DUBAI ALUMINIUM GT1-8 CRANE DESIGN CALCULATIONS

STRENGTH CALCULATION BY BEAM CROSS-SECTION

1. Project Values

Span [L] : 18110 mm Weight of Lifting Group [Par] : 2000 kg

Capacity [Pn] : 15000 kg FEM Group : 1 mA
Trolley Span [r] : 2240 mm Lifting Speed [vh] : 4 m/min
Platform Unit Weight [qp] : 0.35 kg/cm Gap Between Diaphragms [bp] : 1500
Deflection Rate [L/f] : 1000 Material : S235R
Load Case : H Number of Wheels [nw] : 4

2. Beam Section Properties

2.1 Section Values

Section Type : Double Girder

Rail : 45x45 mm
t1 : 8 mm
t2 : 6 mm
t3 : 8 mm
h : 995 mm
b : 500 mm
c : 44 mm
qk [Unit Mass] : 1.90 kg/cm

2.2 Neutral Axis

ey : 55.16 cm
ex : 26.87 cm

2.3 Moments of Inertia

Jxx : 347020 cm4 PS : 2.2 & 2.3 values derived automatically from SolidWorks
Jyy : 72678 cm4 [See Appendix-1]

2.4 Moments of Strength

Wx : 6291 cm3
Wy : 2704 cm3

3. Moments Occuring
3.1 Dead Load Moment
Dead load consist of beams own weight and the platform unit weight on the beam

Total Distributed Load : qt = qk + qp

A B Reaction Forces : rA = rB = qt*L / 4
Support Moment : M1 = qt*L2 / 8

qt = 1.90 + 0.35 = [2.25 kg/cm]

M1= (2.25*18112) / 8 = 922421.53 [kgcm]

3.2 Moments that Consist of Vertical ımposed (live) Loads

Agents constituve of the live loads are;
Par : Weight of the lifting group
Pn : Lifted Load
Pa : Weight of any device attached to the hook block (if any). It's usually added to the lifting load

P P

P loads shown in the figure occurs at the touch points of hoisting group on the beam.
A B These forces are sum of the live loads. Hence ;

Reaction forces on the support are also the forces forming moment.
Assuming the loads shown above spread on both beams;

Pm = (Pn + Pa) / 4 : Wheel load that consists of lifting and device weights
Pma = Par/4 : Wheel load that consists of trolley load

Loads created on the single wheel on the single beam by live loads are also the support reaction forces that form moment.
Accordingly, the moment calculation ;

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Pm Pma
M2= (2 L  r )2 M3 = (2 L  r ) 2
8L 8L

Pm = (15000/4) = 3750 [kg] Pma = (2000/4) = 500 [kg]

2
M2 = (3750/(8*1811))*(2*1811-224) = 2988612.3 [kgcm]
M3 = (500/(8*1811))*(2*1811-224)2 = 398481.64 [kgcm]

3.3 Moments occuring due to crane movement

Moments created by 2 seperate movements will bementioned here. These moments arise from
concentrated loads caused by friction during the movements of the lifting group and the crane beam.

(Ref DIN 15018 Part 1, Figure 3 )

Contraction loads according to DIN 15018;

Kr = 1.5 x 0.2 (min RKr1 + min RKr2) (Ref DIN 15018 Part 1, Page 4 )

Again, according to DIN 15018, the expression "min" above indicates that loads other than load lifted should not be
taken into consideration. Additionlly, when the trolley group being located in the middle is considered as the worst loading
condition Kr1 = Kr2 equation is assured.
Kr = 1.5 * 0.2 * 2 (min RKr)

Kr

RA = RB = Kr / 2 M4 = (Kr * L) / 4
A B min RKr = (qk + qp) * L / 2 + Pa / 4

Kr = 1.5 * 0.2 * 2 * ((1.90+0.35)* 1811/2 + 2000/4) = 1522.43 [kg]

M4 = (1522.43*1811)/4 = 689280.18 [kgcm]

Horizontal loads that are normal to the rail and stressing the structure while two wheel or a wheel pair (Bogie) is rolling
on the rails should be taken into account. With a simple approach, these loads are derived from multiplication of the lamda (l) and the
horizontal load on the single wheel. Lamda (l) is the ratio between crane and trolley span.
The values are obtained from the table below.

l = 1811/224 = 8.08

(Ref FEM 1.001 2.2.3.3 )

One with the l value of 0.2 will be used since the ratio is usually close to 10 with the overhead cranes.

