Design Report - Gantry Crane 20ton8.53mspan

#REF!
MATERIAL HANDLING DEPARTMENT

Project Title : #REF!
Imported
Currency EUR
Currency rate 110 PKR
Sales Tax 0% %
Incom tax 0% %
Import duty 5% %
Clearing tax 5% %
Misc. 5% %
Overheads 5% %
Margin 0% %
Others 0% %
Go to Estimation
Local Package
Materail rate 70 Rs/Kg Loading/unloading
Fabrication Cost 15 Rs/Kg Transportation

GST 0% % Erection
Excise duty 1% % Elect. Installation
Incom Tax 3.50% % Commissioning
Margin 20% % Drafting

Overheads 5% % others
DPT 0% Rs/Kg
MPI 0% Rs/Kg
Radiography 0% Rs/Kg
Third Party Fee 0% Rs/Kg
Design fee 0 Rs/Kg
Sandblasting 0 Rs/Kg
Painting 2 Rs/Kg
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CALCULATION SHEET FOR : Loading for Gantry Girders
Crane Capacity 44080 lbs 20 Ton.
Span 335.826771653543 in 8.53 Mtr.
HOL 216.535433070866 in 5.50 Mtr.
Long Travel 937.007874015748 in 23.81 Mtr.
Bridge weight 8902 lbs 4039.02 Kg.

Trolley weight 3306 lbs
End truck Wheel Base 178 in 4.52 Mtr.
No of wheels per end truck 2 nos
Hook approach 20 in
Max.vertcal static wheel load w/o impact 24507 lbs 109 KN.
Max. Lateral static wheel load w/o impact 2369 lbs 11 KN.
Max.Long. static wheel load w/o impact 2451 lbs 11 KN.
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#REF!

CALCULATION SHEET FOR : Loading for Gantry Girders
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Annex-A
TECHNICAL SPECS & PERFORMA INVOICE
Capacity(Ton) 20 Span(m) 8.5 HOL 5.500011 Long travel(m) 23.8
1 HOIST, Trolley, End Crariage, Power Supply, Control
2 Main hoist Aux. hoist Qty Remarks
3 Wire rope/chain type
4 Standard/Exx.
5 EXX. Marking
6 Gas group
7 Temperature class
8 Hazarodous area class
9 Main voltage V V
10 Control voltage V V
11 Frequency HZ HZ
12 Hoist duty group FEM FEM
13 Hoisting speed control
14 Hoisting speed high m/min m/min
15 Hoisting speed slow m/min m/min
16 Hoisting speed in case of mircomove m/min m/min
17 Hoisting motor power KW KW
18 Overload device type
19 Rope reeving type
20 Condition monitoring
21 Trolley speed control type
22 Trolley speed high m/min

23 Trolley speed low m/min
24 Trolley speed in case of micromove m/min
25 Trolley rail gauge mm
26 Trolley motor power KW
27 Trolley duty group FEM
28 Hoist & trolley weight Kg
29 Overload protector type
30 2-Step limit switch for traverse motion

31 Bridge travelling duty group
32 End-truck wheel dia
33 No of wheels per end truck

#REF!

Annex-A
34 Wheel groove
35 End-truck wheel base
36 Bridge travelling duty group FEM
37 Bridge speed control type
38 Bridge speed high m/min
39 Bridge speed low m/min
40 Bridge speed in case of micromove m/min

41 Bridge motor power KW
42 2-Step limit switch for bridge travelling
43 Crane layout
44 Cross power supply type
45 Bridge travelling power supply type
46 Push button station type
47 Remote control included
48 Hoist owners manual
49 Hoist inspection test record

50 Hook forging certificate
51 EC decleration of conformity
52 Crane Structure, Installation, Comissioning
53
54 Design Code CMAA -70;1983
55 Welding Code AWS D1.1
56 Installing & Commission Code FEM 1.001
57 Installing & Commission Code FEM 1.001
58
Dead loads, Trolley load, Vertical inertia forces from drives,
59 Dsesign loads Lifted loads, Torsional forces & moments due to vertical &
lateral forces
60
61 1- DL(DLFB) + TL(DLFT) + LL(1+HLF) + IFD
62 2- DL(DLFB)+TL(DLFT) +LL(1+HLF) + IFD + WLO + SK
63 3- DL + TL + WLS
64 Load Combinations 4- DL + TL + LL + CF
65 Where
66 DL. Dead load, TL- Trolley load, LL- Lifted laod
67 IFD- Inertai forces from drives, SK- Skewing loads
68 TL- Test loads, CF- Collision forces, WLO- Wind loads
69 Bridge type
#REF!

Annex-A
70 Bridge material
71 Overall bridge girder size

72 Maintenance plateform
73 Trolley rail
74 Operators cabin
75 Gantry girders
76 Track rail
77 Others
78 Transportaion to site
79 Unloading
80 Erection
81 Comissioning
82 Overload test
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
###
###
### Back to homepage
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Annex-A
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#REF! 2-Jul-21
Kind Attn:
Subject:
Dear Sir,
Please refer to your valued inquiry: we are pleased to submit our best offer on the behalf of our Principal:
our offer stands as follows:

#REF! 2-Jul-21
Scope of Supply
Scope of supply for materials, design, manufacturing, supplies, erection, comminsioning & other services shall be as followa;
For detailed specifications & technical features, please see Annex-A.

