to the supporting
soil and is generally termed as the foundation. Footing is that portion of the
foundation which ultimately delivers the load to the soil and is thus in contact with
it. The load of super structure is transmitted to the foundation or sub structure
through either columns or walls
Chapter - 2
2.1 ANALYSIS
2.1.1 Specifications:
Self weight of crane girder excluding trolley = 200kN
Self weight of trolley =100kN
Minimum approach of crane hook = 1.2m
Distance between centres of crane wheels = 3.5m
Span of gantry girder = 6m
Ra= 569.4 kN
Maximum wheel load (W) = 569.4/2 = 285 kN
Live loads:
Calculation of shear force for live loads
Taking moment about ‘B’
Va × (6) = 285×(6) + 285×(2.5)
Va = 403.75kN
Maximum shear due to wheel load = 403.75kN
Maximum shear due to dead load (Va) = wl/2
= 3.45×6/2
= 10.35kN
Vc= 368.12kN
Vd = 2× (285) – 368.12
Vd = 201.8 kN
Maximum bending moment occurs under point load
= 3.45×62/8
= 15.5kN-m
Therefore Bending Moment due to dead load and live load is
Mz = 471.7+15.5 = 487.2 kN-m
Lateral forces:
Lateral forces traverse to the rails = 5% of weight of crab + weight to be lifted
= 5/100× (100+300)
= 20kN
Factored lateral load = 30kN
Factored lateral load on each wheel = 30/2
= 15kN
The maximum horizontal reaction due to lateral force may be taken proportion to
vertical loads.
Maximum bending moment = 15/285 ×428.82
= 22.72 kNm
2.2 DESIGN
Let us try ISWB 600 at 1311.6 N/m with ISMC 300 at 351.2 N/m on its top flange
Igross =1127.42×106mm4
y1`= 510.2mm
Plastic modulus of the section above equal area axis
Zpz1 = (3007.6)×[74.95+21.3+7.6/2] + 2× (90-7.6) ×13.6× (74.95+21.3-90-
7.6/2]+ 250×21.3× (74.95+21.3/2)+74.95×11.2×74.95/2
Zpz1 = 838.775×103mm3
Plastic section modulus of section below equal area axis
Zpz2 = 250×21.3× (600-21.3-74.95-21.3/2) + (600-2×21.3-74.95)2/2×11.2
= 3929.202×103mm3
Zpz = Zpz1+Zpz2
Zpz = 838.775×103+3929.202×103
Zpz = 4767.977×103mm3
Plastic section modulus of compression flange about y-y axis
Zpfy = 250×21.3×250/4+2× [(300-13.6×2)2×7.6/8] + [2× (13.6×90× (300-
13.6/2)]
Zpfy = 824.763×103mm3
Mz/Mdz + My,f/Mdy,f ≤1
487.2/854.127+ 22.72/166.11 = 0.7071≤1
Hence safe
2.2.3.3 Check for buckling resistance in bending:
The elastic lateral torsional bending moment
fcr = c1× π2E/(LLT/ry)2[1+1/20 × (LLT/ry / hf/tf) 2] 0.5
Overall depth of section
hf = h = 600+7.6=607.6mm
= 881.7kN> 454.42kN
For λw = 114.49, fy = 250N/mm2, and the buckling curve c, the design bending
compressive stress from IS: 800-2007 is fcd = 89.64 N/mm2
>241.5 kN
Which is safe.
Chapter- 3
ANALYSIS AND DESIGN OF CRANE GIRDER
3.1Analysis
∑Ma = 0
Rb(18) = 450×1.2+16.6(18)2/2
Rb = 179.4kN
Ra = 569.4kN
At ‘C’ maximum bending moment occurs.
Mc = 569.4×9-16.6×92/2
Mc = 4452.3kN-m
3.2 DESIGN
fe = 410N/mm2,fy = 250N/mm2 fyw= 250 N/mm2
Plate girder:
Design of web
Assume k = 200
Depth of plate girder, d = (Mzk/fy)0.3
d = (4452.3 x 200/250)0.33
= 1600mm
Thickness of web, tw = (Mz/fyk2)0.33
= 7.6 mm
tw = 8mm, d = 1600mm
Assume, c = 2d
C = 2× (1600) =3200mm
Af = Mzγm0/fy×d
= 4452×106×1.10/250×1600
= 12243.8mm2
tf = Af/bf=12244/320 = 40mm
Flange section 320×40mm
For flanges b/tf=320/40 = 8<8ε
Therefore sections are plastic
d/tw =1600/8 = 200>94ε
The web is subjected to buckling
Zpz= (320×40) × (1600 - 40) = 19.99×106mm3
kv= 6.35+4/4
kv = 6.35
τb = fyw/√3 Λw2
= 250/1.732× (2.24)2
=28.7N/mm2
Hq = 1.25×(1847.5)×(1-(367.6/1847.5))
Hq=1850.175kN
I = 8×32003/12=2.2×1010mm4
y = c/2=3200/2 = 1600mm
Mq = 2.2×1010×250/1600×1.1=3125kN-m
Mq= 3125>296kN-m
Hence ok.
