Page 1

DESIGN OF STRUCTURE FOR 50t CAP X 14.3M SPAN;22.3M lift EOT CRANE FOR BHEL, PEM

1 DESIGN DATA:

1. Capacity W1 50 T
2. Span S 14.30 M
3. Classification of crane M5 (Table 7, IS 807-2006)
4. Impact factor Y 1.32 (Table 12, IS 807-2006)
5. Duty factor M 1.06 (Table 13, IS 807-2006)
6. Crab Wheel Base a 1.5 M
7. End Carriage Wheel Base e 5.35 M
8. CT Wheel Gauge c 3.6 M
9. CT Rail Sec. Wt WR 45 Kg/M
10. LT Speed v 30 M/Min

2 DESIGN PROCEDURE:
The two bridge girders are simply supported on the two end carriages as shown.
We will design the girder for strength and deflection to the following codes:
IS 807–2006: Code of Practice for design, erection & testing (Structural Portion) of Cranes and Hoists.
IS 800 – 1984: Code of Practice for General Construction of Steel

3 CRANE STRUCTURE

All dimensions in M

c = 3.6 e=
5.35

a = 1.5

S =14.3

4 DEAD LOAD: ESTIMATED WEIGHTS OF COMPONENTS

[Link] COMPONENT UNIT WEIGHTQTY TOTAL WEIGHT(T)
1 Crab W2 10 1 10
2 Each Girder W3 5 2 10
3 Platform along full length of girder W4 1.5 2 3.0
4 End Carriages W5 2.5 2 5
5 LT Drives, Short platforms, Misc W6 2 2 4
6 LT Machinery etc. W7 1 2 2
7 Cabin W8 0 0 0
Total Weight of Crane 34.0
 Page 2

5 DESIGN OF BRIDGE GIRDER

A. Section Selected Properties

All dimensions in mm
btf btf = 500 Area, A = (btf x ttf + bbf x tbf + 2dtw) / 100 = 340 cm2
ttf = 16 [Link].(without diaphrams) = 0.79A = 269 Kg/M
Iz = (btfttf(YC-ttf/2)2 + bbftbf(ttf+d+tbf/2-YC)2 + 2twd3/12)/104
YC YC = 603.4 = 815061 cm4
Z Z
IY =[2dtw{(bi+tw)/2} +ttfbtf /12+tbfbbf /12]/10 =
2 3 3 4
138679 cm4
d = 1250
tw tw = 8 Section Modulus (Comp.), ZZC = 10 IZ/YC = 13508 cm3
bi bi = 460 Section Mod (T), ZZT = 10 IZ/(ttf+d+tbf-YC) = 12082 cm3
tbf = 12 Section Modulus (Lateral), ZY = 10 IY/(btf/2)= 5547 cm3
bbf bbf = 500

B. Diaphrams
All dimensions in mm Spacing of Full Vertical diaphrams (as shown) in M 1
top height = 150 Spacing of short Vertical diaphrams (top flat) in M 0.5
side width = 100 Full length Horizontal diaphrams provided along the webs
bottom height = 100 at 2/5 of neutral axis from comp. flange = 235 mm
Hor. Diaph. Width = 50 Section Wt. of Diaphrams = 22.4 Kg/M
Dist. From top = 235
Thickness = 6

C. Total Wt. of Girder

W3 = Wt. of Girder = Sec. Wt.(girder + diaphrams + CT Rail) x Span = 4805 Kg

D. Girder Proportions
The limiting girder proportions are given in Cl. 25.1, IS 807-06
a) Span/depth of girder = s/d = 14300 1250 11 < 25 OK
b) Span/Width of girder = s/btf = 14300 500 29 < 60 OK
c) Width/Thk. top plate = bi/ttf = 460 16 29 < 60 OK
d) Min. thickness of web stiffened both horizontally and vertically = d 2/250 (Cl. 6.7.3c), IS 800-84
where d2 = 2xclear [Link] neutral axis from [Link] = 2(Y C-ttf) = 1175 mm
\ Min. thickness of web = d2/250 = 4.7 mm. OK
e) Distance between vertical diaphrams should be between 0.33d and 1.5d (Cl. [Link], IS 800-1984)
where d = clear dist. between horizontal stiffener and tension flange = 1015 mm
Spacing of vertical diaphrams = 1000 mm OK.

