Guidelines For Monorail Design

Doc. No.
: SIP-CIV-GL-001
Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014
Page : 1 of 78
GUIDELINES FOR MONORAIL DESIGN
M. Mohanavel /
15/12/2014 01 Issued for approval M. Mohanavel P.K. Raghuram
P. Rajendran
Date Revision Description of Revision Prepared Checked Approved
This document is property of SIP Ltd. who will safeguard its rights according to the Civil and penal provisions of the law
Doc. No. : SIP-CIV-GL-001
Page : 2 of 78
Revision Summary
Code Date Revision Description of Revision Prepared Checked Approved
M. Mohanavel /
15/12/2014 01 Issued for approval M. Mohanavel P.K. Raghuram
P. Rajendran
Page : 3 of 78
TABLE OF CONTENTS
1. SCOPE AND PURPOSE .........................................................................................................................6
2. REFERENCE DOCUMENTS ...................................................................................................................6
3. GENERAL ...............................................................................................................................................7
3.1 Flange Width Limitation ..................................................................................................................7
3.2 Hangers .........................................................................................................................................7
3.3 Trolley Stops ..................................................................................................................................7
3.4 Monorail Overhangs .......................................................................................................................7
3.5 Joints .............................................................................................................................................8
3.6 Expansion Joints ............................................................................................................................8
3.7 Trolley and Hoist Details ................................................................................................................8
4. DESIGN METHODOLOGY AND CHARTS FOR BS CODES ..................................................................9

4.1 Basics ............................................................................................................................................9
4.2 Loads and Load Factors.................................................................................................................9
4.3 Impact Loads .................................................................................................................................9
4.4 Design Strength .............................................................................................................................9
4.5 Nomenclature ............................................................................................................................... 10
4.6 Design Methodlogy ...................................................................................................................... 12
4.7 Deflection Criteria......................................................................................................................... 13
4.8 Local Flange Check ..................................................................................................................... 14
4.9 Design Charts .............................................................................................................................. 14
5. DESIGN METHODOLOGY AND CHARTS FOR AMERICAN CODES ................................................. 17

5.1 Basics .......................................................................................................................................... 17
5.2 Loads and Load factors ................................................................................................................ 17
5.3 Impact Loads ............................................................................................................................... 17
5.4 Design Strength ........................................................................................................................... 17
5.5 Nomenclature ............................................................................................................................... 18
5.6 Design Methodology .................................................................................................................... 20
5.7 Deflection Criteria......................................................................................................................... 21
5.8 Local Flange Check ..................................................................................................................... 22
5.9 Design Charts .............................................................................................................................. 22
6. LIMITATIONS AND FUTURE DEVELOPMENT .................................................................................... 25

6.1 Limitations .................................................................................................................................... 25
6.2 Future Development..................................................................................................................... 25
Page : 4 of 78
ATTACHMENT A – SAMPLE CALCULATION .............................................................................................26
ATTACHMENT B – SAMPLE VENDOR CATALOGUES ............................................................................. 61
ATTACHMENT C – SAMPLE DETAILS OF MONORAIL ............................................................................. 75

Page : 5 of 78
LIST OF TABLES
1 Guidelines for monorail trolleys and hoists 7
2 Simple span – Monorail net lifting capacity P (in MT) – BS code 14

Overhang spans – Monorail net lifting capacity P (in MT) – BS
3 15
code
4 Simple span – Monorail net lifting capacity P (in MT) – AISC code 22
Overhang spans – Monorail net lifting capacity P (in MT) – AISC
5 23
code
Page : 6 of 78
1. SCOPE AND PURPOSE
The scope of this document is to provide guidelines for monorail design for different codes,
different spans, different load capacities and different end conditions.
The main objectives are:
 to provide the uniform procedure for monorail design
 to provide design charts for different spans and different capacities
 to provide sample design calculation.
 to provide sample vendor details
 to provide typical connection details
2. REFERENCE DOCUMENTS
Saipem Standard
PRG.CP.GEN.0001 - Design Practice – Steel structures for Plants
British Standard
BS 5950-Part1:2000 - Structural use of steel works in buildings
Part 1 – Code of practice for design – Rolled and welded sections.
BS 4-Part1:2000 - Structural steel sections
Part 1 – Specification for hot rolled sections
BS499-Part2-1969 - The use of structural steel in buildings
Part 2 - Specification
American Standard
AISC 360-05-LRFD - Specification for structural steel buildings
AISC - Steel Construction Manual
ASCE/SEI 7-05 - Minimum Design Loads for Buildings and Other Structures
General
CMAA Specification - Crane Manufacturer’s Association of America, Inc (CMAA)
Specification No. 74 – 2000, Specifications for Top Running and
under running single girder electric traveling cranes utilizing under
running trolley hoist.
ANSI MH27.1-2009 - Monorail Manufacturers Association (MMA) – Specification for

Patented Track Under hung Cranes and Monorail Systems.
Page : 7 of 78
SAES-M-001 - Saudi Aramco Engineering Standards – Structural Design Criteria

for Non-Building Structures
B02-E05 - Sabic Engineering Standards – Selection of Monorail Beams
th
Roark’s Formula for Stress and Strain, 7 Edition, Chapter 8 Page 172
3. GENERAL
The document provides design methodology and design charts for monorails, based on British code
(BS 5950-1:2000) and American code (AISC 360:2005-LRFD). Design charts are prepared with UB
sections for British code and S-shape section for American code. Other sections like European
sections, UC British sections and W-shape American sections can also be used for monorails.
However, monorail steel profile should match with the trolley requirement. General monorail
limitations and requirements are provided in the following chapters.
3.1 Flange Width Limitation

Trolley manufacturer has limitations in the monorail flange width. Careful consideration
shall be given, while choosing steel profile for monorail. Refer to table 1 of this document
for suggested flange widths.
3.2 Hangers
Clamps, suspenders/hangers and other fittings from which a monorail is suspended shall
be included as part of the monorail system. Monorail hangers shall support the load
resulting from maximum loading condition. When the monorail is suspended from hangers,
shall be braced to restrain the monorail against damaging lateral and longitudinal
movement.
3.3 Trolley Stops

Stops shall be integral part of the monorail systems and shall prevent a trolley from running
off the open ends of the monorail. Stops shall be designed and provided to resist impact
forces from a fully loaded trolley operating at normal speed.
3.4 Monorail Overhangs

Monorail overhang is the requirement from handling department. The preferred practice is to provide
bracings in the overhang portion of the monorail, both in plan and also in elevation. Due to space
constraints, sometimes may not be possible to provide the bracing. In this document monorail
overhangs are designed without considering the bracing. Typical bracing details are shown in
Attachment C of this document.
Page : 8 of 78
3.5 Joints
All monorail joints shall be provided with web type or other suitable splice. The maximum gap
between ends of the load carrying flange shall not exceed 1.5mm.
3.6 Expansion Joints

Where the monorail system cross building expansion joints, provision shall be made to
accommodate for differential expansion of building and monorail. Expansion can be compensated by
appropriate hanger-rod swing is one possible provision.
3.7 Trolley and Hoist Details

The details of the monorail trolley and hoist are presented in the below table.
TABLE 1 Guidelines for monorail trolleys and hoists
Trolley Weight Weight

of of hand
Min.
Hoist electric operated
No. curve
capacity No. of Wheel Wheel Width of trolley trolley
of Radius
wheels diameter spacing flange and and
axels for
hoist hoist
Monorail
MT Nos. Nos. mm mm m mm kg kg
0.5 2 4 110 200 / 290 1.3 100 to 180 235 16
1.0 2 4 110 200 / 290 1.5 100 to 180 280 25
2.0 2 4 110 200 / 290 1.8 100 to 180 310 59
3.0 2 4 128 230 / 310 2.0 125 to 203 415 78
4.0 2 4 140 / 156 230 / 310 3.0 125 to 203 580 111
5.0 2 4 140 / 156 250 / 330 3.0 125 to 203 745 136
7.5 2/4 4/8 140 / 156 230 / 310 Straight 175 to 300 990 141
10 2/4 4/8 140 / 156 230 / 330 Straight 175 to 300 1290 180
15 2/4 4/8 190 300 Straight 175 to 300 2540 -
20 2/4 4/8 190 300 Straight 175 to 300 2940 -
Note:
 The values provided in the table are referring to different hoist manufacture’s
catalogues. These values are provided as a general guidelines, for exact
values refer the project specific vendor details.
Page : 9 of 78
4. DESIGN METHODOLOGY AND CHARTS FOR BS CODES
4.1 Basics
Monorail beams are designed based on the BS5950-1:2000.The monorail beams are
analysed and designed for the simply supported span and overhang spans. The effect of
lower local flange bending is also addressed in this document.
4.2 Loads and Load Factors

The monorail beam has been designed considering the following load cases:
 Dead load (Ws)
 Operating load (Wo)
 Lateral load (WL)
 Longitudinal load (WLu)
Self-weight of the monorail system is considered as dead load .The operating load includes
the lifting capacity and weight of hoist and trolley.
The following load factors and load combination are considered for the strength check as
per Table 2 of BS 5950-1:2000,
 1.4 Ws + 1.4Wo + 1.4WL + 1.4WLu
The following load factors and load combinations are considered for the serviceability check
as per Table 2 of BS 5950-1:2000,
 1.0 Ws + 1.0 Wo
 1.0 Ws + 1.0 WL
4.3 Impact Loads

The following recommended impact is used in determining the total loads;
 For electrically operated hoist systems, a minimum vertical impact load allowance of 25
percent of the weight to be lifted and, weight of hoist and trolley is considered.
 The lateral force on monorail beams with electrically powered trolleys is calculated as 20
percent of the sum of the rated capacity of the monorail and the weight of the hoist and
trolleys.
 The longitudinal force on the monorail beams are calculated as 10 percent of the rated
capacity of the monorail and the weight of the hoist and trolleys.
4.4 Design Strength

The design strength of steel is considered as 275 N/mm2 (S275JR Grade) as per BS 5950–
1:2000 Table 9.
Page : 10 of 78
4.5 Nomenclature
A - Cross section area of monorail section, mm^2