Assume, b1=100
n2 = 2× (2.5×tf)
= 2×2.2×40
= 200
Fw = (100+200) × (10×250/1.1) = 681.8kN >570kN
Hence bearing stiffeners are not required, but for safety purpose we are providing
stiffeners.
320-8/2=156
Max = 20tqε =20×8 =160, Min=14 tqε = 14×8=112
Say 150×16 stiffeners.
r = √(38.95×106/9920)
= 62.66mm
Λ= KL/r = 0.7×1600/62.66=17.87
fcd = 227-0.787× (227.224)
fcd = 224.639kN
Iz = 320×16803/12-[16003× (320-10)/12]
= 0.1644×1011mm4
Af = 320×40 = 12800mm2
y`= 840mm
qw = 0.5× [570×12800×1840×1000/ (1.644×1010)
= 186.39N/mm2
Assume s = 8mm
tt = 0.7×8 = 5.6mm
Fwd = tt×fy/1.732×γmw
= 5.6×250/ (1.732×1.5)
= 538.8N/mm2.
Fwd > qw
Hence ok.
Chapter- 4
4.1 Analysis:
θ = 26o34’ = 26.57
= 0.110 KN/m2
(0.012+0.205+0.110+0.100) × 6 × 3 = 7.68 kN
As per IS 875
= 7536.24N = 7.6 kN
Load on each end panel points = 7.6/2 = 3.8 kN
Vz = 44×1×1×1 = 44m/sec.
ROOF Ө = 0ᵒ Ө = 90ᵒ
ANGLE EF GH EG FH
20ᵒ -0.7 -0.5 -0.8 -0.6
26.57 -0.37 -0.5 -0.8 -0.73
30ᵒ -0.2 -0.5 -0.8 -0.8
= Ze× fy/γm0
M dz = (1210×104/130.4)×250/1.1×10-6
= 21.6kN-m. > 19.9 kNm
Which is all right.
M dy= (209.2×104×250×10-6)/ (20.1×1.1)
= 23.65kN-m > 4.10 kNm
Which is all right.
Check for overall member strength
Mz/Mdz + My/Mdy ≤ 1
=19.9/21.6 + 4.10/23.65
= 1 ≤ 1 (o.k)
= 5/384×[3687×10-3× (6×103)4]/2×105×1210×104
= 25.7 mm < 33.33mm. (O.K)
4.2 DESIGN
4.2.1 Tie members:
Maximum compressive strength = 100.56 kN.
Factored Maximum compressive strength = 150.84 kN.
Maximum truss strength = 114.97 kN.
Factored Maximum truss strength, T = 172.45 kN.
Net area required, An = T γm1/0.8fu
= 172.45 ×1000×1.25/0.8×410 = 657.2 mm2
Gross area required, Ag = 1.25×657.2 = 821.5 mm2
Trying two angle sections I.S.A 75×75×6.
Ag = 866mm2, r = 23mm,
Connections:-
Provide 20mm diameter bolts
Diameter of hole = 20 mm.
Net tensile stress area of bolt, Anb = 245 mm2
Thickness of plate = 15 mm
Double angle = 75×75×6
Design force = 172.45 kN.
Strength of bolt in double shear
Vdsb = 2×Anb×fub/ (√3×γmb)
= 2×245×400×10-3/ (1.732×1.25)
= 90.528kN.
Strength of bolt in bearing, Vdpb= 2.5×kb×d×t×fu/ ( γmb)
Assuming kb = 1,
V dpb = 2.5×1×20×15×400×10-3/ (1.25)
= 240 kN.
Strength of bolt is least of above 90.5kN
AITS KADAPA, DEPARTEMENT OF CIVIL ENGINEERING Page 31
ANALYSIS AND DESIGN OF GANTRY GIRDER FOR INDUSTRIAL WORKSHOP
Pd = 2×1903×116.296
= 442.6 kN > 192.37kN
Connections:-
Using 16 mm diameter bolts.
