J6 - NEW Luffing Boom

Objekt : Codelco-Chile, Gaby Plant Part : J6
Leach Pad Stacking, Ripios Reclaim

and Ripios Disposal Systems
Order No . : MTF Order No: G 0197.10 Chapter :
Client Project No: C-475
TAKRAF GmbH * Torgauer Str . 336 * 04347 Leipzig page : 1
Structural Calculation
for
New Luffing Boom

of
Mobile Stacking Bridge 160-ME-001
Engineers in charge
Structural engineering
Calculation Müller, W.
Leipzig, 16.06.2010
Mechanical engineering
Revision Date By Remarkes
Rev.:
Order No . : MTF Order No: G 0197.10 Chapter :
0. General
1. Loads
2. Load combinations for overall structural calculation
4. Stress verification
4.0. Von Mises stresses for the complete steelwork
4.1. Boom lower chord
4.2. Boom upper chord
4.3. Boom horizontal cross beams
4.4. Boom vertical beams
4.5. Boom Bracing
4.6. Adapter horizontal beam for belt support
4.7. Adapter main wall beams
4.8. Adapter horizontal cross beams
4.9. Adapter bracings
4.10. FE-Detail for Mounting the Cylinder at Boom
4.11. FE-Detail for Mounting the Cylinder at Adapter
4.12. FE-Detail for Safety Rod
4.13. Mounting of Safety Rod
4.14. FE-Detail for Support of the Adapter
4.15. Verification of pins
5. Hydraulic cylinder data
Rev.:
Order No . : MTF Order No: G 0197.10 Chapter : 1.
J6 New Luffing Boom
0. General
The new luffing boom is designed in accordance with the following standards:
ISO 5049/1 Load assumption und superimposition of loads

Additional to the loads according to ISO 5049/1 imact loads due to falling
material into the receiving chute will be considered.
DIN 18800 The stress assessmet and the stability verifications (buckling of members)
Part 01+02
AISC Design of bolts (all bolts according to ASTM A325)

13 th edition
The load assumptions of ISO 5049/1 are basing on the method of Allowable Stress Design (ASD).
These allowable stresses are safeguarded against the yield strength with the folowing
safety factors:
LC I νLC I = 1,50
LC II νLC II = 1,33
LC III, IV, V νLC III-V = 1,20
LC VI νLC VI = 1,10
The DIN 18800 and the AISC 13th Edition are basing on Limit Resistance Force Design (LRFD)
with a material factor γM and a force factor γF.
The safety factor ν is identical with ν= γM*γF
Setting γM = 1,00
ν= γF
All superimposed loads will be amplified with the factor ν!

The comuted stresses, basing on the amplified loads, will be related with the yield stress σy!
The structural calculation is carried out as a Finite Element Analysis.

The complete steelwork is computed with the FE-program KRASTA, basing on stick elements.
Detail areas are computed with ANSYS basing on shell elements
Rev.:
J6 New Luffing Boom

1. Loads
Dead load DL
[kg] x [m] y [m] z [m]
steelwork new luffing boom 8.700 -12,800 0,000 -0,405
steelwork adapter 8.750 -4,330 0,000 0,686
safety rod 1.500 -8,470 0,000 2,156
walkway adapter 1.150 -3,030 0,400 -0,344
walkway new luffing boom 2.500 -13,600 0,000 -0,944
GPS support 2.500 -4,060 0,000 2,856
chute 2.000 -15,596 0,000 -0,044
liner plates 2.050 -15,875 0,000 -0,124
steelstructure 29.150 -9,376 0,016 0,335
pulley 2.300 -20,640 0,000 -1,570

bent pulley 900 -6,670 0,000 -0,590
belt adapter 690 -2,920 0,000 -1,160
belt boom 1.715 -13,620 0,000 -1,170
idler adapter 440 -3,410 0,000 -0,300
idler boom 5.738 -15,240 0,000 -1,200
belt cleaner 200 -15,600 0,000 -1,360
cable 265 -6,400 -1,400 0,100
Zylinder 3.200 -6,950 0,000 3,060
mechanic 15.448 -12,613 -0,024 -0,286
DL dead load 44.598 -10,498 0,002 0,210
Rev.:
Operating live load LLo
B [m] 1,600 α [°] 40

b [m] 1,39 β [°] 25
l3 [m] 0,545
S1 [m²] 0,1105
S2 [m²] 0,2359
Σ S [m²] S1 + S 2 = 0,3464
γ [t/m³] 1,60
Load per Meter for 100% nominal belt capacity

p [t/m] 0,554
Conveyor material
LLo 554 kg * 19,25 m = 10.665 kg
Live load LL
LL spillage 10% LLo 1.066 kg

incrustation chute 1.760 kg
2.826 kg
Rev.:
Upset live load LLu
Clogging chutes (Receiving chute)
LLu max. capacity of chute 9,3 m³

density 1,6 t/m³
weight 14.880 kg
centric and eccentric considered eccentricity: 60% - 40%
additional there is still considered the weight of incrustation
considered in incrustation: 1.760 kg
total weight of LLu 16.640 kg

163,2 kN
Impact Loads IL
Along the conveyor 10,0 % of conveyor material
10% LLo 1.066 kg

10,7 kN
Rev.:
Transfer points
At transfer points the vertical force due to falling material.
h= 2,5 m
belt speed 5,3 m/s
Pz IL = 14,40 kN
Pz = 1,0 * fn * v n * h
g
fn = 5,54 kN/m
vn = 5,30 m/s
h= 2,5 m
g= 10 m/s²
Pz = 14,68 kN
25,35 kN
Belt tension BT
Belt tension T = 160kN
rear pulley
T3
X= 320 kN
X Z= 0 kN
T3
Z
bend pulley
T3
X= -23,4 kN
X Z= -83,3 kN
T3
Rev.:
Wind Load WL
Standard UBC 97 Part 2

max. storm wind velocity v= 33,3 m/s
v= 120,0 km/h
Velocity pressure qs = v²/16/100

qs = 0,694 kN/m²
Design wind pressure P= Iw*Cq*Ce*fred*qs
Importance factor Iw = 1,0

Pressure coefficients Cq = 1,3 vertical projected area
up to 12,2m
Cq = 1,4 vertical projected area
higher 12,2m
Reducing factor in dependence of the altitude of site:
Altitude of site: 2700 m
Average barometric press. 0m 103,2 kPa