Contraction Moment : M5 = l * (Pm + Pma) * r

M5 = 0.2 * (3750+500)*224 = 190400 [kgcm]

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During the calculations of the stresses caused by moments, load increasing factors will be calculated according to FEM
group and the lifting speed. These factors are used in order to include inertia forces resulting from cranes or its components vertical
moves.

Dead load factor will be ued to increase M1 moment caused by dead load of the crane and the impact factor wil be used
to increase M3 moment caused by the lifted load. Then ;

Dead Load Factor Nominal Load Spectrum Factor (y)

FEM Zf
1mA 1.1
2m 1.2
3m 1.2
4m 1.35

Zf = 1.1
y = 1.1 + 0.0022*4 = 1.1088
( Ref DIN 15018 Part 1, Page 4, Table 2 )

3.4 Maximum Moments

max Mx = 1.1 * (922421.53+398481.64) + 1.1088 *2988612.3 = 4766766.80 [kgcm]

min Mx = 1.1 * (922421.53+398481.64) = 1452993.5 [kgcm]
max My = 689280 + 190400 = 879680 [kgcm]

4. Stresses
4.1 Maximum & Minimum Normal Stresses
Effects of the Mx and My values to the stress , occur in the ae direction on the beam.
Accordingly, the total stress equals to the sum of stress values of the beam according to strength moments on -x nd -y axises

σmax = ((4766766.80*55.16) / 347020) + (879680*26.87) / 72678) = 1082.92 [kg/cm2]

smin = ((1452993.5)*55.16 / 347020) = 230.96 [kg/cm2]
Permissible Tensile Stress σzul = 160 [N/mm2] = 1630.988 [kg/cm2] (Ref DIN 15018 Part 1, Page 12, Table10 )

σmax < σzul

1082.92 < 1630.988 hence tensile strength is safe ✔

4.2 Maximum Shear Stress

Shear stresses on the crane occur as buckling by loading point being out of alingment with beam axis and as shear by vertical loads,
depending on the section properties. And because these stresses are in the same direction, their sum will be used to calculate compa-
sion stress.

Stress by Buckling;
This stress is derived from the moment value calculated by multiplating the nominal load with the distance between beams axis and
the rail that wheel of the lifting group is on. Distance that creates the moment is calculated as b/2-3.3. The value comes from construc-
tion characterics. Accordingly,
Mb = P2w x d

Mb = ((1.1088*15000/2) + (1.1*2000/2) * 21.7 = 204327.2 [kgcm]

The buckling stress produced by this moment is calculated by the formula below that is for the sections with thin walleds.

The Fn is a closed area created by intersection of lines that pass through the middle of the sheet metals on beam section.
Mb
tb =
2* t * Fn
tb = 204327.2 / (2*0.6*4072.18) = 41.813 [kg/cm2]

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Shear Stress;
This stress occurs from the shear force generated by the load on the single wheel of the lifting group.
The section opposing this stress is the metal sheet part under rails. Accordingly ;

P1wl
tk = P1wl = P2 wl / 2
P1wl = (1.1088*15000/4) + (1.1*2000/4) = 4,708 [kg]

t *d

tk = 4708 / (0.6 * 99.5) = 78.86 [kg/cm ]

2

tmax = tb + tk = 41.813 + 78.86 = 120.673 [kg/cm ]

2

Accordingly, to check the structural steel by safe comparasion stress, superposed sums of shear stresses and maximum normal stress
is to be compared.

s comp = s max
2
 3t max
2

s comp = (1090.613) 2  3* (120.673) 2

s comp = 1102.91 [kg / cm 2 ]

2 2
Permissible Comparison Stress σzul = 160 [N/mm ] = 1630.98 [kg/cm ] (Ref DIN 15018 Part 1, Page 12, Table10 )

σcomp < σzul

1102.91 < 1630.98 hence comparison stress is safe ✔

5. Buckling Calculations

The following is assumed for the calculation;

• At the beginning of the loading, the plate is completely plane.
• The buckling deformations rectangular to the plate plane are small.
• The loading acts only on the plate's center plane.
• The material is assumed to behave in an ideal linear.

