DESIGN OF GANTRY

GIRDER

Design a gantry girder to be used in an industrial building carrying SOLUTION :

a manually operated overhead traveling crane for the following
For Fe410 grade of steel:
data:
⚫Crane capacity - 200kN ▪ fu = 410 Mpa
⚫Self-weight of the crane girder excluding trolley - 200kN ▪ fy = fyw = fyf = 410 MPa
⚫Self-weight of the trolley, electric motor, hook, etc. - 40kN For hand operated OT crane:
⚫Approximate minimum approach of the crane hook to the gantry girder - ▪ Lateral loads = 5% of maximum static wheel load
1.20m ▪ Longitudinal loads = 5% of weight of crab and weight lifted
⚫Wheel base - 3.5m
▪ Maximum permissible deflection = L/500
⚫c/c distance between gantry rails - 16m
Partial safety factors
⚫c/c distance between columns (span of gantry girder) - 8m
▪ ‫ע‬m0 = 1.10
⚫Self weight of rail section - 300N/m
▪ ‫ע‬mw = 1.50 (for site welds)
⚫Diameter of crane wheels - 150mm
⚫Steel is of grade Fe 410. Load factor
Design also the field welded connection if required. The support ▪ ‫ע‬m1 = 1.50
bracket connection need to designed. ξ = ξw = ξf = √ (250/ fy) = √ (250/ 250) = 1.0
STEP 1: CALCULATION OF DESIGN FORCES Taking moment about B,
Maximum wheel load: RA x 16 = 360 x (16 - 1.2) + (18.75 x 16 x 16) / 2
▪ Maximum concentrated load on crane = 200 + 40 = 240kN ✔ RA = 483kN

▪ Maximum factored load on crane = 1.5 x 240 = 360kN ✔ RB = 177kN

▪ The crane will carry the self-weight as a UDL = 200/16 = 12.5 kN/m
The reaction from the crane girder is distributed equally on the
two wheels at the end of the crane girder.
▪ Factored uniform load = 1.5 x 12.5 = 18.75kN/m
Therefore, Maximum wheel load on each = 483/2 = 241.5 kN
For maximum reaction on the gantry girder the loads are placed on the
wheel of the crane
crane girder as shown in the figure below,
STEP 2: CALCULATION OF MAXIMUM BM & SF:
Maximum Bending Moment:
▪It consists of maximum moments caused by the moving wheel
loads on the gantry girder and self weight of the gantry girder.

For Maximum Bending Moment, the wheel loads shall be placed as The position of one wheel load from the mid point of span
shown in figure. = Wheel Base/4
= 3.5/4 = 0.875 m
Bending moment due to live load only,
▪Taking moment about D,
Rc x 8 = 241.5 x (8 - 1.375) + 241.5 x 3.125
Rc = 294.33kN
The calculation of maximum bending moments due to wheel loads and
▪Taking moment about C,
self weight of gantry girder has been done separately because
RD x 8 = 241.5 x 1.375 + 241.5 x 4.875
calculation of impact load and bending moment due to it involve live
RD = 188.67kN
load only,
Maximum Bending Moment due to Live Load
Assume, Self Weight of the Gantry Girder as 2 kN/m.
= 188.67 x 3.125 = 589.6 kNm
Total Dead Load, w = 2000 + 300 = 2300 N/m = 2.3 kN/m
Bending Moment due to Impact
Factored Dead Load = 1.5 x 2.3 = 3.45kN/m
= 0.10 x 589.6 = 58.96 kNm
Total Bending Moment due to live load and impact loads
= 589.6 + 58.96 = 648.56 kNm
Bending Moment due to Dead Load
= wl2/8 = 3.45 x (82/8) = 27.6 kNm
Therefore, Taking Moment about D,
Maximum B.M = 648.56 + 27.6 = 676.16 kNm Rc x 8 = (241.5 x 8) + (241.5 x 4.5)
6
= 676.16 x 10 N_mm Rc = 377.34 kN
Maximum Shear Force: Hence,
▪ It consists of maximum shear due to moving wheel loads and self Maximum Shear Force due to wheel loads = 377.34 kN
weight of the girder. STEP 3: CALCULATION OF LATERAL FORCES:
Lateral force transverse to the rails
For maximum shear force the wheel loads shall be placed as shown in
= 5% of weight of crab and weight lifted = 0.05 x 240 = 12kN
figure, i.e one of the wheel loads should at the support.
Factored lateral force = 1.5 x 12 = 18 kN