Average barometric press. 2700m 74,5 kPa
fred = 74,5/103,2 = 0,722

P=
Height Ce f red = Iw*Cq*Ce*fred*qs
[m] [ft] [kN/m²]
18,3 60 1,73 0,722 1,127
15,2 50 1,67 0,722 1,088
12,2 40 1,62 0,722 1,056
9,1 30 1,54 0,722 1,004
7,6 25 1,5 0,722 0,978
6,1 20 1,45 0,722 0,945
4,6 15 1,39 0,722 0,906
0,0 0 1,39 0,722 0,906
Exposure D
Rev.:
Wind force WL = P*A f
Af will be determined in accordance with the shape of the particular elements of

the stacking, reclaiming and disposal system!
The above mentioned wind loads are the maximum wind loads = design wind loads =
= wind out of service
The maximum service wind velocity v= 22,2 m/s

v= 80,0 km/h
Velocity pressure qs = v²/16/100

operational wind qs = 0,309 kN/m²
Ration between operational wind and maximum wind:
f= 0,444
Wind loads luffing boom:
h= 7,6 m above the ground
P= 0,978 kN/m²
Wind in y-direction (across the conveying direction)
Truss area:
h [m] l [m] W [kN]
Upper cord 0,250 30,1 7,35
Lower chord 0,250 40,8 9,97
Vertical member
or 0,200 21,0 4,1
Diagonal member 0,200 14,2 2,8
fixed part 0,300 59,6 17,48
Σ WLy [kN] 41,68
Rev.:
Belt area
h [m] l [m] W [kN]
Carrying belt 0,400 20,4 7,98
Return belt 0,225 21,1 4,64
Σ WLy [kN] 12,62
ΣΣ WLy [kN] 54,30
Single areas:
Receiving chute
Chute A= 8,50 m²
WLy = 8,31 kN
Return pulley
Dm 850 A= 0,57 m²
WLy = 0,55 kN
Zylinder A= 2,96 m²
WLy = 2,89 kN
Σ WLy = 63,16 kN
Seismic Load EL (Standard NCH 2369 - 2003)
Base shear Q0 = C*I*P
Importance factor I= 1,0
Seismic coeffizient C= 2,75*A 0/(g*R)*(T'/T*)n*(0,05/ξ)0,4
*) Maximum effective A0 = 0,3 *g Table 5.2

ground acceleration
Structural response R= 5,0 Table 5.6, Line 3.1

modification factor
Parameter relative to type T'= 0,35 s

of foundation ground n= 1,33 Table 5.4, Soil type II
Rev.:
Damping ratio ξ= 0,02 Techn. Specification

N°100-M-ET-13, Clause 4.9.6
Vibration fundament. period T*= 0,33 s appr. 3,0Hz
C= 0,257 > Cmax = 0,195

Table 5.7
0,26*0,75= 0,195
Horizontal seismic forces according to NCH 2369
ELh = Qo = 0,195 *P
Vertical seismic action Fv = +/- 2/3 (A 0/g)*I*P
ELv = Fv = 0,200 *P
P= DL + 0,7*(LL + LL o )
(See Design Criteria N° 000-C-CD-001, Clause 5.3.3)
Rev.:
2. Load combinations for overall structural calculation

Superimposition according to ISO 5049/1
160-ME-001 NEW luffing boom mobile stacking bridge

LC "H" LC "HZ" LC "HZS" LC "HZS" LC "HZS" LC "HZG"
Normal Normal oper. + Chute clogging+ Out of operation Earthquake Earthquake
operation operation. wind operation. wind + design wind
Safety factor ν 1,50 1,33 1,20 1,20 1,20 1,10
DL 1,0 1,0 1,0 1,0 1,0 1,0
LL Spillage+incrust. 1,0 1,0 1,0 1,0 1,0 1,0
LLo Operat. live load 1,0 1,0 1,0 1,0 1,0 1,0
100% belt capacity
IL Impact load 1,0 1,0 1,0 1,0 1,0
LLu Chute clogging 1,0 1,0
BT 1,0 1,0 1,0 1,0 1,0 1,0
TL 1,0 1,0 1,0 1,0 1,0
WL 0,44 0,44 1,0
EL 1,0 1,0
LC I LC II LC III LC IV LC V LC VI
DL dead load
LL live load = spillage = 10% of conveyor material + incrustation of chutes
LLo operating live load include conveyor material (100% belt cross section)
LLu clogged chutes with 100% chute volume
BT belt tension, maximum value from running mode
IL along the length of conveyor: 10% of conveyor material

impact load include: at transfer points: falling material
TL temperature load
WL design wind load 120km/h

Wind loads will be calculated in two orthogonal directions!
WL = +/- 1,0*WLy or +/- 1,0*WLx
EL earthquake load
Earthquake loads will be calculated as follows:
EL = +/- 1,0*Ehorizontal x or +/- 1,0*Ehorizontal y
+/- 1,0*Evertical +/- 1,0*Evertical
Rev.:
3. KRASTA Input
Dead Load DL
loads, load case: DL_dead_load
total of node loads : .0 , .0 , -214.10398 [kN]

total of beam conc. loads : .0 , .0 , .0 [kN]
total of distrib. loads : .0 , .0 , -235.94388 [kN]
total of all forces : .0 , .0 , -450.04786 [kN]
total of node moments : .0 , .0 , .0 [kNcm]
total of beam conc. moments: .0 , .0 , .0 [kNcm]
total of distrib. moments : .0 , .0 , .0 [kNcm]
total of all moments : .0 , .0 , .0 [kNcm]
reference point : .0 , .0 , .0 [cm]
resulting moments : 364.0188, -4.7254E+05, .0 [kNcm]
intersection point of resulting force
with x-y plane: -1049.97, -.81, .0 [cm]
Values according to chapter 5.4 ∑ DL = 446,0 kN

Operating Live Load LLo
Values according to chapter 5.4 ∑ LLo = 106,6 kN

Live Load LL
Values according to chapter 5.4 ∑ LL = 28,3 kN

Upset Live Load LLu
Values according to chapter 5.4 ∑ LLu = 148 kN

Impact Load IL
Values according to chapter 5.4 ∑ IL = 25,35 kN

Belt Tension BT
Values according to chapter 5.4 ∑ BTx = 296,6 kN

∑ BTz = 83,3 kN
Wind Load WLy
Values according to chapter 5.4 ∑ WLy = 63,2 kN

Seismic Load Elv
loads, load case: ELv_
total of node loads : .0 , .0 , 66.1168 [kN]

total of distrib. loads : .0 , .0 , 63.6164 [kN]
total of all forces : .0 , .0 , 129.7332 [kN]
resulting moments : -72.8038, 1.4905E+05, .0 [kNcm]
with x-y plane: -1148.93, -.56, .0 [cm]
Values according to chapter 5.4 ∑ ELv = 128,9 kN

Seismic Load Elhx
loads, load case: ELhx_
total of node loads : 64.46388, .0 , .0 [kN]

total of distrib. loads : 62.02599, .0 , .0 [kN]
total of all forces : 126.48987, .0 , .0 [kN]
resulting moments : .0 , -2780.1632, 70.9837 [kNcm]
with y-z plane: .0 , -.56, -21.98 [cm]
Values according to chapter 5.4 ∑ ELh = 125,7 kN

Seismic Load Elhy
loads, load case: ELhy_
total of node loads : .0 , 64.46388, .0 [kN]

total of distrib. loads : .0 , 62.02599, .0 [kN]
total of all forces : .0 , 126.48987, .0 [kN]
resulting moments : 2780.1632, .0 , -1.4533E+05 [kNcm]
with x-z plane: -1148.93, .0 , -21.98 [cm]
Values according to chapter 5.4 ∑ ELh = 125,7 kN

Order No.: MTF Order No: G 0197.10 Chapter : 4.
TAKRAF GmbH, Torgauer Str. 336 * 04347 Leipzig Seite 24
4.0. Von Mises stresses for the complete steelwork
Hydraulic cylinder
Stresses according to LFRD-Method!

