IDEA - Binder - Gantry

IDEA IDEA – WORK STANDARD Page : 1
Industrial Designer & Portal crane Date :

Engineer Association
1. GENERAL
The portal crane is one crane shape, which is not popular among the crane builders. The reasons could be among others :
 Portal crane system is statically indefinite system, which is not so convenient to calculate. The acting forces and the stresses
are combination of three-dimensional loading case and they depend on the selected shape of the portal crane. It is time
consuming to calculate the portal crane structure to get its optimum dimensions.
 The total deflection of the crane structure is superposition of the deflection of the girder and the deflection of the portal legs. It
is also three-dimensional. The vibration caused by the deflections of the structure is also three-dimensional and it is not easy
to determine the exact vibration. The deflection and vibration of the structure might be determined using programmable
simulators. In the most cases, only the vertical deflection and the respective frequency are calculated formally. The deflection
in the horizontal directions are estimated and anticipated by the over-dimension of structure in these directions.
 The alignment process during the manufacturing is difficult and time consuming. In order to align the whole crane properly and
accurately, it should be installed in the workshop during the alignment process, so as it will be built later. This requires a large
space and several mobile cranes. Many steel structure workshops do not have the necessary space and the rental of mobile
crane is expensive. Misalignment of portal crane may cause damages in the structural components, especially on wheels and
drive units, in a greater extent compared to the damage on standard overhead cranes due to the same reason.
 Portal cranes require bigger wheels and stronger driving motors due to heavier moveable masses. The wheel load is
increased with the weight of portal leg and the possible counter weight, if cantilever arms are required. The counter weights
are needed to keep the stability of crane against the overturning moment, when the hoist lifts the load at the outer point of
cantilever arm.
 The erection and installation of the portal crane at the job site is as difficult and time consuming as the alignment process. It
requires also expensive mobile cranes.
Despite of all above-mentioned difficulties, portal cranes are still an economical alternative for outdoor cranes. It is often cheaper to
build the portal crane foundation than to build runway columns and their foundations, especially if the ground soil is soft. It is
especially more economical if the crane should travel in long distance and / or the lifting height is big, so the crane should operate
in high speeds. The possibility to have cantilever arms is one of the significant advantages compared to overhead traveling crane.
Other advantage is the greater freedom of good’s movement in the operating area, whereas columns of runway support for the
overhead crane hinder the freedom of movement. Most of portal cranes operate in high speed, high capacity and heavy-duty
conditions.
1.1. DESIGN NOTES

 The formulae for the half portal crane are valid also for full portal crane, because one leg of full portal crane is executed as
flexible leg, which does not transmit moment. The stresses on portal crane are calculated in the same manner as overhead
traveling crane after determining the acting moments on the structure.
 The portal crane structure is shaky compared to the overhead traveling crane due to flexibility of portal legs, especially if the
leg is higher than 5 m. It is sensitive to the structural deflections. Therefore, the structural stiffness of portal crane must be
higher than that of overhead traveling crane.
The deflection of the girder is normally design for 1/1500 to 1/1000 x span. The horizontal deflection of girder and the
respective vibration should be considered, especially for portal crane with wider span. In order to minimize the deflection in
horizontal direction, the ratio Jy / Jx > 0,125 where Jy is the moment of inertia of girder in the horizontal direction and Jx
is the moment of inertia in vertical direction.
The natural frequency of vertical vibration should be f > 3,5 Hz.
 A portal crane tends to slant over the rail due to its bigger flexibility. In order to increase the stability of crane and to secure the
synchronous running of crane, several design considerations are taken;, among others important measures :
o The wheel base b should be greater than 4L or 2H, whichever is bigger, where L is the span of crane and H is the
portal height.
o The heavier portal crane uses separate drive unit for each leg corner.
o To equip the wheel bogies with guide rollers, so that the wheel flange do not have the chance touch the railhead.
 The power equilibrium from the left end-truck to the right end-truck is transmitted by the portal structures. The torsion rigidity of
legs is very important to avoid jerky traveling of crane, especially during starting and braking. Pay attention to the flexible
joints, because they are the most flexible parts of a portal crane system and they are supposed not to transfer moment, so
they are the weakest point in transferring power. The power is transferred by the housing of the flexible joints.
 Sun-roof should be provided for the winch, motors and control panels, so that they are not imposed directly to the sunlight and
also protected against rainfall.
2. FROM OVERHEAD CRANE TO PORTAL CRANE
An overhead traveling crane has relative small displacement ( x )

x between the top of rail and the axis of crane girder.
The girder can be raised or lowered to suit the requirement of

application.
x
After purposely inserting the legs, overhead traveling crane

becomes portal crane.
The portal crane is statically indefinite system.
By inserting a pivot joint on one leg, the system becomes statically

definite system. The deformation of girder and leg is compensated
by the pivot joint.
Pivot joint
If the wheel thread is bigger than the tolerance of the crane span,
the crane will run smoothly, without clamping to the rail.
The necessary thread g = width of rail b + span tolerance x +
deformation of leg l
g = b + x + l + 10 mm
2.1. Typical application for portal cranes is : CONTAINER HANDLING CRANE

Maximum length of container L1 = 40 feet
Tare weight of container Gc = 4 tones
Handling capacity of container SWL = 30 tones
Weight of spreader Gsp = 8 tones
Hoist capacity P = 50 tones
Lifting height H = 20 m, at 5 container stacking
Lifting speed vh = 8 m / min,
Effective working hours th = 12 hours / day,2 shifts
Effective working days ty = 300 days / years

Effective service hours T = 30000 hours, before overhaul
Starting point = A Destination point B
Lowering empty spreader at A

Tying up container
Lifting up the load at A
Crossing with load at A Long travel with load to B Lowering the load at B
Release the load at B
Lifting up empty spreader at B
Crossing with empty spreader at B
Long travel without load back to A
Spreader carrying full container = 40 tones ca. 50 % of total lifts.

Spreader carrying empty container = 12 tones ca. 50 % of total lifts.
3 3
Spectrum factor = Kp = 3  40 t  * 50%   12 t  * 50% = 0,803
 50 t   50 t 
Spectrum class = L4 = very heavy duty.
Component Hoist Crab End-truck Girder

Average working path 15 13 60 - m
Working speed 8 40 63 - m / min
Full load time 4 0,4 1 4 min / cycle
Empty spreader time 4 0,4 1 4 min / cycle
Total cycle time 8 0,8 2 8 min / cycle
Number of cycle / hour 7 7 7 7 cycles / hour
Total cycles 210000 210000 210000 210000 cycles / life
Full load time 14000 2800 3500 - hours / life
Class of utilisation T6 T4 T5 U4 -
Spectrum class L4 L4 L4 L4 -
FEM group M8 M6 M7 A6 -
Industrial Designer & Portal crane – type R1
Engineer Association Date
Bending moment and deflection of girder and leg
1. GENERAL SYSTEM
1.1. Bending moment on girder and portal leg due to traveling load
The reaction forces on point C are found based on the fact, that the deflection on point C is zero.
n  k Mk Mk 
The deflection of C is c =    * * dxk  = 0
 E . Jk C 
k 1  0 
P
y x
 MA = -B*L + C*H + P*b = 0
Mb
C*H P*b
Mp J1 B = 
A L L
b a
H
J2
u
C
L B
Section Moment Mi Mi

C
x C*x x
C*H* y P*b* y
y C*H - B*y = C*H -
-
L L
 H* y  P*b* y H* y
= C*  H -  - H -
 L  L L
z C*H - B*(a + z) + P*z

C*H P*b 
= C*H -   * a  z  + P*z
 L L 
 H*L - H* a - H* z   a*b - L* z  b* z
= C*   - P*  
 L   L 
H a H
= C* *(b - z) - P* *(b - z) *(b - z)
L L L
Usually, the portal leg has variable web height to suit the variable bending moment. The equivalent moment of inertia J2 is
calculated using the Castigliano method, after dividing the portal leg height into n – sections. The finer the division, the more
accurate will be the result.
1 1 n  1  3 * n * ( n - 1) 
= *  
J2 n3 1  Jn 
H H
2 C*H3
E * J2 * x =  C * x * x * dx =  C * x * dx =
0 0 3
a   H.y  P .b .y   H.y 
E * J1 * y =   C . H -  -  .H-  . dy
0   L  L   L 
a  2 2 2   2 
 H2 - 2* H * y  H * y  - P * b * .  H * y - H * y   * dy
=   C*   
0  L L2 L L 
   
a a
 y2 y3  P*b*H  y2 y3 
= C * H2 *  y -   - *  - 
 L 3 .L 2  L  2 3 .L 
0 0
C * H2  P*H* a* b 
= * .  3 * a * L2 - 3 * a2 * L  a3   .  3 * a * L - 2 * a2 
3*L 2   6*L 2  
b  C*H P*a   H 
E * J1 * z =   -  *  b - z   *  *  b - z   * dz
0  L L    L 
b   C * H 2 - P * a * H  
=   *  b 2 - 2 * b * z  z 2   * dz
    
L2 
0    
b
 C * H2 - P * a * H   3 
=   .  b 2 * z - b * z 2  z 
   
 L2  
3
 0
C * H2 * b 3 P * a * H * b3
= -
3 * L2 3 * L2
Deflection of C = C = x + y + z = 0
C * H3 C * H2 C * H2 * b 3
+ *  3 * a * L 2 - 3 * a 2 * L  a 3  + =
3 * E * J2 3 * J1 * L 2   3 * E * J1 * L 2
P* H* a* b  3 * E * J1
*  3 * a * L - 2 * a 2  2 * b 2   multiply the whole equation with 
6 * E * J1 * L 
2  H
C * H 2 * J1 C*H  P*H* a* b 
+ *  3 * a * L 2 - 3 * a 2 * L  a 3  b 3  = .  3 * a * L - 2 * a 2  2 * b 2 
J2 J1 * L 
2  6 * J1 * L 
2 
C * H 2 * J1 P* a*(L - a)*(2*L - a)
with b = L - a  + C*H*L = .
J2 2*L
 J1 * H  P* a* (L - a)*(2*L - a) P* a* b* (L  b)
C*H*L*   1 = . =
 J2 * L  2*L 2*L
J1 * H P* a* b* (L  b)
with  1  N  C*H*L*N =
J2 * L 2*L
P * ( 2 * a * L 2 - 3 * a2 * L  a3 ) P* a*b* (L  b)
Hence, C = =
2 * L2 * H * N 2 * L2 * H * N
P* a* b* (L  b)
Side force on support point C = =
2 * L2 * H * N
P* a* b* (L  b)
Bending moment on portal leg Mb = C.H =
2 * L2 * N
P*a Mb
Vertical reaction support Ap = -
L L
P*b Mb
Vertical reaction support Bp = 
L L
P*a*b b * Mb
Bending moment on girder Mp ( b ) = A.b = -
L L
To find the maximum load either on the portal leg as well as on the girder, it is recommended to divide the girder into n – sections,
and analyze the bending moment on portal leg and girder when the traveling load acts on the sectional point.
Notes : For quick calculation purpose, we may set the load in the middle of the girder and take correction factor ~ 1,2 to the
load P. The equation becomes :
Load P" = = *P

3 * P" * L
Side force on support point Cp =
16 * H * N
3 * P" * L
Bending moment on portalleg Mbp = C*H =
16 * N
P*a Mb P" 3 * P"
Vertical reaction support Ap = - = -
L L 2 16 * N
P*b Mb P" 3 * P"
Vertical reaction support Bp =  = 
L L 2 16 * N
L P" * L 3 * P" * L
Bending moment on girder Mp ( b ) = Ap * = -
2 4 32 * N
1.2. Bending moment on girder and portal leg due to girder own weight
y x q*L2
 Ma = -B*L + C*H + = 0
q Mb 2
C*H q*L
Mq J1 B = 
L 2
A
b a
H
J2
u
C
L B