Maximum horizontal reaction due to lateral force by proportion at C, STEP 4: SELECTION OF PRELIMINARY TRIAL SECTION :
= (lateral force x Reaction at c due to vertical load) Approximate depth of section = L / 12 = (8 x 103) / 12
(maximum wheel load due to vertical load) = 666.66mm ≈ 600mm
= (9 x 294.33) / 241.5 Approximate width of the flange = L / 30 = (8 x 103) / 30
= 10.97 kN = 266.66mm ≈ 300 mm
Horizontal reaction due to lateral force at D Approximate section modulus required, Zpz = 1.4 (Mz / fy )
= 18 - 10.97 = (1.4 x 676.16 x 106) / 250 = 3786.5 x 103 mm3
= 7.03 kN
Maximum bending moment due to lateral load by proportion Let us try ISWB 600 @ 1311.6 N/m
= (9.0 / 241.5) x 589.6 with ISMC300 @ 351.2 N/m on its
= 21.97 kNm
top flange as shown in figure,
Maximum shear force due to lateral load by proportion =
(377.34 / 241.5) x 9.0
= 14.06 kN
 STEP 5: MOMENT OF INERTIA OF GANTRY GIRDER :
I-Section Channel Section
Properties Notation The distance of NA of built up section from the extreme fibre of
ISWB 600 ISMC 300
compression flange,
Area A 17038 mm2 4564 mm2 ỹ = (∑AY) / ∑A = {17038 X (300 +7.6)} + {4564 X 23.6} =
247.59 mm
Thickness of Flange tf 21.3 mm 13.6 mm
(4564 + 17038)
Thickness of Web tw 11.2 mm 7.6 mm Gross Moment of Inertia of the Built-up section
Width of Flange bf 250 mm 90 mm Iz gross = Iz beam + Iz channel
(The channel is placed over the I-section in such a manner that its
Moment of Inertia Iz 106198.5 x 104 mm4 6362.6 x 104 mm4 yy-axis becomes the zz-axis. Therefore, in calculating Iz of the total
Iy 4702.5 x 104 mm4 310.8 x 104 mm4 section, Iy of the channel will become Iz of the channel.)

Depth of Section h 600 mm 300 mm Iz gross = [(106198.5 x 104) + (17038 x (307.6 - 247.59)2)]
Radius at root Rl 17 mm +
Cyy 23.6 mm [(310.8 x 104) + (4564 x (247.59 -23.6)2)]
= 135,543x104 mm4

Plastic section modulus of the section above equal axis,

Iy gross = Iy beam + Iy channel
Zpz1 = [300 X 7.6 X (74.95 + 21.3 + (7.6 / 2))]
= (4702.5 x 104) + (6362.6 x 104)
+ [2 X (90-7.6)x13.6(74.95 + 21.3 – (90-7.6/2))]
= 11,065.1x104 mm4
+ [250 X 21.3 x (74.95 + (21.3/2))]
Zez = (Iy /y)
+ [74.95 X 11.2 X (74.95/2)]
= (135,543 x 104) / (600 + 7.6 - 247.59)
Zpz1 = 838.775 X 103 mm3
= 3764.98x103 mm3
Plastic section modulus of the section below equal axis,
Plastic Modulus of Section
Zpz2 = [250 X 21.3 X ( 600 - 21.3 - 74.95 - ( 21.3/2))]
(Ignoring the Fillets)
+ [((600 – 2 X 21.3 – 74.95)2 / 2)]
Equal area axis (Refer to Fig)
Zpz2 = 3929.202 X 103 mm3
= 4564 + (250 X 21.3) + (ỹ1 t w)
= 250 X 21.3 + (600-2 X 21.3 ỹ1 ) X 11.2
Zpz = Zpz1 + Zpz2 = (838.775 X 103) + (3929.202 X 103)
Z = 74.95 mm
Zpz = 4767.977 X 103 mm3
(From Lower surface of top flange of I – Section)
Plastic section modulus of compression flange about yy – axis, d/tw of web of I-Section = ((h – 2tf) / tw)
Zpfy = [((250 X 21.3 X 250) /4)] + [((2 X (300 – (13.6 X 2))2 X 7.6) / 8)] = ((600 – 2 x 21.3) / 11.2)
+ [2 x (13.6 x 90 x ( 300 – 13.6) / 2)] = 49.76 < 84 (84 ε = 84 x 1 = 84)
3 3
= 824.763 X 10 mm Hence the entire section is plastic, (βb = 1.0)