Diameter of hole d0 = 18mm.
Strength of bolt = 58 kN
Number of bolts = 192.37/58
= 4 (Approx).
Hence use 4 # 16mm diameter bolts.
Connections:-
Diameter of bolt = 12mm.
Diameter of hole d0= 13mm.
Strength of bolt in double shear
Vdsb = 2×Anb×fub/ (√3×γmb)
= 2×84.3×400×10-3/ (1.732×1.25)
= 31.15 kN.
Number of bolts required= 91/31.15
= 4(Approx).
Hence use 4 # 12mm diameter bolts.
= 2×84.3×400×10-3/ (1.732×1.25)
= 31.15 kN.
Number of bolts required = 47.95/31.15
= 2(Approx).
Hence use 2 # 12mm diameter bolts
Note: - Use tack weld to connect the angles i.e. two angles back to back.
Chapter- 5
DESIGN OF BEAM COLUMN
5.1 Analysis
KLz = 10 m
a=3m
c = 10 – 3 – 1 = 6 m
= 149.04 KNm
= 298 KNm
= 11789×250×10-3/1.1
= 2679.3 KN
Mdz = βb Zpzfy/γm0
= 1793.3×103×250×10-6/1.1
= 407.5 KNm
N/Nd + Mz/Mdz ≤ 1
AITS KADAPA, DEPARTEMENT OF CIVIL ENGINEERING Page 36
ANALYSIS AND DESIGN OF GANTRY GIRDER FOR INDUSTRIAL WORKSHOP
tf = 13.7 ≤ 40mm
Hence from the conditions the buckling curve to be used along zz-axis will be
curve a and that along yy-axis will be curve b.
= 0.46
αLT = 0.21
ФLTZ = 0.633
ΧLT = 0.936
Design bending compressive stress,
fbd = ΧLT fy/ γm0 = 0.936×250/1.1 = 212.7 N/mm2
Design bending strength,
Md = βb Zpzfbd = 1793.3×103×212.7×10-6
= 381.43 kNm
> 298 kNm
Which is all right.
Chapter- 6
6.1 Analysis
Minimum length of base plate assuming 160mm projections from column flange,
L = 450+2×200 = 850mm
Taking B = L = 850mm
Referring to fig,
a = 850-2×50/2 = 375mm
2(298×106+414×103×375)/(0.45×20×850)]0.5
= 64mm
≯ 250×314×1.25×10-3/1.10 = 89.2 kN
= 757.57mm ≃ 760mm
Nu = k√fck l1.5
l = 101.2 mm
= 82.25 kNm
= 38636 tb2
tb = 46.13 mm ≃ 47 mm
= 683 kN
= 488.7mm
Provide weld around flanges. Provide nominal 13 mm fillet weld to connect web
with base plate.
Chapter-9
DESIGN OF LINTEL OVER SHUTTERING
= 3.9m
= 50.54kN
Self weight of lintel = 0.3×0.44×1×24
= 3.168 kN
Total load = 53.7kN
= 50.54×4.5/6
AITS KADAPA, DEPARTEMENT OF CIVIL ENGINEERING Page 44
ANALYSIS AND DESIGN OF GANTRY GIRDER FOR INDUSTRIAL WORKSHOP
= 37.9kN-m
Moment due to self weight, M2 = wl2/8
= 3.168 × 4.52/8
= 8kN-m
= 288.7mm
Provide D =440mm,Using 12mm diameter main bars and 8mm diameter stirrups
and keeping nominal cover of 20mm.
×300× 420
= 495.7mm2
Providing 12 mm dia bars
Number of bars required = 495.7/113
= 5(approx.)
Therefore provide 12 mm diameter bars of 5 numbers
9.5.1 Check for shear
= 3.168×4.3/2 + 50.54/2
= 32 kN
Vu = 1.5V = 48kN
= 0.38N/mm2
= 0.448%
τc = 4.4N/mm2.
( τv< τc).
Spacing of stirrups
1. Sv = 0.87× fy × Asv/0.4×b
= 302.46mm.
Chapter-10
DESIGN OF LINTEL OVER WINDOWS
= 0.19N/mm2
Ast = 2×78.53=157.06mm2.
( τv< τc).
However provide minimum shear reinforcement.
Asv= 2×3.14×62/4=56.54mm2
Spacing of stirrups
4. Sv = 0.87× fy × Asv/0.4×b
= 170mm.