Av - Shear area, mm^2
Cz1 - Parallel flange co-efficient
D - Overall depth, mm
Du - Factored dead load, kN/m
E - Young’s modulus, N/mm^2
Fc - Axial force, kN
Ixx - Moment of Inertia along xx direction, mm^4
Iyy - Moment of Inertia along yy direction, mm^4
J - Torsional constant, mm^4
L - Monorail span, mm
Le - Effective length of the beam for lateral torsional buckling, m
lfo - Vertical impact factor for operating load
LLf - Lateral load impact factor
Lof - Longitudinal load impact factor
Mbxx - Buckling resistance moment, kNm
Mcxx - Moment capacity for xx axis, kNm
Mcyy - Moment capacity for yy axis, kNm
MLT - Maximum major axis moment in the segment, kNm
MLu - Maximum factored bending moment for lateral loads, kNm
Mvu - Maximum factored bending moment for vertical loads, kNm
Pb - Bending strength, N/mm^2
Pc - Compression capacity, kN
Pv - Shear capacity, kN
Q - Monorail lifting capacity, MT
Sx - Plastic modulus along xx direction, mm^4
Sxz - Maximum stress, N/mm^2
Sx1 - Stress at web and flange interface, N/mm^2
SY - Plastic modulus along yy direction, mm^4
Sz1 - Stress at web and flange interface, N/mm^2
Vu - Maximum shear force, kN
Wb - Weight of hoist and trolley, kg
WL - Lateral load, kN
WLo - Longitudinal load, kN
WLou - Factored longitudinal load, kN
WLu - Factored lateral load, kN
Wo - Operating load with impact, kN
Ws - Self-weight of beam, kN/m
Page : 11 of 78
Wt - Total load, kN
Wu - Factored operating load, kN
Wun - Vertical load per wheel (with impact), kN
Zx - Elastic modulus along xx direction,mm^3
ZY - Elastic modulus along yy direction, mm^3
a - Distance from wheel to flange edge, mm
b - Outstand of compression flange, mm
b1 - Cantilever length from web to load point, mm
bf - Flange width, mm
d - Depth of web, mm
dL - Actual deflection – lateral, mm
dLa - Allowable deflection – lateral, mm
dv - Actual deflection – vertical, mm
dva - Allowable deflection - vertical, mm
e - Constant
gfd - Load factor for dead load
gfl - Load factor for operating load
h - Flange ratio
hs - Distance between shear centers of flanges, mm
mLT - Equivalent uniform moment factor for lateral torsional buckling
mx, my, myx - Equivalent uniform moment factor for flexural buckling
n - Number of wheels in trolley
pc - Compressive strength, N/mm^2
py - Design strength of steel, N/mm^2
r - Root radius, mm
rxx - Radius of gyration along xx, mm
ryy - Radius of gyration along yy, mm
tf - Flange thickness, mm
tp - Additional plate thickness at bottom flange, mm
tw - Web thickness, mm
u - Buckling parameter
v - Slenderness factor
x - Torsional index
 - Slenderness ratio
L - Constant for single web symmetrical section
LT - Equivalent slenderness
Page : 12 of 78
4.6 Design Methodlogy

Resistance of the monorail beam is calculated using following formulas,
a. Moment capacity for the major axis from clause 4.2.5.2 of BS 5950-1 : 2000,
b. Lateral torsional buckling resistance for the members from clause 4.3.6.4 of BS 5950-1
: 2000,
c. Bending Strength from clause B.2.1 & B.2.2 of BS 5950-1:2000,
d. Moment capacity for the minor axis from clause 4.2.5.2 of BS 5950-1:2000,
e. Compression resistance from clause 4.7.4 of BS 5950-1:2000,
f. Compressive Strength from clause C.1 & C.2 of BS 5950-1:2000,

Page : 13 of 78
g. The following interaction ratio is checked for class 1 plastic or class 2 compact cross
section from clause 4.8.3.2 of BS 5950-P1:2000
h. The buckling resistance of a member is verified by the following relationship from

clause 4.8.3.3.2 (c) of BS 5950-P1:2000
i. The lateral torsional buckling resistance of a member is verified by the following

relationship from clause 4.8.3.3.2 (c) of BS 5950-P1:2000
j. The interactive buckling check of a member is verified by the following relationship

from clause 4.8.3.3.2 (c) of BS 5950-P1:2000
k. Shear capacity of a member from clause 4.2.3 of BS 5950-1:2000,
4.7 Deflection Criteria

Unfactored load combinations are considered for deflection check. The deflection limits used as
per Saipem standards is,
 For vertical deflection of simple span = L / 500, where L is in mm.

 For vertical deflection of overhang span = L / 250, where L is in mm.
Page : 14 of 78
4.8 Local Flange Check

The check for local bending of flange due to wheel load is carried by the two different ways such as
CMAA approach and Roark’s formula for stress and strain approach. Local flange capacity can be
improved by adding additional plate at the bottom of flange.
Wun
a
(bf-tw)/2
CMAA method:
Parallel flange Coefficient Cz1 = 2.230 - 1.49L + 1.390 e -18.33L
For single web symmetrical section L = a / ((bf-tw)/2)
Stress at web and Flange interface Sz1 = Cz1 x Wun/ (tf+tp) ²
Roark's Formula for Stress and Strain (7th Edition):
Stress at web and Flange interface Sx1 = Km(6 x Wun)/(tf+tp)²
Constant (From Roark's Formula Table) Km = 0.509
4.9 Design Charts

 Tables 2 and 3 provide the solutions for selection of monorail beam sizes for simple spans and
overhanging spans respectively.
 Loading values shown in tables are net monorail capacity. Impact factors, load factors, trolley
weights are already considered in calculation.
Page : 15 of 78
 Electrically operated trolley is considered for impact factor and trolley loads.
 The local flange capacity (LFC) values shown in the table 2 & 3 are final wheel load that can be
applied on the flanges. This inclusive of impact factor and load factors.
 Two axels or four wheels are considered.
 Material grade S275 JR is considered.
TABLE 2: Simple spans – Monorail net lifting capacity P (in MT)
SECTION
P
LENGTH OF BEAM L (in M)
SECTION
3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
0.9 0.9 0.9 0.5

UB 203X133X25
UB 203X133X30 1.6 1.6 1.2 0.8 0.6
UB 254X146X37 2.1 2.1 2.1 1.4 1.0 0.7
UB 254X146X43 2.9 2.9 2.5 1.8 1.3 0.9 0.7 0.5
UB 305X165X46 2.4 2.4 2.4 2.2 1.6 1.2 0.9 0.6
UB 305X165X54 3.3 3.3 3.3 2.9 2.2 1.6 1.2 0.9
UB 356X171X57 3.0 3.0 3.0 3.0 2.3 1.7 1.3 0.9
UB 406X178X67 3.6 3.6 3.6 3.6 3.0 2.3 1.7 1.3
UB 406X178X74 4.5 4.5 4.5 4.5 3.5 2.7 2.2 1.7
UB 457X191X89 5.4 5.4 5.4 5.4 4.8 3.7 3.0 2.3
UB 533X210X101 5.3 5.3 5.3 5.3 5.3 4.7 3.7 3.1
UB 610X229X113 5.2 5.2 5.2 5.2 5.2 5.2 4.7 3.8
UB 610X229X125 6.6 6.6 6.6 6.6 6.6 6.6 6.6 4.5
UB 610X229X140 8.4 8.4 8.4 8.4 8.4 8.2 6.6 5.4
UB 610X305X179 9.8 9.8 9.8 9.8 9.8 9.8 9.8 9.8

Page : 16 of 78
Note:
 The highlighted values are governed by local flange capacity.
 Empty cells are having capacity less than 0.5 MT.
TABLE 3 Overhang spans – Monorail net lifting capacity P (in MT)
L Lo
SECTION
LENGTH OF BEAM L & LO (in M)

SECTION L 4.0 5.0 6.0 7.0
Lo 1.0 2.0 3.0 1.0 2.0 3.0 1.0 2.0 3.0 1.0 2.0 3.0
0.9 0.2 0.7 0.5 0.3

UB 203X133X25
1.1 0.3 0.9 0.2 0.8 0.2 0.6 0.2
UB 203X133X30
2.1 0.8 0.2 2.1 0.7 0.2 1.4 0.6 0.2 0.9 0.5 0.2
UB 254X146X37
2.8 1.0 0.4 2.3 0.4 1.8 0.7 0.3 1.3 0.6 0.3
UB 254X146X43 0.8
UB 305X165X46 2.4 1.4 0.5 2.4 1.4 0.5 2.2 1.2 0.5 1.6 1.1 0.5
UB 305X165X54 3.4 1.9 0.7 3.4 1.7 0.7 2.9 1.5 0.7 2.1 1.3 0.6
UB 356X171X57 3.0 2.1 0.8 3.0 2.1 0.8 3.0 2.1 0.8 2.2 1.9 0.8
UB 406X178X67 3.6 2.7 1.1 3.6 2.7 1.1 3.6 2.7 1.1 3.0 2.7 1.1
UB 406X178X74 4.5 3.2 1.4 4.5 3.2 1.4 4.5 3.2 1.4 3.5 3.2 1.4
UB 457X191X89 5.5 4.2 2.0 5.5 4.3 2.0 5.5 4.3 2.0 4.7 4.3 2.0
UB 533X210X101 5.3 5.3 2.5 5.3 5.3 2.5 5.3 5.3 2.5 5.3 5.3 2.5
UB 610X229X113 5.2 5.2 3.3 5.2 5.2 3.3 5.2 5.2 3.3 5.2 5.2 3.3
UB 610X229X125 6.6 6.6 3.8 6.6 6.6 3.8 6.6 6.6 3.8 6.6 6.6 3.8
UB 610X229X140 8.4 8.4 4.4 8.4 8.4 4.4 8.4 8.4 4.4 8.4 8.4 4.4
UB 610X305X179 9.8 9.8 8.8 9.8 9.8 8.8 9.8 9.8 8.8 9.8 9.8 8.8
Note:
Page : 17 of 78
5. DESIGN METHODOLOGY AND CHARTS FOR AMERICAN CODES
5.1 Basics
Monorail beams are designed based on the AISC 360-2005: LRFD method. The monorail
beams are analysed and designed for the simply supported span and overhang spans. The
effect of lower local flange bending is also addressed in this document.
5.2 Loads and Load factors

The monorail beam has been designed considering the following load cases:
 Dead load (Ws)
 Operating load (Wo)
 Lateral load (WL)
 Longitudinal load (WLo)
Self-weight of the monorail system is considered on dead loads. The operating load includes
the lifting capacity and weight of hoist and trolley.
The following load factors and load combinations are considered for the strength check as
per clause 2.3.2 of ASCE 7:2005,
 1.2 Ws + 1.6 Wo + 1.6 WL+1.6 WLo
The following load factors and load combinations are considered for the serviceability check
as per clause 2.3.2 of ASCE 7:2005,
 1.0 Ws + 1.0 Wo
 1.0 Ws + 1.0 WL
5.3 Impact Loads

The following recommended impact factors are used in determining the total load as per
clause 4.10.3 of ASCE 7:2005;
 For electrically operated hoist systems, a minimum vertical impact load allowance of 25
percent of the weight to be lifted is considered.
 The lateral force on monorail beams with electrically powered trolleys is calculated as 20
percent of the sum of the rated capacity of the monorail and the weight of the hoist and
trolleys.
 The longitudinal force on the monorail beams are calculated as 10 percent of the rated
capacity of the monorail and the weight of the hoist and trolleys.
5.4 Design Strength