The above shown stresses will be compared with Fy.
Steel Grad ASTM A572 Grade 50 Fy = 34,5 kN/cm²
Steel Grad ASTM A500 Fy = 30,0 kN/cm²
(HSS shapes)
Rev.:
4.1. Boom lower chord
stresses
max σ = 27,7 kN/cm2 < σR,d = 34,5 kN/cm2
Stability (buckling of members)
Rev.:
cross section DT 200x200x18x10

material:A572 Gr.50 fy,k = 34,5 kN/cm²
z γM = 1,0
h= 20,0 cm th = 1,0 cm
b= 20,0 cm tb = 1,8 cm
2
A= 88,4 cm
4 4
y Iy = 6349 cm Iz = 2402 cm
y 3 3
th h Wy = 635 cm Wz = 240 cm
iy = 8,47 cm iz = 5,21 cm
iP = 9,95 cm
4
IT = 83,2 cm
tb z Iω = 198.870 cm
6
b
W pl,y = 722 cm3 W pl,z = 360 cm3

αy = 1,14 αz = 1,50
Npl,d = 3049,8 kN
Mpl,y,d = 249,2 kNm Mpl,z,d = 124,2 kNm
stresses/inner forces
stability σN,d = 14,0 kN/cm² σM,y,d = 2,9 kN/cm² σM,z,d = 16,0 kN/cm²
Perm. 712 Nd = 1237,6 kN My,d = 18,4 kNm Mz,d = 38,4 kNm
σ N,d , σ M,y,d , σ M,z,d are maximum single stresses and not associating!
check b/t Method Elastic - Elastic DIN 18800 Part 1, Table 12
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
ψweb = (σN,d - σM,y,d)/(σN,d + σM,y,d) = 0,66
σ1web = (σN,d + σM,y,d) = 16,9 kN/cm²
b/t = 18,20 ≤ 57,10
Rev.:
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

ψflange = (σN,d + σM,y,d )/(σN,d + σM,y,d +σM,z,d) = 0,51
σ1flange = (σN,d + σM,y,d + σM,z,d) = 32,9 kN/cm²
b/t = 5,28 ≤ 11,66
buckling geometrie sky = 270 cm skz = 200 cm

torsional length x axis s0 = 200 cm
parameters
DIN 18800 Teil 2 Tab. 11 β m,y = 1,10 β m,z = 1,10
β M,y = 1,10 β M,z = 1,10
DIN 18800 Teil 2 Tab. 9 / 10 Trägerbeiwert n = 2 geschw. Träger

Faktor k n = 0,8
Momentenbeiwert ζ = 1,10
slenderness ratio λa = π√ E / fy,k = 77,5
ηKi,y,d = 14,59 ηKi,z,d = 10,05
λκ,y = sκ,y / iy = 31,9 λκ,z = sκ,z / iz = 38,4
λκ,y = λκ,y / λa = 0,411 λκ,z = λκ,z / λa = 0,495
buckling curve y-Achse b z-Achse c

=> αy = 0,34 => αz = 0,49
parameters ky = 0,62 kz = 0,69

κy = 0,922 κz = 0,846
ay = -0,60 az = -0,39
ky = 1,27 kz = 1,19
Verification of lateral buckling:
Nd My,d x ky Mz,d x kz
+ + < 1
κmin x Npl,d Mpl,y,d Mpl,z,d
0,480 + 0,093 + 0,368 = 0,941 < 1
Rev.:
zp = 0,0 cm Lastangriffspunkt für

Querlasten
c² = 136,9 cm²
NKi,z = 12444 kN
NKi,z,d = 12444 kN
λK,z = 0,495
κz= 0,846
ay = -0,07 az = -0,39
ky = 1,00 kz = 1,19
MKi,y = 1601,4 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,39
κM = 1,00
Verification of lateral torsional buckling:
+ + < 1
κz x Npl,d κM x Mpl,y,d Mpl,z,d
0,480 + 0,074 + 0,368 = 0,921 < 1
Rev.:

z γM = 1,0
h= 20,0 cm th = 1,0 cm
b= 20,0 cm tb = 1,8 cm
2
A= 88,4 cm
4 4
y Iy = 6349 cm Iz = 2402 cm
y 3 3
th h Wy = 635 cm Wz = 240 cm
iy = 8,47 cm iz = 5,21 cm
iP = 9,95 cm
4
IT = 83,2 cm
tb z Iω = 198.870 cm
6
b
W pl,y = 722 cm3 W pl,z = 360 cm3

αy = 1,14 αz = 1,50
Npl,d = 3049,8 kN
Rev.:
Nd = 1290,6 kN My,d = 11,4 kNm Mz,d = 34,8 kNm
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
b/t = 18,20 ≤ 53,27
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 5,28 ≤ 12,01

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 16,31 ηKi,z,d = 19,68

=> αy = 0,34 => αz = 0,49
Rev.:

κy = 0,934 κz = 0,925
ay = -0,55 az = -0,12
ky = 1,25 kz = 1,06
Nd + My,d x ky + Mz,d x kz < 1

0,457 + 0,057 + 0,296 = 0,811 < 1

Querlasten
c² = 109,3 cm²
NKi,z = 25395 kN
NKi,z,d = 25395 kN
λK,z = 0,347
κz= 0,925
ay = -0,09 az = -0,12
ky = 1,00 kz = 1,06
MKi,y = 2920,5 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,29
κM = 1,00

0,457 + 0,046 + 0,296 = 0,800 < 1
Rev.:

z γM = 1,0
h= 20,0 cm th = 1,0 cm
b= 20,0 cm tb = 1,8 cm
2
A= 88,4 cm
4 4
y Iy = 6349 cm Iz = 2402 cm
y 3 3
th h Wy = 635 cm Wz = 240 cm
iy = 8,47 cm iz = 5,21 cm
iP = 9,95 cm
4
IT = 83,2 cm
tb z Iω = 198.870 cm
6
b
W pl,y = 722 cm3 W pl,z = 360 cm3

αy = 1,14 αz = 1,50
Npl,d = 3049,8 kN
Rev.:
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
b/t = 18,20 ≤ 67,82
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 5,28 ≤ 12,05

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 12,16 ηKi,z,d = 18,40

=> αy = 0,34 => αz = 0,49
Rev.:

κy = 0,903 κz = 0,912
ay = -0,68 az = -0,17
ky = 1,30 kz = 1,07

0,437 + 0,314 + 0,114 = 0,865 < 1

Querlasten
c² = 113,2 cm²
NKi,z = 22122 kN
NKi,z,d = 22122 kN
λK,z = 0,371
κz= 0,912
ay = -0,09 az = -0,17
ky = 1,00 kz = 1,07
MKi,y = 2589,3 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,31
κM = 1,00

0,432 + 0,242 + 0,114 = 0,788 < 1
Rev.:

z γM = 1,0
h= 20,0 cm th = 1,0 cm
b= 20,0 cm tb = 1,8 cm
2
A= 88,4 cm
4 4
y Iy = 6349 cm Iz = 2402 cm
y 3 3
th h Wy = 635 cm Wz = 240 cm
iy = 8,47 cm iz = 5,21 cm
iP = 9,95 cm
4
IT = 83,2 cm
tb z Iω = 198.870 cm
6
b
W pl,y = 722 cm3 W pl,z = 360 cm3

αy = 1,14 αz = 1,50
Npl,d = 3049,8 kN
Rev.:
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
ψweb = (σN,d - σM,y,d)/(σN,d + σM,y,d) = -0,41
b/t = 18,20 ≤ 98,07
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 5,28 ≤ 12,77