5. 0.75d = 0.75×200 = 150mm
6. Not greater than 300mm
Hence provide 2 legged 6mm diameter bars of 150 mm c/c.
Chapter-
RESULTS & DISCUSSION
CONCLUSION
This project has covered the analysis and the conceptual design of a typical industrial shed
structure under various loads and their combinations. Wind loads have been considered as
per IS 875 part 3 and the structure analyzed in a simple fashion, by considering the behavior
of a typical frame in the transverse direction. The roof is supported by bamboo tied arches
and the columns are designed as battened bamboo members tied by ferrocement ties. The
proposed structure aims to provide an alternative environment friendly construction for a
steel industrial shed.
It can serve multiple purposes, such as workshop for a cottage industry, warehouse, and
other medium industries. Not only is the structure light compared to conventional steel, it is
at the same time several times cheaper and eco friendly. The program developed for the
design of the bamboo industrial building gives satisfactory results for the computation of
forces and cross – sections of all the components as was seen by comparing manual results
with those obtained by executing the program. The determination of optimum spacing was
also carried out successfully for the two buildings. Hence, the effectiveness of the program to
be used as a preliminary design tool for bamboo industrial buildings has been confirmed.
RECOMMENDATIONS
Although the program gives satisfactory results, there is scope for improvement in the
program.
Some of the recommendations for improvement of the program are as follows:
1. As the analysis and design calculations are done manually, it is very time consuming and
this can be overcome by using software programs.
2. The project doesn’t involves in the design of connections in the truss and also bracings
which can surely be integrated with the program.
3. The program doesn’t optimize the design automatically. It has to be done manually by
changing the span length every time and finding out the corresponding weight of steel
required. It would be highly efficient if the optimization could be done automatically as it
would considerably reduce the time and effort required for optimization.
4. The program does not display any error message if some incorrect (or incompatible)
input is given
A ― Area of cross-section
Ae ― Effective cross-sectional area
Ag ― Gross cross-sectional area
An ― Net area of the total cross-section
Anb ― Net tensile cross-sectional area of bolt
Aq ― Cross-sectional area of a bearing (load carrying) stiffener in contact with the
flange
bf ― Width of the flange
bw ― Width of outstanding leg
c ― Spacing of transverse stiffener
cb ― Moment amplification factor for braced member
cm ― Moment reduction factor for lateral torsional buckling strength calculation
D ― Overall depth/diameter of the cross-section
d ― Depth of web, Nominal diameter
dh ― Diameter of a bolt/ rivet hole
do ― Nominal diameter of the pipe column or the dimensions of the
column in the depth direction of the base plate
E ― Modulus of elasticity for steel
he ― Effective thickness
hf ― Centre to centre distance of flanges
hi ― Thickness of fire protection material
hL ― Height of the lip
hs ― Storey height
hy ― Distance between shear centre of the two flanges of a cross-section
I ― Moment of inertia of the member about an axis perpendicular to the plane of the
frame
Ifc ― Moment of inertia of the compression flange of the beam about the axis
parallel to the web
Ift ― Moment of inertia of the tension flange of the beam about minor axis
Iq ― Moment of inertia of a pair of stiffener about the centre of the web, or a single
stiffener about the face of the web.
Is ― Second moment of inertia
Iso ― Second moment of inertia of the stiffener about the face of the element
perpendicular to the web
IT ― Transformed moment of inertia of the one way system (in terms of equivalent
steel, assuming the concrete flange of width equal to the
spacing of the beam to be effective)
It ― St. Venant’s torsion constant
Iw ― Warping constant
Iy ― Moment of inertia about the minor axis of the cross-section
Iz ― Moment of inertia about the major axis of the cross-section
Kb ― Effective stiffness of the beam and column
Kh ― Reduction factor to account for the high strength friction grip
connection bolts in over sized and slotted holes
KL ― Effective length of the member
KL/r ― Appropriate effective slenderness ratio of the section Draft for comments only
Doc: CED 46(8041)WC October 2015
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KL/ry ― Effective slenderness ratio of the section about the minor axis of the section
KL/rz ― Effective slenderness ratio of the section about the major axis of the
section
― Actual maximum effective slenderness ratio of the laced column o r
KL
― Effective slenderness ratio of the laced column accounting for shear e
r KL
deformation
Kv ― Shear buckling co-efficient
Kw ― Warping restraint factor
k ― Regression coefficient
ksm ― Exposed surface area to mass ratio
Ky, Kz, KLT ― Moment amplification factors (see 4.4.2, 4.4.3.1, 4.4.3.3 and 9.3.2.2)
L ― Actual length, Unsupported length, Length centre to centre distance of the
intersecting members, Cantilever length
Lc ― Length of end connection in bolted and welded members, taken as the
distance between outermost fasteners in the end connection, or the length of the
end weld, measured along the length of the member
LLT ― Effective length for lateral torsional buckling
Lm ― Maximum distance from the restraint to the compression flange at the
plastic hinge to an adjacent restraint (limiting distance)
Lo ― Length between points of zero moment (inflection) in the span
l ― Centre to centre length of the supporting member
le ― Distance between prying force and bolt centre line
lg ― Grip length of bolts in a connection
lj ― Length of the joint
ls ― Length between points of lateral support to the compression flange in a beam.