The design strength of steel is considered as 250 N/mm2 (A36 Grade) as per Table V of AISC steel
construction manual (13th Edition).
Page : 18 of 78
5.5 Nomenclature
A - Cross section area of monorail section, mm^2

Aw - Shear area, mm^2
Cv - Web shear coefficient
Cw - Warping constant, mm^6
Cz1 - Parallel flange co-efficient
D - Overall depth, mm
Du - Factored dead load, kN/m
E - Young’s modulus, N/mm^2
Fcrc - Critical stress, N/mm^2
Fe - Elastic buckling stress, N/mm^2
Fy - Design strength of steel, N/mm^2
Ixx - Moment of Inertia along xx direction, mm^4
Iyy - Moment of Inertia along yy direction, mm^4
J - Torsional constant, mm^3
L - Monorail span, mm
Lb - Length between points braced against displacement, mm
LLf - Lateral load impact factor
Lof - Longitudinal load impact factor
Lp - Limiting unbraced length for limit state of yielding, mm
Lr - Limiting unbraced length for inelastic lateral torsional buckling, mm
Mcxx - Design flexural strength in xx axis, kNm
Mcyy - Design flexural strength in yy axis, kNm
Mnxx - Nominal flexural strength in xx axis
Mnyy - Flexural strength in yy axis, kNm
Mrxx - Maximum factored bending moment for vertical loads, kNm
Mryy - Maximum factored bending moment for lateral loads, kNm
Pc - Design axial compressive strength, kN
Pn - Nominal compressive strength, kN
Pr - Axial compressive force, kN
Q - Monorail lifting capacity, MT
Sx - Plastic modulus along xx direction, mm^4
Sxz - Maximum stress, N/mm^2
Sx1 - Stress at web and flange interface, N/mm^2
SY - Plastic modulus along yy direction, mm^4
Sz1 - Stress at web and flange interface, N/mm^2
Vn - Nominal shear strength, kN
Vr - Design shear strength, kN
Page : 19 of 78
Vu - Maximum shear force, kN

Wb - Weight of hoist and trolley, kN
WL - Lateral load, kN
WLo - Longitudinal load, kN
WLou - Factored longitudinal load, kN
WLu - Factored lateral load, kN
Wo - Operating load with impact, kN
Ws - Self-weight of beam, kN/m
Wt - Total load, kN
Wu - Factored operating load, kN
Wun - Vertical load per wheel (with impact), kN
Zx - Elastic modulus along xx direction,mm^3
ZY - Elastic modulus along yy direction, mm^3
a - Distance from wheel to flange edge, mm
b - Outstand of compression flange, mm
b1 - Cantilever length from web to load point, mm
bf - Flange width , mm
d - Depth of web, mm
dL - Actual deflection – lateral, mm
dLa - Allowable deflection – lateral, mm
dv - actual deflection - vertical, mm
dva - Allowable deflection - vertical, mm
gfd - Load factor for dead load
gfl - Load factor for operating load
ho - Distance between flange centroids, mm
lfo - Vertical impact factor for operating load
n - Number of wheels in trolley
ɸ - Resistance factor for flexure
ɸc - Resistance factor for compression
ɸv - Resistance factor for shear
r - Root radius, mm
rts - Effective radius of gyration, mm
rxx - Radius of gyration along xx, mm
ryy - Radius of gyration along yy, mm
tf - Flange thickness, mm
tw - Web thickness , mm
l - Constant for single web symmetrical section
Page : 20 of 78
5.6 Design Methodology

The strength of monorail beam is calculated using AISC 360 - 2005 standards,
a. Design and nominal flexural strength for major axis from chapter F2 of AISC 360-2005,
For limit states of yielding from Equation F2-1 of AISC 360-2005,
Mnxx = Mpxx = Fy Sx
Mcxx = ɸb Mnxx, where ɸb =0.9 (LRFD)
Lateral torsional buckling resistance from Equation F2-2 & F2-3 of AISC 360-2005,
 When Lb < Lp
No lateral torsional buckling
 When Lp < Lb < Lr
Mnxx = Cb ( Mpxx - ( Mpxx - 0.7 Fy x Zx) (( Lb - Lp ) / (Lr - Lp)) <= Mnxx
 When Lb > Lr
Mnxx = Fcrf x Zx <= Mnxx
Fcrf = ( Cb x ² x E/(Lb/rts)² ) x SQRT(1+0.078(Jc/(Zx x ho))(Lb/rts)²
b. Design and nominal flexural strength for minor axis from chapter F2 of AISC 360-2005,
For limit states of yielding from Chapter F6 ( Equation F6-1 ) of AISC 360-2005,
Mnyy = Fy Sy
Mnyy = 1.6 Fy Zy
Mcyy = ɸb Mnyy, where ɸb =0.9 (LRFD)
c. The following interaction ratio are checked for compact and non-compact cross section from
chapter H1 of AISC 360-2005,
Page : 21 of 78
d. The design and the nominal compressive strength of members from Chapter E3 of AISC 360-
2005,
Where,
e. The design and nominal shear strength of members from chapter G2 of AISC 360-2005,
5.7 Deflection Criteria

Unfactored load combinations are considered for deflection check. The deflection limits used as per
Saipem standard is,
 For vertical deflection of simple span = L / 500, where L is in mm.
 For vertical deflection of overhang span = L / 250, where L is in mm.

Page : 22 of 78
5.8 Local Flange Check

The check for local bending of flange due to wheel load is to be carried by the two different ways
such as CMAA approach and Roark’s formula for stress and strain approach. Local flange capacity
can be improved by adding additional plate at the bottom of flange.
Wun
a
(bf-tw)/2
CMAA method:
Parallel flange Coefficient Cz1 = 2.230 - 1.49L + 1.390 e -18.33L
For single web symmetrical section, L = a / ((bf-tw)/2)
Stress at web and Flange interface Sz1 = Cz1 x Wun/(tf+tp)²
Roark's Formula for Stress and Strain (7th Edition) :
Constant (From Roark's Formula Table) Km = 0.509
5.9 Design Charts

 Tables 4 and 5 provide the solutions for selection of monorail beam sizes for simple spans and
overhanging spans respectively.
Page : 23 of 78
 Loading values shown in tables are net monorail capacity. Impact factors, load factors, trolley
weights are already considered in calculation.
 Electrically operated trolley is considered for impact factor and trolley loads.
 Two axels or four wheels are considered.
 Material grade A36 is considered
TABLE 4 Simple spans – Monorail net lifting capacity P (in MT)
SECTION
P
LENGTH OF BEAM L (in M)
SECTION
3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
S8X18.4 1.5 1.0 0.6
S8X23 1.6 1.2 0.8 0.6
S10X25.4 2.2 1.8 1.3 0.8 0.6
S10X35 2.2 2.2 1.8 1.3 1.0 0.7 0.5
S12X31.8 2.7 2.6 1.9 1.3 0.9 0.6
S12X35 2.7 2.7 2.0 1.4 1.0 0.7 0.5
S12X40.8 4.0 3.6 2.7 2.1 1.5 1.1 0.7 0.7
S12X50 4.0 4.0 3.3 2.5 2.0 1.6 1.2 0.9
S15X42.9 3.5 3.5 3.0 2.2 1.6 1.2 0.8 0.6
S15X50 3.5 3.5 3.2 2.4 1.8 1.4 1.0 0.8
S18X54.7 4.3 4.3 4.3 3.2 2.3 1.8 1.4 1.0
S18X70 4.4 4.4 4.4 4.0 3.1 2.4 1.9 1.5
S20X66 5.7 5.7 5.7 4.2 3.2 2.5 2.0 1.6
S20X75 5.7 5.7 5.7 4.7 3.6 2.9 2.2 1.8
S20X86 7.7 7.7 7.7 6.8 5.3 4.2 3.4 2.8
S20X96 7.7 7.7 7.7 7.4 5.8 4.7 3.9 3.2
S24X106 10.4 10.4 10.4 10.4 8.5 6.8 5.5 4.5
S24X121 11.0 11.0 11.0 11.0 9.3 7.6 6.1 5.1

Page : 24 of 78
Note:
 The highlighted values are governed by local flange capacity.
TABLE 5 Overhang spans – Monorail net lifting capacity P (in MT)
L Lo
SECTION
LENGTH OF BEAM L & LO (in M)

SECTION L 4.0 5.0 6.0 7.0
Lo 1.0 2.0 3.0 1.0 2.0 3.0 1.0 2.0 3.0 1.0 2.0 3.0
S8X18.4 0.9 0.2 0.6 0.4 0.2
S8X23 1.0 0.3 0.8 0.2 0.6 0.2 0.4
S10X25.4 1.8 0.5 1.2 0.5 0.8 0.5 0.6
S10X35 2.2 0.9 0.3 1.8 0.8 0.3 1.3 0.7 0.3 1.0 0.6 0.2
S12X31.8 2.6 0.8 0.3 1.9 0.8 0.3 1.3 0.8 0.3 0.9 0.8 0.3
S12X35 2.7 0.9 0.3 2.0 0.9 0.3 1.4 0.9 0.3 1.0 0.9 0.3
S12X40.8 3.6 1.4 0.6 2.7 1.4 0.6 2.1 1.4 0.6 1.5 1.3 0.6
S12X50 4.0 1.8 0.8 3.3 1.8 0.8 2.5 1.7 0.8 2.0 1.5 0.7
S15X42.9 3.5 1.5 0.6 3.0 1.5 0.6 2.2 1.5 0.6 1.6 1.5 0.6
S15X50 3.5 1.7 0.7 3.4 1.7 0.7 2.4 1.7 0.7 1.8 1.7 0.7
S18X54.7 4.3 2.3 0.9 4.3 2.3 0.9 3.2 2.3 0.9 2.3 2.3 0.9
S18X70 4.3 2.9 1.3 4.3 2.9 1.3 4.0 2.9 1.3 3.1 2.9 1.3
S20X66 5.7 3.1 1.4 5.7 3.1 1.4 4.2 3.1 1.4 3.2 3.1 1.4
S20X75 5.7 3.4 1.6 5.7 3.4 1.6 4.7 3.4 1.6 3.6 3.4 1.6
S20X86 7.8 4.9 2.5 7.8 4.9 2.5 6.8 4.9 2.5 5.5 4.9 2.5
S20X96 7.7 5.3 2.8 7.7 5.3 2.8 7.4 5.3 2.8 5.8 5.3 2.8
S24X106 11 7.5 4.0 11 7.5 4.0 11 7.5 4.0 8.5 7.5 4.0
S24X121 11 8.1 4.3 11 8.1 4.3 11 8.1 4.3 9.3 8.1 4.3
Note:
Page : 25 of 78
6. LIMITATIONS AND FUTURE DEVELOPMENT
6.1 Limitations
 This guideline ignores the effect of torsion due to lateral load as the ends of the
monorails are not torsional restrained.
6.2 Future Development

 Curved monorail beam can be included.
 Euro code design can be included.