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 70,69 ηKi,z,d = 26,74

=> αy = 0,34 => αz = 0,49
Rev.:

κy = 0,974 κz = 0,873
ay = -0,36 az = -0,30
ky = 1,07 kz = 1,07

0,216 + 0,425 + 0,062 = 0,702 < 1

Querlasten
c² = 126,6 cm²
NKi,z = 15362 kN
NKi,z,d = 15362 kN
λK,z = 0,446
κz= 0,873
ay = -0,08 az = -0,30
ky = 1,00 kz = 1,07
MKi,y = 1901,4 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,36
κM = 1,00
+ + < 1
0,216 + 0,397 + 0,062 = 0,675 < 1
Rev.:
4.2. Boom upper chord
stresses

z γM = 1,0
h= 20,0 cm th = 0,8 cm
b= 20,0 cm tb = 1,4 cm
2
y A= 69,76 cm
y 4 4
Iy = 5192 cm Iz = 1867 cm
th h 3 3
Wy = 519 cm Wz = 187 cm
iy = 8,63 cm iz = 5,17 cm
iP = 10,06 cm
tb z 4
b IT = 39,5 cm
6
Iω = 161.517 cm
Rev.:
W pl,y = 580 cm3 W pl,z = 280 cm3

αy = 1,12 αz = 1,50
Npl,d = 2406,7 kN
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b/t = 23,25 ≤ 143,14
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 6,86 ≤ 11,07

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
Rev.:
ηKi,y,d = 171,39 ηKi,z,d = 61,65

=> αy = 0,34 => αz = 0,49

κy = 0,906 κz = 0,695
ay = -0,69 az = -0,85
ky = 1,02 kz = 1,04
+ + < 1
0,042 + 0,456 + 0,370 = 0,868 < 1
Rev.:

Querlasten
c² = 160,8 cm²
NKi,z = 4301 kN
NKi,z,d = 4301 kN
λK,z = 0,748
κz= 0,695
ay = -0,03 az = -0,85
ky = 1,00 kz = 1,04
MKi,y = 599,8 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,58
κM = 0,91
+ + < 1
0,042 + 0,493 + 0,370 = 0,905 < 1
Rev.:
4.3. Boom horizontal cross beams
stresses:

z γM = 1,0
h= 20,0 cm th = 0,5 cm
b= 10,0 cm tb = 1,0 cm
2
A= 29 cm
4 4
y y Iy = 2050 cm Iz = 167 cm
3 3
th h Wy = 205 cm Wz = 33 cm
iy = 8,41 cm iz = 2,40 cm
iP = 8,74 cm
4
IT = 7,4 cm
tb z 6
b Iω = 15.060 cm
Rev.:
W pl,y = 231 cm3 W pl,z = 50 cm3

αy = 1,12 αz = 1,50
Npl,d = 1000,5 kN
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b/t = 38,00 ≤ 182,63
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 4,75 ≤ 13,46

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
Rev.:
ηKi,y,d = 1741,84 ηKi,z,d = 141,80

=> αy = 0,34 => αz = 0,49

κy = 0,908 κz = 0,296
ay = -0,68 az = -2,31
ky = 1,00 kz = 1,02
+ + < 1
0,010 + 0,318 + 0,245 = 0,573 < 1
Rev.:

Querlasten
c² = 236,0 cm²
NKi,z = 411 kN
NKi,z,d = 411 kN
λK,z = 1,560
κz= 0,296
ay = 0,11 az = -2,31
ky = 1,00 kz = 1,02
MKi,y = 69,5 kNm
λM = √ Mpl,y,d / MKi,y,d = 1,07
κM = 0,60
+ + < 1
0,010 + 0,524 + 0,245 = 0,779 < 1
Rev.:
cross section box 187x200x6

γM = 1,0
z
h= 18,7 cm th = 0,6 cm
b= 20,0 cm tb = 0,6 cm
y
2
A= 45 cm
h
y Iy = 2502 cm4 Iz = 2776 cm4
Wy = 268 cm3 Wz = 277,6 cm3
iy = 7,46 cm iz = 7,85 cm
t z
b W pl,y = 310 cm3 W pl,z = 323 cm3
f= 1,16 f= 1,16
Npl,d = 1552,5 kN
Rev.:
σN,d = 1,4 kN/cm² σM,y,d = 6,0 kN/cm² σM,z,d = 11,7 kN/cm²
web z-z: h / th ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
ψweb = (σN,d - σM,y,d + σM,z,d)/(σN,d + σM,y,d + σM,z,d)= 0,37
σ1web = (σN,d + σM,y,d + σM,z,d) = 19,1 kN/cm²
h / th = 30,17 ≤ 65,16
web y-y: b / tb ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
ψweb = (σN,d + σM,y,d - σM,z,d)/(σN,d + σM,y,d + σM,z,d)= -0,23
b / tb = 32,33 ≤ 94,72

β m,y = 1,10 β m,z = 1,00
ηKi,y,d = 97,87 ηKi,z,d = 108,59
buckling curve
y-Achse b z-Achse b
=> α = 0,34 => α = 0,34
Rev.:
Beiwerte: ky = 0,68 kz = 0,66

κy = 0,88 κz = 0,89
ay = -0,745 az = -0,789
ky = 1,034 kz = 1,036
Nd My,d x ky My,d x kz
+ + < 1
κmin x Npl,d Mpl,y,d κ x Mpl,z,d
0,046 + 0,155 + 0,302 = 0,503 < 1
Rev.:
stresses/
cross section Box 400x400x24 calculated

γM = 1,0
z
h= 40,0 cm th = 2,4 cm
b= 40,0 cm tb = 2,4 cm
y
2
A= 360,96 cm
h
y Iy = 85398 cm4 Iz = 85398 cm4
Wy = 4270 cm3 Wz = 4270 cm3
iy = 15,38 cm iz = 15,38 cm
t z
b W pl,y = 5096 cm3 W pl,z = 5096 cm3
f= 1,19 f= 1,19
Npl,d = 12453,1 kN
Rev.:

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 15,67 ≤ 50,62

27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b / tb = 15,67 ≤ 76,93

β m,y = 1,10 β m,z = 1,00
ηKi,y,d = 5830,60 ηKi,z,d = 5830,60
buckling curve
y-Achse c z-Achse c
=> α = 0,49 => α = 0,49
Rev.:

κy = 0,98 κz = 0,98
ay = -0,244 az = -0,293
ky = 1,001 kz = 1,001
+ + < 1
0,003 + 0,262 + 0,535 = 0,800 < 1
Rev.:
4.4. Boom vertical beams
stresses/

z γM = 1,0
h= 20,0 cm th = 0,8 cm
b= 20,0 cm tb = 1,4 cm
2
A= 69,76 cm
4 4
y Iy = 5192 cm Iz = 1867 cm
y 3 3
th h Wy = 519 cm Wz = 187 cm
iy = 8,63 cm iz = 5,17 cm
iP = 10,06 cm
4
IT = 39,5 cm
tb z Iω = 161.517 cm
6
b
W pl,y = 580 cm3 W pl,z = 280 cm3

αy = 1,12 αz = 1,50
Rev.:
Npl,d = 2406,7 kN
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b/t = 23,25 ≤ 129,74
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 6,86 ≤ 12,13