C
x C*x x
q* y2 C* H* y q*L* y q * y2
y C*H - B*y + = C*H - - 
2 L 2 2
 H* y  q H* y
= C* H -  - *  L * y - y 2  H-
 L  2   L
H H C * H3
E * J2 * x = = 2 =
 C * x * x * dx  C * x * dx
0 0 3
L  H* y  q   H* y 
E * J1 * y =  C* H -  - *  L * y - y 2   *  H -  * dy
0  L  2    L 
L   2* y y 2  q * H  y 3  
=  C*H
2 * 1 -  - . L * y - 2 * y2   * dy
 L L 2  2  L 
0    
L L
 y2 y3  q * H  L * y2 2 * y3 y4 
= 2
C*H *  y -   - . -  
 L 3 * L 2  0 2  2

3 4*L 
0
1 1
= * C * H2 * L - * q * H * L3
3 24
Deflection of C = C = x + y = 0
C * H3 C * H2 * L q * H * L3 3 * J1
 - = 0  multiplied by :
3 * E * J2 3 * E * J1 24 * E * J1 H
 J1 * H  q * L3  J1 * H 
C*H* L *   1 =  with   1 = N
 J2 * L  8  J2 * L 
q * L2
Side force on support point Cq = =
8*H*N
q * L2
Bending moment on portal leg Mbq = Cq * H =
8*N
q*L Mb
Vertical reaction support Aq = = -
2 L
q*L Mb
Vertical reaction support Bq = = 
2 L
q * b2 q* b*(L -b) q*L*b

Bending moment on girder Mq ( b ) = Aq * b - = -
2 2 8*N
Mb q*L q*L L L

Maximum bending moment when  0  - q* b - = 0  b = -
b 2 8*N 2 8*N
2
q * L2 q * L2 q * L2 q * L2  1 
Hence, Mq,max = -  = * 1 - 
8 16 * N 128 * N2 8  4*N 
1.3. Deflection of girder due to traveling load
P 1
y x y x
Mb Mb1
Mp J1 Mp1 J1
A A
L/2 L/2 L/2 L/2
H
H
J2 J2
u u
C C
L B L B
P*L 3*P*L 3 * P * L
Real moment of girder due to load P = Mp = - Mb =
4 32 * N 16 * N
L 3*L 3 * L
Virtual moment of girder due to load 1 = Mp1 = - Mb1 =
4 32 * N 16 * N
H H  -3*P*L   -3*L  3 * P * L2 * H
E * J2 * x = * Mb * Mb1 = * *  =
3 3  16 * N   16 * N  256 * N2
1 L  Mb * Mp1 Mp * Mb1 
E * J1 * y = * *  Mb * Mb1    Mp * Mp1 
3 2  2 2 
 - 3 * P * L    3 * L  1  - 3 * P * L   L 3*L  1  P*L 3*P*L   -3*L  

 *   * * -   * - * 
L  16 * N   16 * N  2  16 * N   4 32 * N  2  4 32 * N   16 * N  
= * 
6  2
 L 3*L  
  P*  -  
  4 32 * N  
P * L 3  63 12 1 
= . - 
24  256 * N2 32 * N 4 
 
2 
1 L L  L 3*L  P * L 3  1 6 9 
E * J1 * z = * * Mp * Mp1 = *P* -  = * - 
3 2 6  4 32 *N 24  4 32 * N 256 * N2 
 
Total deflection  = x + y + z
3 * P * L2 * H P * L 3  63 12 1  P * L 3  1 6 9 
 = + * -  + * - 
256 * N2 * E * J2 24 * E * J1  256 * N2 32 * N 4  24 * E * J1  4 32 * N 256 * N2 
  
3 * P * L2 * H P * L 3  72 18 2 
= + * - 
256 * N2 * E * J2 24 * E * J1  256 * N2 32 * N 4 
 
3 * P * L2 * H 3 * P * L3 3 * P * L3 P * L3
= + - 
256 * N2 * E * J2 256 * N2 * E * J1 128 * N * E * J1 48 * E * J1
3 * P * L3  H * J1  3 * P * L3 P * L3 H * J1
= *   1  -   with  1  N
256 * N2 * E * J1  L * J2  128 * N * E * J1 48 * E * J1 L * J2
3 * P * L3 6 * P * L3 P * L3
= - 
256 * N * E * J1 256 * N * E * J1 48 * E * J1
P * L3 3 * P * L3 P * L3  1 3 
 = - = * - 
48 * E * J1 256 * N * E * J1 16 * E * J1  3 16 * N 
1.4. Deflection of girder due to girder own weight

The deflection of girder can be considered as the superposition of girder under unit load q and the upward deflection.
y
z y
z q
A J1 J1
A
+
L/2
H
J2 J2
x x
C C
B B
L L
1.4.2.1. Deflection due to unit load q ( 1.st part )

1
y x y x
q Mb1
Mq1 J1 Mp1 J1
A A
L/2 L/2
L/2 L/2
H
J2
J2
u u
C C
L B L B
q * L2
Real moment of girder due to load q = Mq1 = Mb = 0
8
L 3*L 3*L
4 32 * N 16 * N
E * J2 * x = 0
L Mq1 * ( 3 * Mb1  5 * Mp1 ) L q * L2  - 9 * L 5*L 15 * L 

E * J1 * y = * = * .  - 
2 12 24 8  16 * N 4 32 * N 
q * L4  5 33 
= . - 
192  4 32 * N 
L 5 * Mq1 * Mp1 L q * L2  5 * L 15 * L  q * L4  5 15 
E * J1 * z = * = * . -  = . - 
2 12 24 8  4 32 * N  192  4 32 * N 
g = x + y + z
q * L4  5 33  q * L4  5 15 
= 0 + . -  + . - 
192 * E * J1  4 32 * N  192 * E * J1  4 32 * N 
q * L4  3 
g 1 = * 5 - 
384 * E * J1  N
1.4.2.2. Deflection due to unit load q ( 2.nd part )
y x y x
Mq2 Mb Mb1
J1 Mp1 J1
A A
L/2 L/2
L/2 L/2
H
H
J2
J2
u u
C C
L B L B
 q * L2  q * L2
Real moment of girder due to load q Mq = ; Mb =
16 * N 8*N
L 3*L 3*L
Virtual moment of girder due to load 1 Mp1 = - ; Mb1 =
4 32 * N 16 * N
H H  - q * L 2   - 3*L 
 . q * L3 * H
E * J2 * x = * Mb * Mb1 = *  =
3 3  8*N   16 * N  128 * N2
 
L 1  Mb * Mp1 Mq * Mb1 
E * J1 * y = * *  Mb * Mb1    Mq * Mp1 
2 3  2 2 
  - q * L2   - 3 * L  1   q * L 2   L 3 * L  1  - q * L 2   - 3 * L 
 *   * * -   * * 
  8 * N   16 * N  2  8*N   4 32 * N  2  16 * N   16 * N 
L       
= * 
6   -q* 2 L 
 L   3*L 
  * -  
  16 * N   4 32 * N  
L  21 * q * L 3 2 * q * L3 

= * -
6  512 * N2 64 * N 
 
L 1 L  - q * L 2   L 3*L  L  - q * L 3 3 * q * L3 
E * J1 * z = * * Mq * Mp1 = * * -  = *  
2 3 6  16 * N   4 32 * N  6  64 * N 512 * N2 
   
g2 = x + y + z
q * L3 * H L  21 * q * L 3 2 * q * L 3  L  - q * L3 3 * q * L 3 
= + * - + * 
128 * E * J2 * N2 6 * E * J1  512 * N2 64 * N  6 * E * J1  64 * N 512 * N2 
  
q * L3 * H q * L 4  24 3 
=  * -
128 * E * J2 * N2 
6 * E * J1 512 * N2 64 * N 
 
3
q*L *H q*L 4 q*L 4 q * L4  H * J1  q * L4
=  - = * 1  -
128 * E * J2 * N2 128 * E * J1 * N2 128 * E * J1 * N 128 * E * J1 * N2  L * J2  128 * E * J1 * N
= 0
Total deflection due to dead weight of girder
q * L4  3 
g = g1 + g2 = * 5 - 
384 * E * J1  N
Industrial Designer & Portal crane – type R1a
1. GENERAL SYSTEM
1.1. Bending moment on girder and portal leg due to traveling load ( cantilever on fixed leg )
 E . Jk C 
k 1  0 
P
y
Mp  MA = -B*L - C*H + P*(a+L) = 0
P*(aL) C*H
J1 B = 
Mb1 a L L
A
J2
H
C
L B

C
x C*x x
y C*H + B*y - P(a+y) =

C*H* y P*(aL)* y
C*H -  - P*(a-y) =
L L
 H* y   y  H* y
C*  H -  + P*a* - 1 H -
 L   L  L
1 1 n  1  3 * n * ( n - 1) 
= *  
J2 n3 1  Jn 
H H
2 C*H3
E * J2 * x =  C * x * x * dx =  C * x * dx =
0 0 3
L  H.y  y   H.y 
E * J1 * y =   C . H -  - P * a *   1  * .  H -  . dy
0  L  L   L 
L  2 2 2   2 
=   C*  H2 - 2 * H * y  H * y  - P * a * .  - H  2 * H * y - H * y   * dy
 L2   L 2  
0  
L
 
L
L L
 y2 y3   y2 y3 
= C * H2 *  y -   - P* a*H* y - - 
 L 3 .L 2 
0
 L 3 * L2 
0
C * H2 * L P* a*H*L
= 
3 3
C * H3 C * H2 * L P* a* H*L C * H 2 * L  H * J1  P* a*H*L
 =  *  1 
3 * E * J2 3 * E * J1 3 * E * J1 3 * E * J1  L * J2  3 * E * J1
J1 * H
with  1  N  C*H*N = P*a
J2 * L
P*a
H*N
P*a
N
 N -1 
Bending moment on girder Mp = P * a - Mb = P*a* 
 N 
P*(aL) C*H P * a  N-1 
Vertical reaction support Bp =  = P  * 
L L L  N 
P * a  N-1 
Vertical reaction support Ap = B - P = * 
L  N 
1.2. Bending moment on girder and portal leg due to traveling load ( cantilever on flexible leg )
P x
Mp Mb1  MA = -B*L + C*H + P*a = 0
a J1 P*a C*H
A B = 
L L
J2
H
C
B
L

C
x -C*x -x
C*H* y P*a* y
y -C*H + B*y = -C*H + 
L L
 H* y  y H* y
C *  -H   + P*a* -H +
 L  L L
H H
2 C*H3
E * J2 * x =  - C * x * ( - x ) * dx =  C * x * dx =
0 0 3
L  H.y  y  H.y 
E * J1 * y =   C . - H    P* a*  * .  -H   . dy
0  L  L   L 
L  2 2 2   2 
=   C*  H2 - 2 * H * y  H * y  - P * a * .  - H * y  H * y   * dy
 L2   L 2  
0  
L

L

L L
 y2 y3   y2 y3 
= C * H2 *  y -   - P* a*H* - - 
 L 3 .L 2 
0
 2 * L 3 * L 2 
0
C * H2 * L P* a* H* L
= 
3 6
C * H3 C * H2 * L P* a*H*L C * H 2 * L  H * J1  P* a*H*L
 =  *  1 
3 * E * J2 3 * E * J1 6 * E * J1 3 * E * J1  L * J2  6 * E * J1
J1 * H P*a
with  1  N  C*H*N =
J2 * L 2
P*a
2*H*N
P*a
2*N
Bending moment on girder Mp = = P*a

P*a C*H P * a  2 * N-1 
Vertical reaction support Bp =  = * 
L L L  2*N 
P * a  2 * N-1 
Vertical reaction support Ap = B + P = P + * 
L  2*N 
IDEA IDEA WORK STANDARD Page : 1
Industrial Designer & SUMMARY PORTAL CRANE R1
1 . GENERAL SYSTEM
L = crane span
J1 H = portal height
A J1 = moment of inertia of girder
J2 = average moment of inertia of leg
J2 A = vertical reaction force on upper saddle
H
B = vertical reaction force on lower saddle
C = horizontal reaction force on lower saddle
C Mp = maximum bending moment due to traveling load
Mq = maximum bending moment due to own weight
L B Mb = maximum bending moment on leg
dp = deflection of girder due to traveling load
dg = deflection of girder due to own weight
J1 * H
N = geometrical factor =  1
J2 * L
1.1. Under traveling load
Mb
Mp J1
A
b a
H
J2
C
Notes : For quick calculation purpose, we may set the load
L B in the middle of the girder and take correction factor ~ 1,2
to the load P. The equation becomes : P" =  * P
P* a* b* (L  b) 3 * P" * L
C = C =
2 * L2 * H * N 16 * H * N
P* a* b* (L  b) 3 * P" * L
Mb = Mb =
2 * L2 * N 16 * N
P*a*b b * Mb P" * L 3 * P" * L

