Appendix A.

1 Monorail Beam design with 3MT SWL, S2 type ( Fy = 250 Mpa)

Structural Design calculations - Monorail, as per MOQ-DDE-DUI-002

1. Trolley Technical Data

Carrying capacity of the trolly SWL = 20 MT
Hoist weight SWHoist = 2.4 kg
Total weight of trolley SWTrolley = 0 kg

Geometry & Dimension

No of wheels = 4 Nos
A= mm
N= 150 mm
C = b + 70 >> = 224 + 70 = 294 mm

Max bottom flange thickness tf.max = 24 mm

Max bottom flange width bf.max = 224 mm
Min bottom flange width bf.min = 224 mm

2. Monorail beam data

No of continous Span = 1
Maximum Span Length L= 4.0 m
Cantilever Span ( if required) Lcant = 1.5 m

Section parameter
Section NPB 600X220X154.5
Depth of section h= 610 mm
Flange Width b= 224 mm ( bf.min > bf > bf.max ) \ O.K
Thickness of flange tf = 24 mm (tf > tf.max) \ Revise
Thickness of web tw = 15 mm
Root Radius r1 = 24 mm
Root Radius r2 = 1 mm
Distance d= 610 mm
Section area A= 196.8 cm2
Second moment of area (major axis) Iz = 118302 cm4
Second moment of area (minor axis) Iy = 4520.8 cm4
Elastic modulus (major axis) Zz = 3678.8 cm3
Elastic modulus (minor axis) Zy = 403.6 cm3
Elastic modulus Bottom flange Zy.bf = 200.7 cm3
Radious of gyration (major axis) rz = 24.517913 cm
Radious of gyration (minor axis) ry = 4.7928639 cm
Self weight of member w= 154.488 kN/m

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3. Check the stopping arrangement for Trolley as per EN1993 -6

m+n = 0.5 * (b - tw) - 0.8*r1 >>

m+n = 0.5*(224-15)-0.8*24
m+n = 85.300 mm
Minimum Distance from wheel to End of monorail
Xe.min = 2*Sqrt(2) *(m+n)
= 0.5*(1-196.8)-0.8*118302
= 241.26 mm
Distance from beam end to trolley edge
Xe1 = 145 mm
Distance from trolley edge to centre of outer wheel
Xe2 = (A-N)/2 >> Xe2 = -75 mm
Distance provided from the outer wheel to End of monorail
Xe = 70 mm < 241.26 Revise

Xe1 Xe2 SL = N
4. Design Load
Weight of lift SWL = 10.0 MT
Total weight of Trolley and hoist assumed for design
SW = 1.5 MT >= SWHoist +SWTrolley = 0.002MT
Dynamic Amplification factor DAF = 1.25 (BS-2853 : Cl 4.1)

Design Vertical load Fv = (SWL+SW) *DAF

= (10+1.5)*1.25
= 14.4 MT
= 143.75 kN
Design Lateral load FL = 0.1 SWL
= 0.1 * 10
= 1 MT
= 10 kN
UDL on the beam due to self wt wsw = 154.49 kN/m

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5 Design of Monrail beam as per BS2853-1957

5.1 Case1 : Load at centre of span

5.1.1 Results from Analysis

ANALYSIS OF SIMPLY SUPPORTED BEAM FOR MOVING LOAD Span in mm

0 2000 4000 6000 8000 10000
Moment - kN.m

40900 N 40900 N 40900 N 40900 N -20000000

0
20000000
200 mm 1200 mm 200 mm 40000000
60000000
80000000
100000000
120000000
a
Span in mm
L= 4000 mm 0 2000 4000 6000 8000 10000
-100000
Shear - N

-50000
0

Run 50000
Modulus of Elasticity 2.05E+05 N/mm2
100000
Momenet of inertia 1.18E+09 mm4 150000
Deflection at N points 50
Span in mm
0 2000 4000 6000 8000 10000
Deflection - mm

0
Results 0
Location Distance "a" 0
0
mm mm 0
Max M 1.10E+08 N.mm 2320 2520 1
1
Max V 130471.00 N 0 1610 1
Min V -127608.00 N 3920 3920 1

Max Delta 0.7513 mm 2000 2800

Load case No =
Maximum Span L = 4.0 m
Maximum bending moment (Major axis) Mz = 110.0 kN.m
Maximum shear force Fv = 130.5 kN
Maximum bending moment (Minor axis) My = 5.5 kN.m
Actual Deflection = 0.8 mm

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5.1.2 Check for Longitudinal bending stress

Maximum bending moment Mz = 110.0 kN.m

Longitudinal bending stress f1 = Mz/Zz.e
= (110*10^6)/(3678.8*10^3)
= 29.9 N/mm2
= 1.9 tonf/in2 (i.e 15.44 Mpa = 1 tonf/in2)