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 85,70 ηKi,z,d = 30,82
Rev.:

=> αy = 0,34 => αz = 0,49

κy = 0,906 κz = 0,695
ay = -0,69 az = -0,85
ky = 1,04 kz = 1,07
+ + < 1
0,083 + 0,488 + 0,186 = 0,757 < 1

Querlasten
c² = 160,8 cm²
NKi,z = 4301 kN
NKi,z,d = 4301 kN
λK,z = 0,748
κz= 0,695
ay = -0,03 az = -0,85
ky = 1,00 kz = 1,07
MKi,y = 599,8 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,58
κM = 0,91
+ + < 1
0,083 + 0,516 + 0,186 = 0,786 < 1
Rev.:

z γM = 1,0
h= 20,0 cm th = 0,6 cm
b= 20,0 cm tb = 0,8 cm
2
A= 43,04 cm
4 4
y Iy = 3262 cm Iz = 1067 cm
y 3 3
th h Wy = 326 cm Wz = 107 cm
iy = 8,71 cm iz = 4,98 cm
iP = 10,03 cm
4
IT = 8,2 cm
tb z Iω = 98.336 cm
6
b
W pl,y = 358 cm3 W pl,z = 160 cm3

αy = 1,10 αz = 1,50
Npl,d = 1484,9 kN
Rev.:
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b/t = 32,00 ≤ 125,10
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 12,13 ≤ 12,15

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 174,55 ηKi,z,d = 57,09

=> αy = 0,34 => αz = 0,49
Rev.:

κy = 0,908 κz = 0,676
ay = -0,70 az = -0,90
ky = 1,02 kz = 1,04
+ + < 1
0,043 + 0,637 + 0,066 = 0,746 < 1

Querlasten
c² = 119,0 cm²
NKi,z = 2457 kN
NKi,z,d = 2457 kN
λK,z = 0,777
κz= 0,676
ay = -0,02 az = -0,90
ky = 1,00 kz = 1,04
MKi,y = 294,8 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,65
κM = 0,87
+ + < 1
0,043 + 0,716 + 0,066 = 0,825 < 1
Rev.:
4.5. Boom Bracing
cross section HSS 3,5"x3,5"x3/16"

γM = 1,0
z
b h= 8,89 cm th = 0,47 cm
b= 8,89 cm tb = 0,47 cm
2
A= 15,40 cm
Iy = 178 cm4 Iz = 178 cm4
h y
t
Wy = 40 cm3 Wz = 40,0 cm3
iy = 3,40 cm iz = 3,40 cm
W pl,y = 48 cm3 W pl,z = 48 cm3

f= 1,20 f= 1,20
Npl,d = 462,0 kN
Rev.:

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 17,91 ≤ 61,02

27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
ψweb = (σN,d + σM,y,d - σM,z,d)/(σN,d + σM,y,d + σM,z,d)= 1,00
b / tb = 17,91 ≤ 61,02

β m,y = 1,10 bm,z = 1,00
ηKi,y,d = 2,07 ηKi,z,d = 2,07
buckling curve
y-Achse b z-Achse b
=> α = 0,34 => α = 0,34
Rev.:

κy = 0,45 κz = 0,45
ay = -2,063 az = -2,314
ky = 1,500 kz = 1,500
Nd + My,d x ky + My,d x kz < 1

0,684 + 0,000 + 0,000 = 0,684 < 1
Rev.:
stresses
cross section HSS 5"x5"x3/16"

γM = 1,0
z
b
h= 12,70 cm t= 0,48 cm
b= 12,70 cm tb = 0,48 cm
2
A= 22,7 cm
4 4
h y Iy = 559 cm Iz = 559 cm
3 3
t Wy = 88 cm Wz = 88 cm
iy = 4,96 cm iz = 4,96 cm
W pl,y = 103 cm3 W pl,z = 103 cm3

αy = 1,17 αz = 1,17
Npl,d = 681,0 kN
Tension only member, no further check required.
Rev.:
4.6. Adapter horizontal beam for belt support

z γM = 1,0
h= 21,4 cm th = 0,8 cm
b= 20,0 cm tb = 1,4 cm
2
A= 70,88 cm
4 4
y Iy = 6038 cm Iz = 1868 cm
y 3 3
th h Wy = 564 cm Wz = 187 cm
iy = 9,23 cm iz = 5,13 cm
iP = 10,56 cm
4
IT = 39,8 cm
tb z Iω = 186.752 cm
6
b
W pl,y = 629 cm3 W pl,z = 280 cm3

αy = 1,11 αz = 1,50
Rev.:
Npl,d = 2445,4 kN
Maximum compression stresses!
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b/t = 25,00 ≤ 175,40
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 6,86 ≤ 18,08

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 155,65 ηKi,z,d = 48,14
Rev.:

=> αy = 0,34 => αz = 0,49

κy = 0,932 κz = 0,730
ay = -0,58 az = -0,74
ky = 1,03 kz = 1,04
+ + < 1
0,060 + 0,216 + 0,067 = 0,342 < 1

Querlasten
c² = 162,8 cm²
NKi,z = 5118 kN
NKi,z,d = 5118 kN
λK,z = 0,691
κz= 0,730
ay = -0,04 az = -0,74
ky = 1,00 kz = 1,04
MKi,y = 718,3 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,55
κM = 0,92
+ + < 1
0,060 + 0,229 + 0,067 = 0,356 < 1
Rev.:
4.7. Adapter main wall beams
stresses

z γM = 1,0
h= 27,2 cm th = 0,8 cm
b= 30,0 cm tb = 1,6 cm
2
A= 115,2 cm
4 4
y Iy = 16671 cm Iz = 7201 cm
y 3 3
th h Wy = 1226 cm Wz = 480 cm
iy = 12,03 cm iz = 7,91 cm
iP = 14,40 cm
4
IT = 86,0 cm
tb z Iω = 1.179.827 cm
6
b
W pl,y = 1344 cm3 W pl,z = 720 cm3

αy = 1,10 αz = 1,50
Rev.:
Npl,d = 3974,4 kN
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b/t = 32,00 ≤ 46,00
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 9,13 ≤ 12,35

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 12,53 ηKi,z,d = 21,66
Rev.:

=> αy = 0,34 => αz = 0,49

κy = 0,940 κz = 0,961
ay = -0,56 az = 0,00
ky = 1,36 kz = 1,00
+ + < 1
0,638 + 0,126 + 0,048 = 0,812 < 1

Querlasten
c² = 177,3 cm²
NKi,z = 51644 kN
NKi,z,d = 51644 kN
λK,z = 0,277
κz= 0,961
ay = -0,10 az = 0,00
ky = 1,00 kz = 1,00
MKi,y = 7564,3 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,25
κM = 1,00
+ + < 1
0,625 + 0,093 + 0,048 = 0,765 < 1
Rev.:
stresses

z γM = 1,0
h= 30,0 cm th = 0,8 cm
b= 30,0 cm tb = 2,0 cm
2
A= 140,8 cm
4 4
y Iy = 24732 cm Iz = 9001 cm
y 3 3
th h Wy = 1649 cm Wz = 600 cm
iy = 13,25 cm iz = 8,00 cm
iP = 15,48 cm
4
IT = 164,4 cm
tb z Iω = 1.764.234 cm
6
b
W pl,y = 1815 cm3 W pl,z = 900 cm3