Mp = - Mp = -
L L 4 32 * N
P*a Mb P" 3 * P"
A = - A = -
L L 2 16 * N
P*b Mb P" 3 * P"
B =  B = 
L L 2 16 * N
P * L3 3 * P * L3
p = -
48 * E * J1 256 * N * E * J1
IDEA IDEA WORK STANDARD Page : 2
Industrial Designer & SUMMARY PORTAL CRANE R1
1.2. Under girder own weight
q * L2
C =
8* H*N
q Mb
q * L2
Mq J1 Mb =
8*N
A
2
b a
q * L2  1 
H
J2 Mq = * 1 - 
8  4*N 
q*L q*L
C A = -
2 8*N
L B q*L q*L
B = 
2 8*N
q * L4  3 
q = * 5 - 
384 * E * J1  N
1.3. Under cantilever load on fixed leg

P*a
C =
P H*N
P*a
Mp Mb =
N
J1 Mb1 a  N -1 
A Mp = P*a* 
 N 
J2
H
P * a  N-1 
A = * 
L  N 
C P * a  N-1 
B = P  * 
L B L  N 
1.4 Under cantilever load on flexible leg

P*a
P C =
2*H*N
Mp Mb1 P*a
Mb =
a J1 2*N
A
Mp = P*a
J2
H
P * a  2 * N-1 
A = P + * 
L  2*N 
C
P * a  2 * N-1 
B = * 
B L  2*N 
L
1. GENERAL SYSTEM
1.1. Bending moment on girder and portal leg due to traveling load
 E . Jk C 
k 1  0 
P
z y
Mb Mb  MA = -B*L + P*b = 0
Mp J1 P*b
u B =
L
b a
H
 MB = -P*a + A*L = 0
J2 J2
x
P*a
D C A =
L
A B
L

C
x C*x x
P*b* y
y C*H - B*y = C*H - H
L
P*b
z C*H - B*(a + z) + P*z = C*H - * a  z  + P*z
L
P P
= C*H - *(b*a  b* z - L* z) = C*H + *(-b* a  z* (L-b)
L L
P* a*(z-b)
= C*H + H
L
u C*(H-u) - B*L + P*b = C*(H-u) H-u
1 1 n  1  3 * n * ( n - 1) 
= *  
J2 n3 1  Jn 
Deflections :
H H
2 C*H3
E * J2 * x =  C * x * x * dx =  C * x * dx =
0 0 3
a P*B* y  a P*B*H* y 
E * J1 * y = = 2
  C*H -  * H * dy   C*H -  * dy
0  L  0  L 
a
 P*b*H*y2  P * b * H * a2
=  C * H2 * y -  = C * H2 * a -
 2*L  2*L
0
b P*a*(z-b) b P* a*H* z P* a*b*H

E * J1 * z 2
=   C*H   * H * dz =   C*H    * dz
0 L  0 L L 
b
 P * a * H * z2 P * a * b * H * z 
 2
 C * H * z  

=
 2*L L  0
P * a * H * b2 P * a * H * b2 P * a * H * b2
= C * H2 * b   = C * H2 * b 
2*L L 2*L
H H
 C *  H - u  * du  C *  H  2 * H * u  u  * du
E * J2 * u = 2 = 2 2
 
0 0
H
 2 2 * H * u2 u3  C*H3
=  C* (H * u -   =
 2 3  3
0
Deflection of C = C = x + y + z + u = 0
2 * C * H3 C * H2 * ( a  b ) P * b * H * a2 P * a * H * b2 P* a* b*H* (a b)
+ = + =
3 * E * J2 E * J1 E * J1 * 2 * L E * J1 * 2 * L E * J1 * 2 * L
C * H2  2 * H 3*L  C * H 2 * L  2 * H * J1  P*a*b*H
*   = *  3 =
3 * E  J2 J1  3 * E * J1  J2 * L  E * J1 * 2
2 * J1 * H C*H*L*N P*a*b
with  3  N  
J2 * L 3 2
3*P* a* b
Hence, C =
2*L *H*N
3*P* a* b
2*L *H*N
3*P* a* b
2*L*N
P*a*b
Bending moment on girder Mp ( b ) = A . b - Mb = - Mb
L
P*a
Vertical reaction support Ap =
L
P*b
Vertical reaction support Bp =
L
C   a * ( l - a ) L
The maximum moment occur at  0   0  l - 2*a = 0  a 
a a 2
L L
3*P* *
3*P* a* b 2 2 3*P*L
C =  C = =
2*L *H*N 2*L*H*N 8*H*N
3*P*L
Side force on support point C = D =
8*H*N
3*P*L
Bending moment on portal leg Mb = C*H =
8*N
P
Vertical reaction support Ap = Bp =
2
L P*L 3*P*L
Bending moment on girder Mp = Ap * - Mb = -
2 4 8*N
1.2. Bending moment on girder and portal leg due to girder own weight
y
q*L2
 Ma = -B*L + = 0
Mb q Mb 2
q*L
Mq J1 B =
z 2
L/2 L/2
H
J2 J2
x
D C
A B
L

C
x C*x x
q* y2 q*L* y q * y2
y C*H - B*y + = C*H - 
2 2 2
q 
= C * H - *  L * y - y 2  H
2  
q * L2
z C*(H-z) - B*L + = C*(H-z) H-z
2
H H
2 C * H3
E * J2 * x =  C * x * x * dx =  C * x * dx =
0 0 3
L
L   L * y2 y3  
q 2   C * H2 * y - q * H * 
E * J1 * y =   C * H - *  L * y - y   * H * dy = - . 
0 2    2  2 3  
   0
1
= C * H2 * L - * q * H * L3
12
H
H  z3  C * H3
 C *  H - z  * dx
E * J2 * z = 2 = C *  H2 * z - H * z 2 - . =
0  3  3
0
2 * C * H3 C * H2 * L q * H * L3 C * H2 * L  2 * H * J1  q * H * L3
 - = 0  *  3 -  0
3 * E * J2 E * J1 12 * E * J1 3 * E * J1  L * J2  12 * E * J1
 2 * H * J1  q * L2
with   3 = N  C =
 L * J2  4*H*N
q * L2
4*H*N
q * L2
Bending moment on portal leg Mb = C*H =
4*N
q*L
Vertical reaction support A = B =
2
q 
Bending moment on girder Mq = - C*H  *  L * y - y 2  at y = L / 2
2  
q * L2 q*L 2
= -
8 4*N
1.3. Deflection of girder due to traveling load
P 1
Mb Mb Mb1 Mb1
Mp J1 Mp1 J1
L/2 L/2 L/2 L/2
H
J2 J2 J2 J2
D C D C
A B A B
L L
P*L 3*P*L 3*P*L

Real moment of girder due to load P = Mp = - Mb =
4 8*N 8*N
L 3*L -3*L
4 8*N 8*N
H H  -3*P*L   -3*L  3 * P * L2 * H
E * J2 * x = * Mb * Mb1 = * *  =
3 3  8*N   8*N  64 * N2
1 L  Mb * Mp1 Mp * Mb1 
E * J1 * y = * *  Mb * Mb1    Mp * Mp1 
3 2  2 2 
 - 3 * P * L   - 3 * L  1  - 3 * P * L   L 3 * L  1  P*L 3*P*L   -3*L  
 *   * * -   * - *  
L  8 * N   8 * N  2  8 * N   4 8 * N  2  4 8*N   8*N  
= * 
6  2
 L 3*L  
  P* -  
  4 8 * N  
9*P*L 3 3*P*L 3 P*L 3
= - 
128 * N 2 64 * N 96
Due to symmetry of structure, total deflection  = 2 * ( x + y )
 3 * P * L2 * H 9 * P * L3 3 * P * L3 P * L3
 = 2*   -  
 E * J2 * 64 * N2 E * J1 * 128 * N2 E * J1 * 64 * N 
96 * E * J1
 
 3
3 * P * L * H  2 * H * J1  3*P*L 3 P*L 3  2 * H * J1
= 2*  *  3 -   with  3  N
 E * J1 * 128 * N 2  L * J2  E * J1 * 64 * N 96 * E * J1  L * J2
 
P * L3 3 * P * L3
 = -
48 * E * J1 64 * E * J1 * N
1.4. Deflection of girder due to girder own weight

1.4.1. Deflection due to unit load q ( 1.st part )
1
x y x
q Mb1 Mb1
Mq1 J1 Mp1 J1
z
L/2 L/2 H L/2 L/2
H
J2 J2 J2 J2
u u
D C D C
A B
L L
q * L2
Real moment of girder due to load P = Mq1 = Mb = 0
8
L 3*L 3*L
4 8*N 8*N
E * J2 * x = 0
L Mq1 * ( 5 * Mp1  3 * Mb1 ) L q * L 2  5 * L 15 * L 9 * L 

E * J1 * y = * = * * - - 
2 12 24 8  4 8*N 8*N 
4
q*L  5 24 
= . - 
192  4 8*N 
2 * q * L4  5 24 
g1 = 0 + . -  =
192 * E * J1  4 8*N 
q * L4  12 
g 1 = * 5 - 
384 * E * J1  N 
1.4.2. Deflection due to unit load q ( 2.nd part )
Mb Mq2 Mb Mb1 Mb1

J1 Mp1 J1
L/2 L/2 L/2 L/2
H
J2 J2 J2 J2
D C D C
A B A B
L L
 q * L2  q * L2
Real moment of girder due to load q Mq2 = ; Mb =
4*N 4*N
L 3*L 3*L
Virtual moment of girder due to load 1 Mp1 = - ; Mb1 =
4 8*N 8*N
H H  - q * L 2   -3*L 
. q * L3 * H
E * J2 * x = * Mb * M1b = *  =
3 3  4*N   8*N  32 * N2
 
L 1 L  - q * L 2   L 3*L -3*L 
E * J1 * y = * * Mq2 *  Mp1  Mb1  = * *  -  
2 2 4  4*N   4 8*N 8*N 
 
 q * L4 3 * q * L4
= 
64 * N 64 * N2
 q * L3 * H q * L4 3 * q * L4 
d = 2* -  
 E * J2 * 32 * N2 E * J1 * 64 * N E * J1 * 64 * N2 
 
q * L4  2 * H * J1  q * L4
= *   3   = 0
E * J1 * 64 * N2  L * J2  E * J1 * 64 * N
Total deflection due to dead weight of girder
q * L4  12 
g = g1 + g2 = * 5 - 
384 * E * J1  N 
1. GENERAL SYSTEM
1.1. Bending moment on girder and portal leg due to traveling load on cantilever
 E . Jk C 
k 1  0 
Mp
y P
Mb  MA = -B*L + P*(a+L) = 0
J1 Mb
z a P*(aL)
B =
L
H
J2 J2  MB = P*a - A*L = 0
x
P*a
D C A =
L
A B
L

C
x -C*x -x
P*(aL)* y
y -C*H - B*y + P(a+y) = -C*H -  P*(ay) =
L
P* a*(Ly )
-C*H + -H
L
z -C*(H-z) - B*L + P(a+L) = -C*(H-z) + 0 -(H-z)
1 1 n  1  3 * n * ( n - 1) 
= *  
J2 n3 1  Jn 
Deflections :
H H
2 C*H3
E * J2 * x =  - C * x * ( - x ) * dx =  C * x * dx =
0 0 3
L P* a* (L- y ) L P* a* H* (L - y )
E * J1 * y 2
=   -C*H   * ( - H ) * dy =   C*H   * dy =
0 L  0 L 
L
  y 2  
=  C * H2 * y  P * a * H 
* L* y - = C * H2 * L -
P* a* H* L
 L  2  2
  0
H H
 C *  H - z  * dz
E * J2 * z 2  2 2
=  C *  H  2 * H * z  z  * du
=
 
