LARSEN & TOUBRO LIMITED

ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

For crane loads Refer Doc. No. -Analysis of STG building - Page no :

Design of gantry girder (9.5 m span):

Input data:

Span of girder L = 9.5 m

Total weight of Crane = 850 KN

Weight of Crab = 250 KN

Total number of wheels = 8 ( 4 nos each side)

Number of wheels on each side N = 4

Lifting capacity = 850 KN

Distance between two consecutive wheels = 2 m

Distance between two inner wheels = 3.65 m

Maximum static wheel Load Wst = 350 KN

Impact factor = 1.25

Height of rail (Assumed) = 150 mm

Self weight of rail = 0.6 kN/m

Width of walkway = 600 mm

Walkway live load - 3 kN/m2 = 3x(600/1000)/2

= 0.9 kN/m
Analysis:

437.5KN 437.5KN 437.5KN 437.5KN

2m 3.65m 2m

(I) Maximum static wheel load including impact of 25 %

Wst = 437.5 kN

(ii) Lateral load :

= 10%of(weight of trolley+Lifted load)

H = 110 KN

Load per wheel Ht = 27.5 kN

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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

(iii)Longitudinal load :
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Max longitudinal load for all wheels = 5% of maximum wheel load on one side

= 0.05x350x4

Plong = 70 kN

Maximum shear force:

The trailing load at the left support yields maximum shear force in girder.

A B

2 3.65 2

9.5

Total self weight of girder, rails and walkway = 3.81+0.6+0.9

= 5 kN/m

RA = 437.5+(437.5x(9.5-2)+437.5x(9.5-2-3.65)+437.5x(9.5-2-3.65-2))/9.5 +5.31X9.5/2

RA = 679 kN

Maximum vertical bending moment:

Maximum bending moment occurs when centre of gravity of load system

and the load near the cg (section x-x) are equidistant from the centre of span.

1.83 0.9125 X Centre line of span

2.00 3.65 2 1.84

0.013 9.5 X

cg of load system

Reaction at the supports:

RA = (437.5X(9.5-2-0.0125)+437.5x(9.5-0.0125)+437.5x(2+1.8375)+437.5x1.8375)/9.5

+5.31X9.5/2

= 1068 kN

Maximum bending moment Mx= 1895 kNm

 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Maximum lateral bending moment:

27.5 27.5 27.5 27.5

Lateral load on crane girder shall be carried by top flange of crane gantry girder. The top

flange is laterally supported by surge girder(latticed), which is designed to carry the lateral

surge of crane. So the top flange of crane girder will be checked for axial force arrived from

lateral load.

Surge girder Gantry girder

800

775

PLAN view of surge girder

Unsupported length of top flange ly = 0.8 m

Maximum lateral bending moment =27.5x0.8/4 My = 5.5 kNm

Max lateral BM in surge girder 27.5x1895.42/437.5 Ms = 119.1 kNm

Depth of surge girder+half width of top flange ds = 775 mm

Longitudinal moment at bottom of rail due to longitudinal load

= 70x10^3x150 Mlx = 10500000 Nmm

Maximum axial load:

Axial compression = Plong+Ms/ds

= 70+119.14/775 P = 224 kN
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Section design:

Assuming built up section for girder consists of top, web and bottom plates.

350

25
20

1550 1600

25

350

Width of top plate wt = 350 mm

Thickness of top plate tt = 25 mm

Height of web plate ww = 1550 mm

Thickness of web plate tw = 20 mm

Width of bottom plate wb = 350 mm

Thickness of bottom plate tb = 25 mm

Overall depth D = 1600 mm

Area of section = wtxtt+wwxtw+wbxtb A = 48500 mm2

0.0485 m2

Density of steel = 78.5 kN/m3

Self weight of girder = Sw = 78.5x0.0485 = 3.81 kN/m

Minimum Web thickness:

The thickness of the web plate (t) shall not be less than the greater of following as per

clause 6.7.3.1:

(I) 1/180*(smallest clear panel dimension)

= 0.01x1550

= 8.61 mm

(ii) d2*SQRT(fy)/3200

= 7.66 mm

(iii) d2/200
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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

= 7.75 mm
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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

(iv) 8 mm

Minimum web thickness required(t) = 8.61 mm

Provided web thickness 20 > 8.61 mm

SAFE .