αy = 1,10 αz = 1,50
Npl,d = 4857,6 kN
Rev.:
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
b/t = 35,00 ≤ 95,31
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 7,30 ≤ 13,62
buckling geometrie sky = 342 cm skz = 2*342 = 684 cm

parameters
β M,y = 1,80 β M,z = 1,80

Faktor k n = 0,8
ηKi,y,d = 42,06 ηKi,z,d = 3,83

=> αy = 0,34 => αz = 0,49
Rev.:

κy = 0,952 κz = 0,482
ay = -0,03 az = 0,06
ky = 1,01 kz = 0,97
+ + < 1
0,445 + 0,265 + 0,098 = 0,808 < 1

Querlasten
c² = 279,3 cm²
NKi,z = 15950 kN
NKi,z,d = 15950 kN
λK,z = 0,552
κz= 0,482
ay = 0,00 az = 0,06
ky = 1,00 kz = 0,97
MKi,y = 4718,5 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,36
κM = 1,00
+ + < 1
0,445 + 0,263 + 0,098 = 0,806 < 1
Rev.:
stresses

z γM = 1,0
h= 30,0 cm th = 0,8 cm
b= 30,0 cm tb = 1,6 cm
2
A= 117,44 cm
4 4
y Iy = 20661 cm Iz = 7201 cm
y 3 3
th h Wy = 1377 cm Wz = 480 cm
iy = 13,26 cm iz = 7,83 cm
iP = 15,40 cm
4
IT = 86,5 cm
tb z Iω = 1.452.052 cm
6
b
W pl,y = 1507 cm3 W pl,z = 720 cm3

αy = 1,09 αz = 1,50
Npl,d = 4051,7 kN
Rev.:
Steg: b/t ≤ 27,1*(1 - 0,278*ψ - 0,025*ψ²)*(8,2/(ψ+1,05))1/2*(240/(σ1*γM))1/2 1>ψ>0

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
b/t = 35,50 ≤ 170,72
Flansch: b/t ≤ 19,7*(0,57-0,21*(ψ+0,07*ψ²)1/2*(240/(σ1*γM))1/2

b/t = 9,13 ≤ 14,44

parameters
β M,y = 1,10 β M,z = 1,10

Faktor k n = 0,8
ηKi,y,d = 1577,14 ηKi,z,d = 549,69

=> αy = 0,34 => αz = 0,49
Rev.:

κy = 0,953 κz = 0,809
ay = -0,50 az = -0,51
ky = 1,00 kz = 1,00
+ + < 1
0,007 + 0,367 + 0,126 = 0,500 < 1

Querlasten
c² = 255,8 cm²
NKi,z = 12911 kN
NKi,z,d = 12911 kN
λK,z = 0,560
κz= 0,809
ay = -0,06 az = -0,51
ky = 1,00 kz = 1,00
MKi,y = 2271,4 kNm
λM = √ Mpl,y,d / MKi,y,d = 0,48
κM = 0,95
+ + < 1
0,007 + 0,387 + 0,126 = 0,520 < 1
Rev.:
4.8. Adapter horizontal cross beams

γM = 1,0
z
h= 20,0 cm th = 0,8 cm
b= 20,0 cm tb = 0,8 cm
y
2
A= 61,44 cm
h
y Iy = 3781 cm4 Iz = 3781 cm4
Wy = 378 cm3 Wz = 378 cm3
iy = 7,85 cm iz = 7,85 cm
t z
b W pl,y = 443 cm3 W pl,z = 443 cm3
f= 1,17 f= 1,17
Npl,d = 2119,7 kN
Rev.:

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 24,00 ≤ 65,16

1/2 1/2
27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
b / tb = 24,00 ≤ 94,72

β m,y = 1,10 β m,z = 1,00
ηKi,y,d = 108,34 ηKi,z,d = 108,34
buckling curve
y-Achse b z-Achse b
=> α = 0,34 => α = 0,34
Rev.:

κy = 0,89 κz = 0,89
ay = -0,687 az = -0,782
ky = 1,031 kz = 1,035
+ + < 1
0,045 + 0,153 + 0,300 = 0,498 < 1
Rev.:

γM = 1,0
z
h= 42,4 cm th = 2,4 cm
b= 54,8 cm tb = 2,4 cm
y
2
A= 443,52 cm
h
Iy = 126605 cm4 Iz = 189802 cm4
y
Wy = 5972 cm3 Wz = 6927 cm3
iy = 16,90 cm iz = 20,69 cm
z
t W pl,y = 6957 cm3 W pl,z = 8332 cm3
b
f= 1,16 f= 1,20
Npl,d = 15301,4 kN
Rev.:

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 16,67 ≤ 56,30

1/2 1/2
27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
b / tb = 21,83 ≤ 74,55

β m,y = 1,10 β m,z = 1,00
ηKi,y,d = 335,00 ηKi,z,d = 502,22
buckling curve
y-Achse c z-Achse c
=> α = 0,49 => α = 0,49
Rev.:

κy = 0,99 κz = 1,00
ay = -0,234 az = -0,159
ky = 1,014 kz = 1,010
+ + < 1
0,062 + 0,252 + 0,397 = 0,711 < 1
Rev.:
4.9. Adapter bracings
stresses
Tensile stresses!

γM = 1,0
z
b h= 8,89 cm th = 0,47 cm
b= 8,89 cm tb = 0,47 cm
2
A= 15,40 cm
y Iy = 178 cm4 Iz = 178 cm4

h
t
Wy = 40 cm3 Wz = 40,0 cm3
iy = 3,40 cm iz = 3,40 cm
W pl,y = 48 cm3 W pl,z = 48 cm3

f= 1,20 f= 1,20
Npl,d = 462,0 kN
Rev.:

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 17,91 ≤ 75,55

27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b / tb = 17,91 ≤ 75,55

β m,y = 1,10 bm,z = 1,00
ηKi,y,d = 3,90 ηKi,z,d = 3,90
buckling curve
y-Achse b z-Achse b
=> α = 0,34 => α = 0,34
Rev.:

κy = 0,52 κz = 0,52
ay = -1,840 az = -2,066
ky = 1,500 kz = 1,500

0,388 + 0,000 + 0,000 = 0,388 < 1
stresses
Rev.:

γM = 1,0
z
b h= 8,89 cm th = 0,47 cm
b= 8,89 cm tb = 0,47 cm
2
A= 15,40 cm
y Iy = 178 cm4 Iz = 178 cm4

h
t
Wy = 40 cm3 Wz = 40,0 cm3
iy = 3,40 cm iz = 3,40 cm
W pl,y = 48 cm3 W pl,z = 48 cm3

f= 1,20 f= 1,20
Npl,d = 462,0 kN

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 17,91 ≤ 55,54

27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b / tb = 17,91 ≤ 53,18
Rev.:

β m,y = 1,10 bm,z = 1,00
ηKi,y,d = 2,32 ηKi,z,d = 2,32
buckling curve
y-Achse b z-Achse b
=> α = 0,34 => α = 0,34