Page : 26 of 78
ATTACHMENT A – SAMPLE CALCULATION
Example 1: Monorail beam design for British standards - For simply supported span
DESIGN OF MONORAIL (Simply supported and Overhang span) :
(CODE BS 5950: Part 1 :2000 )
Input Data:
Span of monorail L = 4.00 m
Whether monorail has overhang NO NO
Span of overhang portion Lo = 0.00 m
Monorail Lifting Capacity Q = 0.9 MT
Monorail Section size UB 203x133x25 Preferred section
Additional plate thickness at bottom flange tp = 0 mm
Steel grade S275JR
Hoist & Trolley Weight 280 kgs
4.00
UB 203x133x25
0.9 MT
Section Properties:
Flange width bf = 133.2 mm
Flange thickness tf = 7.8 mm
Overall depth D = 203.2 mm
Web thickness tw = 5.7 mm
Root radius r = 7.6 mm
Moment of Inertia along xx axis Ixx = 2.34E+07 mm^4
Moment of Inertia along yy axis Iyy = 3.08E+06 mm^4
Plastic modulus along xx axis Sx = 2.58E+05 mm^3
Plastic modulus along yy axis SY = 7.09E+04 mm^3
Elastic modulus along xx axis Zx = 2.30E+05 mm^3
Elastic modulus along yy axis Zy = 4.62E+04 mm^3
Radius of Gyration along xx axis rxx = 85.6 mm
Radius of Gyration along yy axis ryy = 31.0 mm
Cross-sectional area of Monorail section A = 3200 sq. mm
Material Properties:
Design Strength of Steel py = 275 N/mm^2 (Table 9 BS:5950-1:2000/AISC)
Young's Modulus E = 2.05E+05 N/mm^2 (Cl. 3.1.3 BS:5950-1:2000/AISC)
Load calculation:
Vertical Load:
Self-weight of the beam Ws = 0.246 kN/m
Load factor for dead load gfd = 1.40 (Table 2 of BS 5950-P1:2000)
Factored dead load Du = Ws x gfd
Page : 27 of 78
= 0.246 x 1.40
= 0.345 kN/m
Weight of Hoist and Trolley Wb = 2.75 kN

Monorail Lifting Capacity Q = 8.83 kN
Total load (Lifting Capacity + Trolley + Hoist) Wt = Wb + Q
= 2.746 + 8.83
= 11.57 kN
Vertical Impact factor for operating load Ifo = 25 %

Operating load with Impact Wo = (1+Ifo/100) x Wt
= 1.25 x 11.57
= 14.47 kN
Load factor for operating load gfl = 1.40 (Table 2 of BS 5950-P1:2000)

Factored operating load Wu = Wo x gfl
= 14.47 x 1.40
= 20.25 kN
Lateral Load:
Lateral load factor LLf = 20 %
Lateral load WL = LLf/100 x Wt
= 0.20 x 11.57
= 2.31 kN
Factored Lateral load WLu = WL x gfl

= 2.314 x 1.40
= 3.24 kN
Longitudinal Load:
Longitudinal load factor Lof = 10 %
Longitudinal load WLo = Lof/100 x Wt
= 0.10 x 11.57
= 1.16 kN
Factored Longitudinal load WLou = WLo x gfl

= 1.157 x 1.40
= 1.62 kN
Axial force Fc = WLou/2

= 1.62/2
= 0.81 kN
Maximum Axial force Fc = 0.81 kN
Bending Moment Calculation:
Maximum factored bending moment for

Vertical Loads Mvu1 = Du*L2 / 8 + Wu x L / 4
= (0.345 x 4.00^2 / 8) + (20.25 x 4.00 / 4)
Page : 28 of 78
= 20.94 kN-m
Lateral Load MLu1 = WL x L / 4
= 3.24 x 4.00 / 4
= 3.24 kN-m
Shear Force Calculation:
Maximum shear force Vu1 = Du x L / 2 + Wu

(Load assumed to act directly below the support) = 0.345 x 4.00 / 2 + 20.25
= 20.94 kN
Section classification: (Table 11 BS 5950-1 : 2000)

Constant e = (275/p y)^0.5
= (275/275)^0.5
= 1.00
Outstand of compression flange b = b f/2
= 133/2
= 66.6 mm
b/tf = 8.5
b/tf <= (9 x e) = 9.00 - SECTION PLASTIC
Depth of web d = D- (2 x tf ) - (2 x r)
= 172.4 mm
d/tw = 30.2
d/tw <=(80 x e) = 80.00 - SECTION PLASTIC
Moment Capacities: (For PLASTIC and COMPACT sections) (Cl.4.2.5.2 BS 5950-1 : 2000)
Major Axis (xx - Axis)
Moment Capacity for xx axis MCxx = py Sx
= 275 x 2.58E+05
= 7.10E+07 N.mm
= 70.95 kN-m
Lateral Torsional Buckling Moment Resistance: (Cl.4.3. BS 5950 - 1 : 2000)
Eff. length of the beam for Lateral Torsional Buckling Le1 = 4.00 m (Table 13 BS 5950 - 1 : 2000)
Equivalent slenderness LT = u v   W Cl.4.3.6.7/B.2.3 BS 5950 - 1 : 2000)
Slenderness Ratio  = Le1/ryy

= 4000/31.0
= 129.03
Ratio  = 1-(Iyy/Ixx)  = 0.87 (B.2.3 BS 5950 - 1 : 2000)

0.25
Buckling Parameter u = (4 Sx²/(A² hs²))
Distance bet. Shear centers of flanges hs = 195.4 mm
u = (4 x 2.58E+05^2 x 0.87/(3200^2 x 195.4^2))^0.25

= 0.88
Page : 29 of 78
Flange Ratio (for Equal flange) h = 0.5 (Cl.4.3.6.7 BS 5950 - 1 : 2000)

Torsional Constant J = 1/3 (2 bf tf³+(D-2tf) tw³)
= 1/3(2 x 133.2 x 7.8³ + (203.2 - 2 x 7.8) x 5.7³)
= 5.37E+04 mm^4
Torsional Index x = 0.566hs(A/J)0.5 (B.2.3 BS 5950 - 1 : 2000)

= 0.566 x 195.4 x (3200/5.37E+04)^0.5
= 26.99
Slenderness Factor v = 1/(1+0.05(/x)²)^0.25

= 1/(1+0.05(129.03/26.99)²)^0.25
= 0.827
Ratio W = 1.0 (Cl.4.3.6.9 BS 5950 - 1 : 2000)
Equivalent slenderness LT = 0.88 x 0.827 x 129.03 x sqrt(1.0)

= 93.85
Bending Strength Pb = p E x py/(LT + (LT² - pE x p y)0.5)
(B.2.1 & B.2.2 BS 5950 - 1 : 2000)

0.5
p E =²E/LT² = 229.70 LO = 0.4(²E/p y) = 34.31  LT = 7.0
LT =  LT(LT - LO)/1000 > 0 = 0.417 LT = (py+(LT+1)p E))/2 = 300.24
Pb = 135.99 N/mm^2
Buckling Resistance Moment Mbxx1 = Pb Sx (Cl.4.3.6.4 BS 5950 - 1 : 2000)

= 135.99 x 2.58E+05
= 3.51E+07 N.mm
= 35.09 kN-m
Minor Axis moment capacity (yy - Axis)

Moment Capacity for yy axis Mcyy = p y Sy (Cl.4.2.5.2 BS 5950-1 : 2000)
= 275 x 7.09E+04
= 1.95E+07 N.mm
= 19.50 kN-m
Axial Capacity: (Cl.4.7.4 BS 5950 - 1 : 2000)
Major axis axial capacity

Compression Capacity Pc = A x pc
Slenderness Ratio xx 1 = Le1/rxx

= 4000/85.60
= 46.73
xx = 46.73
(C.1 & C.2 BS 5950-1:2000)
Page : 30 of 78
Compressive strength pcxx = pE x py/( + (² - pE x py)0.5)

0.5
pE =²E/xx² = 926.576 O = 0.2(²E/py) = 17.2 = 2.0
 =  ( - O)/1000 > 0 = 0.059  = (py + ( + 1) pE )) / 2 = 628.191
pcxx = 254.27 N/mm^2
Pcxx = 3200 x 254.27

= 8.14E+05 N
= 813.66 kN
Minor axis axial capacity
Slenderness Ratio yy 1 = Le1/ryy

= 4000/31.00
= 129.03
yy = 129.03
(C.1 & C.2 BS 5950-1:2000)
Compressive strength pcyy = pE x py/( + (² - pE x py)0.5)
0.5
pE =²E/yy² = 121.523 O = 0.2(²E/py) = 17.2 = 3.5
 =  ( -O)/1000 > 0 = 0.392  = (py + ( + 1) pE )) / 2 = 222.054
pcyy = 96.00 N/mm^2
Pcyy = 3200 x 96.00

= 3.07E+05 N
= 307.20 kN
CHECKS:
Check for Major Axis Moment = Mvu/Mcxx
= 20.940/70.950
= 0.295 < 1.0 SAFE
Check for Minor Axis Moment = MLu/Mcyy

= 3.240/19.498
= 0.166 < 1.0 SAFE
Check for Axial Compression = Fc/(A x py)

= 810/(3200 x 275)
= 0.001 < 1.0 SAFE
Interaction Checks
i) Cross-section capacity check
Fc/(A x py)+Mvu/Mcxx + MLu/Mcyy ≤ 1 ( Clause 4.8.3.2 BS:5950 -1-2000 )

810/(3200 x 275) + 20.94/70.95 + 3.24/19.50
= 0.001 + 0.295 + 0.166
= 0.46 < 1.0 SAFE
Page : 31 of 78
ii) Major axis buckling check
Equivalent uniform moment factor mx, my, myx = 0.9 (Table 26 BS 5950 - 1 : 2000)
(for flexural buckling)
(Fc/Pcxx)+((mx x Mvu)/Mcx) x (1+(0.5Fc/Pcx)) + (0.5myx x MLu)/Mcy ≤ 1 (Clause 4.8.3.3.2 BS:5950 -1-2000 )

(0.81/813.66) + (0.9 x 20.94/70.95(1+0.5x(0.81/813.66) + 0.5 x(0.9 x 3.24/19.50)
= 0.00 + 0.27 + 0.07
= 0.34 < 1.0 SAFE
iii) Lateral-torsional buckling check
Equivalent uniform moment factor m LT = 0.85 (Table 18 BS 5950 - 1 : 2000)

(for lateral torsional buckling)
Max. major axis moment in the segment MLT = Mvu1
(Fc/Pcyy)+((m LT x MLT)/Mbxx1)) + ((my x MLu)/Mcy) x (1+Fc/Pcy) ≤ 1 ( Clause 4.8.3.3.2 BS:5950 -1-2000 )