E. Permitted Stresses
(sbc) = Max. Allowed bending Compressive stress = 1235 Kgf/cm2 (Table 30, IS 807-06)
(sbt) = [Link] bending tensile Stress = 50% YS = 1300 Kg/cm2 (B-2, Annex B, IS 807-06)
(ss) = [Link] Shear Stress = 40% YS = 1040 Kg/cm2 (B-2, Annex B, IS 807-06)

F. Max. Forces on girder

(a) PY = [Link] wheel load = (W1+W ) / 4 =2 50.0 10.0 / 4 = 15.0 T
(b) PiY =[Link] Wheel Load = (W1Y+W2)/4 = 66.0 10.0 / 4 = 19.0 T
(c) WY = Dead load of girder & platform = W3 + W4 = 4.8 2 = 6.3 T
(d) Horizontal inertia force due to LT Travel = b x Vertical Load,
 Page 3

where b = 0.01 \/ LT speed = 0.0548 (Cl. [Link], IS 807-06)

G. Max. Bending Moments

The maximum bending moments will occur when the C/L of the fully loaded crab is at the centre of the
girder as shown below.
PY PY
Y
PiY PiY
L= a= WY= 2
x 6.4 1.5
z

Span, S = 14.30 M
Distance of CT Wheel from end. L= (S-a)/2 6.4 M
Max. Vert.B.M. due to static load, M1 Z = Duty Factor x PY L = 1.06 x 15.0 x L = 101.8 T-M
Max. Vertical [Link] to dynamic load, M2Z = D. F.x PiY L = 1.06 x 19.0 x L = 128.9 T-M
Max. [Link] to dead load M3Z = D.F.x WYS/8 = 1.06 x 6.3 x 14.3 / 8 = 11.9 T-M

Combination 1:
Max. Vertical B.M. under static load, MV1Z = M1Z + M3Z = 101.8 + 11.9 = 113.7 T-M
Max. horizontal B.M. due to LT inertia, MH Y = b x MV1Z = 0.0548 x 113.7= 6.2 T-M

Combination 2:
Max. Vertical B.M. under dynamic load, MV2Z = M2Z + M3Z = 128.9 + 11.9 = 140.8 T-M

H. Max. Stresses

1. Max. bending stresses in compression, sbc

sbc under static & horizontal loads = MV1Z/ZZC + MHY/ZY = 842 + 112 = 954 Kg/cm2
sbc under dynamic load = MV2Z/ZZC = 141 x 10 / 13508 = 1043 Kg/cm2
5

Max. allowed bending compressive stress, (sbc ) = 1235 Kg/cm2

Hence safe

2. Max. bending stresses in tension, sbt

sbt under static & horizontal loads = MV1 Z/ZZT + MHY/ZY = 941 +
112 = 1053 Kg/cm2
sbt under dynamic load = MV2Z/ZZ t = 141 x 10 5 / 12082 = 1166 Kg/cm2
(sbt) = [Link] bending tensile Stress = 50% YS = 1300 Kg/cm2 (B-2, Annex B, IS 807-06)
Hence safe

3. Max. shear stress, ss

Max. shear force at end of girder = SF = PiY(S-a)/S + WY/2 = 20.2 T
Height of web at end of girder = 150 mm Shear Area = 36 cm2
Ave. Shear Stress = ss = 560 Kg/cm2
(ss) = [Link] Shear Stress = 40% YS = 1040 Kg/cm2 (B-2, Annex B, IS 807-06)
Hence safe

I. Max. Deflection under full load

Deflection of the girder will be maximum when the fully loaded crab is at the centre of span.
Max. deflection, d = 2 x (PYx103 x S3x106 / (48 xE x IZ) = 1.1 cm
Max. permitted deflection = S/750 = 1.9 cm.
E = Young's Modulus = 2.08 x 106
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Hence safe
 Page 5