κy = 0,58 κz = 0,58
ay = -1,649 az = -1,854
ky = 1,500 kz = 1,500

0,706 + 0,083 + 0,063 = 0,852 < 1
Rev.:
stresses

γM = 1,0
z
b h= 12,70 cm th = 0,48 cm
b= 12,70 cm tb = 0,48 cm
2
A= 22,7 cm
y Iy = 559 cm4 Iz = 559 cm4

h
t
Wy = 88 cm3 Wz = 88,0 cm3
iy = 4,96 cm iz = 4,96 cm
W pl,y = 103 cm3 W pl,z = 103 cm3

f= 1,17 f= 1,17
Npl,d = 681,0 kN
Rev.:

1/2 1/2
≤ 27,1*(7,81 - 6,29*ψ + 9,78*ψ²) *(240/(σ1*γM)) 0 > ψ > -1
h / th = 25,46 ≤ 63,48

27,1*(7,81 - 6,29*ψ + 9,78*ψ²)1/2*(240/(σ1*γM))1/2 0 > ψ > -1
b / tb = 25,46 ≤ 63,48

β m,y = 1,10 bm,z = 1,00
ηKi,y,d = 19,61 ηKi,z,d = 19,61
buckling curve
y-Achse b z-Achse b
=> α = 0,34 => α = 0,34
Rev.:

κy = 0,92 κz = 0,92
ay = -0,594 az = -0,679
ky = 1,184 kz = 1,210

0,309 + 0,000 + 0,000 = 0,309 < 1
Rev.:
4.10. FE-Detail for Mounting the Cylinder at Boom
material: A572 Gr.50
Rev.:
Fx = 758 kN
Fy = 485 kN
t = 24 mm
t = 40 mm
FE-Modell with plate thickness and forces
Equivalent stress σeqv [N/mm 2]

Proof of stress according to DIN 18800 part 1:
max σeqv = 302 N/mm 2 < σR,d = 345 N/mm 2
Rev.:
4.11. FE-Detail for Mounting the Cylinder at Adapter
F = 900 kN
350
N
460
560
Rev.:
Maximum tension force on one bolt
Rd = 5*N*56+4*46/56*N*46 = 431*N
Sd = 900*35 = 31500 kNcm
N = ft = 31500/431 = 73 kN
High-strength bolts - ASTM A 325 Diameter 1"
yield stress fy,b,k = 62 kN/cm 2
Ft = 236 kN AISC 13th Editon
ft/Ft = 0,31 < 1,0
Proof of shear force:
No of shear planes n= 1,0
total shear force V = 900 kN
number of bolts: 24
shear force on one bolt Vg = fv = 37,5 kN
Fv = 125 kN AISC 13th Editon

Threads in shear plane
fv/Fv = 0,30 < 1,0
Combined tension and shaer
F'nt = 306,8 -94,4 = 212,4 < 236,0
Proof of bearing stresses:
tPL = 40 mm
d= 25,4 mm
fP = fv/A = 3,7 kN/cm²
FP = 80,6 kN/cm² AISC 13th Editon

ASTM A572 Grade 50
fp/Fp = 0,05 < 1,0
Rev.:
4.12. FE-Detail for Safety Rod
Rev.:
Fx = 450kN
t = 25 mm
t = 40 mm

Rev.:
4.13. Mounting of Safety Rod
Fx = 758 kN
Fy = 485 kN
t = 40 mm
FE-Modell with plate thickness and forces
Rev.:
Lower pins safety rod
Geometry and loads
L1
D= 120,0 mm
FF
W= 169646 mm³
L= 95,0 mm
D t1 = 40 mm
D
t2 = 40 mm
F/2
F/2 s= L-t1/2-t2/2
B2
t1 s= 55 mm
B1
t2
LL2
Fax [kN] Faz [kN] R [kN] requ. safety

900 0 900 1,25 Safety according to DIN 18800, Part 1, Formula (67)
Steel grade σy σU
Pin 42CrMo4V 550,0 800,0 [N/mm²]
Reduced yield strength σ' = σy/ν

τ' = σ'/1,732
Pin
σ' 440,0 [N/mm²]
τ' 254,0 [N/mm²]
Shearing τm = 4*Q/(P*D²)
Q = F/2
max τ = 1,5*τm
Pin
τm 39,8 [N/mm²]
max τ 59,7 [N/mm²]
Utilization [%] 23
Rev.:
Bolt bending σ= Mb/W
Pin
Mb *) 38250000 [Nmm] *) Mb = F/8 (t2 + 4s + 2t1)
σ 225,5 [N/mm²] See DIN 18800, Part 1, Picture 27
Utilization [%] 51
Von Mises Stresses σv = [σ/σ']² + [τm/τ']²

Pin
σv 0,287 [N/mm²]
Bearing stresses
t1 t2
40 40 [mm]
σlt1 94 188 [N/mm²]
σlt1 345 345 [N/mm²] σy of steel grade ASTM A572, Grade 50
Utilization [%] 27 54
Upper pins safety rod
Geometry and loads
L
L1
D= 120 mm
F/2 F/2
W= 169646 mm³
F/2 F/2
L1= 400 mm
L2= 190 mm
DD
t1 = 40 mm
t2 = 40 mm
F/2 Bt21 F/2
B2
t1 L2
L2
LL1
3

Rev.:
Steel grade σy σU
Pin 42CrMo4V 550,0 800,0 [N/mm²]

τ' = σ'/1,732
Pin
σ' 440,0 [N/mm²]
τ' 254,0 [N/mm²]
Q = F/2
max τ = 1,5*τm
Pin
τm 39,8 [N/mm²]
max τ 59,7 [N/mm²]
Utilization [%] 23
Pin
Mb 47250000 [Nmm] Mb = F/2*(L1-L2)/2
σ 278,5 [N/mm²]
Utilization [%] 63

Pin
σv 0,425 [N/mm²]
Bearing stresses
t1 t2
40 40 [mm]
σlt1 94 94 [N/mm²]
Rev.:
4.14. FE-Detail for Support of the Adapter
Rev.:
Lower support point
t = 40 mm Fx = -2400kN
t = 80 mm

Proof for bearing pressure according to DIN 18800 part 1:
d= 120 mm t= 80 mm
with σL = F/(d*t) and F= 2380 kN
σL = 247 N/mm 2
< σR,d = 517,5 N/mm 2 = 1,5*fy,k
Rev.:
Contact pressure according to Hertz assuming 1 mm gap between the diameter of bolt and hole:
r1 60,0 mm
r2 -60,5 mm
1/r 0,000138 1/mm
F 2400000 N with
E 210000 N/mm^2 max σ = √ FE/(2πrl(1-ν2))
r 7260 mm
l 80 mm
ν 0,3
max σ 389,6 N/mm^2 < σR,d ≈ 1200 N/mm 2 = 3,5*fy,k

a 49,0 mm
The calculated equivalent stress is smaller than both stress criteria.

max σeqv = 351 N/mm 2 < σR,d = 517,5 N/mm 2 = 1,5*fy,k
Rev.:
Upper support point
t = 40 mm Fx = 2100 kN
t = 80 mm
Rev.:
Proof for bearing pressure according to DIN 18800 part 1:

d= 120 mm t= 80 mm
with σL = F/(d*t) and F= 2380 kN

σL = 247 N/mm 2
< σR,d = 517,5 N/mm 2 = 1,5*fy,k
Contact pressure according to Hertz assuming 1 mm gap between the diameter of bolt and hole:
r1 60,0 mm
r2 -60,5 mm
1/r 0,000138 1/mm
F 2100000 N with
E 210000 N/mm^2 max σ = √ FE/(2πrl(1-ν2))
r 7260 mm
l 80 mm
ν 0,3
max σ 364,4 N/mm^2 < σR,d ≈ 1200 N/mm 2 = 3,5*fy,k

a 45,9 mm
The calculated equivalent stress is smaller than both stress criteria.