Sr # Description Principal Fabcon Client Remarks/Notes
1 Complete hoisting unit
2 Complete end carraiges
3 Complete supply for cross travel
4 Complete supply for long travel
5 Elecrical panel for hoisting & traverse mechanisms
6 Elecrical panel for long travel mechanisms
7 Design of bridge girders
8 Design of gantry girders

9 Manufacturing of main bridge
10 Manufacturing of gantry girders
11 Manufacturing of maintenance plateform
12 Manufacturing of operators cabin
13 Trolley rail & related fixing element if applicable
14 Track rail & related fixing element if applicable
15 Paint to main bridge girders
16 Paint to gantry girders

17
18
19
20
Price package:
Our price for local & imported equipment shall be as follows;
a- Imported Package
C & F price for the imported package shall be 7,000 EUR

b- Local suplies & ervices
FOR price for local package as per Scope of Supply shall be 1,195,810 PKR
Mode of Payment:
a- 100% in advance payment for imported package shall be paid through Irrevocable L/C payable at site in the favour of our Principal
b- Payment for local package shall be paid in PKRs as follows
i- 50% advance with firm Purchase Order.

#REF! 2-Jul-21
ii- 40% balance shall be paid upon the delivery to your site/completion at our works on pro-rata basis.
iii- 10% balnace shall be paid after crane erection, commissioning & handing over.
Technical Specs & Performa Invoice:

Technical specs & performa invoice is enclosed herewith as Annex-A
Sales Tax:
Our price is exclusive of GST & other texation by the government during the currency of the contract. The tax shall be paid against the actual
invoice as per law.
Client responsibilities
Client shall arrange the following facilities during erection & commissiong at site;
i- Boarding & lodging
ii- Storage of tools & tackles.
iii- Electricity & other utilities
Exclusions & clarifications

Following & those activities mentioned in Scope of Supply shall be done by the client;
i- Any type of civil works.
ii- Embedded plates & anchoring.
Guarantee
we & our pricipal shall give a gurantee of one year staring from the day of handing over against the following defects & malfuntioning
i- Operational malfunctioning.
ii- Nonconformities to those stated in the performa invoice
iii- Structural instability
Validity:
Our offer shall be valid for a period of 60 days from the day of submission & thereafter subject to written confirmation.
We believe that you will find our offer best suiting to your requirement. We look forward to hearing from you soon.
Thanking you, we remain
Your's faithfully,
For Fabcon Design & Engineering (Pvt.)Limited
Syed Sameen Aslam
Managing Director & CEO

#REF! 2-Jul-21
Back
Estimation Sheet
EST-1- Imported Supplies
Incom Import Clearing
GST
tax duty tax Misc
Sr Item Scope qty cur rate c&f amount (PKR)
0% 0% 5% 5%
5% Landed cost
1 Main hoist Yes 1 EUR 110 7,000 770,000 0 0 38,500 38,500 38,500 885,500
2 Aux. hoist Yes 1 EUR 110
3 Compl. End tru Yes 1 EUR 110
4 cross supply Yes 1 EUR 110
5 LT supply Yes 1 EUR 110
6 hoist pannel Yes 1 EUR 110
7 trolley panel Yes 1 EUR 110
8 crane panel Yes 1 EUR 110
9 Cond. monitoring Yes 1 EUR 110
10 overload device Yes 1 EUR 110
11 thermal protect Yes 1 EUR 110

12 cross limit swit Yes 1 EUR 110
13 crane limit swit Yes 1 EUR 110
14 push button sys Yes 1 EUR 110
15 main switch Yes 1 EUR 110
16 hoist manual Yes 1 EUR 110
17 wire rope cert. Yes 1 EUR 110
18 hook forge cert. Yes 1 EUR 110

hoist inspect
19 Yes 1 EUR 110
record
20 EC declaration Yes 1 EUR 110
21 EUR 110
25 EUR 110
7,000 Total cost 885,500

Overheads 5% 44275
Margin 0% 0
EST-1 929,775
EST-2: Steel Structure See BOQ
Net weight Gr.Wt Mat cost Fab.cost Total cost GST Ex.duty Inc.tax margin
Sr Item Scope
Mat Kg 5% 70 15 PKR 0% 1% 3.50% 20.00%
1 main bridge Yes A-36 2588 2717.58 190230.472 40,764 230,994 0 2,310 8,085 46,199
2 trolley rail Yes A-36 335 351.54 24607.9838 5,273 29,881 0 299 1,046 5,976
3 plateform Yes A-36 1116 1171.74 82021.4724 17,576 99,598 0 996 3,486 19,920
4 gantry girders Yes A-36 5000 5250.00 367500 78,750 446,250 0 4,463 15,619 89,250
5 track rails Yes A-36 0.00 0 0 0 0 0 0 0
6 cabin Yes A-36 0.00 0 0 0 0 0 0 0
7 others Yes A-36 500 525.00 36750 7,875 44,625 0 446 1,562 8,925
Total 9539 10015.86 701,110 150,253 851,348 0 8,513 29,797 170,270
EST-2 1,059,928
EST-3- Design, Q/C & Inspection, Installation, Paint
GST Ex.duty Inc.tax margin overhds
Sr job Scope Cost
Wt Rate/Kg 0% 1.00% 3.50% 20% 5% Remarks
1 DPT Y 9539 0 0.00 0 0 0 0 0
2 MPI Y 9539 0 0.00 0 0 0 0 0
3 Radiography Y 9539 0 0.00 0 0 0 0 0
4 3rd party fee Y 9539 0 0.00 0 0 0 0 0
5 tranportation Y 9539 1 9538.91 0 95.389105879 334 1,908 477
6 unloading at sit Y 9539 1 9538.91 0 95.389105879 334 1,908 477
7 mech. Installati Y 9539 2 19077.82 0 190.77821176 668 3,816 954
8 elect. Installatio Y 9539 2 19077.82 0 190.77821176 668 3,816 954
9 comissioning Y 9539 1 9538.91 0 95.389105879 334 1,908 477
11 drafting Y 9539 2 19077.82 0 190.77821176 668 3,816 954
13 sand blasting Y 9539 0 0.00 0 0 0 0 0
14 painting Y 9539 2 19077.82 0 190.77821176 668 3,816 954
15 others Y 9539 0 0.00 0 0 0 0 0
Total 11 ### 0 1,049 3,672 20,986 5246
EST-3 135,882
Imported C&F 7,000 EUR