6 DESIGN OF END CARRIAGE

A. Section Selected Properties

All dimensions in mm
btf btf = 350 Area, A = (btf x ttf + bbf x tbf + 2dtw) / 100 = 188 cm2
ttf = 12 [Link].(without diaphrams) = 0.79A = 149 Kg/M
IX = (btfttf(YC-ttf/2)2 + bbftbf(ttf+d+tbf/2-YC)2 + 2twd3/12)/104
YC YC = 337.0 = 128648 cm4
Z Z
IY =[2dtw{(bi+tw)/2} +ttfbtf /12+tbfbbf /12]/10 =
2 3 3 4
34867 cm4
d = 650
tw tw = 8 Section Modulus (Comp.), ZXC = 10 IZ/YC = 3817 cm3
bi bi = 310 Section Mod (T), ZXT = 10 IZ/(ttf+d+tbf-YC) = 3817 cm3
tbf = 12 Section Modulus (Lateral), ZY = 10 IY/(btf/2)= 1992 cm3
bbf bbf = 350

B. Girder Proportions
The limiting girder proportions are given in Cl. 25.1, IS 807-06
a) Span/depth of girder = e/d = 8 < 25 OK
b) Span/Width of girder = e/btf = 15 < 60 OK
c) Width/Thk. top plate = bi/ttf = 26 < 60 OK

C. Permitted Stresses
(sbc) = Max. Allowed bending Compressive stress = 1235 Kgf/cm2 (Table 30, IS 806-06)
(sbt) = [Link] bending tensile Stress = 50% YS = 1300 Kg/cm2 (B-2, Annex B, IS 807-06)
(ss) = [Link] Shear Stress = 40% YS = 1040 Kg/cm2 (B-2, Annex B, IS 807-06)

D. Max. Bending Moments

The maximum loading will occur when the fully loaded crab is at the end of the girder as shown below.

Y
PeY = 41.7 PeY = 41.7
W5= 2.5
Z c = 3.6

e = 5.35

PeY = Max. vert. load = PiY[1+(S-a)/S] + WY/2 + W5 + W8 = 41.7 T

Max. Vertical B.M. MX = D.F. (PeY x (e-c) / 2 + W5/8) = 39.0 T-M

E. Max. Stresses

1. Max. bending stresses in compression, sbc

sbc = MX / ZXC = 1021 Kg/cm2
(sbc ) = 1235 Kg/cm2
Hence safe
 Page 6

2. Max. bending stresses in tension, sbt

sbt = MX / ZXt = 1021 Kg/cm2
(sbt ) = 1300 Kg/cm2
Hence safe

3. Max. shear stress, ss

[Link] force at end of the EC = Pe Y + W5/2 = 42.9 T
Height of web at end of girder = 300 mm Shear Area = 48 cm2
Ave. Shear Stress = ss = 893.95 Kg/cm2
(ss) = 1040 Kg/cm2
Hence safe
 Page 7

DESIGN OF STRUCTURE FOR 45t CAP X 9.0M SPAN;24.5M lift EOT CRANE FOR BHEL, PEM R1 1

1 DESIGN DATA:
1. Capacity W1 45 T
2. Span S 9.00 M
3. Classification of crane M5 (Table 7, IS 807-2006)
4. Impact factor Y 1.32 (Table 12, IS 807-2006)
5. Duty factor M 1.06 (Table 13, IS 807-2006)
6. Crab Wheel Base a 1.5 M
7. End Carriage Wheel Base e 5.35 M
8. CT Wheel Gauge c 3.6 M
9. CT Rail Sec. Wt WR 45 Kg/M
10. LT Speed v 30 M/Min

2 DESIGN PROCEDURE:
The two bridge girders are simply supported on the two end carriages as shown.
We will design the girder for strength and deflection to the following codes:
IS 807–2006: Code of Practice for design, erection & testing (Structural Portion) of Cranes and Hoists.
IS 800 – 1984: Code of Practice for General Construction of Steel