STEP 6: CLASSIFICATION OF SECTION: STEP 7: CHECK FOR MOMENT CAPACITY:

Outstand of flange of I-Section, Local Moment capacity, Mdz = βb Zpz (fy / ‫ע‬m0 ) ≤ 1.2 x Ze (fy / ‫ע‬m0 )
b = bf/2 = 250/2 = 125 mm. Mdz = 1.0 x 4767.977 x 103 x (250 x 10-6 / 1.10)
b/tf of flange of I-section = 1083.63 kNm ≤ 1.2 x 3764.98 x 103 x (250 x 10-6 / 1.10)
= 125/21.3 = 5.86 < 8.4 (8.4ε = 8.4 x 1 = 8.4) = 1026.81 kNm
Outstand of flange of Channel Section, Hence, Moment capacity of the section,
b = bf - tw = 90 - 7.6 = 82.4 mm. Mdz = 1026.81 kNm > 676.16 kNm
b/tf of flange of Channel section which is safe.
= 82.4/13.6 = 6.05 < 8.4 (8.4 ε = 8.4 x 1 = 8.4)

STEP 8: BUCKLING RESISTANCE IN BENDING CHECK:

Moment capacity of compression flange about y-axis,
The elastic lateral buckling moment,
Mdy,f = βb Zpyf (fy / ‫ע‬m0 ) ≤ 1.2 x Zey,f (fy / ‫ע‬m0 )
Mcr = c1(π2EIYhf/2L2LT)[1+1/20((LLT/ry)/(hf/tf))2]0.5
= 1.0 x 824.76 x 103 x (250 x 10-6 / 1.10)
= 187.44 kNm ≤ 1.2 x 580.92 x 103 x (250 x 10-6 / 1.10) Overall depth of the section,
= 158.43 kNm hf = h = 600 + 7.6 = 607.6 mm
Note: hf is the centre to centre distance between flanges. In the
Hence moment capacity of flange,
calculation, value of hf has been taken equal to overall depth of the
Mdy,f = 158.43 kNm
section to avoid cumbersome calculations. Further, this approximation
will result in conservative design.
Combined check for local moment capacity,
Effective length, LLT = 8 x 102 mm
(Mz / Mdz ) + (My,f / Mdy,f) ≤ 1.0
Thickness of flange, tf = 21.3 + 7.6 = 28.9 mm
(676.16 / 1026.81) + (21.97 / 158.43) = 0.797 < 1.0
Radius of gyration, ry = √(IY/A)
Which is safe.
= √((11065.1x104)/(17038+4564))
= 71.57mm
The coefficient, c1 = 1.132 (From Appendix XIV, assuming uniform load χLTz = [1/( ΦLTz + ΦLTz2 - λLTz2)0.5]
condition) = [1/(0.891 + 0.8912 – 0.8092)0.5]
Mcr = [(1.132x2x2x105x11065.1x104x607.6) / (2x(8x103)2)] = 0.791
3 2 0.5
x [1+1/20((8x10 /71.57)/(607.6/28.9)) ]
= 1823.24 x 106 Nmm Design bending compressive stress,
Non dimensional slenderness ratio, fbd = χLTz (fy / ‫ע‬m0 )
λLTz = √(βb Zpz fy / Mcr) = 0.791 (250/1.10)
= √((1 x 4783.594 x 103 x 250) / (1823.24 x 106)) = 179.77 N/mm2
= 0.809 The design bending strength,
ΦLTz = 0.5 [1 + αLT (λLTz – 0.2) + λLTz2] Mdz = βb Zpz fbd
αLT= 0.21 (assuming connection of channel with I-section flange by = 1.0 x 4767.977 x 103 x 179.77 x 10-6
intermittent fillet welds. For uniform weld, αLT = 0.49) = 857.14 kNm > 676.16 kNm (which is alright)
ΦLTz = 0.5 x [1+0.21 x (0.809 – 0.2) + 0.8092]
= 0.891 Hence, the beam is safe in bending under vertical load.