Draft for comments only Doc: CED 46(8041)WC October 2015
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lv ― Distance from bolt centre line to the toe of fillet weld or to half the root radius for
a rolled section
lw ― Length of weld
M ― Bending moment
Ma ― Applied bending moment
Mcr ― Elastic critical moment corresponding to lateral torsional buckling of the
beam
Md ― Design flexural strength
Mdv ― Moment capacity of the section under high shear
Mdy ― Design bending strength about the minor axis of the cross-section
Mdz ― Design bending strength about the major axis of the cross-section
Meff ― Reduced effective moment
Mfr ― Reduced plastic moment capacity of the flange plate
Mfd ― Design plastic resistance of the flange alone
Mnd ― Design bending strength under combined axial force and uniaxial moment
Mndy, Mndz ― Design bending strength under combined axial force and the respective
uniaxial moment acting alone
Mp ― Plastic moment capacity of the section
Mpb ― Moment in the beam at the intersection of the beam and column centre lines
Mpc ― Moments in the column above and below the beam surfaces
Mpd ― Plastic design strength
Mpdf ― Plastic design strength of flanges only
Mq ― Applied moment on the stiffener
Ms ― Moment at service (working) load
Mtf ― Moment resistance of tension flange Draft for comments only Doc: CED
46(8041)WC October 2015
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Su ― Ultimate strength
sc ― Anchorage length of tension field along the compression flange
st ― Anchorage length of tension field along the tension flange
sa ― Actual stiffener spacing
T ― Temperature in degree Celsius; Factored tension
Tb ― Applied tension in bolt
Tcf ― Thickness of compression flange
Td ― Design strength under axial tension
Tdg ― Yielding strength of gross section under axial tension
Tdn ― Rupture strength of net section under axial tension
Tdb ― Design strength of bolt under axial tension, Block shear strength at end
connection
Te ― Externally applied tension
Tf ― Factored tension force of friction type bolt
Tl ― Limiting temperature of the steel
Tnb ― Nominal strength of bolt under axial tension
Tnd ― Design tension capacity
Tndf ― Design tension capacity of friction type bolt
Tnf ― Nominal tensile strength of friction type bolt
Ts ― Actual tension under service load
t ― Thickness of element/angle, time in minutes
tf ― Thickness of flange
tp ― Thickness of plate
tpk ― Thickness of packing
tq ― Thickness of stiffener
ts ― Thickness of base slab Draft for comments only Doc: CED 46(8041)WC October
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U ― Horizontal deflection of the top of storey due to combined gravity and notional
load
― Inclination of the tension field stress in web
― Unit weight of steel
f ― Partial safety factor for load
m ― Partial safety factor for material
m0 ― Partial safety factor against yield stress and buckling
m1 ― Partial safety factor against ultimate stress
mb ― Partial safety factor for bolted connection with bearing type bolts
mf ― Partial safety factor for bolted connection with High Strength Friction Grip
bolts
fft ― Partial safety factor for fatigue load
mft ― Partial safety factor for fatigue strength
mv ― Partial safety factor against shear failure
mw ― Partial safety factor for strength of weld
ε ― Yield stress ratio, (250 / fy) 1/2
― Non dimensional slenderness ratio = = = E r KL f 2 2 / ) / ( y cc y f f / cc y P P
/
cr ― Elastic buckling load factor
e ― Equivalent slenderness ratio
LT ― Non-dimensional slenderness ratio in lateral bending
scr ― Elastic buckling load factor of each storey
― Poisson’s ratio
c ― Correction factor
f ― Coefficient of friction (slip factor) Draft for comments only Doc: CED
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