Import Landed Price 929775.00 PKR
Local Package 1,195,810 PKR

Complete 2,125,585
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#REF!
BILL OF QUANTITY
Crane capacity 20 ton
Span 8530 mm
HOL 5500 mm
Long travel
Sr# Part Thk Size Kg/m Material Qty Unit weight Total weight
1 Top flange 10 300 x 8530 A-36 2 200.8815 401.763

2 Bottom fllange 10 300 x 8530.00 A-36 2 200.8815 401.763
3 Right web 6 600 x 8530.00 A-36 2 241.0578 482.1156
4 Left web 6 600 x 8530.00 A-36 2 241.0578 482.1156
5 Vertcal stiffeners 6 550 x 210.00 A-36 34.1 5.44005 185.614506

6 Long. Stiffeners …. L 75x75x 6 7.2922 A-36 4 62.2024319 248.809728
7 Cover plates 20 210.00 600 A-36 4 19.782 79.128
8 Trolley end stops 25 A-36 4 20 80
9 Trolley rail …. 50 x 50 A-36 2 167.40125 334.8025
10 Cheq. Plate 6 1400.00 x 1400.00 …. A-36 7 92.316 646.212
11 C-Channels 125 x 65 x 1510 12.8 A-36 7 19.328 135.296
12 C-Channels 125 x 65 x 150 LG 12.8 A-36 7 1.92 13.44
13 Angles 50 x 50 x 6 x Span 13.6 A-36 1 116.008 116.008
14 Angles 50 x 50 x 6 x 150 1250 13.6 A-36 7 17 119

15 Railing 1 1/2 NPS, Sch 40 5.04 A-36 2 42.9912 85.9824
16 Others A-36 1 226.860254 226.860254
17
18
19
20
21
22
23
Total weight 4038.91058785118
Notes: Plateform weight 1115.9384
All dimensions are in mm. Trolley rail weight 334.8025
Weights are in Kgs. Girders weight 2588.16968785118
BOQ is based on one crane only.
Gantry girders & crane rail are not included in the BOQ Back
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FABCON DESIGN & ENGINEERING

Project Title :
CALCULATION SHEET FOR :
Input
Designed by Fabcon F
Mfged by Fabcon F
Hoist by MORRIS M
Crane type MOT M
Bridge type DG,TR DT

Capcity 25 Ton
Span 25 meter
HOL 15 meter
LT 100 meter
Project title
FF M M DT 25 25 15 100
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FABCON DESIGN & ENGINEERING

Project Title :
CALCULATION SHEET FOR :
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CALCULATION SHEET FOR : EOT/Exx. Crane (Double Girder) box type girder
Contents
Page
1- General notes
2- Design calculations
3- Referrences
Attachment-1 Commercial
Attachment-2 BOQ
Attachment-3 Estimation
Attachment-4 Quotation
Attachment-5 Technical performa invoice
Attachment-6 Loading for gantry girders
1- General Notes
1.1 Material
All structural steel shall confirm to ASTM-A36 specifications or shall be an accepted type for the purpose for which the steel is to be used and for the
operations to be performed on it. Other suitable materials may be used provided that the parts are proportioned to compareable design factors.
1.2 Welding
All welding designs and procedures shall confirm to the current issue of AWS D14.1,"Specifications for Welding of Industrial & Mill Cranes &
Other Material handling Equipment" with the exception of Section 705 which shall be in accordance with the Crane Manufacturer's Standard
Tolerancefor deviation from specified camber & sweep , with all measurements taken from manufaturer's plant prior to shipment. Base weld stresses
shall be applicable to load combinations as per ....
1.3 Structure
1.3.1 General
The crane girders shall be structural steel box sections fabricated from structural plates & shapes.
1.3.2 Loadings
The carne structures are subjected in service to repeated loading varying with the time which induce variable stresses in the members and
connections throug the interaction of the structural system & the cross sectional shapes. The loads acting on the structures are devided into
three different categories. All of the loads having an influence on engineering strength analysis are regarded as principal loads, namely
dead loads,which are always present ;the hoist load,acting during each cycle;the inertia forces acting during the movements of the cranes ,
crane components, & the hoist loads. Loads effects , such as operating wind loads , skewing forces, snow loads, temerature effects, loads
on walkways, stairways, platforms & handrails are classed as additional lodas & are only considered for the general strength analysis and
in stability analysis. Other loads such as collision, out of service wind loads, & the test loads applied during the load test are regarded as
extraordinary loads & except for collision & out of service wind loads are not part of specifications. Seismic forces are not considered in
this design report.
1.3.2.1 Principal loads
1.3.2.1.1 Dead Load (DL)
The weight of all effective parts of the bridge structure, the machinary parts & the fixed equipment supported by the structure
1.3.2.1.2 Trolley Load (TL)