0 0
H

2 2 * H * z2 z 3  C*H3
=  C* (H * z -   =
 2 3  3
0
Deflection of C = C = x + y + z + u = 0
2 * C * H3 C * H2 * L P* a*H*L
+ =
3 * E * J2 E * J1 E * J1 * 2
C * H2  2 * H 3*L  C * H 2 * L  2 * H * J1  P* a*H*L
*   = *  3 =
3 * E  J2 J1  3 * E * J1  J2 * L  E * J1 * 2
2 * J1 * H C*H*N P*a 3*P* a
with  3  N    C =
J2 * L 3 2 2*N*H
3*P* a
2*N*H
3*P* a
2*N
2*N - 3
Bending moment on girder Mp ( b ) = P * a - Mb = P*a* 
 2*N 
-P* a
Vertical reaction support Ap =
L
P* (aL)
Vertical reaction support Bp =
L
1.2. Bending moment on girder and portal leg due to a pair of traveling load
b a  Ma = 0  B*L - P*(L-a) - P*a = 0

P P
z y P*L - P*a  P*a
B = = P
Mb J1 Mb L
u Mp
L/2
H
J2 J2
x
D C
A B
L

C
x C*x x
y C*H - B*y = C*H - P*y H
z C*H - B*(a+z) + P*z = C*H - P*(z+a) + P*z = C*H - P*a H
Deflections :
H H
2 C*H3
E * J2 * x =  C * x * x * dx =  C * x * dx =
0 0 3
a a
  C * H  P * y  * H * dy
E * J1 * y  2 
= =   C * H  P * H * y  * dy =
 
0 0
a
 P * H * y2  P * H * a2
=  C * H2 * y   = C * H2 * a -
 2  2
0
b b
  C * H - P * a  * H * dz   C * H - P * a * H  * dz
E * J2 * z = = 2  with b = L/2 - a
 
0 0
=  C * H2 * z - P * a * H * z 

b
 0
= C * H 2
 L 
- P*a * -a 
 2 
Deflection of C = C = 2 * ( x + y + z ) = 0 ( symmetry )
2 * C * H3 C * H2 * L P * a * H * L - P * a2 * H
+ =
3 * E * J2 E * J1 E * J1
C * H2  2 * H 3*L  C * H 2 * L  2 * H * J1  P* a*H* L - a 
*   = *  3 =
3 * E  J2 J1  3 * E * J1  J2 * L  E * J1
2 * J1 * H C*H*L *N 3*P* a*(L - a)
with  3  N   P* a*(L-a)  C =
J2 * L 3 L*H*N
3*P* a* (L - a)
L *N*H
3*P* a* (L - a)
L*N
3*P* a*(L - a)
Bending moment on girder Mp = P * a - Mb = P*a -
L*N
Vertical reaction support A = B = P
1.3. Bending moment on girder and portal leg due to a pair of traveling load on cantilever
                      Ma = 0  - B * L - P * ( a + L ) = 0
Mp
y P
P*(a  L)
Mb B =
L
J1 Mb
z a
H
J2 J2
x
D C
A B
L

C
x -C*x -x
P*(aL)* y L
y -C*H - B*y + (a+y) = -C*H - + P*(a+y )*
L L
P* a*(Ly)
= -C*H + -H
L
z -C*(H-z) - B*L + P*A+L) = C*(H - z) -(H-z)
Deflections :
H H
2 C*H3
E * J2 * x =  - C * x * ( - x ) * dx =  C * x * dx =
0 0 3
L P* a* (L- y )  a P* a*H* (L- y )

E * J1 * y 2
=   -C*H   * ( - H ) * dy =   C*H   * dy =
0 L  0 L 
L
 P * a * H  y 2  P* a*H*L
=  C * H2 * y  * L*y - = C * H2 * L -
 L  2  2
   0
H H C*H3
 C *  H - z  * dz   C * ( H - 2 * H * z  z  * dz
E * J2 * z = 2 = 2 2
=
  3
0 0
Deflection of C = C = x + y + z = 0
2 * C * H3 C * H2 * L P* a*H*L
+ = 
3 * E * J2 E * J1 2 * E * J1
C * H2  2 * H 3*L  C * H 2 * L  2 * H * J1  P* a* H*L
*   = *  3 =
3 * E  J2 J1  3 * E * J1  J2 * L  2 * E * J1
2 * J1 * H C*H*N P*a 3*P* a

with  3  N    C =
J2 * L 3 2 2*H*N
3*P* a
2*H*N
3*P* a
2*N
3*P* a
Bending moment on girder Mp = P * a - Mb = P*a -
2*N
P*(aL)
Vertical reaction support B = =
L
P*a
A = =
L
1.4. Bending moment on girder and portal leg due to transversal load
P
P Mb Mb C = D =
2
J1
P*H
Mb = C*H =
2
H
J2 J2 P*H
A = B =
L
D C
A B
L
P
2
P*H
2
P*H
Vertical reaction support B = A =
L
Industrial Designer & Portal leg Date :
1. PORTAL LEG
P
y x y x
Mbp q Mbq
Mp J1 Mq J1
A A
b a
b a
H
J2
J2
hn
hn
u u
C C
L B L B
The bending moment on portal leg is not constant over the leg height. In order to utilize the properties of material, the height of the
leg is often formed in accordance with the shape of the bending moment, so that the bending stress is almost the same in every
section.
The variable height along the leg causes variable moment of inertia too. It is necessary to calculate the equivalent moment of
inertia, assuming that the deflection of the leg with variable moment of inertia is the same as the deflection of the leg, if the leg
would have the constant moment of inertia.
The calculation is made using Castigliano theorem, where the leg is divided into n - sections. The finer is the division, the better is
the result
t4 hn t4
t2
hn
Mb
n Jn
b4
d2
b4
x(n-1)
t2
n-1
hj
Mbj j Ixj, Iyj
Jc x4
h3
3
H
x3
h2
2
Hj
H
H3
x2
h1
1
H2
t4 h0 t4
t2
H
H1
x1
C 0 J0
b4
d2
b4
h0
t2
C * H3
The deflection of leg having the equivalent moment of inertia Jc  e =
3 * E * Ic
The actual deflection of portal leg :
Range Bending moment M

C
x1 C * x1 x1
x2 C * ( x2 + H / n ) x2 + H / n
x3 C * ( x3 + 2 * H / n ) x3 + 2 * H / n
x4 C * ( x4 + 3 * H / n ) x4 + 3 * H / n
xi
xn C * ( xn + ( n - 1 ) * H / n xn + ( n - 1 ) * H / n
Total deflection
H/n
H/n  1  C * H3
E * J1 * 1 =  C * x1 * x1 * dx1 = C *  * x13  =
0  3 0 3 * n3
H/ n 2 H/n  2 
 H   2 2 * x2 * H   H   * dx2
E * J2 * 2 =  C *  x2   * dx2  C *  x2 
=

0  n  0 n n
 
H/ n
 x2 3 x2 2 * H x2 * H2  7 * C * H3
= C*     =
 3 n n2  0 3 * n3
H/ n 2 H/ n  2 
 2*H   x3 2  2 * x3 * 2 * H   2 * H   * dx2
E * J3 * 3 =  C *  x3   * dx2 = C *
   
0  n  0 n  n 
 
H/ n
 x3 3 2 * x3 2 * H x3 * 4 * H2  19 * C * H3
= C*     =

3 n n2  0 3 * n3
H/ n 2
 ( n - 1) * H 
E * Jn * n =  C *  xn   * dxn
0  n 
H/ n  2 
 2 2 * xn * ( n - 1 ) * H   ( n - 1 ) * H   * dxn
=  C *  xn  
0 n  n 
 
H/ n
 xn 3 xn 2 * ( n - 1 ) * H x3 *  n  1 2 * H2 
= C*    
 3 n n2 
0
C * H3  C * H3
= *  1  3 * ( n - 1 )  3 *  n - 1  2  = *  1  3 * n * ( n - 1 )
3 * n3   3 * n3
Total deflection  = 1 + 2 + 3 + .......... + n =
C * H3  1 7 19 1  3 * n * ( n - 1)  C * H3 n  1  3 * n * ( n - 1) 
= *    .....   = *  
3 * E * n3  J1 J2 J3 Jn  3 * E * n3 1  Jn 
C * H3 C * H3 n  1  3 * n * ( n - 1) 
With e =   = *   
3 * E * Ic 3 * E * n3 1  Jn 
1 1 n  1  3 * n * ( n - 1) 
Equivalent moment of inertia :  *  
Jc n3 1  Jn 
1.1. PRACTICAL USE

Height of leg H = mm
Division of leg n = -
H
Increment H = mm
n
hn - h0
Increment angle tan  = -
H
Height at section j Hj = j * H mm
Height of web at j hj = h0 + Hj * tan  mm
 b4 * t4 3 t2 * hj 3
2
 hj  t4  
Moment of inertia Ixj = 2*   b4 * t4 *    mm4
 12 12  2 
 
 t4 * b4 3 hj * t2 3
2 
 d2  t2 
Moment of inertia Iyj = 2*   hj * t2 *  
 mm4
 12 12  2  
 
Ixj
Modulus of section Wx1j = ( at structure ) mm3
0.5 * hj  t4
Iyi
Wy1j = mm3
0.5 * b4
Ixj
Modulus of section Wx2j = ( at weld ) mm3
0.5 * hj
Iyj
Wy2j = mm3
0.5 * d2  t2
Sectional area Asj = 2 * ( b4 * t4 + t2 * hj ) mm2
Mbx * Hj
Bending moment at j Mbxj = Nmm
H
Mby * Hj
Mbyj = Nmm
H
Vertical force Vl = Vp +Vg / 2 N
Mbxj Mbyj  * Vl
Stress x1j =   N / mm2
Wx1j Wy1j Asj
Mbxj Mbyj  * Vl
x2j =   N / mm2
Wx 2 j Wy2j Asj
1.1.1. EQUIVALENT MOMENT OF INERTIA
n Hj hj Ixj Iyj sx sy
1 1
1 H1H h1 = h0 + H1 * tan  Ix1 Iy1 sx1 = sy1 =
Ix1 Iy1
7 7
2 H2 = 2 * H h2 = h0 + H2 * tan  Ix2 Iy2 sx2 = sy2 =
Ix 2 Iy 2
19 19
Ix 3 Iy 3
37 37
Ix 4 Iy 4
… … … … … … …
1  3 * n * ( n - 1) 1  3 * n * ( n - 1)
n Hn = n * H hn = h0 + H * tan  Ixn Iyn sxn = syn =
Ixn Iyn
n n
Sx =  sxn Sy =  syn
1 1
1 Sx n3
  Equivalent moment of inertia Ixc =
Ixc n3 Sx
1 Sy n3
  Equivalent moment of inertia Iyc =
Iyc n3 Sy
1.1.2. STRESS ON LEG
 
n Hj hj Ixj Iyj Wx1j Wx2j Wy1j Wy2j Mbxj Mbyj x1j x2j
structure weld structure weld
Mbx * H1 Mby * H1 Mbx1 Mby1  * Vl Mbx1 Mby1  * Vl
1 H1H h1 = h0 + H1 * tan  Ix1 Iy1 Wx11 Wx21 Wy11 Wy21 Mbx1 = Mby1 = x11 =   x21 =  
H H Wx11 Wy11 As1 Wx 21 Wy21 As1

2 H2 = 2 * H h2 = h0 + H2 * tan  Ix2 Iy2 Wx12 Wx22 Wy12 Wy22 Mbx2 = Mby2 = x12 =   x22 =  

Mbx * H4 Mby * H4 Mbx 4 Mby4  * Vl Mbx 4 Mby4  * Vl

… … … … … … … … … … … … …
Mbxn Mbyn  * Vl Mbxn Mbyn  * Vl

n Hn = n * H hn = h0 + H * tan  Ixn Iyn Wx1n Wx2n Wy1n Wy2n Mbxn = Mbx Mbyn = Mby x1n =   x2n =  
Wx1n Wy1n Asn Wx 2n Wy2n Asn
Industrial Designer & SINGLE GIRDER GANTRY CRANE
Date :
R1 = one fixed leg + one flexible leg R39 = both fixed leg
1. GENERAL DATA
Safe Working load SWL = = kg = N
Weight of crab Gc = = kg = N
Number of crab wheel nwc = = -
Width of crab wheel bwc = = -
Lifting speed vh = = m / min = m/s
Traveling speed vc = = m / min = m/s
Crane span L = = m = mm
Height of leg H = = m = mm
Wind scale = at outdoor operation = Beaufort scale
Wind speed vw = = km / h = m/s
Wind pressure pw = 0.638 * vw 2 = N / m2
1.1. CLASS OF UTILISATION