(0.81/307.20) + ((0.85 x 20.94)/35.09) + ((0.9 x 3.24)/19.50) x (1+(0.81/307.20))
= 0.00 + 0.51 + 0.15
= 0.66 < 1.0 SAFE
iv) Interactive buckling check ( Clause 4.8.3.3.2 BS:5950 -1-2000 )
(mx x Mvu(1+0.5(Fc/Pcxx)))/(Mcx(1-Fc/Pcxx))+(my x MLU(1+(Fc/Pcyy)))/(Mcyy(1-Fc/Pcyy)) ≤ 1

(0.9 x 20.94(1+0.5(0.81/813.66)))/(70.95(1-0.81/813.66)) + (0.9x3.24(1+0.81/307.20)))/(19.50 x (1-0.81/307.20))
= 0.27 + 0.15
= 0.42 < 1.0 SAFE
Check for shear capacity

Shear Capacity Pv = 0.6 py Av (Clause 4.2.3, BS :5950-1-2000)
Shear Area Av = tw x D
= 5.7 x 203.2
= 1158 sq. mm
Pv = 0.6 x 275 x 1158.2/1000

= 191.11 kN
Vu/Pv = 20.94/191.11
= 0.11 < 1.0 SAFE
Check for Deflection:
Check for Vertical Deflection

(Load at the mid span)
Actual Deflection -vertical dv1 = (Wt x L3/(48 x E x Ixx)) + (5xWsxL^4/(384 x E x Ixx))
= (11572 x 4000³) /(48 x 2.05E+05 x 2.34E+07) + (5 x 0.246 x 4000^4)/(384 x 2.05E+05 x 2.34E+07)
= 3.217 + 0.171
= 3.388 mm
Allowable Deflection -vertical d va1 = L/500 (Cl. 2.5.2 PRG.CP.GEN.001)

= 8.000 mm
Vertical deflection ratio dv1/d va1 = 0.42 < 1.0 SAFE

Page : 32 of 78
Check for Local bending of flange due to wheel load:
tw
Wun
a
bf (bf-tw)/2
Number of wheels in trolley n = 4 Nos.

Vertical Load per wheel (with impact) Wun = 20.25 / 4
= 5.06 kN
Distance from wheel to flange edge a = 25.0 mm
Method 1: CMAA Procedure
Parallel flange Coefficient Cz1 = 2.230 - 1.49 L + 1.390e-18.33L
For single web symmetrical section L = a/((bf-tw)/2)

= 25/((133.2 - 5.7)/2)
= 0.39
Cz1 = 2.230 -1.49 x 0.39 + 1.390e^(-18.33x0.39)

= 1.65

= 1.650 x 5060/(8 + 0)²
= 137.23 N/mm^2
Method 2: Roark's Formula for Stress and Strain (7th Edition)

(Refer Cl. 8.11 Page 172)
Cantilever length from web to load point b = (bf-tw)/2-a

= (133.2 - 5.7)/2 - 25
= 38.8 mm
Constant (from Table) Km = 0.509
Sx1 = 0.509x(6 x 5060/(8 + 0.00)²

= 254.00 N/mm^2
Maximum stress Sxz = Max (Sz1, Sx1)

= 254.00 N/mm^2
Stress ratio Sxz / py = 253.998/275

= 0.92 < 1.0 SAFE
Page : 33 of 78
Example 2: Monorail beam design for British standards - For simply supported with overhang span
DESIGN OF MONORAIL (Simply supported and Overhang span) :
(CODE BS 5950: Part 1 :2000 )
Input Data:
Whether monorail has overhang YES YES
Span of overhang portion Lo = 1.00 m
Monorail Section size UB 203x133x25 Preferred section
Steel grade S275JR
4.00 1.00
UB 203x133x25
0.9 MT
Section Properties:
Design Strength of Steel py = 275 N/mm^2 (Table 9 BS:5950-1:2000/AISC)
Load calculation:
Vertical Load:
Load factor for dead load gfd = 1.40 (Table 2 of BS 5950-P1:2000)
Page : 34 of 78
= 0.246 x 1.40
= 0.345 kN/m

Total load (Lifting Capacity + Trolley + Hoist) Wt = Wb + Q
= 2.746 + 8.83
= 11.57 kN
Vertical Impact factor for operating load Ifo = 25 %

= 1.25 x 11.57
= 14.47 kN
Load factor for operating load gfl = 1.40 (Table 2 of BS 5950-P1:2000)

= 14.47 x 1.40
= 20.25 kN
Lateral Load:
Lateral load factor LLf = 20 %
= 0.20 x 11.57
= 2.31 kN

= 2.314 x 1.40
= 3.24 kN
Longitudinal Load:
Longitudinal load factor Lof = 10 %
= 0.10 x 11.57
= 1.16 kN

= 1.157 x 1.40
= 1.62 kN
Axial force Fc1 = WLou/2 For simply supported span

= 1.62/2
= 0.81 kN
Axial force Fc2 = WLou For overhang span

= 1.62 kN
Maximum Axial force Fc = 1.62 kN

Page : 35 of 78
a) For simply supported span :

Vertical Loads Mvu1 = Du*L 2 / 8 + Wu x L / 4
= (0.345 x 4.00^2 / 8) + (20.25 x 4.00 / 4)
= 20.94 kN-m
Lateral Load MLu1 = WL x L / 4
= 3.24 x 4.00 / 4
= 3.24 kN-m
b) For overhang span :

Vertical Loads Mvu2 = Du*Lo^2 / 2 + Wu x Lo
= (0.345 x 1.00^2 / 2) + (20.25 x 1.00 )
= 20.42 kN-m
Lateral Load MLu2 = WL x Lo
= 3.24 x 1.00
= 3.24 kN-m

= 20.94 kN
Maximum shear force Vu2 = Du x (L+Lo)^2/2L + Wu(L+Lo)/L
(Load at the free end) = 0.345 x (4.00 + 1.00)²/(2 x 4.00) + 20.25(4.00 + 1.00)/4.00
= 26.39 kN
Section classification: (Table 11 BS 5950-1 : 2000)

Constant e = (275/p y)^0.5
= (275/275)^0.5
= 1.00
Outstand of compression flange b = b f/2
= 133/2
= 66.6 mm
b/tf = 8.5
b/tf <= (9 x e) = 9.00 - SECTION PLASTIC
= 172.4 mm
d/tw = 30.2
d/tw <=(80 x e) = 80.00 - SECTION PLASTIC
Moment Capacities: (For PLASTIC and COMPACT sections) (Cl.4.2.5.2 BS 5950-1 : 2000)
Major Axis (xx - Axis)
Moment Capacity for xx axis MCxx = p y Sx
= 275 x 2.58E+05
= 7.10E+07 N.mm
= 70.95 kN-m
Page : 36 of 78
Lateral Torsional Buckling Moment Resistance: (Cl.4.3. BS 5950 - 1 : 2000)

Equivalent slenderness LT = u v   W Cl.4.3.6.7/B.2.3 BS 5950 - 1 : 2000)

= 4000/31.0
= 129.03
Ratio  = 1-(Iyy/Ixx)  = 0.87 (B.2.3 BS 5950 - 1 : 2000)

0.25
Buckling Parameter u = (4 Sx²/(A² hs²))
Distance bet. Shear centers of flanges hs = 195.4 mm
u = (4 x 2.58E+05^2 x 0.87/(3200^2 x 195.4^2))^0.25

= 0.88
Flange Ratio (for Equal flange) h = 0.5 (Cl.4.3.6.7 BS 5950 - 1 : 2000)

Torsional Constant J = 1/3 (2 bf tf³+(D-2tf) tw³)
= 1/3(2 x 133.2 x 7.8³ + (203.2 - 2 x 7.8) x 5.7³)
= 5.37E+04 mm^4
Torsional Index x = 0.566hs(A/J)0.5 (B.2.3 BS 5950 - 1 : 2000)

= 0.566 x 195.4 x (3200/5.37E+04)^0.5
= 26.99

= 1/(1+0.05(129.03/26.99)²)^0.25
= 0.827
Ratio W = 1.0 (Cl.4.3.6.9 BS 5950 - 1 : 2000)

= 93.85
Bending Strength Pb = p E x p y/(LT + (LT² - p E x p y)0.5)
(B.2.1 & B.2.2 BS 5950 - 1 : 2000)

0.5
p E =²E/LT² = 229.70 LO = 0.4(²E/py) = 34.31  LT = 7.0
LT =  LT(LT - LO)/1000 > 0 = 0.417 LT = (py+(LT+1)p E))/2 = 300.24
Pb = 135.99 N/mm^2

= 135.99 x 2.58E+05
= 3.51E+07 N.mm
= 35.09 kN-m
Page : 37 of 78

Equivalent slenderness LT = u v   W ( Cl.4.3.6.7/B.2.3 BS 5950 - 1 : 2000)

= 3000/31.00
= 96.77

= 1/(1+0.05(96.77/26.99)²)^0.25
= 0.883

= 75.22
Bending Strength Pb = pE x py/(LT + (LT² - pE x py)0.5)

(B.2.1 & B.2.2 BS 5950 - 1 : 2000)
0.5
pE =²E/LT² = 357.56 LO = 0.4(²E/py) = 34.31  LT = 7.0
LT =  LT(LT - LO)/1000 > 0 = 0.286 LT = (py+(LT+1)pE))/2 = 367.411
Pb = 175.94 N/mm^2

= 175.94 x 2.58E+05
= 4.54E+07 N.mm
= 45.39 kN-m
Minor Axis moment capacity (yy - Axis)

Moment Capacity for yy axis Mcyy = py Sy (Cl.4.2.5.2 BS 5950-1 : 2000)
= 275 x 7.09E+04
= 1.95E+07 N.mm
= 19.50 kN-m
Axial Capacity: (Cl.4.7.4 BS 5950 - 1 : 2000)
Major axis axial capacity

Compression Capacity Pc = A x pc
Slenderness Ratio xx 1 = Le1/rxx For simply supported span

= 4000/85.60
= 46.73
xx 2 = Le2/rxx For overhang span

= 3000/85.60
= 35.05
xx = 46.73
Page : 38 of 78
(C.1 & C.2 BS 5950-1:2000)

Compressive strength pcxx = p E x py/( + (² - p E x py)0.5)
0.5
pE =²E/xx² = 926.576 O = 0.2(²E/py) = 17.2 = 2.0
 =  ( - O)/1000 > 0 = 0.059  = (py + ( + 1) pE )) / 2 = 628.191
pcxx = 254.27 N/mm^2
Pcxx = 3200 x 254.27

= 8.14E+05 N
= 813.66 kN
Minor axis axial capacity
Slenderness Ratio yy 1 = Le1/ryy For simply supported span