The weight of the trolley & the equipment attached to the trolley.
1.3.2.1.3 Lifted Load (LL)
The lifted load consists of the working load & the weight of the lifting devices used for handling & holding the working load such as the
load block, lifting beam , bucket , magnet, grab & the other supplemental devices.
1.3.2.1.4 Verrtical Inertia Forces (VIF)
The vertical inertia forces include those due to the motion of the cranes or crane components & those due to lifting or lowering of the hoist
load. These additional loadings may be included in a simplified manner by the application of a separtae factor for the dead load ( DLF) &
for the hoist load (HLF) by which the vertical acting loads , the member forces or the stresses due to them, must be multiplied.
1.3.2.1.4. Dead Load Factor (DLF)
This factor covers only the dead loads of the crane, trolley, & its associated equipment & shall be taken according to Table 3.3.3.1.1.4.1-1,
page # 11 (CMAA 70), that has been copied here; Table 1
Travel Speed ( feet per minute) Dead Load Factor ( DLF)
Up to 200 1.1
Over 200 1.2
Table 1; Dead Load Factor as a function of travel speed

1.3.2.1.4. Hoist Load Factor (HLF)
This factor applies to the motion of the rated load in the vertical direction, & covers inertia forces , the mass forces due to sudden lifting of
the hoist load & the uncertainities in allowing for other influences. The hoist load factor is 0.5 % of hoisting speed in feet per minuite , but
shall not be less than 15 % or more than 50 % , except for bucket & magnet cranes for which the impact value shall be 50 % of the rated
capacity of the bucket or magnet hoist, so
HLF= 0.15 =< 0.5 % of hoist speed (FPM) =< 0.5
1.3.2.1.5 Inertia Forces From Drives (IFD)
The inertia forces occure during acceleration/deceleration of the crane motions & depend upon the driving & braking torques applied by
the drive units & the brakes during each cycle.
The lateral load due to acceleration/deceleration shall be a percentage of the vertical load & shall be considered as 7.8 times the
acceleration rate (FT/SEC2) but not less than 2.5 % of the vertical load. This percentage shall be applied to both live & dead loads
exclusive of endtrucks & ties. The live load shall be located in the same position as when calculating the vertical moment. The lateral load
shall be equally devided between the two girders & the moment of inertia of the entire girder section about its vertical axis shall be used to
determine the stresses due to lateral forces. The inertia forces during acceleration & deceleration shall be calculated in each case with the
trolley in the worst position for the component being analyzed.
1.3.2.2 Additional loads
1.3.2.2.1 Operating Wind Load (WLO)
1.3.2.2.2 Forces Due to Skewing (SK)
When two wheels (or two boggies ) roll along a rail, the horizontal forces normal to the rail , and tending to skew the structure shall be
taken into consideration. The horizontal forces shall be obtained by multiplying the vertical exerted forces on each wheel ( or boggie ) by
the cofficient SSK which depends upon the ratio of span to wheel base & can be obtained from the Graph on page no. 12 of CMAA
70;1983.
1.3.2.3 Extraordinary Loads
1.3.2.3.1 Stored Wind Loads (WLS)

This is the maximumm force that a crane is designed to withstand during out of service condition. The speed & the test pressure varies
with the height of the crane above the surrounding ground level , geographical location & degree of exposure to prevailing winds (see
ANSI A 58.1).
1.3.2.3.2 Collision Forces (CF)
Special loading of the crane structure resulting from the bumper stops, shall be calculated with the crane at 0.4 times the rated speed
assuming the bumper system is capable of absorbing the energy within its design stroke. Load suspended from the lifing equipment & free
oscillationg load need not be taken into consideration. Where the load cannot swing, the bumper effect shall be calculated in the same
manner , taking into account the value of the load. The kinetic energy released on the collision of two cranes with the moving masses of
M1 & M2, & a 40% maximum travelling speed of Vt1 & Vt2 shall be determined from the following equation.
E = M1.M2.(0.4Vt1 + 0.4Vt2)^2/2(M1+M2)
The bumper forces shall be distributed in accordance with the bumper characteristics & the freedom of motion of the structure with the
trolley in its worst position.
CALCULATION
The bumper forces shall SHEET FOR in
be distributed : accordance
EOT/Exx.
withCrane (Double
the bumper Girder) box
characteristics & type girder of motion of the structure with the
the freedom
trolley in its worst position.
1.3.3 Torsional Forces & Moments
1.3.3.1 Due to Starting & Stopping of the Bridge Motors
The twisting moment due to the staring & stopping of bridge motors shall be considered as the starting torque of the bridge motor at 200 %
of full load torque multiplied by the gear ratio between the motor & cross shaft.
1.3.3.2 Due to Vertcal Loads
1.3.3.2.1 Torsional moments due to vertical forces acting eccentric to the vertical neutral axix of the girder shall be considered as
those vertcal forces multiplied by the horizontal distance between the centerline of the forces & the shear center of the girder.
1.3.3.3 Due to Lateral Loads
1.3.3.3.1 The torsional moments due to lateral forces acting eccentric to the horizontal neutral axix of the girder shall be considered as
those horizontal forces multiplied by the vertical distance between the centerline of the forces & shear center of the girder.
1.3.4 Longitudinal Distribution of the Wheel Load
Local stresses in the rail, rail base, flanges, welds, & in the web plate due to wheel load acting normal & transversely to the rail shall be
determined in accordance with the rail & flange system. The indivisual wheel load can be uniformly distributed in the direction of the rail
over a length of S= 2(R+C)+2 in, provided that the rail is directly supported on the flange as shown in the Fig. 1
Wheel
Rail
Gantry girder
H=R+C 45° 45°

C
2"
Fig. 1; Longitudinal disrtibution of wheel load Center line
1.3.5 Load Combinations
1.3.5.1 Case 1 (Stress Level 1)
(Crane in regular use under principal loading).

DL(DLFB) + TL(DLFT) + LL(1+HLF) + IFD
1.3.5.2 Case 2 ( Stress Level 2)
(Crane in regular use under principal & additional loading).