Working cycle / day c = = c/h
Working days / year d = = d/y
Service life sl = = years
Total working cycle Nc = c * d * sl = cycles
Class of utilisation Ui = f ( Nc ) = -
1.2. LOAD SPECTRUM

Girder capacity P = SWL + Gc = kg = N
Lifted load 100% SWL + Gc 75% SWL + Gc 50% SWL + Gc 25%SWL + Gc
m1 = m2 = m3 = m4 = N
Number of cycle n1 = n2 = n3 = n4 = cycle
3 3 3 3
m1  n1  m2  n2  m3  n3  m4  n4 
Spectrum factor kp = 3 *   *   *   *  = -
P  Nc  P  Nc  P  Nc  P  Nc 
Crane group Ai = f ( Ui , kp ) = -
Duty factor K = f ( Ai ) = -
0.6 * vh
Impact factor  = 1 , minimum  = 1.1 = -
60
Date :
1.3. PROPERTIES OF GIRDER MATERIAL

Material = -
Yield strength s = = N / mm2
s
Basic allowable stress a = = N / mm2
1.5
Modulus of elasticity E = = N / mm2
1.3.1. GENERAL ALLOWABLE STRESS

Material Weldment
Welding test procedure - RT / UT / MPT / DPT -
Stress correction factor w = - w = f ( test ) = -
Tensile bending stress ba = baa = baw = w * a = N / mm2
Compression stress ca = ca = a = caw = w * 0.85 * a = N /mm2
Transversal stress ya = 0.85 * ba = yw = 0.85 * baw = N / mm2

a = a = aw = w * a =
Shear stress a = 3 3 N / mm2
1.3.2. FATIGUE ALLOWABLE STRESS

Damaged influence factor b = fatigue damaged lead destruction of crane = -
Critically factor w = = -
Inspection factor i = difficult inspection on installed crane = -
Stress correction factor  = b * w * i = -
For normal stress Material Weldment

Fatigue strength grade fn = fnw = f ( test ) = -
Normal stress factor Co = f ( fn ) = Cow = f ( fn ) = -
Curve inclination factor m = m = -
Basic stress range  = m Co = w = m

Co
= N / mm2
Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 
For shear stress fs = fsw = f ( test ) = -

Factor for normal stress Do = f ( fs ) = Dow = f ( fs ) = -
Inclination factor n = n = -
Basic stress range  = n Do = w = n

Do
= N / mm2
Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 
Date :
2. CRANE GIRDER + FIXED LEG

2.1. GIRDER TYPE.
b4
t4
4
t4
b4 4 3
t2 d3 t2
3
h5
h3
t2 t2
y
d2
t5
h2
b4
2 ys
9 t2 d2 t2 2
t4
h2
i 1 9
s
t1
b1 1
i
t1 s
Type 1
b1
Type 2
thickness width height distance

Bottom plate t1 = b1 = - - mm
Web plate t2 = - h2 = d2 = mm
Middle plate ( option 2 ) t4 = b4 = - - mm
Upper web ( option 2 ) t2 = - h3 = d3 = mm
Top plate t4 = b4 = - - mm
Top wing ( option 1 ) t5 = h5 = - b4 = mm
Weight of girder Gg = = kg = N
2.1.1. PROPERTIES
Moment of inertia Ixg = = mm4
Moment of inertia Iyg = = mm4
Ratio k = Iyg / Ixg = > 0.12
Point 1 Point 2 Point 3 Point4 Point 9

Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = Wx9 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = Wy9 = mm3
Moment of area Sx1 = - - Sx4 = - mm3
Flange factor cx1 = cx2 = - - cx9 = -
Flange factor cy1 = cy2 = - - cy9 = -
Date :
2.2. FIXED LEG ( BOX TYPE )
t4 hn t4
t2
hn
Mb
n Jn
b4
d2
b4
x(n-1)
t2
n-1 GIRDER SIDE
hj
Mbj j Ixj, Iyj
Jc x4
h3
3
H
x3
h2
2
Hj
H
H3
x2
h1
1
H2
t4 h0 t4
t2
H
H1
x1
C 0 J0
b4
d2
b4
h0
t2
Web plate on girder side t2 = - h2 = d2 = mm
Web plate on saddle side t2 = - h3 = d2 = mm
Weight of leg Gl = = kg = N
2.2.1. PROPERTIES
Girder side Saddle side
Point 1 = 4 Point 2 = 3 Point 1 = 4 Point 2 = 3
Moment of inertia Ix1 = Ix2 = mm4
Iy1 = Iy2 = mm4
Modulus of section Wx1,4 = Wx2,3 = Wx1,4 = Wx2,3 = mm3
Modulus of section Wy1,4 = Wy2,3 = Wy1,4 = Wy2,3 = mm3
Moment of area Sx1,4 = - - Sx1,4 = mm3
Polar modulus of section Wt1 = Wt2 = mm3
Sectional area As1 = As2 = mm2
Iy1 Iy 2
Radius of gyration iy1 = iy2 = mm
As1 As1
H H
Slenderness ratio 1 = 2 = -
iy1 iy 2
Compression factor   -
Date :
H
Increment H = mm
n
hn - h0
H
 b4 * t4 3 t2 * hj 3
2
 hj  t4  
 12 12  2 
 
 t4 * b4 3 hj * t2 3
2 
 d2  t2 
 mm4
 12 12  2  
 

1 1
Ix1 Iy1
7 7
Ix 2 Iy 2
19 19
Ix 3 Iy 3
37 37
Ix 4 Iy 4
… … … … … … …
1  3 * n * ( n - 1) 1  3 * n * ( n - 1)
n Ixn Iyn sxn = syn =
Hn = n * H hn = h0 + H * tan  Ixn Iyn
n3 n3
Equivalent moment of inertia : Ixc = ; Iyc =
n n
 sxn  syn
1 1
2.3. DEFLECTION OF GIRDER
Gg * L 3  3 
Deflection due to DWT dg = * 5   = mm
384 * E * Ix  Nx 
P * L3  1 3 
Deflection due to SWL dp = *   = mm
16 * E * Ix  3 16 * Nx 
Allowable deflection dp,all = L / 900 = mm
5
Frequency of girder fg = > 3.5 Hz = Hz
( 0.78 * dg  dp ) / 10
Date :
2.4. LOAD OF GIRDER
A B Vg / 2 Vg / 2 Vg / 2 +
+ Vp + Vp Vp
Mb Mb
H H H
Gg Gg
P K * Gp P K * Gp
H1
H1
R1 Vs R39 Vs
H1
H1
L es es L es
Rmax Rmax Rmax Rmax Rmax Rmax
View A View B
Vertical static load Vg = K * Gg = N

Vertical dynamic load Vp = K**P = N
Vp
Crab wheel load Rc = = N
nwc
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N
2.2 * ( h2  h3 ) * L * pw * K
Wind load Hw = + 0.5 * SWL * pw * K = N
1 000 000
Total horizontal load Vh = Hg + Hp + Hw = N
Ixg * H
Geometrical factor k1 = = -
Ixc * L
Date :
Frame type R1 = one fixed leg + flexible leg R39 = both legs are fixed
Geometrical factor Nx = k1 + 1 Nx = 2 * k1 + 3
Vg * L  1  Vg * L  1 1 
Mq = * 1 -  Mb = * - 
Bending moment due to DWT 8  2 * Nx  4  2 Nx 
 * Vp * L  3  Vp * L  3 
Bending moment due to SWL Mp = * 1 -  Mp = * 1 - 
4  8 * Nx  4  2 * Nx 
Total moment Mx = Mq + Mp Mx = Mq + Mp
My =
 Hg  Hw  * L 
Hp * L
My =
 Hg  Hw  * L 
Hp * L
Horizontal moment
8 4 8 4
Date :
2.4.1. STRESS ON GIRDER

Point 1 Point 2 Point3 Point 4 Point 9
Mxg Mxg Mxg Mxg Mxg
Minimum longitudinal stress xmin = = = = = = N / mm2
Wx1 Wx 2 Wx 3 Wx 4 Wx 9
Mx My cx1 * Rw Mx My cx2 * Rw Mx My Mx My Mx My cx9 * Rw
Maximum longitudinal stress x =         N / mm2
Wx1 Wy1 t12 Wx 2 Wy2 t12 Wx 3 Wy3 Wx 4 Wy4 Wx 9 Wy9 t12
Allowable general stress x,all = ba > x1 baw > x2 caw > x3 ca > x4 ba > x9 N / mm2
x min x min x min x min x min

Stress ratio kx = x1 x2 x3 x 4 x9 -
1.3 * ( 1 - kx ) 1.3 * ( 1 - kx )
Stress ratio factor cr = - - 1.6 - kx 1.6 - kx - -
Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) cr3 * w1 > ( x3 - x3min ) cr4 * 1 > ( x4 - x4min ) 1 > ( x9 - x9min ) N / mm2
cy1 * Rw cy2 * Rw cy9 * Rw

Maximum transversal stress y = - - N / mm2
t12 t12 t12
Allowable general stress x,all = ya > y1 yaw > y2 - - ya > y9 N / mm2
Allowable fatigue stress fx,all = 1 > y1 w1 > y2 - - 1 > y9 N / mm2
Vp * Sx1 Vp * Sx4
Maximum shear stress  = - 2 * Ix * t2 2 * Ix * t2 - - N / mm2
Allowable general stress ,all = - aw > 2 aw > 3 - - N / mm2
Allowable fatigue stress f,all = - w2 > 3 w3 > 3 - - N / mm2
2 2 2 2
Combined stress c = x1 x 2  y - x * y  3 *  x12  3 *  x4 x12  y - x * y N / mm2
Allowable general stress c,all = ba > c1 baw > c2 caw > c3 ca > c4 ba > c9 N / mm2
Allowable fatigue stress fc,all = 1 > c1 w1 > c2 cr3 * w1 > c3 cr4 * 1 > c4 1 > c9 N / mm2
Date :
2.5. BUCKLING STRESS

2.5.1. UNSTIFFENED WEB PLATE UNDER COMPRESSION STRESS
Length of panel a = mm
 c
Height of panel H = mm
H = Height of web
diaphragm
Thickness of panel t2 = mm
diaphragm
Neutral axis
a
Dimension ratio  = > 1
H
Compression stress c = N / mm2
t
a
Tensile stress t = N / mm2
Web plate
Shear stress  = N / mm2
2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * H2
 
t
Stress ratio  = - -
c
Normal stress factor ks = ( 1 +  ) * 7.636 -  * 23.9 + 10 *  * ( 1 +  ) -
4
Shear stress factor kt = 5.34 + -
2
Ideal buckling stress ki = ks * E N / mm2
Ideal buckling stress ki = kt * E N / mm2
c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 
If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
 if vki < s  vk = vki
 s 
 if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
 if vki > 2.04 * s  vk = s
vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
Date :
2.5.2. WEB PLATE WITH STIFFENER AT NEUTRAL AXIS

 c
Height of panel b = mm
diaphragm
diaphragm
H = Height of web
b
Stiffener a
Neutral axis b
Tensile stress t = 0 N / mm2
t
a Shear stress  = N / mm2
t
Stress ratio  = - = 0 -
c
2.5.2.1. Dimension of stiffener
Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
h
As
web
x Auxiliary factor  = -
b* t
t
2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
Required moment of inertia Jr = 2*b* t 3 ( BS 2573 ) mm4
Condition Ja > Jr
If Ja cannot be bigger than Jr due to any restriction, then the buckling of the compression side must be checked :
2 * E * t2 2
12 *  1 -  2  * b 2
 