Allowable longitudinal bending stress in tension ( Bottom flange) (BS-2853 : Cl 4b.1)

PbT = 10.7 tonf/in2 >= 1.9 SAFE
= 165.0 N/mm2 U.R = 0.18

Allowable longitudinal bending stress in Compression ( Top flange) (BS-2853 : Cl 4b.1)

Effective Length factor = 1
Effective Length Leff = 4000.0 mm
h/tf = =610/24 = 25.4
L/ry = =4000/47.928639366716 = 83.5

Interpolation for Values of P bc

h/tf
L/ry
25 30 25.4
80 11.1 11.1 11.10
85 10.5 10.5 10.50
83.5 10.69 10.69 10.69

Allowable bending stress in Compression PbT = 10.7 tonf/in2 >= 1.9 SAFE
165.0 N/mm2 U.R = 0.18

5.1.3 Check for Transverse bending stress

2
Transverse stress f2 = 1.4*C*W / (K1*T )
Where
W = FV = Effective loads = 143.75 kN
= 14.43 tonf (i.e 9.964 kN = 1 tonf)
T = tf = Mean Thickness of flange = 24 mm
= 0.945 in
b = Flange width = 224 mm
= 8.819 in
N = Trolley Wheels centres Longitudinal = 150 mm
= 5.906 in
Interpolation for Values of C
Flange Four Wheeled trolley wheel centres
Width 5 6 5.9
5.25 0.575 0.515 0.52
5.75 0.6 0.55 0.55
8.82 0.75 0.76 0.76

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 C = a constant from Table 3 of BS2853 = 0.76
K1 = a constant from Table 4 of BS2853 = 1.0
2
Transverse stress f2 = 1.4*C*W / (K1*T )
= 1.4*0.76376028*14.43/(1*0.945^2)
= 17.3 tonf/in2
(i.e 15.44 Mpa = 1 tonf/in 2 ) = 266.8 N/mm2

Allowable trasverse bending stress (BS-2853 : Cl 4b.ii)

PbT = 14.5 tonf/in 2
< 17.3 UNSAFE
= 223.9 N/mm2 U.R = 1.19

5.1.4 Check for Combined bending stress

Longitudinal bending stress f1 = 1.9 tonf/in2
Transverse stress f2 = 17.3 tonf/in2

f1 & f2 falling under the hatch area hence safe

16

15

14

13

12

11

10

0
20 18 16 14 12 10 8 6 4 2 0

5.1.5 Check for shear stress

Maximum shear force Fv = 130.5 kN

Applied shear stress fv = Fv/ (h.tw)
= 130.5*1000/(610*15)
= 14.3 N/mm2

Allowable shear stress PbT = 8.5 tonf/in2 (BS-2853 : Cl 4e)

= 131.2 N/mm 2
>= 14.3 SAFE
U.R = 0.11

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5.1.6 Check for weak axis bending

Maximum bending moment My = 5.5 kN.m

Actual bending stress fweak = M/Zy.bf
= (5.5*10^6)/(200.7*10^3)
= 27.4 N/mm2

Allowable bending stress fall = 0.75 fy

PbT = 258.8 N/mm2 >= 27.4 SAFE
U.R = 0.11
5.1.7 Check for Combined weak axis bending & Transverse bending

Combined utilisation ratio = 1.19+0.11

= 1.30 >= 1.0 UNSAFE
U.R = 1.30
5.1.8 Check for Deflection
Actual Deflection = 0.8 mm
Allowable deflection for runway beams = L /500 (BS-2853 : Cl 4k)
= 8.0 mm >= 0.8 SAFE
U.R = 0.09
5.1.9 Check for weld
Weld thickness tweld = 15.0 mm (Thickness of stiffener considered)
Length of weld (Portion of stiffener) Lweld = 420.0 mm
(Conservatively the length of weld between stiffener and the monorail web location is considered)
Weld meterial strength fu.weld = 410 Mpa

Maximum force on weld V = 130.5 kN

Shear stress on weld = V/(tweld*Lweld)

= 130.5*1000/(15*420)
= 20.7 N/mm2

Allowable shear stress on weld fv.all = 0.3 fu.weld (AISC manual-9ed : Table 25)
= 0.3*410
fv.all = 123.0 N/mm2 >= 20.7 SAFE
U.R = 0.17

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5.2 Case2 : Load at Cantilever edge

5.2.1 Results from Sacs

Load case No = 301

Maximum Span L = 1.5 m
Maximum bending moment (Major axis) Mz = 187.8 kN.m
Maximum shear force Fv = 139.5 kN
Maximum bending moment (Minor axis) My = 13.6 kN.m
Actual Deflection = 2.9 mm