STEP 9: STEP 10: CHECK FOR SHEAR CAPACITY :

Since lateral forces are also acting, the beam must be checked for Maximum shear force due to wheel load = 377.34 kN
bi-axial bending. The bending strength about y-axis will be provided by Impact load = 0.1 x 377.34
the top flange only as the lateral loads are applied there only. = 37.73 kN
Mdy =Zyt (fy/γm0) Design shear force = 377.34 + 37.73
Zyt = section modulus of top flange about yy-axis. = 415.05 kN
= (4702.5x104/2 +6362.6x104)/(300/2) = 580.92 x 103 mm3 Shear capacity = Av fyw / (√3 x γmo)
(Assuming the moment of inertia of top flange to be half of the moment = [((600x11.2) x 250x10-3) / (√3x1.1) ]
of inertia of I-section) = 881.77 kN > 415.07kN, which is safe.
Mdy = 580.92 x 103 x (250/1.1) x (10-6) = 132.02kNm. Maximum shear,
(Mz/Mdz) + (My/Mdy) < 1.0 V = 415.07 kN < 529 kN
= (676.16/859.946) + (21.97/132.02) = 0.952 < 1.0 (i.e. 0.6*Vd = 0.6 x 881.77 = 529kN)
Hence, the section is safe. Since V < 0.6*Vd, the case is of low shear.
No reduction will be therefore there in the moment capacity.
STEP 11: WEB-BUCKING CHECK: STEP 12: DEFLECTION CHECK:
We should check for buckling under the wheel load. δ = wL3x(3a/4L –a3/L3)
Buckling Resistance = (b1+n1)tw*fcd 6EI
Where, b1 = bearing length=150mm(diameter of wheel) W = Maximum Static Wheel Load = (241.5 / 1.5)
n1 = (600/2) +2x7.6 = 315.2 mm = 161 kN
Slenderness ratio of the web, a = (L - c) /2 = [(8x103) – (3.5x103)] / 2
λw = 2.45 (d1/tw) = 2.25 x 103 mm
= 2.45(600 -2x(21.3 + 17))/11.2 = 114.49 Therefore, Vertical deflection
For λw=114.49, fy=250N/mm2 and buckling curve c, the design = (161x103)x(8x103)3x{(3x2.25x103)/(4x8x103)-(2.25x103)3/(8x103)3)
compressive stress from Table 7.6, [6 x (2x105) x 135,543x104]
fcd = 89.64 N/mm2 = 9.56 mm
Therefore, Buckling Resistance = (150 + 315.2) x 7.6 x 89.64 x 10-3 Permissible maximum deflection, = L / 500
= 316.9 kN > 241.5kN = 8000 / 500
(which is safe) = 16 mm > 9.56 mm, which is safe.

STEP 13: DESIGN OF CONNECTIONS :

The required shear capacity of the weld,
q = Vaỹ / Iz
V = 377.34 kN
A = 4564 mm2 (area above the section)
ỹ = (247.59 -7.6) = 239.9 mm
Iz = 135,543x104 mm4 DRAWINGS & DETAILING
Therefore, q = [(377.34 x 103) x 4564 x 239.9] / [135,543x104]
= 304.82 N/mm
Let us provide 3 mm weld to connect channel with flange of I-section.
Strength of the weld provided, = (0.7x3x410)/(√3x1.50)
= 331.39 N/mm > 304.82 N/mm
Hence, provide 3 mm size intermittent fillet welds for making the
connection.