8.4
Normal stress factor ks = -
1.1  
4
2
c 2  3 *  2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 

 s 
 if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
 if vki > 2.04 * s  vk = s
vk
c 2  3 * 2
Date :
2.5.3. WEB PLATE WITH ONE STIFFENER AT HALF DISTANCE OF FLANGE TO NEUTRAL AXIS
 c Length of panel a = mm
diaphragm
H = Height of web
diaphragm
Stiffener
b
b/2
Stiffener a
Neutral axis b
t Tensile stress t = 0 N / mm2

a
t
c
h
h1
h
As
web
x Ratio of area  = -
b * t2
t
Auxiliary factor  = 1 + 2* -
2 2
t * h3  h ( h - t ) * t3  t 
12  2 12  2 
  2 * 16 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =  0.53  0.47 *   *   if < 8*  - 1
 2 
  8 *  - 1  2   
" =  0.53  0.47 *   *   if > 8*  - 1
 2 
" * b * t 3
Required moment of inertia Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr
In case Ja cannot be bigger than Jr due to any restriction, then the buckling of the compression side must be checked :
2 * E * t2 2
12 *  1 -  2  * b 2
 
Ja * 12 *  1 -  2 
Actual auxiliary factor  =   -
b * t2 3
2
 1   2   2 * 
2
Normal stress factor ks = *   if  < 4 1 2 * 
0.95 *    1.1   * 1  2*  
2
4 1  1 2 * 
ks = * if  > 4 1 2 * 
0.95 *    1.1  1  2*  
Date :
2 2 2
Auxiliary factors n =  1  2  ; p =  1  9 * 2  ; q =  9  2 
     
10.24 * n  3.16 * p  4.05 *  10.24 * n  0.41 * q  13.11 * 
x = 
n* p  2*  * n  2*  * p n * q  2 *  * q  162 *  * n
Shear stress factor kt =


4.93 * 1   2  -
3 * x

c 2  3 *  2
2 2
  1     c     3 -    c     
  4  *  ki      4  *  ki     ki 
         
 s 
 if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
 if vki > 2.04 * s  vk = s
vk
c 2  3 * 2
Date :
3. PORTAL LEG
3.1. PROPERTIES AND LOAD OF FIXED LEG
V Mean moment of inertia Ixc = = mm4

Mx1 H Mean moment of inertia Iyc = = mm4
My1 Vg
Vertical static load Vgl = = N
2
Vertical dynamic load Vpl = Vp = N
Hg  Hwg
Horizontal static load Hg l = = N
2
Horizontal dynamic load Hp l = Hp = N
2.2 * ( h2  h3 ) * H * pw
Wind load Hwl = = N
Mx2 1 000 000
My2
 b4 * t4 3 t2 * hj 3
2
 hj  t4  
Moment of inertia Ixj = 2*   b4 * t4 *    = mm4
 12 12  2 
 
 t4 * b4 3 hj * t2 3
2 
 d2  t2 
 = mm4
 12 12  2  
 
Ixj
Modulus of section Wx1j = ( at structure ) = mm3
0.5 * hj  t4
Iyi
Wy1j = = mm3
0.5 * b4
Polar modulus of section Wtj = ( hj + t4 ) * ( d2 + t2 ) * 2 * t2
Sectional area Asj = 2 * ( b4 * t4 + t2 * hj ) = mm2
Mbx * Hj
Bending moment at j Mbxj = = Nmm
H
Mby * Hj
Mbyj = = Nmm
H
( Hg  Hw ) * L Hp * L
Torsion moment Mt =  = Nmm
12 8
Vertical force Vl = Vp +Vg / 2 = N
Mbxj Mbyj  * Vl
Longitudinal stress x1j =   = N / mm2
Wx1j Wy1j Asj
Mt
Torsion stress tj = = N / mm2
Wtj
Combined stress scj = x1j 2  3 * j 2 < c,all = N /mm2
Check also the stress on weld joints

Industrial Designer & SINGLE GIRDER GANTRY CRANE Date :
3.1.1. BENDING MOMENT ON LEG
Frame type R1 R39

Ixg * H 2 * Ixg * H
Geometrical factor Nx = 1  3
Ixc * L Ixc * L
Bending moment Girder side Saddle side Girder side Saddle side
Vg * L H1 Vg * L Vg * L H1 Vg * L
Due to DWT Mxg = * * Nmm
8 * Nx H 8 * Nx 4 * Nx H 4 * Nx
3 * Vp * L H1 3 * Vp * L 3 * Vp * L H1 3 * Vp * L
Due to SWL Mxp = * * Nmm
16 * Nx H 16 * Nx 8 * Nx H 8 * Nx
Total bending moment Mbx = Mxg + Mxp Mxg + Mxp Mxg + Mxp Mxg + Mxp Nmm
Due to DWT Mygl = 0 Hgl * H 0 Hgl * H Nmm

Due to SWL Mypl = 0 Hpl * H 0 Hpl * H Nmm
Due to wind force Myhl = 0 Hwl * ( 2/3 )* H 0 Hwl * ( 2/3 )* H Nmm
Total bending moment Mby = Mygl + Mypl + Myhl Mygl + Mypl + Myhl Mygl + Mypl + Myhl Mygl + Mypl + Myhl Nmm
( Hg  Hw ) * L Hp * L ( Hg  Hw ) * L Hp * L
Torsion moment Mt =   Nmm
12 8 12 8
Date :
3.1.2.1. Stress on leg

  
n Hj hj Ixj Iyj Wx1j Wy1j Mbxj Mbyj xj j cj
Mbx * H1 Mby * H1 Mbx1 Mby1  * Vl Mt
1 H1H h1 = h0 + H1 * tan  Ix1 Iy1 Wx11 Wy11 Mbx1 =
H
Mby1 =
H
x1 =  
Wx11 Wy11 As1
1 =
Wt1
c1 = x1 2  3 * 1 2
2 H2 = 2 * H h2 = h0 + H2 * tan  Ix2 Iy2 Wx12 Wy12 Mbx2 =
H
Mby2 =
H
x2 = 
Wx12 Wy12

As2
2 =
Wt 2
c2 = x2 2  3 * 2 2
H
Mby3 =
H
x3 = 
Wx13 Wy13

As3
3 =
Wt 3
c3 = x3 2  3 * 3 2
Mbx * H4 Mby * H4 Mbx 4 Mby4  * Vl Mt
H
Mby4 =
H
x4 = 
Wx14 Wy14

As4
4 =
Wt 4
c4 = x4  2  3 * 4  2
… … … … … … … … … … … …
Mbxn Mbyn  * Vl Mt
n Hn = n * H hn = h0 + H * tan  Ixn Iyn Wx1n Wy1n Mbxn = Mbx Mbyn = Mby xn =  
Wx1n Wy1n Asn
n =
Wtn
cn = xn 2  3 * n 2
Date :
4. SADDLE
4.1. MIDDLE OF SADDLE
b4
t4
4 Vp + Vg / 2 + Vl
3 My
t2 d2 t2
h2
2 Rmax Rmax
es
1
t1
b1

Bottom plate tf = bf = - - mm
Web plate tw = - hw = d2 = mm
Top plate tf = bf = - - mm
Top reinforcement tr = d2 = - b4 = mm
Weight of saddle Gs = = kg = N
L
Wheel base es = = mm
6.3
4.1.1. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12
Polar modulus of section Wt = = mm3
Point 1 Point 2 Point 3 Point4

Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3
4.1.2. LOAD OF MIDDLE OF SADDLE

Vertical static load Vs = K * Gs = N
Vgs = Vg / 2 + K * Gp = N
Vertical dynamic load Vps = Vp = N
Date :
Vertical bending moment

Vs * es Vgs * es
due to DWT Mxg =  = Nmm
8 4
Vps * es
due to SWL Mxp = = Nmm
4
Total bending moment Mx = Mxg + Mxp + Myl ( from leg ) = Nmm
Hs * es ( Hp  Hg ) * es
Total horizontal moment My =  = Nmm
8 4
Torsion moment Mt = ( Vgs + Vps ) * ( d2 + tw ) / 2 = Nmm
4.1.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
Mxg Mxg
Minimum longitudinal stress xmin = = = N / mm2
Wx1 Wx 2
Mx My Mx My
Maximum longitudinal stress x =   N / mm2
Wx1 Wy1 Wx 2 Wy2
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
x min x min
Stress ratio kx = -
x1 x 2
Stress ratio factor cr = - - -
Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) N / mm2
Mt Vp * Sx1 Vps Mt
Maximum shear stress  =   N / mm2
Wt 2 * Ix * t2 2 * tw * hw Wt
Allowable general stress ,all = a > t1 aw > 2 N / mm2
Allowable fatigue stress f,all =  > t1 w2 > 3 N / mm2
2 2
Combined stress c = x 2  3 *  x 2  3 *  N / mm2
Allowable general stress c,all = ba > c1 baw > c2 N / mm2
Allowable fatigue stress fc,all = 1 > c1 w1 > c2 N / mm2
Moveable mass Mm = Gg + 2 * Gs + P = kg = N
Gg  2 * Gs P
Maximum wheel load Rmax =  = N
4 2
Date :
4.2. SADDLE CONNECTION TO WHEEL SET
bf
tf
he
3 R
t2 d2 t2
he
he
2
Rmax
bf 1 eh
tf

Web plate te = - he = d2 = mm
Wheel distance eh = = mm
4.2.1. PROPERTIES
Ratio k = Iy / Ix = > 0.12
Depth of cut t = hw - he = mm
Radius of cut R = = mm
Ratio x1 = R/t = -
Ratio x2 = R / he = -
1
Notch effect factor k = 1 = -
0.5 * X1  12 * X2 *  1  2 * X2 2
4.2.2. LOAD ON CONNECTION

Maximum wheel load Rmax = = N
Bending moment Mxe = Rmax * eh = Nmm
Horizontal moment Mye = 0.15 * Mxe = Nmm
Torsion moment Mte = Mts = Nmm
Date :
4.2.3. STRESS ON CONNECTION
 Mxe Mye   Mxe Mye 

Maximum longitudinal stress x = k *    k *    N / mm2
 Wx1 Wy1   Wx2 Wy2 
Allowable fatigue stress fx,all = 1 > x1 w1 > x2 N / mm2
 Mt Rmax   Mt Rmax 
Maximum shear stress  = k *    k *    N / mm2
 Wt 2 * te * he   Wt 2 * te * he 
Allowable general stress ,all = a > 1 aw > 2 N / mm2

Allowable fatigue stress f,all = 1 > 1 w2 > 3 N / mm2
2 2
5. FLEXIBLE LEG
5.1. LOAD OF FLEXIBLE LEG
es
Vg / 2 tan  =  cos  = -
+ Vp 2*H
Vg Hgl
Vertical static load Vgl =  = N
H 2 * 2 * cos  sin 
Vp Hp
Vertical dynamic load Vpl =  = N
2 * cos  sin 
Bending moment Mb = 0 ( no bending moment )
es
Rmax Rmax
Selected profile
Smaller moment of inertia Iyf = = mm4
Sectional area Asf = = mm2
Iyf
Radius of gyration iyf = = mm
Asf
H
Slenderness ratio yf = = -
iyf
Compression factor f = f ( yf ) = -
Date :
5.2. STRESS ON LEG

f * Vgl
Minimum stress xmin = = N / mm2
Asf
f *  Vgl  Vpl 
Maximum stress xmax = = N / mm2
Asf
Allowable general stress x,all = ba > xmax = N / mm2
x min
Stress ratio kx = = -
x1
1.3 * ( 1 - kx )
Stress ratio factor cr = = -
1.6 - kx
Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) = N / mm2
Industrial Designer & DOUBLE GIRDER GANTRY CRANE Date :
R1 = one fixed leg + one flexible leg R39 = both fixed leg
1. GENERAL DATA
Safe Working load SWL = = kg = N
Weight of crab Gc = = kg = N
Number of crab wheel nwc = = -
Width of crab wheel bwc = = -
Crab track gauge spw = = mm
Lifting speed vh = = m / min = m/s
Traveling speed vc = = m / min = m/s
Crane span L = = m = mm
Height of leg H = = m = mm
Wind scale = at outdoor operation = Beaufort scale
Wind speed vw = = km / h = m/s
Wind pressure pw = 0.638 * vw 2 = N / m2
1.1. CLASS OF UTILISATION