max σeqv = 294 N/mm 2 < σR,d = 517,5 N/mm 2 = 1,5*fy,k
Rev.:
4.15. Verification of pins (DIN 18800)
B)
A)
C)
A) Pins between luffing boom and adapter
Geometry and loads
L1
D= 120,0 mm
FF
W= 169646 mm³
L= 72,5 mm
D t1 = 25 mm
D
t2 = 80 mm
F/2
F/2 s= L-t1/2-t2/2
B2
t1 s= 20 mm
B1
t2
LL2
Rev.:

Steel grade σy σU
Pin 42CrMo4V 550,0 800,0 [N/mm²]

τ' = σ'/1,732
Pin
σ' 440,0 [N/mm²]
τ' 254,0 [N/mm²]
Q = F/2
max τ = 1,5*τm
Pin
τm 53,2 [N/mm²]
max τ 79,8 [N/mm²]
Utilization [%] 31
Pin
Mb *) 31500000 [Nmm] *) Mb = F/8 (t2 + 4s + 2t1)
Utilization [%] 42

Pin
σv 0,471 [N/mm²]
Bearing stresses
t1 t2
25 80 [mm]
σlt1 200 125 [N/mm²]
Rev.:
B) Pins between adapter and stacking bridge, upper hinge
Geometry and loads
L1
D= 120,0 mm
FF
W= 169646 mm³
L= 72,5 mm
D t1 = 40 mm
D
t2 = 80 mm
F/2
F/2 s= L-t1/2-t2/2
B2
t1 s= 12,5 mm
B1
t2
LL2

Steel grade σy σU
Pin 42CrMo4V 550,0 800,0 [N/mm²]

τ' = σ'/1,732
Pin
σ' 440,0 [N/mm²]
τ' 254,0 [N/mm²]
Q = F/2
max τ = 1,5*τm =
Pin
τm 91,9 [N/mm²]
max τ 137,9 [N/mm²]
Utilization [%] 54
Rev.:
Pin
Mb *) 53812500 [Nmm] *) Mb = F/8 (t2 + 4s + 2t1)
Utilization [%] 72

Pin
σv 0,807 [N/mm²]
Bearing stresses
t1 t2
40 80 [mm]
σlt1 217 217 [N/mm²]
C) Pins between adapter and stacking bridge, lower hinge
Geometry and loads
L1
D= 120,0 mm
FF
W= 169646 mm³
L= 72,5 mm
D t1 = 40 mm
D
t2 = 80 mm
F/2
F/2 s= L-t1/2-t2/2
B2
t1 s= 12,5 mm
B1
t2
LL2
Rev.:

Steel grade σy σU
Pin 42CrMo4V 550,0 800,0 [N/mm²]

τ' = σ'/1,732
Pin
σ' 440,0 [N/mm²]
τ' 254,0 [N/mm²]
Q = F/2
max τ = 1,5*τm =
Pin
τm 110,7
max τ 166,1 [N/mm²]
Utilization [%] 65
Pin
Mb *) 59062500 [Nmm] *) Mb = F/8 (t2 + 4s + 2t1)
Utilization [%] 79

Pin
σv 0,903 [N/mm²]
Bearing stresses
t1 t2
40 80 [mm]
σlt1 261 261 [N/mm²]
Rev.:
5. Hydraulic cylinder
Zylinder Forces: LC I Normal operation 910 kN
LC II Normal operation 910 kN

+ oper. wind y
LC III Chute clogging 1300 kN
+ oper. wind y
LC IV Out of operation 850 kN
+ design wind y
LC V Earthquake 1150 kN
LC VI Earthquake 1600 kN
incl. chute clogging
Cylinder data:
Ring area 704 cm²

Working pressure 250 bar
Test pressure 375 bar
max tensile force (250bar)
N= 1760 kN > 1600 kN
Rev.:
Rev.:

J6 - NEW Luffing Boom

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J6 - NEW Luffing Boom

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Objekt : Codelco-Chile, Gaby Plant Part : J6

Leach Pad Stacking, Ripios Reclaim

New Luffing Boom

Mobile Stacking Bridge 160-ME-001

Revision Date By Remarkes

2. Load combinations for overall structural calculation

5. Hydraulic cylinder data

J6 New Luffing Boom

ISO 5049/1 Load assumption und superimposition of loads

AISC Design of bolts (all bolts according to ASTM A325)

The safety factor ν is identical with ν= γM*γF

All superimposed loads will be amplified with the factor ν!

The structural calculation is carried out as a Finite Element Analysis.

J6 New Luffing Boom

pulley 2.300 -20,640 0,000 -1,570

DL dead load 44.598 -10,498 0,002 0,210

Operating live load LLo

B [m] 1,600 α [°] 40

Load per Meter for 100% nominal belt capacity

LL spillage 10% LLo 1.066 kg

Upset live load LLu

Clogging chutes (Receiving chute)

LLu max. capacity of chute 9,3 m³

centric and eccentric considered eccentricity: 60% - 40%

additional there is still considered the weight of incrustation

considered in incrustation: 1.760 kg

total weight of LLu 16.640 kg

Along the conveyor 10,0 % of conveyor material

10% LLo 1.066 kg

Belt tension T = 160kN

Standard UBC 97 Part 2

Velocity pressure qs = v²/16/100

Design wind pressure P= Iw*Cq*Ce*fred*qs

Importance factor Iw = 1,0

Reducing factor in dependence of the altitude of site:

Altitude of site: 2700 m

Average barometric press. 0m 103,2 kPa

fred = 74,5/103,2 = 0,722

Wind force WL = P*A f

Af will be determined in accordance with the shape of the particular elements of

The maximum service wind velocity v= 22,2 m/s

Velocity pressure qs = v²/16/100

Ration between operational wind and maximum wind:

Wind loads luffing boom:

h= 7,6 m above the ground

Wind in y-direction (across the conveying direction)

Upper cord 0,250 30,1 7,35

Lower chord 0,250 40,8 9,97

or 0,200 21,0 4,1

Diagonal member 0,200 14,2 2,8

fixed part 0,300 59,6 17,48

Σ WLy [kN] 41,68

Carrying belt 0,400 20,4 7,98

Return belt 0,225 21,1 4,64

Σ WLy [kN] 12,62

ΣΣ WLy [kN] 54,30

Seismic Load EL (Standard NCH 2369 - 2003)

Base shear Q0 = C*I*P

Importance factor I= 1,0

Design wind pressure P= IwCqCefredqs

Base shear Q0 = CIP

Seismic coeffizient C= 2,75A 0/(gR)(T'/T)n*(0,05/ξ)0,4

) Maximum effective A0 = 0,3 g Table 5.2

Vertical seismic action Fv = +/- 2/3 (A 0/g)IP

Steg: b/t ≤ 27,1(1 - 0,278ψ - 0,025ψ²)(8,2/(ψ+1,05))1/2(240/(σ1γM))1/2 1>ψ>0

Flansch: b/t ≤ 19,7(0,57-0,21(ψ+0,07ψ²)1/2(240/(σ1*γM))1/2