= 4000/31.00
= 129.03
yy 2 = Le2/ryy For overhang span

= 3000/31.00
= 96.77
yy = 129.03
(C.1 & C.2 BS 5950-1:2000)
Compressive strength pcyy = p E x py/( + (² - p E x py)0.5)
0.5
pE =²E/yy² = 121.523 O = 0.2(²E/py) = 17.2 = 3.5
 =  ( -O)/1000 > 0 = 0.392  = (py + ( + 1) pE )) / 2 = 222.054
pcyy = 96.00 N/mm^2
Pcyy = 3200 x 96.00

= 3.07E+05 N
= 307.20 kN
CHECKS:
Check for Major Axis Moment = Mvu/Mcxx
= 20.940/70.950
= 0.295 < 1.0 SAFE
Check for Minor Axis Moment = MLu/Mcyy

= 3.240/19.498
= 0.166 < 1.0 SAFE
Check for Axial Compression = Fc/(A x py)

= 1620/(3200 x 275)
= 0.002 < 1.0 SAFE
Interaction Checks
i) Cross-section capacity check
Fc/(A x py)+Mvu/Mcxx + MLu/Mcyy ≤ 1 ( Clause 4.8.3.2 BS:5950 -1-2000 )

1620/(3200 x 275) + 20.94/70.95 + 3.24/19.50
= 0.002 + 0.295 + 0.166
= 0.46 < 1.0 SAFE
Page : 39 of 78
ii) Major axis buckling check
Equivalent uniform moment factor mx, my, myx = 0.9 (Table 26 BS 5950 - 1 : 2000)
(for flexural buckling)
(Fc/Pcxx)+((mx x Mvu)/Mcx) x (1+(0.5Fc/Pcx)) + (0.5myx x MLu)/Mcy ≤ 1 (Clause 4.8.3.3.2 BS:5950 -1-2000 )

(1.62/813.66) + (0.9 x 20.94/70.95(1+0.5x(1.62/813.66) + 0.5 x(0.9 x 3.24/19.50)
= 0.00 + 0.27 + 0.07
= 0.34 < 1.0 SAFE
iii) Lateral-torsional buckling check


(0.81/307.20) + ((0.85 x 20.94)/35.09) + ((0.9 x 3.24)/19.50) x (1+(0.81/307.20))
= 0.01 + 0.51 + 0.15
= 0.66 < 1.0 SAFE


(1.62/307.20) + ((1.00 x 20.42)/45.39) + ((0.9 x 3.24)/19.50) x (1+(1.62/307.20))
= 0.01 + 0.45 + 0.15
= 0.61 < 1.0 SAFE
iv) Interactive buckling check ( Clause 4.8.3.3.2 BS:5950 -1-2000 )
(mx x Mvu(1+0.5(Fc/Pcxx)))/(Mcx(1-Fc/Pcxx))+(my x MLU(1+(Fc/Pcyy)))/(Mcyy(1-Fc/Pcyy)) ≤ 1

(0.9 x 20.94(1+0.5(1.62/813.66)))/(70.95(1-1.62/813.66)) + (0.9x3.24(1+1.62/307.20)))/(19.50 x (1-1.62/307.20))
= 0.27 + 0.15
= 0.42 < 1.0 SAFE
Check for shear capacity

Shear Capacity Pv = 0.6 py Av (Clause 4.2.3, BS :5950-1-2000)
Shear Area Av = tw x D
= 5.7 x 203.2
= 1158 sq. mm
Pv = 0.6 x 275 x 1158.2/1000

= 191.11 kN
Vu/Pv = 26.39/191.11
= 0.14 < 1.0 SAFE
Page : 40 of 78
a) For simply supported span:

Actual Deflection -vertical dv1 = (Wt x L3/(48 x E x Ixx)) + (5xWsxL^4/(384 x E x Ixx))
= (11572 x 4000³) /(48 x 2.05E+05 x 2.34E+07) + (5 x 0.246 x 4000^4)/(384 x 2.05E+05 x 2.34E+07)
= 3.217 + 0.171
= 3.388 mm
Allowable Deflection -vertical dva1 = L/500 (Cl. 2.5.2 PRG.CP.GEN.001)

= 8.000 mm
Vertical deflection ratio dv1/dva1 = 0.42 < 1.0 SAFE
b) For overhang span:

(Load at the free end)
Actual Deflection -vertical
dv2 = (Wt x Lo^2(Lo+L)/(3 x E x Ixx)) + (WsxLo(4xLo^2xL-L^3+3 x Lo^3/(24 x E x Ixx))
= 4.021 + -0.096
= 3.924 mm
Allowable Deflection -vertical dva2 = Lo/250 (Cl. 2.5.2 PRG.CP.GEN.001)

= 4.000 mm
Vertical deflection ratio dv2/dva2 = 0.98 < 1.0 SAFE

Actual Deflection -lateral dL2 = (WL x Lo3) / (3 x E x Iyy)
= (2314 x 1000³) /(3 x 2.05E+05 x 3.08E+06) = 1.222 mm
Allowable Deflection -lateral dLa2 = L/250 (Cl. 2.5.2 PRG.CP.GEN.001)

= 4.000 mm
Lateral deflection ratio dL2/dLa2 = 0.31 < 1.0 SAFE

Page : 41 of 78
tw
Wun
a
bf (bf-tw)/2

= 5.06 kN
Parallel flange Coefficient Cz1 = 2.230 - 1.49 L + 1.390e -18.33L

= 25/((133.2 - 5.7)/2)
= 0.39
Cz1 = 2.230 -1.49 x 0.39 + 1.390e^(-18.33x0.39)

= 1.65

= 1.650 x 5060/(8 + 0)²
= 137.23 N/mm^2

Cantilever length from web to load point b = (bf-tw)/2-a

= (133.2 - 5.7)/2 - 25
= 38.8 mm
Constant (from Table) Km = 0.509
Sx1 = 0.509x(6 x 5060/(8 + 0.00)²

= 254.00 N/mm^2
Maximum stress Sxz = Max (Sz1, Sx1)

= 254.00 N/mm^2
Stress ratio Sxz / py = 253.998/275

= 0.92 < 1.0 SAFE
Page : 42 of 78
Example 3: Monorail beam design for American standards - For simply supported span
DESIGN OF MONORAIL (Simply supported & Overhang span):

(CODE AISC 360:2005-LRFD)
Input Data:
Whether monorail has overhang NO NO

Span of overhang portion Lo 0.00 m
Monorail Section size S 8 x 18.4 Preferred section
Steel grade A36
4.00
S 8 x 18.4
0.9 MT
Section Properties:
Torsional Constant J = 1.41E+05 mm^4
Warping Constant Cw = 1.45E+10 mm^6
Design Strength of Steel Fy = 250 N/mm^2 (Table 9 BS:5950-1:2000/AISC)
Page : 43 of 78
Load calculation:
Vertical Load:
Load factor for dead load gfd = 1.20 (Cl. 2.3.2 ASCE 7:2005)

= 0.269 x 1.20
= 0.322 kN/m

Total load (Lifting capacity + Trolley+Hoist) Wt = Wb + Q
= 2.746 + 8.83
= 11.57 kN
Vertical Impact factor for operating load Ifo = 25 % (Cl. 4.10.2 ASCE 7:2005)
= 1.25 x 11.57
= 14.47 kN
Load factor for operating load gfl = 1.60 (Cl. 2.3.2 ASCE 7:2005)
= 14.465 x 1.60
= 23.14 kN
Lateral Load:
Lateral load factor LLf = 20 % (Cl. 4.10.3 ASCE 7:2005)
= 0.20 x 11.57
= 2.31 kN

= 2.314 x 1.60
= 3.70 kN
Longitudinal Load:
Longitudinal load factor Lof = 10 % (Cl. 4.10.4 ASCE 7:2005)
= 0.10 x 11.57
= 1.16 kN

= 1.157 x 1.60
= 1.85 kN
Axial force Pr = WLou/2

= 1.85/2
= 0.93 kN
Maximum Axial force Pr = 0.93 kN

Page : 44 of 78

Vertical Loads Mrxx1 = Du*L2 / 8 + Wu x L / 4
= (0.322 x 4.00^2 / 8) + (23.14 x 4.00 / 4)
= 23.78 kN-m

Lateral Load Mryy1 = WLu x L / 4
= 3.70 x 4.00 / 4
= 3.70 kN-m

= 23.78 kN
Section classification: (Table B4.1 AISC 360:2005)

Flange check:
Outstand of compression flange b = bf/2
= 102/2
= 51.0 mm
b/tf = 4.7
Limiting Width - Thickness Ratios (Flange) 0.38(E/Fy) = 10.88

1.0(E/Fy) = 28.64
Flange classification < 0.38SQRT(E/Fy) = Flange Compact
Web check:
= 164.4 mm
d/tw = 23.8
Limiting Width - Thickness Ratios (Web) 3.76(E/Fy) = 107.67

5.70(E/Fy) = 163.22
Web classification < 3.76SQRT(E/Fy) = Web Compact
Flexural Strength: (For COMPACT and NON COMPACT sections) (Sec. F2 AISC 360:2005)
Yielding in Major Axis (xx - Axis)
Nominal Flexural strength in xx axis Mnxx = Mpxx = Fy Sx (Eq. F2-1 AISC 360:2005)
= 250 x 2.68E+05
= 6.70E+07 N.mm
= 67.00 kN-m
Page : 45 of 78
Lateral Torsional Buckling: (Sec. F2.2 AISC 360:2005)
Length bet. Points braced against displacement Lb1 = 4.00 m

= 4000 mm
Limiting unbraced length Lp = 1.76 x ryy x SQRT(E/Fy) (Eq. F2-5 AISC 360:2005)
(for Limit state of yielding) = 1.76 x 21.10 x SQRT(2.05E+05/250)
= 1063.4 mm
Limiting unbraced length (for Limit state of inelastic lateral-torsional buckling) (Eq. F2-6 AISC 360:2005)
Lr = 1.95 rts E/(0.7Fy)x SQRT(Jc/Zx ho)*SQRT(1+SQRT(1+6.76(0.7 Fy x Zx ho (E x Jc))))
Effective radius of gyration rts = SQRT(Iyy x ho/2Zx)
Distance bet. Flange centeriods ho = D - tf

= 192.2 mm
rts = SQRT(1.56E+06 x 192.2/(2 x 2.36E+05))

= 25.2 mm
Lr = 4791.3 mm
Case-1
Check Lb1 < Lp ? Lb1 > Lp Limit state of lateral-torsional buckling is applicable - Not Case 1
Case-2
Check Lp < Lb1 < Lr ? 1063.4 < 4000 < 4791.3 Case 2
Mn = Cb(Mpxx-(Mpxx-0.7Fy x Zx)((Lb1-Lp)/(Lr-Lp)) <=Mpxx
Lateral-torsional buckling modification factor Cb = 1.0 (Sec. F1 AISC 360:2005)
Mn = 1.0(6.70E+07 - (6.70E+07 - 0.7 x 250 x 2.36E+05) x ((4000.0 - 1063.4) / (4791.3 - 1063.4)))