DL(DLFB) + TL(DLFT) + LL(1+HLF) + IFD + WLO + SK
1.3.5.3 Case 3 (Stress Level 3)
(Crane subjected to extraordinary loads)
1.3.5.3.1 Crane subjected to out of service wind
DL + TL + WLS
1.3.5.3.2 Crane in collision
DL + TL + LL + CF
1.3.5.3.3 Test loads
CMAA recommends test load not to excced 125 % of rated load.
1.3.6 Design Criterion
The crane structure shall be analysed against the following design checks;
1- Uniaxail stresses ( compressive & tensile )
2- Bearing stresses
3- Shear stresses
4- Combined stresses
5- Buckling
6- Deflection
Design limitaions shall be considered as per para. 3.5; CMAA 70;1983.
Longitudinal stiffeners shall confirm to para. 3.5.2 ; CMAA 70;1983
Diaphragms & vertical stiffners shall meet the requirements of para. 3.5.4; CMAA 70;1983.
1.3.7 Allowable stresses
The induced stresses in each member shall be lower than permitted by the following table that is copied from CMAA 70;1983
Allowable
Sress Level compression Allowable tension stress Allowable shear stress Allowable bearing stress
stress
1 0.6*Y 0.6*Y 0.35*Y 0.75*Y
2 0.66*Y 0.66*Y 0.375*Y 0.8*Y

3 0.75*Y 0.75*Y 0.43*Y 0.9*Y
Table 2; Allowable stresses per CMAA 70;1983
In case of comined state of stress, the referrence stress shall be calculated as when comparing it with allowable
stress given above in Table 2.
∂t= sqrt (∂x2 + ∂y2 - ∂x.∂y + 3ƒxy2)

where
Y= yield strength
∂t= The referrence stress
ƒxy= shear stress
1.3.8 Allowable deflection
The maximum vertical defelection of the girder prodced by the weight of the trolley & the rated load shall not exceed 0.001125 inch per
inch of span. VIF shall not be considered while calculation this defelection;see para 3.5.5.1: CMAA 70;1983.
1.3.9 Units
Both US customory & SI units shall be followed throughout, however former ones shall govern. Following table gives the conversion
from one to the other.
US SI
1 inch 25.4 mm
2.204 lbs 1 Kg.
2204 lbs 1 Ton
145 psi 1 Mpa
2- Design Calculations
(Users are requested to fill the data in green boxes only)
Input Data
Design code CMAA 70;1983
Crane type based on driving mechanism
EOT
Crane type based on hazardness Standard
Crane type based on bridge Double Girder, Top Running

Hoist type Wire rope
CALCULATION SHEET FOR :Wire rope
EOT/Exx. Crane (Double Girder) box type girder
Hoisting speed Single
Cross speed Single
Travel speed Single
Safe working load SWL: 44,080 lbs SWL means rated capacity
Span L: 336 in dist. b/w c/c of gantry rails
HOL HOL: 217 in HOL means actual HOL
Long travel LT: 937 in
Trolley load TL: 3,306 lbs see hoist manufacturer's catalogue

Trolley wheel base wb: 55 in see hoist manufacturer's catalogue
Hook load HL: 1,000 lbs see hoist manufacturer's catalogue
Plateform weight Wpl: - lbs based on past experience See BOQ

Trolley rail cross section 50 x 50 mm see Kone Crane Manual, page 187-191
Cabin weight Wcab: - lbs see hoist manufacturer's catalogue
Miscellaneous weight Wmis: 500 lbs based on past experience
Yield Strength of Material Fy 36,000 psi
(Miscellaneous weight includes weight of power supply support system, power supply components, motors &
their panals, stoppers, welds etc)
Hoisting speed high Vhmax: 10.00 FPM
Hoisting speed low Vhmin: 2.00 FPM enter zero in case of single speed
Trolley speed high Vtmax: 10.00 FPM
Trolley speed low Vtmin: 2.00 FPM enter zero in case of single speed
Travel speed high Vcmax: 10.00 FPM
Travel speed low Vcmin: 2.00 FPM enter zero in case of single speed
Crane acceleration ac: 1.20 FT/Sec2 see hoist manufacturer's catalogue
Main girder dimensional data
Flange width B: 300 mm

minimum
Clear distance between webs b: 210 mm 131.23076923
required
minimum
Web depth dw: 600 mm 341.2
required
minimum
Web depth if girder is oblique dw1: 400 mm 150
required
Top flange thk tft: 10 mm
Bottom flange
tfb: 10 mm
thk
Right web thk twr: 6 mm
Left web thk twl: 6 mm
No of vertical stiffeners Nv: 17.06 mm

Max. distance b/w any two
Smax: 500 mm
stiffners
Stiffeners thk tvs: 6 mm
Stiffeners dimensions 210 x 550 mm
No of longitudinal stiffeners Nl: 2 no.

Descrption of longitudinal L 75x75x
per AISC ASD manual of steel construction, 9th Ed.
stiffners (LS) 6
Moment of inertia of LS, in4 Mls: 1.24 per AISC ASD manual of steel construction, 9th Ed.
Area of LS, in2 Als: 1.44 per AISC ASD manual of steel construction, 9th Ed.
Weight lb/ft of
Wls: 4.9 per AISC ASD manual of steel construction, 9th Ed.
LS
End plate thk tpl: 20 mm
B= 300 A
tft = 10
twl = 6 150 min if dw > 720

D
620
=
b= 210 dw = 600
550 twr= 6
tfb= 10
View A-A A
Elevation
Fig. 2.1; General dimensions of Box Girder & Internals