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5.2.2 Check for Longitudinal bending stress
Maximum bending moment Mz = 187.8 kN.m
Longitudinal bending stress f1 = M/Zz.e
= (187.84*10^6)/(3678.8*10^3)
= 51.1 N/mm2
= 3.3 tonf/in2 (i.e 15.44 Mpa = 1 tonf/in2)

Allowable longitudinal bending stress in tension (BS-2853 : Cl 4b.1)

PbT = 14.5 tonf/in 2
>= 3.3 SAFE
= 223.9 N/mm2 U.R = 0.23

Allowable longitudinal bending stress in Compression (BS-2853 : Cl 4b.1)

Effective Length factor = 2
Effective Length Leff = 3000.0 mm
h/tf = =610/24 = 25.4
L/ry = =3000/47.928639366716 = 62.6
Interpolation for Values of P bc
h/tf
L/ry
15 20 25.4
85 13.2 12.1 10.91
90 12.8 11.5 10.09
62.6 14.99 14.79 14.57

Allowable bending stress in Compression PbT = 14.6 tonf/in2 >= 3.3 SAFE
224.9 N/mm 2
U.R = 0.23

5.2.3 Check for Transverse bending stress

2
Transverse stress f2 = 1.4*C*W / (K1*T )
Where

W = FV = Effective loads = 143.75 kN

= 14.43 tonf (i.e 9.964 kN = 1 tonf)
T = tf = Mean Thickness of flange = 24 mm
= 0.945 in
b = Flange width = 224 mm
= 8.819 in
N = Trolley Wheels centres Longitudinal = 150 mm
= 5.906 in

Interpolation for Values of C

Flange Four Wheeled trolley wheel centres
Width 9 10 5.9
6.5 0.5 0.5 0.50
6.75 0.5 0.5 0.50
8.82 0.50 0.50 0.50

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 C = a constant from Table 3 of BS2853 = 0.50
K1 = a constant from Table 4 of BS2853 = 1.00
2
Transverse stress f2 = 1.4*C*W / (K1*T )
= 1.4*0.5*14.43/(1*0.945^2)
= 11.3 tonf/in2
(i.e 15.44 Mpa = 1 tonf/in 2 ) = 174.6 N/mm2

Allowable trasverse bending stress (BS-2853 : Cl 4b.ii)

PbT = 14.5 tonf/in2 >= 11.3 SAFE
= 223.9 N/mm 2
U.R = 0.78

5.2.4 Check for Combined bending stress

Longitudinal bending stress f1 = 3.3 tonf/in2
Transverse stress f2 = 11.3 tonf/in2

f1 & f2 falling under the hatch area hence safe

16

15

14

13

12

11

10

0
20 18 16 14 12 10 8 6 4 2 0

5.2.5 Check for shear stress

Maximum shear force Fv = 139.54 kN
Applied shear stress fv = Fv/ (h.tw)
= 139.54*1000/(610*15)
= 15.3 N/mm2

Allowable shear stress PbT = 8.5 tonf/in2 (BS-2853 : Cl 4e)

= 131.2 N/mm 2
>= 15.3 SAFE
U.R = 0.12

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5.2.6 Check for weak axis bending
Maximum bending moment My = 13.6 kN.m
Actual bending stress fweak = M/Zy.bf
= (13.55*10^6)/(200.7*10^3)
= 67.5 N/mm2
Allowable bending stress fall = 0.75 fy
PbT = 258.8 N/mm2 >= 67.5 SAFE
U.R = 0.26

5.2.7 Check for Combined weak axis bending & Transverse bending
For Cantilever case combined weak axis bending and transverse bending is not required. Since for max weak
axis bending moment at support the trasverse bending will be at end and both will be at different location

5.2.8 Check for Deflection

Deflection = 2.9 mm
Allowable deflection for runway beams = L /250 (BS-2853 : Cl 4k)
= 6.0 mm >= 2.9 SAFE
U.R = 0.48

5.2.9 Check for weld

Weld thickness tweld = 15.0 mm (Thickness of stiffener considered)
Length of weld (Portion of Stiffener) Lweld = 420.0 mm
(Conservatively the length of weld between stiffener and the monorail web location is considered)
Weld meterial strength fu.weld = 410 Mpa

Maximum force on weld V = 139.5 kN

Shear stress on weld = V/(tweld*Lweld)

= 139.54*1000/(15*420)
= 22.2 N/mm2

Allowable shear stress on weld fv.all = 0.3 fu.weld (AISC manual-9ed : Table 25)
= 0.3*410
fv.all = 123.0 N/mm2 >= 22.2 SAFE
U.R = 0.18

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