2 2
 s max   t max 
 1
 s    (Ref DIN 18800 Part 3, Page 7 )
 xP , R ,d   t P , R ,d 

σmax (N/mm2) Maximum normal stress on plate

τmax (N/mm2) Maximum shear stress on plate
σxP,R,d (N/mm2) Critical plate buckling normal stress
τP,R,d (N/mm2) Critical plate buckling shear stress

Critical plate buckling normal stress "σxP,R,d"

kks * kk X *Re
s xP , R ,d = (Ref DIN 18800 Part 3, Page7, el (502), f (11) )
gM

Critical plate shear stress "τP,R,d"

kkt * Re
t P , R ,d =
3 *g M (Ref DIN 18800 Part 3, Page 7, el (502), f(12) )

kkσ [-] Normal stress reduction factor

kkτ [-] Shear stress reduction factor
kkX [-] Buckling reduction factor
Re N/mm2 Yield Strength
gM [-] Partial safety factor

kkX = 0.8 (Ref DIN 18 800 Part 2 )

Re = 240 N/mm2 (S235JR) (Ref DIN 18 800 Part 1, Table 1, Row 1 )
gM = 1.2 (Ref DIN 18 800 Part 1 )

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5.1 Calculating the Buckling Stress of Side Plates

Side Ratio (a) (Ref DIN 18800 Part 3, Page 3, el (113) )

a = bp / h = 150/99.5 = 1.51

Calculation of the buckling values according to DIN 4114

Hence a>1

For k = -1 ks= 23.9 [Buckling factor ks, as a function of k] (Ref DIN 4114 Part 1, Page 15, Table 6, Row 4 )
4 4
kt = 5.34  = 5.34  (Ref DIN 4114 Part 1, Page 15, Table 6, Row 5 )
a2 1.512
kt = 7.094

Euler critical stress :

p2 *E
2 2
 t  3.14 *210000  6 
2
se= * 2  = *  = 6.90[ N / mm ]
2
(Ref DIN 18800 Part 3, Page 3, el (113) )
12*(1  m )  h 
2
12*(1  0.32 )  995 

2
E N/mm Elastic module 210,000
m [-] Poisson ratio 0.3
t2 mm Thickness of side plate 6
h mm Height of side plate 995
p [-] Number pi 3.14

Critical plate buckling stress if edge stresses σ are effective

s Pi = ks *s e = 23.9*6.9 = 164.9 [ N / mm2 ] (Ref DIN 18800 Part 3, Page 3, el (113) )

Critical plate buckling stress if edge stresses τ are effective

t Pi = kt *s e = 7.094*6.9 = 48.95 [ N / mm2 ] (Ref DIN 18800 Part 3, Page 3, el (113) )

Normal stress reduction coefficient "kks"

First admissible slenderness ratio calculated ;

Re 240
lPs = = = 1.2 (Ref DIN 18800 Part 3, Page 3, el (113) )
s Pi 164.9

lPs [-] Admissible slenderness ratio

Re [N/mm2] Yield Strength
sPi [N/mm2] Critical plate buckling normal stress

 1 0.22 
kks = c *   2  1
l
 Ps lPs 
for k F min = 1
c = 1.25  0.12k F min = 1.37
1.25 cks > 1.25
c=
cks Other cases
c = 1.37 > 1.25 hence cks = 1.25
(Ref DIN 18800 Part 3, Page 8, Table 1, Row 1 )
 1 0.22 
kks = 1.25 *   2 
= 0.85
 1.2 1.2 
1 kks > 1
kks =
kks Other cases
kks = 0.85  1 hence kks = 0.85

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Shear stress reduction coefficient "kkt"

First admissible slenderness ratio calculated ;

Re 240
lPt = = = 1.68
t Pi * 3 48.95* 3 (Ref DIN 18800 Part 3, Page 3, el (113) )