Notes:
The following notes refer to only Fig. 2.1.
Girder shall not be given any obliqity at the end if web depth is less than 720, for further details see KONE Crane Manual, page 188
Fig. 2.1 is not as per scale, rather it just indicates the defined parameters.
Fig. 2.1 does not confirm rules of an engineering drawing so internals are shown in elevation view.
Load Calculations
Unfactored loads
Unfactored lifted load P: SWL+HL
: 45080.00 lbs
Unfactored trolley load TL: 3306.00 lbs
Trolley rail load Trl: 368.95 lbs
Plateform weight Wpl: 0.00 lbs
Cabin weight Wcab: 0 lbs
Miscellaneous weight Wmis: 500 lbs
(Miscellaneous weight includes weight of power supply support system, power supply components, motors &
CALCULATION SHEET
(Miscellaneous weight FOR
includes :
weight ofEOT/Exx. Crane
power supply (Double
support Girder)
system, box
power type components,
supply girder motors &
Girder weight summery
Item Shape/material1 dimensions2 thk weight (lbs) Qty3
Top flange Plate 300 x 8530.00 10 442.742826 1
Bottom flange Plate 300 x 8530.00 10 442.742826 1
Right web Plate 600 x 8530.00 6 531.291391 1
Left web Plate 600 x 8530.00 6 531.291391 1
Vertical stiffene Plate 210 x 550.00 6 204.547186 17

Long. Stiffners Angle L 75x75x 6 274.25853 2
End plates4 Plate 300 x 620.00 20 128.722416 2
Total weight (lbs) 2556 135.956307087402
Table 2.1; weight summery of main girder 1,161.82 Kg
Notes:
1-Material is ASTM A-36 for each item, unless otherwise specified.
2- All dimensions in table are in mm, unless otherwise specified.
3- Quantity is based on one girder only.
4- Obliqity has not been taken into account while calculating the weight of end plate.
Girder weight Wg: 2556.00 lbs
Total dead load Wdead: Wg+Wpl+Trl+Wmis+Wcab
: 3424.95 lbs
Pay load per wheel Pw: (P+TL)/4
: 12096.50 lbs
(It is assumed that trolley has four wheels & each wheel carries equal load)
Factored loads
Dead load factor for trolley DLFt: 1.10 per Table 3.3.2.1.1.4.1-1, page 11, CMAA-70;1983
Dead load factor for bridge wei DLFb: 1.10 per Table 3.3.2.1.1.4.1-1, page 11, CMAA-70;1983
Hoist load factor HLF: 0.15 per para 3.3.2.1.1.4.2, page 11, CMAA-70;1983
Total factored dead load Wdeadf: DLFb x Wdead
: 3767.45 lb
: 11.22 lb/in
Factored pay load per wheel Pwf: [P(1+HLF)+(DLFt x TL)]/4
: 13869.65
(It is assumed that trolley has four wheels & each wheel carries equal load)
Part of this factoed wheel load shall also act in lateral direction, that will induce bending stresses minor plane.
This lateral load is referred to inertia force from drives, in CMAA-70;1983, due to accleration/deceleration of crane
motions & shall be calculated void para. 3.3.2.1.1.5, page 11, CMAA-70;1983.
Lateral load from lifted load Plat1: max((7.8 x ac)*Pwf/100,2.5% of Pwf
: 1298.20 lbs
Lateral load from bridge motion Plat2: max((7.8 x ac)*Wdeadf/100,2.5% of
: 352.63 lbs
: 1.05 lb/in
Required Moment of Inertia

By calculating actual deflection in vertical direction, comparing with that allowable void para. 3.5.5.1,page 27, CMAA;1983,
rough estaimate of required moment of inertia shall be established. CMAA-70;1983 does not guide regarding deflection in
lateral direction, so rought in this sense Moment of inertia is.
The main girder shall be supposed to be a simply supported beam loaded in the worst conditionunder moving load.
Vertical inertia forces & Dead load are not considered in calculating the defelection.
Pw (lbs): 12096.50 12096.50 :Pw(lbs)
140.35433071 55.12 " X= 140.35433
L= 335.83
Fig. 2.2, loading diagram

Allowable deflection Yall: 0.001125 x span per 3.5.5.1, page 27, CMAA-70;1983
: 9.60 mm
Ix, required Ix: Pw.X/(24E.Yall) x (3L2-4X2)
: 1675.77 in^4
E is taken to be 29000 ksi.
Actual moment of Inertia

Location of centroid
# Item Area, Ai Yi Xi Y¯ X¯ 1845000
1 Top flange 3000 615 150.00 15000
2 Bottom flange 3000 5 150.00 1116000
3 Right web 3600 310 258.00 1116000
4 Left web 3600 310 42.00 77385

332.2308 150
5 Vertical stiffene 231 335 150.00 455384.329408998
6 Angle right 929.0304 490.171612693189 200.19 455384.329408998
7 Angle left 929.0304 490.171612693189 99.81 9158.26494724502

8 End plates 4
29.542790152 310 150.00 5089311.92376524
Table 2.1; Location of Centroid 332.230799877667
450000
450000
150 928800
X¯ 151200
34650
119.828387 185982.595776
C/L of angles 92726.524224
299.57097
2293359.12
149.71071654823
490.171613
310.42903 Y¯
39
Fig. 2.3; Location of centroid

Legend:
A1 A2 A3 A4
X1, X2, X3 & X4 Y1, Y2, Y3 &Y4 Ref. axis Centrodal axix
Moment of Inertia
Moment of Inertia wrt major axix of the girder: Ix