Working cycle / day c = = c/d
Working days / year d = = d/y
Service life sl = = years
Total working cycle Nc = c * d * sl = cycles
Class of utilisation Ui = f ( Nc ) = -
1.2. LOAD SPECTRUM

Girder capacity P = SWL + Gc = N
Lifted load 100% SWL + Gc 75% SWL + Gc 50% SWL + Gc 25%SWL + Gc
m1 = m2 = m3 = m4 = N
Number of cycle n1 = n2 = n3 = n4 = cycle
3 3 3 3
m1  n1  m2  n2  m3  n3  m4  n4 
Spectrum factor kp = 3 *   *   *   *  = -
P  Nc  P  Nc  P  Nc  P  Nc 
Crane group Ai = f ( Ui , kp ) = -
Duty factor K = f ( Ai ) = -
0.6 * vh
Impact factor  = 1 , minimum  = 1.1 = -
60
1.3. PROPERTIES OF GIRDER MATERIAL

Material = -
Yield strength s = = N / mm2
s
Basic allowable stress a = = N / mm2
1.5
Modulus of elasticity E = = N / mm2
1.3.1. GENERAL ALLOWABLE STRESS

Material Weldment
Welding test procedure - RT / UT / MPT / DPT -
Stress correction factor w = - w = f ( test ) = -
Tensile bending stress ba = baa = baw = w * a = N / mm2
Compression stress ca = ca = a = caw = w * 0.85 * a = N /mm2
Transversal stress ya = 0.85 * ba = yw = 0.85 * baw = N / mm2
a = a = a = aw = w * a = N / mm2
Shear stress 3 3
1.3.2. FATIGUE ALLOWABLE STRESS

Damaged influence factor b = fatigue damaged lead destruction of crane = -
Critically factor w = = -
Inspection factor i = difficult inspection on installed crane = -
Stress correction factor  = b * w * i = -
For normal stress Material Weldment

Fatigue strength grade fn = fnw = f ( test ) = -
Normal stress factor Co = f ( fn ) = Cow = f ( fn ) = -
Curve inclination factor m = m = -
Basic stress range  = m Co = w = m Co = N / mm2

Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 
For shear stress fs = fsw = f ( test ) = -

Factor for normal stress Do = f ( fs ) = Dow = f ( fs ) = -
Inclination factor n = n = -
Basic stress range  = n Do = w = n Do = N / mm2

Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 
2. CRANE GIRDER
2.1. GIRDER TYPE.
b4
spw
t4
tr
3
t2 d2 t2
h2
b1 1
t1

Web plate under rail t2 = - h2 = d2 = mm
Web plate opposite rail t3 = - h2 = d2 = mm
Crab rail tr = hr = - - mm
Longitudinal distance of diaphragm ld = = mm
Weight of girder Gg = = kg = N
2.1.1. PROPERTIES
Ratio k = Iy / Ix = > 0.12
Moment of inertia Ixx = = mm4
Modulus of section Wxx1 = Wxx2 = Wxx3 = Wxx4 = mm3
2.2. FIXED LEG ( BOX TYPE )
t4 hn t4
t2
hn
Mb
n Jn
b4
d2
b4
x(n-1)
t2
n-1 GIRDER SIDE
hj
Mbj j Ixj, Iyj
Jc x4
h3
3
H
x3
h2
2
Hj
H
H3
x2
h1
1
H2
t4 h0 t4
t2
H
H1
x1
C 0 J0
b4
d2
b4
h0
t2
Web plate on girder side t2 = - h2 = d2 = mm
Web plate on saddle side t2 = - h3 = d2 = mm
Weight of leg Gl = = kg = N
2.2.1. PROPERTIES
Girder side Saddle side
Point 1 = 4 Point 2 = 3 Point 1 = 4 Point 2 = 3
Moment of inertia Ix1 = Ix2 = mm4
Iy1 = Iy2 = mm4
Modulus of section Wx1,4 = Wx2,3 = Wx1,4 = Wx2,3 = mm3
Modulus of section Wy1,4 = Wy2,3 = Wy1,4 = Wy2,3 = mm3
Moment of area Sx1,4 = - - Sx1,4 = mm3
Polar modulus of section Wt1 = Wt2 = mm3
Sectional area As1 = As2 = mm2
Iy1 Iy 2
Radius of gyration iy1 = iy2 = mm
As1 As1
H H
Slenderness ratio 1 = 2 = -
iy1 iy 2
Compression factor   -
H
Increment H = mm
n
hn - h0
H
 b4 * t4 3 t2 * hj 3
2
 hj  t4  
 12 12  2 
 
 t4 * b4 3 hj * t2 3
2 
 d2  t2 
 mm4
 12 12  2  
 

1 1
Ix1 Iy1
7 7
Ix 2 Iy 2
19 19
Ix 3 Iy 3
37 37
Ix 4 Iy 4
… … … … … … …
1  3 * n * ( n - 1) 1  3 * n * ( n - 1)
n Ixn Iyn sxn = syn =
Hn = n * H hn = h0 + H * tan  Ixn Iyn
n3 n3
Equivalent moment of inertia : Ixc = ; Iyc =
n n
 sxn  syn
1 1
2.3. DEFLECTION OF GIRDER

Gg * L 3  3 
Deflection due to DWT dg = * 5 -  = mm
384 * E * Ix  Nx 
0.56 * P * L 3  1 3 
Deflection due to SWL dp = * -  = mm
16 * E * Ix  3 16 * Nx 
Allowable deflection dp,all = L / 900 = mm
5
Frequency of girder fg = > 3.5 Hz = Hz
( 0.78 * dg  dp ) / 10
2.4. LOAD OF GIRDER

Vg / 2 + Vp Vg / 2 + Vp Vg / 2 + Vp Vg / 2 + Vp
A B
S S
Mb Mb
Gg Gg
P K * Gp K * Gp P K * Gp
H1
H1
R1 Vs Vs R39 Vs
H1
H1
L es es L es
Rmax Rmax Rmax Rmax Rmax Rmax
View A View B
Vertical static load Vg = K * Gg = N

Vertical dynamic load Vp = 0.56 * K *  * P = N
2 * Vp
Crab wheel load Rc = = N
nwc
2.2 * ( h2  h3 ) * L * pw * K
Wind load Hw = + 0.5 * SWL * pw * K = N
1 000 000
Total horizontal load Vh = Hg + Hp + Hw = N
Crab acceleration / braking S = ( SWL + Gc ) * a = N
Ixg * H
Geometrical factor k1 = = -
Ixc * L
Industrial Designer & DOUBLE GIRDER GANTRY CRANE
Date :
Frame type R1 = one fixed leg + flexible leg R39 = both legs are fixed
Geometrical factor Nx = k1 + 1 Nx = 2 * k1 + 3
Vg * L  1  Vg * L  1 1 
Mq = * 1 -  Mb = * - 
Bending moment due to DWT 8  2 * Nx  4  2 Nx 
 * Vp * L  3  Vp * L  3 
Bending moment due to SWL Mp = * 1 -  Mp = * 1 - 
4  8 * Nx  4  2 * Nx 
Total moment Mx = Mq + Mp Mx = Mq + Mp
My =
 Hg  Hw  * L 
Hp * L
My =
 Hg  Hw  * L 
Hp * L
Horizontal moment
8 4 8 4
Vp * Ld Vp * Ld
Secondary bending moment Mxx = Mxx =
5 5
Vp * ( d2  t2 ) Vp * ( d2  t2 )
Torsion moment Mt = Mt =
2 2
2.4.1. STRESS OF GIRDER

Mxg Mxg
Minimum longitudinal stress xmin = = = N / mm2
Wx1 Wx 3
Mx My Mxx Mx My Mxx
Maximum longitudinal stress x =     N / mm2
Wx1 Wy1 Wxx1 Wx 3 Wy3 Wxx3
Allowable general stress x,all = ba > x1 caw > x3 N / mm2
x min x min
Stress ratio kx = -
x1 x 3
1.3 * ( 1 - kx ) 1.3 * ( 1 - kx )
Stress ratio factor cr = -
1.6 - kx 1.6 - kx
Allowable fatigue stress fx,all = cr1 > ( x1 - x1min ) cr * cr3 * w1 > ( x3 - x3min ) N / mm2
Rc
Maximum transversal stress y = -
( 2 * ( hr  t4  t2 )  50 ) * t2 N / mm2
Allowable general stress x,all = - ya > y1 N / mm2
Allowable fatigue stress fx,all = - 1 > y1 N / mm2
Mt Vp * Sx1 Mt
Maximum shear stress  =   0.2 * y N / mm2
Wt 2 * Ix * t2 Wt
2 2 2
Combined stress c = x12  3 *  x 2  y - x * y  3 *  N / mm2
Allowable general stress c,all = ba baw N / mm2
Allowable fatigue stress fc,all = 1 w1 N / mm2
Date :
2.5. BUCKLING STRESS

2.5.1. UNSTIFFENED WEB PLATE UNDER COMPRESSION STRESS
 c
Height of panel H = mm
H = Height of web
diaphragm
diaphragm
Neutral axis
a
H
t
a
Tensile stress t = N / mm2
Web plate
2 * E * t2 2
12 *  1 -  2  * H2
 
t
Stress ratio  = - -
c
Normal stress factor ks = ( 1 +  ) * 7.636 -  * 23.9 + 10 *  * ( 1 +  ) -
4
2
c 2  3 *  2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 
if vki < s  vk = vki
 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s
vk
c 2  3 * 2
Date :
2.5.2. WEB PLATE WITH STIFFENER AT NEUTRAL AXIS

 c Height of panel b = mm
diaphragm
diaphragm
H = Height of web
a
b
Stiffener b
Neutral axis Compression stress c = N / mm2
t t
a Stress ratio  = - = 0 -
c

h
h1
h
As
web
x Auxiliary factor  = -
b* t
t
2 2
t * h3  h ( h - t ) * t3  t 
12  2 12  2 
Required moment of inertia Jr = 2*b* t 3 ( BS 2573 ) mm4
Condition Ja > Jr
2 * E * t2 2
12 *  1 -  2  * b 2
 
8.4
Normal stress factor ks = -
1.1  
4
2
c 2  3 *  2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 
 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s
vk
c 2  3 * 2
Date :
2.5.3. WEB PLATE WITH ONE STIFFENER AT HALF DISTANCE OF FLANGE TO NEUTRAL AXIS
 c Length of panel a = mm
diaphragm
H = Height of web
diaphragm
Stiffener
b
a

b/2
Stiffener Dimension ratio = > 1
b
Neutral axis Compression stress c = N / mm2
t
a t
c

h
h1
As
h

t
Ratio of area = -
x b * t2
web
t Auxiliary factor  = 1 + 2* -
2 2
t * h3  h ( h - t ) * t3  t 
12  2 12  2 
  2 * 16 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =  0.53  0.47 *   *   if < 8*  - 1
 2 
 0.53  0.47 *   *   8 *  - 1    
 2 
" = if > 8*  - 1
 2 
" * b * t 3
Required moment of inertia Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr
2 * E * t2 2
12 *  1 -  2  * b 2
 
Ja * 12 *  1 -  2 
Actual auxiliary factor  =   -
b * t2 3
2
 1   2   2 * 
2
Normal stress factor ks = *   if  < 4 1 2 * 
0.95 *    1.1   * 1  2*  
2
4 1  1 2 * 
ks = * if  > 4 1 2 * 
0.95 *    1.1  1  2*  
Date :
2 2 2
Auxiliary factors n =  1  2  ; p =  1  9 * 2  ; q =  9  2 
     
10.24 * n  3.16 * p  4.05 *  10.24 * n  0.41 * q  13.11 * 
x = 
n* p  2*  * n  2*  * p n * q  2 *  * q  162 *  * n
Shear stress factor kt =


4.93 * 1   2  -
3 * x

c 2  3 *  2
2 2
  1     c     3 -    c     
  4  *  ki      4  *  ki     ki 
         
 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s
vk
c 2  3 * 2
Date :
3. PORTAL LEG
3.1. PROPERTIES AND LOAD OF FIXED LEG
V Mean moment of inertia Ixc = = mm4