= 4.68E+07 N.mm
= 46.76 kN-m
Limiting value for case 2 = 46.76 kN-m
Case-3
Check Lb1 > Lr ? 4000 < 4791.3 Not Case 3
(Eq. F2-4 AISC 360:2005)

Critical Stress Fcrf = Cb x ² x E/(Lb/r ts )² x SQRT(1+0.078Jc/(Zxx x ho)(Lb/r ts )²
For a doubly symmetric I-shape c = 1.0 (Eq. F2-8a AISC 360:2005)
Fcrf = 214.11 N/mm^2

Page : 46 of 78
Mnxx = Fcrf x Zxx <= Mp

= 214.11 x 2.36E+05
= 5.05E+07 N.mm
= 50.53 kN-m
Limiting Value for case 3 = 50.53 kN-m
Nominal Flexural Strength Mnxx = 46.80 kN-m (From governing case 1/2/3)
Design Flexural strength in xx axis Mcxx =  Mn
Resistance factor for flexure  = 0.9 (Sec. F1 AISC 360:2005)
Mcxx1 = 0.9 x 46.80

= 42.12 kN-m
Flexural Strength in Minor Axis (yy - Axis) (Sec. F6 AISC 360:2005)

Flexural Strength in yy axis Mnyy = Mpyy = Fy Sy (Eq.F6-1 AISC 360:2005)
= 250 x 5.24E+04
= 1.31E+07 N.mm
= 13.10 kN-m
Limiting Flexural Strength in yy axis = 1.6 x Fy x Zy (Eq.F6-1 AISC 360:2005)

= 1.6 x 250 x 3.05E+04
= 1.22E+07 N.mm
= 12.20 kN-m
Nominal Flexural Strength in yy axis Mnyy = 12.20 kN-m
Design Flexural strength in yy axis Mcyy =  Mn
Mcyy = 0.9 x 12.20

= 10.98 kN-m
Compressive Strength: (Sec. E3 AISC 360:2005)
Nominal Compressive Strength Pn1 = Fcrc x A (Eq. E3-1 AISC 360:2005)
Slenderness Ratio = Le1/ryy

= 4000/21.10
= 189.57
Slenderness Limiting value = 4.71 SQRT(E/Fy)

= 4.71 SQRT(2.05E+05/250)
= 134.87
Page : 47 of 78
189.57 > 134.87 Fcrc = 0.877 Fe (Eq. E3-2,3 AISC 360:2005)
Elastic buckling stress Fe = ²E/(Le1/ryy)²

= 3.1416² x 2.05E+05 / (189.57)²
= 56.30 N/mm^2
Critical Stress Fcrc = 49.37 N/mm^2
Pn1 = 49.37 x 3482

= 1.72E+05 N
= 171.92 kN
Design Axial Compressive Strength Pc1 = c x Pn1 (Sec.E1 AISC 360:2005)
Resistance factor for Compression c = 0.9
Pc1 = 0.9 x 171.92

= 154.73 kN
Design Axial Compressive Strength Pc = 154.73 kN
CHECKS:
Flexural Check for Major Axis = Mrxx/Mcxx
= 23.780/42.121
Flexural Check for Minor Axis = Mryy/Mcyy

= 3.700/10.980
= 0.337 < 1.0 SAFE
Check for Axial Compression = Pr/Pc

= 0.93/154.73
= 0.006 < 1.0 SAFE
Interaction Checks (Sec. H1 AISC 360:2005)
Pr/(2Pc1) + Mrxx1/Mcxx1 + Mryy1/Mcyy1 ≤ 1 (Eq. H1-1b AISC 360:2005)

0.93/(2 x 154.73) + 23.78 / 42.12 + 3.70 /10.98
= 0.003 + 0.565 + 0.337
= 0.90 < 1.0 SAFE
Page : 48 of 78
Check for Shear Strength

Nominal Shear Strength Vn = 0.6 Fy Aw Cv (Eq. G2-1 AISC 360:2005)
Shear Area Aw = tw x D
= 6.9 x 203.0
= 1401 sq. mm
Web shear cooefficient Cv = 1.0 (Eq. G2-2 AISC 360:2005)
Vn = 0.6 x 250 x 1400.7 x 1.0

= 2.10E+05 N
= 210.11 kN
Design Shear Strength Vr = v x Vn (Sec. G1 AISC 360:2005)
Resistance factor for Shear v = 1.0
Vr = 1.0 x 210.11
= 210.11 kN
Vu/Vr = 23.78/210.11
= 0.11 < 1.0 SAFE

Actual Deflection -vertical dv1 = (Wt x L3/(48 x E x Ixx)) + (5xWsxL4/(384 x E x Ixx))
= (11572 x 4000³) /(48 x 2.05E+05 x 2.39E+07) + (5 x 322 x 4000^4)/(384 x 2.05E+05 x 2.39E+07)
= 3.149 + 0.183
= 3.332 mm

= 8.00 mm
Vertical deflection ratio dv1/d va1 = 0.42 < 1.0 SAFE

Page : 49 of 78
tw
Wun
a
(bf-tw)/2
bf

= 5.79 kN

= 25/((102.0 - 6.9)/2)
= 0.53
Cz1 = 2.230 -1.49 x 0.53 + 1.390e^(-18.33x0.53)

= 1.44

= 1.440 x 5790/(11 + 0)²
= 71.48 N/mm^2

Cantilever length from web to load point b1 = (bf-tw)/2-a

= (102.0 - 6.9)/2 - 25
= 22.6 mm
Constant (from Roark's Formula Table) Km = 0.509
Sx1 = 0.509x(6 x 5790/(11 + 0.00)²

= 151.60 N/mm^2
Maximum stress Sxz = Max(Sz1, Sx1)

= 151.60 N/mm^2
Stress ratio Sxz / Fy = 151.60/250

= 0.61 < 1.0 SAFE
Page : 50 of 78
Example 4: Monorail beam design for American standards – For simply supported with overhang
span
DESIGN OF MONORAIL (Simply supported & Overhang span):

(CODE AISC 360:2005-LRFD)
Input Data:
Whether monorail has overhang YES YES
Span of overhang portion Lo 1.00 m
Monorail Section size S 8 x 18.4 Preferred section
Steel grade A36
4.00 1.00
S 8 x 18.4
0.9 MT
Section Properties:
Torsional Constant J = 1.41E+05 mm^4
Warping Constant Cw = 1.45E+10 mm^6
Design Strength of Steel Fy = 250 N/mm^2 (Table 9 BS:5950-1:2000/AISC)
Page : 51 of 78
Load calculation:
Vertical Load:
Load factor for dead load gfd = 1.20 (Cl. 2.3.2 ASCE 7:2005)

= 0.269 x 1.20
= 0.322 kN/m

Total load (Lifting capacity + Trolley+Hoist) Wt = Wb + Q
= 2.746 + 8.83
= 11.57 kN
Vertical Impact factor for operating load Ifo = 25 % (Cl. 4.10.2 ASCE 7:2005)
= 1.25 x 11.57
= 14.47 kN
Load factor for operating load gfl = 1.60 (Cl. 2.3.2 ASCE 7:2005)
= 14.465 x 1.60
= 23.14 kN
Lateral Load:
Lateral load factor LLf = 20 % (Cl. 4.10.3 ASCE 7:2005)
= 0.20 x 11.57
= 2.31 kN

= 2.314 x 1.60
= 3.70 kN
Longitudinal Load:
Longitudinal load factor Lof = 10 % (Cl. 4.10.4 ASCE 7:2005)
= 0.10 x 11.57
= 1.16 kN

= 1.157 x 1.60
= 1.85 kN
Axial force Pr1 = WLou/2 For simply supported span

= 1.85/2
= 0.93 kN
Axial force Pr2 = WLou For overhang span

= 1.85 kN
Maximum Axial force Pr = 1.85 kN

Page : 52 of 78

Vertical Loads Mrxx1 = Du*L2 / 8 + Wu x L / 4
= (0.322 x 4.00^2 / 8) + (23.14 x 4.00 / 4)
= 23.78 kN-m

Lateral Load Mryy1 = WLu x L / 4
= 3.70 x 4.00 / 4
= 3.70 kN-m

Vertical Loads Mrxx2 = Du*Lo2 / 2 + Wu x L o
= (0.322 x 1.00^2 / 2) + (23.14 x 1.00 )
= 23.30 kN-m
Lateral Load Mryy2 = WL x Lo
= 3.70 x 1.00
= 3.70 kN-m

= 23.78 kN
Maximum shear force Vu2 = Du x (L+Lo)^2/2L + Wu(L+Lo)/L

(Load at the free end) = 0.322 x (4.00 + 1.00)²/(2 x 4.00) + 23.14(4.00 + 1.00)/4.00
= 29.93 kN
Section classification: (Table B4.1 AISC 360:2005)

Flange check:
Outstand of compression flange b = bf/2
= 102/2
= 51.0 mm
b/tf = 4.7
Limiting Width - Thickness Ratios (Flange) 0.38 (E/Fy) = 10.88

1.0(E/Fy) = 28.64
Flange classification < 0.38SQRT(E/Fy) = Flange Compact
Page : 53 of 78
Web check:
= 164.4 mm
d/tw = 23.8
Limiting Width - Thickness Ratios (Web) 3.76(E/Fy) = 107.67

5.70 (E/Fy) = 163.22
Web classification < 3.76SQRT(E/Fy) = Web Compact
Flexural Strength: (For COMPACT and NON COMPACT sections) (Sec. F2 AISC 360:2005)
Yielding in Major Axis (xx - Axis)
Nominal Flexural strength in xx axis Mnxx = Mpxx = Fy Sx (Eq. F2-1 AISC 360:2005)
= 250 x 2.68E+05
= 6.70E+07 N.mm
= 67.00 kN-m
Lateral Torsional Buckling: (Sec. F2.2 AISC 360:2005)

= 4000 mm
= 1063.4 mm
Lr = 1.95 rts E/(0.7Fy)x SQRT(Jc/Zx ho)*SQRT(1+SQRT(1+6.76(0.7 Fy x Zx ho (E x Jc))))

= 192.2 mm
rts = SQRT(1.56E+06 x 192.2/(2 x 2.36E+05))

= 25.2 mm
Lr = 4791.3 mm
Case-1
Page : 54 of 78
Case-2
Mn = 1.0(6.70E+07 - (6.70E+07 - 0.7 x 250 x 2.36E+05) x ((4000.0 - 1063.4) / (4791.3 - 1063.4)))

= 4.68E+07 N.mm
= 46.76 kN-m
Case-3
(Eq. F2-4 AISC 360:2005)