3 CRANE STRUCTURE

All dimensions in M

c = 3.6 e=
5.35

a = 1.5

S =9

4 DEAD LOAD: ESTIMATED WEIGHTS OF COMPONENTS

[Link] COMPONENT UNIT WEIGHTQTY TOTAL WEIGHT(T)
1 Crab W2 10 1 10
2 Each Girder W3 3 2 6
3 Platform along full length of girder W4 1.0 2 2.0
4 End Carriages W5 2 2 4
5 LT Drives, Short platforms, Misc W6 2 2 4
6 LT Machinery etc. W7 1 2 2
7 Cabin W8 0 0 0
Total Weight of Crane 28.0
 Page 8

5 DESIGN OF BRIDGE GIRDER

A. Section Selected Properties

All dimensions in mm
btf btf = 400 Area, A = (btf x ttf + bbf x tbf + 2dtw) / 100 = 216 cm2
ttf = 12 [Link].(without diaphrams) = 0.79A = 171 Kg/M
Iz = (btfttf(YC-ttf/2)2 + bbftbf(ttf+d+tbf/2-YC)2 + 2twd3/12)/104
YC YC = 512.0 = 345795 cm4
Z Z
IY =[2dtw{(bi+tw)/2}2+ttfbtf3/12+tbfbbf3/12]/104 = 52987 cm4
d = 1000
tw tw = 6 Section Modulus (Comp.), ZZC = 10 IZ/YC = 6754 cm3
bi bi = 360 Section Mod (T), ZZT = 10 IZ/(ttf+d+tbf-YC) = 6754 cm3
tbf = 12 Section Modulus (Lateral), ZY = 10 IY/(btf/2)= 2649 cm3
bbf bbf = 400 Radius of Gyration, RY = \
/ (IY/A) = 15.66 cm

B. Diaphrams
All dimensions in mm Spacing of Full Vertical diaphrams (as shown) in M 1
top height = 150 Spacing of short Vertical diaphrams (top flat) in M 0.5
side width = 100 Full length Horizontal diaphrams provided along the webs
bottom height = 100 at 2/5 of neutral axis from comp. flange = 200 mm
Hor. Diaph. Width = 50 Section Wt. of Diaphrams = 17.4 Kg/M
Dist. From top = 200
Thickness = 6

C. Total Wt. of Girder

W3 = Wt. of Girder = Sec. Wt.(girder + diaphrams + CT Rail) x Span = 2098 Kg

D. Girder Proportions
The limiting girder proportions are given in Cl. 25.1, IS 807-06
a) Span/depth of girder = s/d = 9000 1000 9 < 25 OK
b) Span/Width of girder = s/btf = 9000 400 23 < 60 OK
c) Width/Thk. top plate = bi/ttf = 360 12 30 < 60 OK
d) Min. thickness of web stiffened both horizontally and vertically = d 2/250 (Cl. 6.7.3c), IS 800-84
where d2 = 2xclear [Link] neutral axis from [Link] = 2(Y C-ttf) = 1000 mm
\ Min. thickness of web = d2/250 = 4.0 mm. OK
e) Distance between vertical diaphrams should be between 0.33d and 1.5d (Cl. [Link], IS 800-1984)
where d = clear dist. between horizontal stiffener and tension flange = 800 mm
Spacing of vertical diaphrams = 1000 mm OK.
f) Slenderness Ratio, l = L/ RY, where L = Effective Length = s. l = 57.5