Clause 3.5.2.2 for effective sectional area:

MI1= 560x20/SQRT(250) Mi2= 35x20

= 708 mm = 700 mm

Lesser of (Mi1, Mi2) Min= 700 mm

1550 > 700 Hence the excess width shall be assumed to be located centrally and its

sectional area shall be neglected when calculating the effective geometrical properties of

section.

Excess width to be located centrally Ew = 850.00 mm

800
350
Neutral axis
850
X X

350 800

Net area of section to be considered for calculating geometrical properties

Anet= 350x25+350x25+700/2x20x2

= 31500 mm2

Moment of inertia:

About xx axis:

Top plate: Ixx1 = wt*tt^3/12+wt*tt*((ww+tt)/2)^2

= 5426822917 mm4

= 5.43E+09 mm4

Web plate Ixx2 = 20x350^3/12+20x350x(850/2+350/2)^2x2

 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

= 5111458333.33333 mm4
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

= 5.11E+09 mm4

Btm plate Ixx3 = wb*tb^3/12+wb*tb*((ww+tb)/2)^2

= 5426822917 mm4

5.43E+09 mm4

Total Ixx = Ixx1+Ixx2+Ixx3

= 15965104167 mm4

= 1.60E+10 mm4

Section modulus = 15965104166.6667x2/1600

Zxx = 2.00E+07 mm3

About yy axis:

Iyy= tt*wt^3/12+Min*tw^3/12+tb*wb^3/12

= 179112500 mm4

= 1.79E+08 mm4

Section modulus = 25x350^2/6

Zyy = 5.10E+05 mm3 (For top flange only)

Zyy = 179112500/(350/2) mm3

= 1.02E+06 (For complete section)

Radius of gyration = rx = SQRT(15965104166.67/31500)

= 712 mm

Radius of gyration = ry = SQRT(179112500/31500)

= 75 mm

Depth of neutral axis from top yt = 800 mm

Depth of neutral axis from bottom yb = 800 mm

Coefficient 'k1' as per clause 6.2.4 & Table 6.3 (IS 800) k1 = 1

Coefficient 'k2' as per clause 6.2.4 & Table 6.4 (IS 800) k2 = 0

c1 = 800 mm

c2 = 800 mm

Factor 'n' as per clause 6.2.3 n = 1.40

Elastic modulus of steel Es = 2E+05 N/mm2

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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Yield strength of steel fy = 250 N/mm2

 LARSEN & TOUBRO LIMITED
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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Calculation of allowable stresses:

Elastic critical stress in compression fcc = 3.14^2x200000/(0.8x1000/75.41)^2

as per Clause 5.1.1 = 17537 N/mm2

Allowable compressive stress sac = 0.6x17537.4x250/(17537.4^1.4+250^1.4)^(1/1.4)

as per clause 5.1.1 = 149.72 N/mm2

Calculation of elastic critical stress in bending: (Clause 6.2.4)

Y = 2650000/(0.8x1000/75.41)^2

= 23544 N/mm2

X = 23544.05xSQRT(1+1/20x(0.8x1000x25/(75.41x1600))^2)

= 23560 N/mm2

Elastic critical stress in bending fcb1 = k1*(X+k2*Y)*c2/c1

= 1x(23560.22+0x23544.05)x800/800

= 23560 N/mm2

Depth of web d1 = 1600-2x25

= 1550 mm

Clause 6.2.4.1

T= tt & t = tw

T/t = 1.25 < 2

d1/t= 78 1344/SQRT(fy) = 85

78 < 85 Hence 20% increase in elastic stress.

fcb = 28272 N/mm2

Max permissible bending compressive stress for major axis bending

as per clause 6.2.3 sbcx = 0.66x28272x250/(28272^1.4+250^1.4)^(1/1.4)

= 164.84 N/mm2

Max permissible bending compressive stress for minor axis bending

sbcy = 0.66x250
= 165.00 N/mm2

Actual stresses:

The axial compression and the lateral bending moment are assumed solely to be carried by
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

top flange.
 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Axial compressive stress sac,cal = P/A+M/Z

= 224x1000/(350x25)+10500000/19956380.21

= 26.10 N/mm2

Bending compressive stress about major axis

sbcx,cal = 1895.42x10^6/19956380.21
94.98 N/mm2

Bending compressive stress about minor axis

sbcy,cal = 5.5x10^6/510416.67
10.78 N/mm2

Interaction of stresses:

Stress ratio for axial load = Q1 = 26.1/149.72

= 0.174 N/mm2

Elastic critical stress in the plane of bending as per clause 5.1.1

fccx = 3.14^2x200000/(9.5x1000/711.92)^2

= 11085.21 N/mm2

fccy = fcc

Coefficient as per clause 7.1.3 Cm = 1.00

Clause 7.1.1:

Qr1 = sac,cal Cm*sbcx,cal Cm*sbcy,cal

+ +
sac (1-sac,cal/(0.6*fccx))*sbcx (1-sac,cal/(0.6*fccy))*sbcy

0.1743 + 0.5784 + 0.07

Final combined ratio

Qr1 = 0.82

Allowable ratio is to be increased by 10% as per clause 3.9.3

Qall = 1.10

Qr1 < Qall SAFE.

Check for shear:

Actual vertical shear stress in web t,cal = 21.91 N/mm2

Allowable shear stress, t = 0.4*fy t = 100.00 N/mm2

 LARSEN & TOUBRO LIMITED
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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

21.91 < 100 N/mm2 SAFE.

 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Check for deflection:

Moment without impact factor = 1895.42/1.25

Mser = 1516 kNm

Actual deflection = Mser*L^2/(10*Es*Ixx)

= 1516.34x10^6x9.5x1000^2/(10x200000x15965104166.67)

= 4.29 mm

Allowable deflection = span/1000 = 9.5 mm

4.29 < 9.5 mm SAFE.

Check for web buckling: (Clause 6.7.5.1)

Concentrated load P = 437.5 kN

437.5 kN

45

N A

800 800

Longitudinal view of girder

Load is dispersed at an angle of 45 degrees to horizontal.

Length dispersed by load at 45 degrees to level of B = D/2+D/2

neutral axis = 1600 mm

Clear depth of web between root filets d1 = 1550 mm

Thickness of web tw = 20 mm

Slenderness ratio l = d1*sqrt(3)/tw

= 134.234

From table 5.1 of IS 800,

Permissible axial compressive stress sac = 54.6 N/mm2

 LARSEN & TOUBRO LIMITED
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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Permissible axial compressive load = sac*tw*B

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PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

= 1747.2 kN

Concentrated load 437.5 < 1747.2 kN

Load bearing web stiffener is not required.

Requirement of intermediate stiffener:

As per clause 1.3 d1 = 1550 mm

As per clause 1.3 d2 = 1550 mm

As per clause 6.7.3.1:

d1/tw = 77.5 mm < 85

Vertical stiffeners are not required.

Check clause 3.5.2.1(b) for outstand of flange plate:

Outstand of flange plate provided Pr = (wt-tw)/2

= (350-20)/2

165 mm

Plates in compression with unstiffened edges is lesser of following:

PL1= 256x25/SQRT(250) PL2= 16x25

= 404.77 mm = 500 mm

Lesser of (PL1, PL2) PL = 404.8 mm

165 < 405 mm SAFE.

Design of weld for Gantry Girder:

a. Flange and Web Joint

The joint between flange and web is subjected to shear stresses

The shear stress q = VQ / I

= 679 * 1000 * (350 * 25* ( 1600/2- 0.5 * 25)/15965104166.6667

294 N/mm

Size of weld = 8 mm

Strength of weld /mm ( both sides) =

2 * 0.707 * 8 *108 = 1222 N/mm

 LARSEN & TOUBRO LIMITED
ECC Division - EDRC

PROJECT: DOCUMENT NO. DATE

445 MW Konaseema CCPP
CTG23603
TITLE: DESIGNED CHECKED SHEET
STG building - Design of gantry girder
CBR SM

Hence provide 8mm weld for the connection between web and flange