Ix about
Indivisua Ix= Ixi +
# Item indivisual Yi Y¯ Y¯-Yi
centroidal axix l area A(Y¯-Yi)2
1 Top flange 25000 3000 615 282.77 239900262
2 Bottom flange 25000 3000 5 327.23 321264989
3 Right web 108000000 3600 310 22.23 109779150
4 Left web 108000000 3600 310 332.23 22.23 109779150
5 Vertical stiffene 2911562500 231 335 2.77 147907465
6 Long. Stiffners 516126.96774 929.0304 490.17161 157.94 23691069.3
7 End plates4 5958200000 29.54279 310 22.23 35483857.2
987805943 mm4
Ix= ∑Ixi 2373.21327 in4

: 987805943.21 mm4
: 2373.2132714 in^4
Iy about
Moment of Inertia wrt minor axix of the girder: Iy
indivisual
centroidal Indivisua Iy= Iyi+A(X¯-
# Item axix l area Xi X¯ X¯-Xi Xi)2
1 Top flange 22500000 3000 150.00 0.00 22500000

2 Bottom flange 22500000 3000 150.00 0.00 22500000
3 Right web 10800 3600 258.00 108.00 42001200
4 Left web 10800 3600 42.00 150.00 108.00 42001200
5 Vertical stiffene 424462500 231 150.00 0.00 21562695
6 Long. Stiffners 516126.96774 929.0304 200.19 50.19 17011.0803
7 End plates4 1395000000 29.54279 150.00 0.00 8307854.63
158889961 mm4
381.734658 in4
Iy= ∑Iyi
: 158889960.71 mm4
: 381.73465755 in^4
Ix 2373.21327140312 in4
Iy 381.734657545226 in4
Sectional Modulie
Sx
Ix (in4) Yt (in) Yb (in) Sxt (in3) Sxb (in3)
2373.2132714 11.329496068 13.07995 209.4720945397 181.438978914162
Sy
Iy (in4) Xt (in) Xb (in) Syt (in3) Syb (in3)
381.734657545 5.905511811 5.905512 64.6404020109915 64.6404020109915
Sxt 209.4720945397 in3

Sxb 181.438978914162 in3
Syt 64.6404020109915 in3
Syb 64.6404020109915 in3
Load Case # 1; Stress Level 1

Load Combination
(Crane in regular use under principal loading).

DL(DLFB) + TL(DLFT) + LL(1+HLF) + IFD
Loading diagrames
Pwf Pwf
140.354330709 55.12 140.35433

Dead Load (UDL)
Plat1 Plat1
Factored pay load per wheel Pwf: 13869.65 lbs
Total factored dead load Wdeadf: 11.22 lb/in
Lateral load from lifted load Plat1: 1298.20 lbs

Lateral load from bridge motion Plat2: 1.05 lb/in
Bending moments
B.M due to moving load MX1: Pwf/2L(L-0.5a)

2
AISC ASD Manual of Steel Construction
: 1962349 lb-in 9th Edition, page 2-310
: 163.5291 Kip-ftt
B.M1 due to Plat1 MY1: Pwf/2L(L-0.5a) AISC ASD Manual of Steel Construction
2
: 183675.88 lb-in 9th Edition, page 2-310
: 15.306323 Kip-ft
B.M due to dead load MX2: (Wdeadf x L )/8

2
AISC ASD Manual of Steel Construction
: 13.179268 Kip-ft
B.M1 due to Plat2 MY2: (Platx L )/8 AISC ASD Manual of Steel Construction
2
: 1.2335795 Kip-ft
Torsional moment due to vertica : 114670.33 lb-in
: 9.5558612 Kip-ft
Torsional moment due to lateral : 36799.349 lb-in
: 3.0666124 Kip-ft
Shear Force
Shear force due to live load Sf1: 25462.921 lbs

Shear force due to dead load Sf2: 1883.7238 lbs
Total shear force Sf: Sf1 + Sf2 lbs
: 27346.645 lbs
Arae of hollow box girder Ahb: 20.460041 in2
Shaer stresses Ss: Sf/Ahb psi
: 1336.588 psi
Allowable shear stresses Ss,all: 12600 psi
Actual shear stresses are less than allowable….OK
In case of oblique girder at the edge portion, the whole area of the girder shall not be availble to resist the shear
force; that area must be checked.
Reduced area due to obliquity Ared: 16.740033 in2
Shear stresses Ss1: Sf/Ared psi
: 1633.6076 psi
Actual shear stresses are less than allowable….OK
Now, it shall be assumed that the whole shear stresses are restricted by the web & the flanges shall only
restrict the bending due to both lateral & vertical laods. This concept was presented by H.H. Broughton
Web area Aweb: 5.5800112 in2
Web area when girder is obliqu Aweb1: 3.7200074 in2
Shear stress Ss2: 4900.8227 psi (when girder is not oblique) OK

Shear stress Ss3: 7351.234 psi (When girder is oblique) OK
Shaer stresses due to torsional moments
(Ref. Warren C.Young, Richard G.Budynas:"Roark's Formulas for Stress & Strain", 7th Ed., McGraw-Hill, New York)
Torsional moment due to vertica T1: 9.5558612 kip.ft
Torsional moment due to lateral T2: 3.0666124 Kip-ft
t (in)= 0.3937007874 t1(in)= 0.2362205 b(in)= 8.7401575 a(in)= 24.409448818898

Shear stresses due to T1 ƒs1: T2/(2t(a-t)(b-t1)
: 228.83777 psi OK
Shear stresses due to T1 ƒs1: T1/(2t1(a-t)(b-t1)
: 1188.4677 psi OK
Bending strsses:
In vertical direction:
Total moment My: 176.70836 kip-ft

Sectional modulas of the top
of cross section Sxt: 209.47209 in3
in3
of cross section Sxb: 181.43898
Minimum sectional modulas Sxmin: 181.43898 in3
Bending stress ƒbx: 11687.127 psi OK
Allowable bending stress ƒall: 0.66*Fy psi
where
Fy: 36000 psi
ƒall: 23760 psi
In lateral direction
Total moment My: 16.539903 kip-ft