0.84 0.84
kkt = 1 = 0.5 (Ref DIN 18800 Part 3, Page 8, Table 1, Row 2 )
lPt 1.68

Critical plate buckling normal stress "sxP,R,d"

kks * kk X * Re 0.85*0.8* 240

s xP , R ,d = =
gM 1.2 (Ref DIN 18800 Part 3, Page7, el (502), f (11) )

s xP , R ,d = 136 [ N / mm ] = 1386.34 [kg / cm ]

2 2

Critical plate buckling shear stress "tP,R,d"

kkt * Re 0.5* 240

t P , R ,d = =
3 *g M 3 *1.2 (Ref DIN 18800 Part 3, Page 7, el (502), f(12) )
t P , R ,d = 57.74 [ N / mm2 ] = 588.53 [kg / cm 2 ]

Buckling control of side plates's;

2 2
 s   t max 
Scalc. =  max      1
s
 xP , R , d   t P , R ,d 
2 2 ✔
 1090.613   120.673 
Scalc. =     1
 1386.34   588.53 
Scalc. = 0.66  1 hence the plate buckling safety is sufficient

5.2 Calculating the Buckling Stress of Top Plate

2 2
 s max   t max 
      1 (Ref DIN 18800 Part 3, Page 7, el (502), f(12) )
 s xP , R ,d   t P , R ,d 
Side Ratio (aH)
aH=bp / (b-2c)=1500/(500-2*44)=3.64

Calculation of the buckling values according to DIN 4114

aH>1 hence kFmax = 1

8.4 8.4
ks = =  ks = 4 (Ref DIN 4114 Part 1, Page 15, Table 6 )
1.1  k F max 1.1  1

4 4
kt H = 5.34  = 5.34   kt H = 5.64 (Ref DIN 4114 Part 1, Page 15, Table 6 )
a H2 3.642

Euler critical stress :

p 2 * E  t1  3.142 *2.1x105  8 
2 2

se = *  = *   = 71.56 [ N / mm2 ] (Ref DIN 18800 Part 3, Page 3, el (113) )

12*(1  m 2 )  b  2c  12*(1  0.32 )  412 
Critical plate buckling stress if edge stresses σ are effective

s Pi = ks *s e = 4*71.56 = 286.24 [ N / mm2 ]

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Critical plate buckling stress if edge stresses τ are effective

t Pi = kt *s e = 5.64*71.56 = 403.6 [ N / mm2 ]

Normal stress reduction coefficient "kks"
First admissible slenderness ratio calculated ;

Re 240
l ps = = = 0.915 (Ref DIN 18800 Part 3, Page 3, el (113) )
s Pi 286.24

 1 0.22 
kks = c *   2  1
 lPs lPs 
for k F min = 1
c = 1.25  0.12k F min = 1.37
1.25 cks > 1.25
c=
cks Other cases
c = 1.37 > 1.25 hence cks = 1.25

(Ref DIN 18800 Part 3, Page 8, Table 1, Row 1 )

 1 0.22 
kks = 1.25    = 1.04
 0.915 0.915 
2

1 kks > 1
kks =
kks Other cases
kks = 1.04 > 1 hence kks = 1

Shear stress reduction coefficient "kkt"

First admissible slenderness ratio calculated ;

Re 240
lPt = = = 0.586 (Ref DIN 18800 Part 3, Page 3, el (113) )
t Pi * 3 403.6* 3

0.84 0.84
kkt = 1 = 1.43 (Ref DIN 18800 Part 3, Page 8, Table 1, Row 2 )
lPt 0.586
Critical plate buckling normal stress "sxP,R,d"

kks * kk X * Re 1*0.8* 240

s xP , R ,d = =
gM 1.2 (Ref DIN 18800 Part 3, Page7, el (502), f (11) )

s xP , R ,d = 160 [ N / mm2 ] = 1630.98 [kg / cm 2 ]

Critical plate buckling shear stress "tP,R,d"

kkt * Re 1.43* 240

t P , R ,d = =
3 *g M 3 *1.2 (Ref DIN 18800 Part 3, Page 7, el (502), f(12) )

t P , R ,d = 165.12 [ N / mm2 ] = 1683.2 [kg / cm2 ]

Buckling control of top plate's;
2 2
 s   t max 
Scalc. =  max    
s
 xP , R ,d   t P , R ,d 
2 2
 1090.613   120.673  ✔
Scalc. =    
 1630.98   1683.2 
Scalc. = 0.452  1 hence the top plate buckling safety is sufficient

6. Deflection Control
In the formula used for deflection control "L" is crane span, "r" is trolley span, Fwv is the load on the single wheel, "E" is
modules of elasticity and "Jx" is the beam's moment of inertia.