Critical Stress Fcrf = Cb x ² x E/(Lb/rts )² x SQRT(1+0.078Jc/(Zxx x ho)(Lb/r ts )²
Fcrf = 214.11 N/mm^2
Mnxx = Fcrf x Zxx <= Mp

= 214.11 x 2.36E+05
= 5.05E+07 N.mm
= 50.53 kN-m
Mcxx1 = 0.9 x 46.80

= 42.12 kN-m

= 3000 mm
= 1063.4 mm
Lr = 1.95 r ts E/(0.7Fy)x SQRT(Jc/Zx ho)*SQRT(1+SQRT(1+6.76(0.7 Fy x Zx ho (E x Jc))))
Page : 55 of 78

= 192.2 mm
rts = SQRT(1.56E+06 x 192.2/(2 x 2.36E+05))

= 25.2 mm
Lr = 4791.3 mm
Case-1
Case-2
Mn = 1.0(6.70E+07 - (6.70E+07 - 0.7 x 250 x 2.36E+05) x ((3000.0 - 1063.4) / (4791.3 - 1063.4)))

= 5.36E+07 N.mm
= 53.65 kN-m
Case-3
(Eq. F2-4 AISC 360:2005)

Critical Stress Fcrf = Cb x ² x E/(Lb/r ts )² x SQRT(1+0.078Jc/(Zxx x ho)(Lb/rts )²
Fcrf = 300.69 N/mm^2
Mnxx = Fcrf x Zx <= Mp

= 300.69 x 2.36E+05
= 7.10E+07 N.mm
= 70.96 kN-m
Mcxx2 = 0.9 x 53.68

= 48.31 kN-m
Page : 56 of 78
Flexural Strength in Minor Axis (yy - Axis) (Sec. F6 AISC 360:2005)

Flexural Strength in yy axis Mnyy = Mpyy = Fy Sy (Eq.F6-1 AISC 360:2005)
= 250 x 5.24E+04
= 1.31E+07 N.mm
= 13.10 kN-m
Limiting Flexural Strength in yy axis = 1.6 x Fy x Zy (Eq.F6-1 AISC 360:2005)

= 1.6 x 250 x 3.05E+04
= 1.22E+07 N.mm
= 12.20 kN-m
Nominal Flexural Strength in yy axis Mnyy = 12.20 kN-m
Design Flexural strength in yy axis Mcyy =  Mn
Mcyy = 0.9 x 12.20

= 10.98 kN-m
Compressive Strength: (Sec. E3 AISC 360:2005)
Nominal Compressive Strength Pn1 = Fcrc x A (Eq. E3-1 AISC 360:2005)

= 4000/21.10
= 189.57

= 4.71 SQRT(2.05E+05/250)
= 134.87
189.57 > 134.87 Fcrc = 0.877 Fe (Eq. E3-2,3 AISC 360:2005)

= 3.1416² x 2.05E+05 / (189.57)²
= 56.30 N/mm^2
Pn1 = 49.37 x 3482

= 1.72E+05 N
= 171.92 kN
Pc1 = 0.9 x 171.92

= 154.73 kN
Page : 57 of 78
Nominal Compressive Strength Pn = Fcrc x A (Eq. E3-1 AISC 360:2005)

= 9000/21.10
= 426.54

= 4.71 SQRT(2.05E+05/250)
= 134.87
426.54 > 134.87 Fcrc = 0.877 Fe (Eq. E3-2,3 AISC 360:2005)

= 3.1416² x 2.05E+05 / (426.54)²
= 11.12 N/mm^2
Pn2 = 9.75 x 3482

= 3.40E+04 N
= 33.96 kN
Pc2 = 0.9 x 33.96

= 30.56 kN
Design Axial Compressive Strength Pc = 30.56 kN
CHECKS:
Flexural Check for Major Axis = Mrxx/Mcxx
a ) For simply supported span = 23.780/42.121

= 0.565 < 1.0 SAFE
b ) For overhang span = 23.300/48.312

= 0.482 < 1.0 SAFE
Flexural Check for Minor Axis = Mryy/Mcyy

= 3.700/10.980
= 0.337 < 1.0 SAFE
Check for Axial Compression = Pr/Pc

= 1.85/30.56
= 0.061 < 1.0 SAFE
Page : 58 of 78
Interaction Checks (Sec. H1 AISC 360:2005)
a ) For simply supported span:

0.93/(2 x 154.73) + 23.78 / 42.12 + 3.70 /10.98
= 0.003 + 0.565 + 0.337
= 0.90 < 1.0 SAFE
b ) For overhang span:

1.85/(2 x 30.56) + 23.30 / 48.31 + 3.70 /10.98
= 0.030 + 0.482 + 0.337
= 0.85 < 1.0 SAFE
Check for Shear Strength

Nominal Shear Strength Vn = 0.6 Fy Aw Cv (Eq. G2-1 AISC 360:2005)
Shear Area Aw = tw x D
= 6.9 x 203.0
= 1401 sq. mm
Web shear cooefficient Cv = 1.0 (Eq. G2-2 AISC 360:2005)
Vn = 0.6 x 250 x 1400.7 x 1.0

= 2.10E+05 N
= 210.11 kN
Design Shear Strength Vr = v x Vn (Sec. G1 AISC 360:2005)
Resistance factor for Shear v = 1.0
Vr = 1.0 x 210.11
= 210.11 kN
Vu/Vr = 29.93/210.11
= 0.14 < 1.0 SAFE

Actual Deflection -vertical dv1 = (Wt x L3/(48 x E x Ixx)) + (5xWsxL4/(384 x E x Ixx))
= (11572 x 4000³) /(48 x 2.05E+05 x 2.39E+07) + (5 x 322 x 4000^4)/(384 x 2.05E+05 x 2.39E+07)
= 3.149 + 0.183
= 3.332 mm

= 8.00 mm
Vertical deflection ratio d v1/dva1 = 0.42 < 1.0 SAFE

Page : 59 of 78

(Load at the free end)
Actual Deflection -vertical

d v2 = (Wt x Lo^2(Lo+L)/(3 x E x Ixx)) + (WsxLo(4xLo^2xL-L^3+3 x Lo^3/(24 x E x Ixx))
= 3.937 + -0.103
= 3.834 mm
Allowable Deflection -vertical d va2 = Lo/250 (Cl. 2.5.2 PRG.CP.GEN.001)

= 4.000 mm
Vertical deflection ratio d v2/d va2 = 0.96 < 1.0 SAFE

Actual Deflection -lateral dL2 = (WL x Lo3) / (3 x E x Iyy)
= (2314 x 1000³) /(3 x 2.05E+05 x 1.56E+06) = 2.412 mm
Allowable Deflection -lateral dLa2 = Lo/250 (Cl. 2.5.2 PRG.CP.GEN.001)

= 4.000 mm
Lateral deflection ratio d L2/dLa2 = 0.60 < 1.0 SAFE
tw
Wun
a
(bf-tw )/2
bf
Page : 60 of 78

= 5.79 kN

= 25/((102.0 - 6.9)/2)
= 0.53
Cz1 = 2.230 -1.49 x 0.53 + 1.390e^(-18.33x0.53)

= 1.44

= 1.440 x 5790/(11 + 0)²
= 71.48 N/mm^2

Cantilever length from web to load point b1 = (bf-tw)/2-a

= (102.0 - 6.9)/2 - 25
= 22.6 mm
Constant (from Roark's Formula Table) Km = 0.509
Sx1 = 0.509x(6 x 5790/(11 + 0.00)²

= 151.60 N/mm^2
Maximum stress Sxz = Max(Sz1, Sx1)

= 151.60 N/mm^2
Stress ratio Sxz / Fy = 151.60/250

= 0.61 < 1.0 SAFE
Page : 61 of 78
ATTACHMENT B – SAMPLE VENDOR CATALOGUES

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ATTACHMENT C – SAMPLE DETAILS OF MONORAIL

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Guidelines For Monorail Design

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Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

GUIDELINES FOR MONORAIL DESIGN

Date Revision Description of Revision Prepared Checked Approved

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

Code Date Revision Description of Revision Prepared Checked Approved

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

1. SCOPE AND PURPOSE .........................................................................................................................6

2. REFERENCE DOCUMENTS ...................................................................................................................6

4. DESIGN METHODOLOGY AND CHARTS FOR BS CODES ..................................................................9

5. DESIGN METHODOLOGY AND CHARTS FOR AMERICAN CODES ................................................. 17

6. LIMITATIONS AND FUTURE DEVELOPMENT .................................................................................... 25

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

ATTACHMENT A – SAMPLE CALCULATION .............................................................................................26

ATTACHMENT B – SAMPLE VENDOR CATALOGUES ............................................................................. 61

ATTACHMENT C – SAMPLE DETAILS OF MONORAIL ............................................................................. 75

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

1 Guidelines for monorail trolleys and hoists 7

2 Simple span – Monorail net lifting capacity P (in MT) – BS code 14

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

1. SCOPE AND PURPOSE

The main objectives are:

 to provide the uniform procedure for monorail design

 to provide design charts for different spans and different capacities

 to provide sample design calculation.

 to provide sample vendor details

 to provide typical connection details

ANSI MH27.1-2009 - Monorail Manufacturers Association (MMA) – Specification for

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

SAES-M-001 - Saudi Aramco Engineering Standards – Structural Design Criteria

B02-E05 - Sabic Engineering Standards – Selection of Monorail Beams

3.1 Flange Width Limitation

3.3 Trolley Stops

3.4 Monorail Overhangs

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

3.6 Expansion Joints

3.7 Trolley and Hoist Details

Trolley Weight Weight

0.5 2 4 110 200 / 290 1.3 100 to 180 235 16

1.0 2 4 110 200 / 290 1.5 100 to 180 280 25

2.0 2 4 110 200 / 290 1.8 100 to 180 310 59

3.0 2 4 128 230 / 310 2.0 125 to 203 415 78

15 2/4 4/8 190 300 Straight 175 to 300 2540 -

20 2/4 4/8 190 300 Straight 175 to 300 2940 -

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

4. DESIGN METHODOLOGY AND CHARTS FOR BS CODES

4.2 Loads and Load Factors

4.3 Impact Loads

4.4 Design Strength

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

A - Cross section area of monorail section, mm^2

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

4.6 Design Methodlogy

c. Bending Strength from clause B.2.1 & B.2.2 of BS 5950-1:2000,

e. Compression resistance from clause 4.7.4 of BS 5950-1:2000,

f. Compressive Strength from clause C.1 & C.2 of BS 5950-1:2000,

Guidelines for Monorail Design Rev.: 01 Date : 15/12/2014

h. The buckling resistance of a member is verified by the following relationship from

i. The lateral torsional buckling resistance of a member is verified by the following

j. The interactive buckling check of a member is verified by the following relationship

k. Shear capacity of a member from clause 4.2.3 of BS 5950-1:2000,

4.7 Deflection Criteria