Mx1 H Mean moment of inertia Iyc = = mm4
My1 Vg
Vertical static load Vgl = = N
2
Vertical dynamic load Vpl = Vp = N
Hg  Hwg
Horizontal static load Hg l = = N
2
Horizontal dynamic load Hp l = Hp = N
2.2 * ( h2  h3 ) * H * pw
Wind load Hwl = = N
Mx2 1 000 000
My2
 b4 * t4 3 t2 * hj 3
2
 hj  t4  
Moment of inertia Ixj = 2*   b4 * t4 *    = mm4
 12 12  2 
 
 t4 * b4 3 hj * t2 3
2 
 d2  t2 
 = mm4
 12 12  2  
 
Ixj
Modulus of section Wx1j = ( at structure ) = mm3
0.5 * hj  t4
Iyi
Wy1j = = mm3
0.5 * b4
Polar modulus of section Wtj = ( hj + t4 ) * ( d2 + t2 ) * 2 * t2
Sectional area Asj = 2 * ( b4 * t4 + t2 * hj ) = mm2
Mbx * Hj
Bending moment at j Mbxj = = Nmm
H
Mby * Hj
Mbyj = = Nmm
H
( Hg  Hw ) * L Hp * L
Torsion moment Mt =  = Nmm
12 8
Vertical force Vl = Vp +Vg / 2 = N
Mbxj Mbyj  * Vl
Longitudinal stress x1j =   = N / mm2
Wx1j Wy1j Asj
Mt
Torsion stress tj = = N / mm2
Wtj
Combined stress scj = x1j 2  3 * j 2 < c,all = N /mm2
Check also the stress on weld joints

3.1.1. BENDING MOMENT ON LEG
Frame type R1 R39

Ixg * H 2 * Ixg * H
Geometrical factor Nx = 1  3
Ixc * L Ixc * L
Bending moment Girder side Saddle side Girder side Saddle side
Vg * L H1 Vg * L Vg * L H1 Vg * L
Due to DWT Mxg = * * Nmm
8 * Nx H 8 * Nx 4 * Nx H 4 * Nx
3 * Vp * L H1  3 * Vp * L  3 * Vp * L H1  3 * Vp * L 
Due to SWL Mxp = *   S*H *  S * H Nmm
16 * Nx H  16 * Nx  8 * Nx H  8 * Nx 
Total bending moment Mbx = Mxg + Mxp Mxg + Mxp Mxg + Mxp Mxg + Mxp Nmm
Due to DWT Mygl = 0 Hgl * H 0 Hgl * H Nmm

Due to SWL Mypl = 0 Hpl * H 0 Hpl * H Nmm
Due to wind force Myhl = 0 Hwl * ( 2/3 )* H 0 Hwl * ( 2/3 )* H Nmm
Total bending moment Mby = Mygl + Mypl + Myhl Mygl + Mypl + Myhl Mygl + Mypl + Myhl Mygl + Mypl + Myhl Nmm
( Hg  Hw ) * L Hp * L ( Hg  Hw ) * L Hp * L
Torsion moment Mt =   Nmm
12 8 12 8
3.1.2. Stress on leg

  
n Hj hj Ixj Iyj Wx1j Wy1j Mbxj Mbyj xj j cj
1 H1H h1 = h0 + H1 * tan  Ix1 Iy1 Wx11 Wy11 Mbx1 =
H
Mby1 =
H
x1 =  
Wx11 Wy11 As1
1 =
Wt1
c1 = x1 2  3 * 1 2
H
Mby2 =
H
x2 = 
Wx12 Wy12

As2
2 =
Wt 2
c2 = x2 2  3 * 2 2
H
Mby3 =
H
x3 = 
Wx13 Wy13

As3
3 =
Wt 3
c3 = x3 2  3 * 3 2
Mbx * H4 Mby * H4 Mbx 4 Mby4  * Vl Mt
H
Mby4 =
H
x4 = 
Wx14 Wy14

As4
4 =
Wt 4
c4 = x4  2  3 * 4  2
… … … … … … … … … … … …
Mbxn Mbyn  * Vl Mt
n Hn = n * H hn = h0 + H * tan  Ixn Iyn Wx1n Wy1n Mbxn = Mbx Mbyn = Mby xn =  
Wx1n Wy1n Asn
n =
Wtn
cn = xn 2  3 * n 2
4. SADDLE
( Vp + Vg ) / 2 ( Vp + Vg ) / 2
+ Vl + Vl
t4
b4
4
3
t2 d2 t2
h2
spw + d2 + t2
2
Rmax Rmax
b1 1 es
t1

Web plate tw = - hw = d2 = mm
Top reinforcement tr = d2 = - b4 = mm
Weight of saddle Gs = = kg = N
Girder distance eg = spw + d2 + t2 = mm
L
Wheel base es = max ( spw + 2 * d2 + 1000, ) = mm
6.3
4.1. PROPERTIES
Ratio k = Iy / Ix = > 0.12

4.2. LOAD OF MIDDLE OF SADDLE

Vertical static load Vs = K * Gs = N
Vgs = Vg / 2 + K * Gl = N
Vertical dynamic load Vps = Vp = N
Vertical bending moment

Vs * es Vgs * es
due to DWT Mxg =  = Nmm
8 4
Vps * ( es - eg )
due to SWL Mxp = = Nmm
2
Total bending moment Mx = Mxg + Mxp = Nmm
Total horizontal moment My =  * Mx = Nmm
Torsion moment Mts = ( Vgs + Vps ) * ( d2 + tw ) / 2 = Nmm
4.3. STRESS OF SADDLE

Mxg Mxg
Minimum longitudinal stress xmin = = N / mm2
Wx1 Wx 2
Mx My Mx My
Maximum longitudinal stress x =   N / mm2
Wx1 Wy1 Wx 2 Wy2
x min x min
Stress ratio kx = x1 x 2 -
Stress ratio factor cr = - - -

Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) N / mm2
Vps * Sx1 Vps

Maximum shear stress  = -  N / mm2
2 * Ix * t2 2 * tw * hw
Allowable general stress ,all = - aw > 2 N / mm2
Allowable fatigue stress f,all = - w2 > 3 N / mm2
2
Combined stress c = x1 x 2  3 *  N / mm2
Allowable general stress c,all = ba baw N / mm2
Allowable fatigue stress fc,all = 1 w1 N / mm2
Moveable mass Mm = 2 * ( Gg + Gs ) + P = kg = N
2 * ( Gg  Gs ) P
Maximum wheel load Rmax =  = N
4 2
4.4. SADDLE CONNECTION TO WHEEL SET
bf
tf
he
3 R
t2 d2 t2
he
he
2
Rmax
bf 1 eh
tf

Web plate te = - he = d2 = mm
4.4.1. PROPERTIES
Ratio k = Iy / Ix = > 0.12
Depth of cut t = hw - he = mm
Radius of cut R = = mm
Ratio x1 = R/t = -
Ratio x2 = R / he = -
1
Notch effect factor k = 1 = -
0.5 * X1  12 * X2 *  1  2 * X2 2
4.4.2. LOAD ON CONNECTION

Maximum wheel load Rmax = = N
Bending moment Mxe = Rmax * eh = Nmm
Horizontal moment Mye = 0.15 * Mxe = Nmm
Torsion moment Mte = Mts = Nmm
4.4.3. STRESS ON CONNECTION

 Mxe Mye   Mxe Mye 
Maximum longitudinal stress x = k *    k *    N / mm2
 Wx1 Wy1   Wx2 Wy2 
Allowable fatigue stress fx,all = 1 > x1 w1 > x2 N / mm2
 Mt Rmax   Mt Rmax 
Maximum shear stress  = k *    k *    N / mm2
 Wt 2 * te * he   Wt 2 * te * he 

2 2

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IDEA IDEA – WORK STANDARD Page : 1

Industrial Designer & Portal crane Date :

1.1. DESIGN NOTES

2. FROM OVERHEAD CRANE TO PORTAL CRANE

An overhead traveling crane has relative small displacement ( x )

The girder can be raised or lowered to suit the requirement of

After purposely inserting the legs, overhead traveling crane

The portal crane is statically indefinite system.

By inserting a pivot joint on one leg, the system becomes statically

2.1. Typical application for portal cranes is : CONTAINER HANDLING CRANE

Effective working days ty = 300 days / years

Starting point = A Destination point B

Lowering empty spreader at A

Spreader carrying full container = 40 tones ca. 50 % of total lifts.

Component Hoist Crab End-truck Girder

Section Moment Mi Mi

z C*H - B*(a + z) + P*z

Load P" = = *P

Section Moment Mi Mi

q * b2 q* b*(L -b) q*L*b

Mb q*L q*L L L

1.3. Deflection of girder due to traveling load

 - 3 * P * L    3 * L  1  - 3 * P * L   L 3*L  1  P*L 3*P*L   -3*L  

1.4. Deflection of girder due to girder own weight

1.4.2.1. Deflection due to unit load q ( 1.st part )

L Mq1 * ( 3 * Mb1  5 * Mp1 ) L q * L2  - 9 * L 5*L 15 * L 

1.4.2.2. Deflection due to unit load q ( 2.nd part )

Total deflection due to dead weight of girder

Section Moment Mi Mi

y C*H + B*y - P(a+y) =

Section Moment Mi Mi

Bending moment on girder Mp = = P*a

1.1. Under traveling load

P*a*b b * Mb P" * L 3 * P" * L

1.2. Under girder own weight

1.3. Under cantilever load on fixed leg

1.4 Under cantilever load on flexible leg

Section Moment Mi Mi

u C*(H-u) - B*L + P*b = C*(H-u) H-u

b P*a*(z-b) b P* a*H* z P* a*b*H

Section Moment Mi Mi

1.3. Deflection of girder due to traveling load

L/2 L/2 L/2 L/2

P*L 3*P*L 3*P*L

Due to symmetry of structure, total deflection  = 2 * ( x + y )

1.4. Deflection of girder due to girder own weight

L/2 L/2 H L/2 L/2

L Mq1 * ( 5 * Mp1  3 * Mb1 ) L q * L 2  5 * L 15 * L 9 * L 

Due to symmetry of structure, total deflection  = 2 * ( x + y )

1.4.2. Deflection due to unit load q ( 2.nd part )

Mb Mq2 Mb Mb1 Mb1

L/2 L/2 L/2 L/2

Due to symmetry of structure, total deflection  = 2 * ( x + y )

Total deflection due to dead weight of girder

Section Moment Mi Mi

z -C*(H-z) - B*L + P(a+L) = -C*(H-z) + 0 -(H-z)

b a  Ma = 0  B*L - P*(L-a) - P*a = 0

Section Moment Mi Mi

y C*H - B*y = C*H - P*y H

z C*H - B*(a+z) + P*z = C*H - P*(z+a) + P*z = C*H - P*a H

Deflection of C = C = 2 * ( x + y + z ) = 0 ( symmetry )

Section Moment Mi Mi

z -C*(H-z) - B*L + P*A+L) = C*(H - z) -(H-z)

z CH - B(a + z) + P*z

q * b2 q* b(L -b) qL*b

Mb qL qL L L

 - 3 * P * L    3 * L  1  - 3 * P * L   L 3L  1  PL 3PL   -3*L  

L Mq1 * ( 3 * Mb1  5 * Mp1 ) L q * L2  - 9 * L 5L 15 L 

y CH + By - P(a+y) =

Pab b * Mb P" * L 3 * P" * L

u C(H-u) - BL + Pb = C(H-u) H-u

b Pa(z-b) b P* aH z P* abH

PL 3P*L 3PL

z -C(H-z) - BL + P(a+L) = -C*(H-z) + 0 -(H-z)

b a  Ma = 0  BL - P(L-a) - P*a = 0

y CH - By = CH - Py H

z CH - B(a+z) + Pz = CH - P(z+a) + Pz = CH - Pa H

z -C(H-z) - BL + PA+L) = C(H - z) -(H-z)

L P* a* (L- y )  a P* aH (L- y )

2 * J1 * H CHN Pa 3P* a