Fwv
f = ( L  r ) *(3L2  ( L  r ) 2 )
48* E * Jx

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f [mm] Amount of deflection

Fwv [N] Load on the single wheel
E [N/mm2] Modules of elasticity
Jx [mm4] Moment of inertia on x axis
L [mm] Crane Span
r [mm] Trolley Span

Load on the single wheel (Fwv) ;

y * Pn   * Par (1.10088*15000)  (1.1* 2000)
Fwv = =
nw 4
Fwv = 4708 [kg ] = 46185.48 [ N ]

ψ [-] Nominal load spectrum factor

Pn [kg] Lifting Load
υ [kg] Self Weight Factor
Par [kg] Weight of Trolley

ψ=1.1+0.0022*vh = 1.1+0.0022*4 = 1.1088

υ=1.1

(Ref DIN 15018 Part 1, Page 4, Table 2 ) (Ref DIN 15018 Part 1, Page 3, Table 1 )

Fwv
f = ( L  r ) * (3L2  ( L  r ) 2 )
48 * E * Jx
46185.48
f = * (18110  2240) * (3 *18110 2  (18110  2240) 2 )
48 * 2.1*105 * 347020 *10 4
f = 15.34 [mm] ✔

L 18110
Deflection Rate (k f ) = = = 1180.6  1000 hence deflection ratio is safe.
f 15.34
L / f ratio can be selected between 800  1200 as specified in Stahl Im Hochbau 12. Edition Clause 10.2.2.1.7.3

7.Perpetually Dynamic Safety Stress

After all calculations, statically valid crane beam will be checked under dynamic stresses. Becauses the cranes loading characteristic will
be always be "+", alternative loading characteristic will be considered. Welding seams notch factor will also be taken into consideration
here. As a result of these, factors, perpetually dynamic safe operating stress is obtained from table below.

(Ref DIN 15018 Part 1, Page 16, Table 17 )

At this point "K" and "B" values are determined by the welding seam type used and its properties;

K4 B2

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Accordingly, perpetually dynamic safe operating stress ;

sD(-1)SAF. = 108 [N/mm ] = 1100.91 [kg/cm ]
2 2
(Ref DIN 15018 Part 1, Page 16, Table 17, Row 2, Column 11 )

Dynamic tensile stress formula in case of single directional fluctuationing loading (k=0);

5 s D ( 1) SAF . k calc. =

s min
=
230.96
= 0.21
s Dt (0) SAF . = * s max 1082.92
3  5 s D ( 1) SAF . 
1  1  *  * k calc. k calc. = Ratio between the extreme stresses
 3 0.75* Rm  ( See title "4.1 Maximum & Minumum Normal Stresses " for the s max & s min values)
(Ref DIN 15018 Part 1, Page 17, Figure 7 )
(Ref DIN 15018 Part 1, Page 17, Table 18 )

2 2
Rm= 360 [N/mm ] = 3669.7 [kg/cm ] Tensile strength (Ref DIN 18800 Part 1, Page 5, Table 1, Row 1, Column 4 )
k=1 Limiting stress ratio (= 1 for pure comparasion ; = -1 for pure bending)

(DIN 15018 Part 1, Figure 9) (DIN 15018 Part 1, Table 18)

5 1100.91
s Dt (0) SAF . = *
3  5 1100.91 
1  1  *  * 0.21
 3 0.75 * 3669.7 
s Dt (0) SAF . = 1972.96 [kg / cm 2 ]
✔

s comp  s Dt (0) SAF . condition must be provided

1110.46  1972.96 therefore satisfied
( See title "4. Stresses " for the s comp value)

All stresses are valid according to the table permissible stresses below as per St37, Load case H

(Ref DIN 15018 Part 1, Table 10 )

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