E. Permitted Stresses for IS 2062, 250 Mpa Steel (As per IS 800-84)
a) Max. permissible Bending Compressive Stress (s bc)
Elastic Crritical Stress, fcb = k1(X + k2Y)c2/c1 (Cl 6.2.4, IS 800-84), where k1 = 1 for uniform flanges,
Y = 26.5 x 105/(L/RY)2 = 803 Mpa, X = Y\/[(1 + lT/D)2/20] = 812 Mpa
w = ITF/(ITF+IBF) = ttf2/(ttf2+tbf2) = 0.5 , and Coeff. for inequality of flanges, k2 = 0 (Table 6.4)
c2 = (d + ttf + tbf - Yc)/10 = 51.2 cm, c1 = Yc/10 = 51.2 cm. ... fcb = 812 Mpa
... (s bc) for 250p Mpa Steel = 145 Mpa = 1479 Kgf/cm2 (Table 6.2, IS 800-84)
b) Max. permissible Bending Tensile Stress (s bt)
(sbt) = 0.66 YS(250 MPa) = 165 Mpa = 1683 Kgf/cm2 (Cl. 6.2, IS 800-84)
c) Max. permissible Average Shear Stress (t va)
(t va) = 0.4 YS for unstiffened webs= 100 Mpa = 1020 Kgf/cm2 (Cl. 6.4.2, IS 800-84)
 Page 9

F. Max. Forces on girder

(a) PY = [Link] wheel load = (W1+W ) / 4 =
2 [ 45.0 +10.0 ] / 4 = 13.8 T
(b) PiY =[Link] Wheel Load = (W1Y+W2)/4 = [ 59.4 + 10.0 ] / 4 = 17.4 T
(c) WY = Dead load of girder & platform = W3 + W4 = 2.1 + 1 = 3.1 T
(d) Horizontal inertia force due to LT Travel = b x Vertical Load,
where b = 0.01 \/ LT speed = 0.0548 (Cl. [Link], IS 807-06)

G. Max. Bending Moments

The maximum bending moments will occur when the C/L of the fully loaded crab is at the centre of the
girder as shown below.
PY PY
Y
PiY PiY
L= a= WY= 1
x 3.75 1.5
z

Span, S = 9.00 M
Distance of CT Wheel from end. L= (S-a)/2 3.75 M
Max. Vert.B.M. due to static load, M1 Z = Duty Factor x PY L = 1.06 x 13.8 x L = 54.7 T-M
Max. Vertical [Link] to dynamic load, M2Z = D. F.x PiY L = 1.06 x 17.4 x L = 69.0 T-M
Max. [Link] to dead load M3Z = D.F.x WYS/8 = 1.06 x 3.1 x 9.0 / 8 = 3.7 T-M

Combination 1:
Max. Vertical B.M. under static load, MV1Z = M1Z + M3Z = 54.7 3.7 = 58.4 T-M
+
Max. horizontal B.M. due to LT inertia, MHY = b x MV1Z = 0.0548 x 58.4 = 3.2 T-M

Combination 2:
Max. Vertical B.M. under dynamic load, MV2Z = M2Z + M3Z = 69.0 3.7 = 72.7 T-M
+

H. Max. Stresses

1. Max. bending stresses in compression, sbc

sbc under static & horizontal loads = MV1 Z/ZZC + MHY/ZY = 864 + 121 = 985 Kg/cm2
sbc under dynamic load = MV2Z/ZZC = 73 x 10 5 / 6754 = 1076 Kg/cm2
Max. allowed bending compressive stress, (sbc ) = 1479 Kg/cm2
Hence safe

2. Max. bending stresses in tension, sbt

sbt under static & horizontal loads = MV1Z/ZZT + MHY/ZY = 864 + 121 = 985 Kg/cm2
sbt under dynamic load = MV2Z/ZZ t = 73 x 10 5 / 6754 = 1076 Kg/cm2
(sbt) = [Link] bending tensile Stress = 1683 Kg/cm2 Hence safe

3. Max. shear stress, ta

Max. shear force at end of girder = SF = PiY(S-a/2)/S + WY/2 = 17.5 T

w= 200 mm

Shear Area, As = 2 x 20 x 0.6 = 24 cm2

Ave. Shear Stress = ta= SF / As = 727 Kg/cm2
(ta) = [Link] Average Shear Stress = 1020 Kg/cm2
 Page 10

Hence safe
I. Max. Deflection under full load

Deflection of the girder will be maximum when the fully loaded crab is at the centre of span.
Max. deflection, d = 2 x (PYx103 x S3x106 / (48 xE x IZ) = 0.6 cm
Max. permitted deflection = S/750 = 1.2 cm.
E = Young's Modulus = 2.08 x 106
Hence safe