64.640402 in3
of cross section Syt:
64.640402 in3
of cross section Syb:
Minimum sectional modulas Sxmin: 64.640402 in3
Bending stress ƒby: 3070.5074 psi OK
Allowable bending stress ƒall: 0.66*Fy psi
where
Fy: 36000 psi
ƒall: 23760 psi
Stress Ratio
Biaxial bending
ƒbx/ƒall + ƒby/ƒall < 1

where
ƒbx: 11687.13 psi
ƒby: 3070.507 psi
ƒall: 23760 psi
ƒbx/ƒall + ƒby/ƒall = 0.621112557

since
ƒbx/ƒall + ƒby/ < 1 OK
Deflection
deflection allowable ∆all: L/888
∆all: 0.3781833 in……….. 9.6058559 mm

actual deflection ∆act: Pw.X/(24E.Ix) x (3L -4X )
2 2
where
Pw: 12096.50 lbs
X: 140.35 in
E: ### psi
Ix: 2373.21 in
4
L: 335.83 in
∆act: 0.2670428 in……… 6.7828872 mm
Since
∆act < ∆all OK
Design limitations:
Span in inches L: 335.83 in……… 8530 mm
Distance b/w web plates b: 8.2677165 in………. 210 mm
Depth of the girder h: 24.409449 in……….. 620 mm
L/h: 13.75806
L/b: 40.61905
Since
L/h < 25 OK
L/b < 65 OK
Longitudinal Stiffeners
Required moment of inertai Ixreq: 1.2[0.4+0.6(a/h) +0.9(a/h)2 + 8Asa/h2t]ht3
where
a= distance b/w vertical stiffeners= 19.685039 in
h= Depth of the girder= 24.409449 in

As= Area of the stiffener= 1.44 in
t= Thk of the web plate= 0.2362205 in
b= Distance b/w web plates= 8.2677165 in

Ixreq 1.1893285 in4
Actual moment of inertia Ixact: 1.24 in4
Since
Ixact > Ixreq……………………. OK
Note: The centerline of the angle shall be at a distance 120 mm away from inner surface of top flange
Vertical Stiffeners:
maximum distance b/w stiffners amax: 350t/sqrt(V)
where
web thickness…………… t: 0.2362205 in
Shear stresses in the webs V: 7.351234 ksi
amax: 30.493372 in…………774.53165 mm
actual distance b/w stiffners a: 19.685039
Since
a < amax…………………………… OK
a < max(72,h)………….. OK
Required moment of inertia Ixreq: 1.2h3t3/a2
: 0.2473984 in
4
Actual moment of inertia Ixact: 199.85877 in4
Since
Ixact > Ixreq……………………. OK
Back to Top
1/1/00 0 j kl jjj
1/2/00 1 j jj jjj
1/3/00 2 j jj jjj
1/4/00 3 j jj jjj

Design Report - Gantry Crane 20ton8.53mspan

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#REF!

MATERIAL HANDLING DEPARTMENT

Currency rate 110 PKR

Materail rate 70 Rs/Kg Loading/unloading

Fabrication Cost 15 Rs/Kg Transportation

Excise duty 1% % Elect. Installation

Incom Tax 3.50% % Commissioning

Margin 20% % Drafting

Design fee 0 Rs/Kg

Date Rev. Prepared By Checked By

MATERIAL HANDLING DEPARTMENT

MATERIAL HANDLING DEPARTMENT

Crane Capacity 44080 lbs 20 Ton.

Span 335.826771653543 in 8.53 Mtr.

HOL 216.535433070866 in 5.50 Mtr.

Long Travel 937.007874015748 in 23.81 Mtr.

Bridge weight 8902 lbs 4039.02 Kg.

End truck Wheel Base 178 in 4.52 Mtr.

No of wheels per end truck 2 nos

Max.Long. static wheel load w/o impact 2451 lbs 11 KN.

Date Rev. Prepared By Checked By Approved By

MATERIAL HANDLING DEPARTMENT

MATERIAL HANDLING DEPARTMENT

Capacity(Ton) 20 Span(m) 8.5 HOL 5.500011 Long travel(m) 23.8

1 HOIST, Trolley, End Crariage, Power Supply, Control

2 Main hoist Aux. hoist Qty Remarks

3 Wire rope/chain type

8 Hazarodous area class

12 Hoist duty group FEM FEM

13 Hoisting speed control

14 Hoisting speed high m/min m/min

15 Hoisting speed slow m/min m/min

16 Hoisting speed in case of mircomove m/min m/min

17 Hoisting motor power KW KW

18 Overload device type

19 Rope reeving type

21 Trolley speed control type

22 Trolley speed high m/min

24 Trolley speed in case of micromove m/min

25 Trolley rail gauge mm

26 Trolley motor power KW

27 Trolley duty group FEM

28 Hoist & trolley weight Kg

29 Overload protector type

30 2-Step limit switch for traverse motion

32 End-truck wheel dia

33 No of wheels per end truck

MATERIAL HANDLING DEPARTMENT

35 End-truck wheel base

36 Bridge travelling duty group FEM

37 Bridge speed control type

38 Bridge speed high m/min

39 Bridge speed low m/min

40 Bridge speed in case of micromove m/min

42 2-Step limit switch for bridge travelling

44 Cross power supply type

45 Bridge travelling power supply type

46 Push button station type

47 Remote control included

48 Hoist owners manual

49 Hoist inspection test record

52 Crane Structure, Installation, Comissioning

54 Design Code CMAA -70;1983