6 DESIGN OF END CARRIAGE

A. Section Selected Properties

All dimensions in mm
btf btf = 350 Area, A = (btf x ttf + bbf x tbf + 2dtw) / 100 = 180 cm2
ttf = 12 [Link].(without diaphrams) = 0.79A = 142 Kg/M
IX = (btfttf(YC-ttf/2)2 + bbftbf(ttf+d+tbf/2-YC)2 + 2twd3/12)/104
YC YC = 312.0 = 107454 cm4
Z Z
IY =[2dtw{(bi+tw)/2} +ttfbtf /12+tbfbbf /12]/10 =
2 3 3 4
32845 cm4
d = 600
tw tw = 8 Section Modulus (Comp.), ZXC = 10 IZ/YC = 3444 cm3
bi bi = 310 Section Mod (T), ZXT = 10 IZ/(ttf+d+tbf-YC) = 3444 cm3
tbf = 12 Section Modulus (Lateral), ZY = 10 IY/(btf/2)= 1877 cm3
bbf bbf = 350 Radius of Gyration, RY = \
/ (IY/A) = 13.51 cm

B. Girder Proportions
The limiting girder proportions are given in Cl. 25.1, IS 807-06
a) Span/depth of girder = e/d = 9 < 25 OK
b) Span/Width of girder = e/btf = 15 < 60 OK
c) Width/Thk. top plate = bi/ttf = 26 < 60 OK
d) Slenderness Ratio, l = L/ RY, where L = Effective Length = e. l = 66.6

C. Permitted Stresses for IS 2062, 250 Mpa Steel (As per IS 800-84)
a) Max. permissible Bending Compressive Stress (s bc)
Elastic Crritical Stress, fcb = k1(X + k2Y)c2/c1 (Cl 6.2.4, IS 800-84), where k1 = 1 for uniform flanges,
Y = 26.5 x 105/(L/RY)2 = 597 Mpa, X = Y\/[(1 + lT/D)2/20] = 598 Mpa
w = ITF/(ITF+IBF) = ttf2/(ttf2+tbf2) = 0.5 , and Coeff. for inequality of flanges, k2 = 0
(Table 6.4)
c2 = (d + ttf + tbf - Yc)/10 = 31.2 cm, c1 = Yc/10 = 31.2 cm. ... fcb = 598 Mpa
... (s bc) for 250p Mpa Steel = 137 Mpa = 1397 Kgf/cm2 (Table 6.2, IS 800-84)
b) Max. permissible Bending Tensile Stress, (sbt) = 1683 Kgf/cm2 (Cl. 5E(c) above)
c) Max. permissible Average Shear Stress, (tva) = 1020 Kgf/cm2 (Cl. 5E(d) above)
 Page 11

D. Max. Bending Moments

The maximum loading will occur when the fully loaded crab is at the end of the girder as shown below.

Y
PeY = 36.8 PeY = 36.8
W5= 2
Z c = 3.6

e = 5.35

PeY = Max. vert. load = PiY[1+(S-a/2)/S] + WY/2 + W5 + W8 = 36.8 T

Max. Vertical B.M. MX = D.F. (PeY x (e-c) / 2 + W5/8) = 34.4 T-M

E. Max. Stresses

1. Max. bending stresses in compression, sbc

sbc = MX / ZXC = 998.82 Kg/cm2
(sbc ) = 1397 Kg/cm2
Hence safe

2. Max. bending stresses in tension, sbt

sbt = MX / ZXt = 998.82 Kg/cm2
(sbt ) = 1683 Kg/cm2
Hence safe

3. Max. shear stress, ss

[Link] force at end of the EC = Pe Y + W5/2 = 37.8 T
Height of web at end of girder = 300 mm
Shear Area, As = 2 x 30 x 0.8 = 48 cm2
Ave. Shear Stress = ta = SF / As = 788 Kg/cm2
(ta) = [Link] Average Shear Stress = 1020 Kg/cm2
Hence safe