Design Example 2

Illustration of Design of a Heavy-Duty Plate Girder Type Crane Runway Beam

Design Criteria Value/Units

Codes and Standards CSA S16-01

Importance (see NBCC 2005) N.A.

Life of the Structure N.A.

Materials (Plates, Shapes, Fasteners, etc.) CSA G40.21 Grade 350W

Span 15 240 mm

Provision for Future Expansion? N.A.

Simple Span? Yes

Lateral Support for Top Flange? Yes

Top of Rail Elevation, or Height from Main Floor N.A.

Required Clearances to U/S Beam N.A.

Side Thrust Equally Distributed Both Sides of Runway? Yes

Number of Cranes, Each Runway 2 identical cranes

Collector Rail Mounting Details N.A.

Design for Future Additional Cranes N.A.

Jib Cranes, or Provision for Jib Cranes No

Design for Future Upgrades N.A.

Class of Cranes CMAA Class D

Service (Description) Heavy

Type of Duty (see table 2.1) Steel Mill, cab operated or radio controlled

Crane Hook Capacity # hook(s) each 1

Capacity each hook 45 tonnes

Weight of Crane Bridge 106 600 kg*

95
 Design Criteria Value/Units

Weight of Crane Trolley 29 500 kg*

Bridge Wheels per Rail Total Number 4

Driven 2

Bridge Wheel Spacing See Figure A12

Minimum Distance Between Wheels of Cranes in Tandem 3 658 mm

Maximum Wheel Load, Each Crane (not including impact) 276 kN

Crane Rail Description Bethlehem 135 lb/yd
Self Load 0.657 kN/m
Rail Joints (bolted or welded) Yes

Resilient Pad Under Rail? Yes

Bridge Speed 1.5 m/sec

Type of Bumpers N.A.

Bumpers Supplied with Crane? N.A.

Bumper Forced on Runway End Stop (Ultimate Load) N.A.

Fatigue Criteria:
Vertical - Equivalent passes on one crane, maximum 1 000 000
wheel loads
Horizontal - Equivalent cycles of side thrust at 50% of 500 000
maximum side thrust

Deflection Criteria:
Vertical Limit (one crane, not including impact) Span/800
Horizontal Limit Span/400

Impact Criteria:
25%
Percentage of maximum wheel loads, one crane only

Use elastomeric pad under rail. First two

Other Considerations
axles of each crane are driven.

*Weight Certified? No

96
 Crane A Crane B

1829 3658 1829 3658 1829 3658 1829

15 240 mm 15 240 mm

Bumpers Compressed

Figure A12
Wheel Configuration - Two Cranes

Design Data
A preliminary analysis shows that a moment of inertia in the strong axis of approximately 15 × 109 mm4 will
be required. A computerized moving load analysis for one and two cranes using I =14.5 × 109 mm4 yields the
following results:

3048

Figure A13
Wheel Location - One Crane

M max , 1 Crane, no Impact

M LL , specified = 2 751 kN·m
V LL , specified = 839.0 kN

762

Figure A14
Wheel Location - Two Cranes

M max , 2 Crane, no Impact

M LL , specified = 3 051 kN·m
V LL , specified = 960.5 kN

97
From the crane data provided, moments and shears for one crane without impact are as follows.

CL Span

276 kN (typical)
914 914

C.G. Wheels
15 240 mm

Wheel Position for Mmax

2423

1884
2751

2726
2726
1884

2423
1110

1110
Crane Live Load Bending Moment Envelope kN.m (Unfactored)

839
728
618
508
397
287
199
132
77.3
27.6

27.6
77.3
132
199
287
397
508
618
728
839

Crane Live Load Shear Force Envelope kN (Unfactored)

Figure A15
Bending Moments and Shears - One Crane

98
Moments and shears for two cranes in tandem, bumpers compressed, without impact, are as follows.

CL Span

276 kN (typical) 457 457

C.G. Wheels
15 240 mm

Wheel Position for Mmax

2549

2019
3051

3051

2927
2927
2019

2549
1211

1211
Crane Live Load Bending Moment Envelope kN.m (Unfactored)

960
795
640
508
397
287
199
132
77.3
27.6

27.6
77.3
132
199
287
397
508
640
795
960

Crane Live Load Shear Force Envelope kN (Unfactored)

Figure A16
Bending Moments and Shears - Two Cranes

99
Consider the Forces from Traction, Cls (One crane only)

Wheels are positioned for M max .

Criterion for Cls is 20% of the load in the driven wheels. For worst case, assume all horizontal load resisted at
RHS (RH).

Cls , specified load = 0.2 # 2 # 276 = 110.4 kN

RR = RL = 110.4 # 1.646 = 11.92 kN
15.24

The maximum (+) moment Mr will occur under the same wheel as for gravity loads =11.92 × 8.534 = 101.7 kN
Note: Axial load is not significant for this section and will not be considered further in this example.

1) Calculate Side Thrust

Refer to Section 2.3.1 and Table 2.1 for cranes of type "Cab Operated or Radio Controlled". Total side thrust for
one crane is the greatest of:
- 40% of lifted load 0.4 × 45 × 9.81 = 176.6 kN
- 20% of (lifted load + trolley) 0.2 × (45 + 29.5) × 9.81 = 146.2 kN
- 10% of (lifted load + crane weight) 0.1 × (45 + 136.1) × 9.81 = 177.7 kN Governs

Stiffness in the direction of side thrust is the same on both sides of the runway, therefore the maximum value,
177.7 kN will be distributed equally to each side,
177.7 22.21 kN per wheel
2#4=
Therefore moments and shears due to side thrust will be 22.21 = 0.0805 times the vertical wheel load moments
276
and shears.

Summary Table - Unfactored Live Load Bending Moment and Shear Summary

Shears (kN)
Moments
(kN·m) at End at 1524 at 3048 at 4572 at 6096 at 7620

Live Load 2751 839.0 728.0 618.0 508.0 397.0 287.0

Impact 687.8 209.8 182.0 154.5 127.0 99.25 71.75

One Crane
Side thrust 221.5 67.54

Traction 101.7 11.92

Live Load 3051 960.0 795.0 640.0 508.0 397.0 287.0

Impact – – – – – – –
Two
Cranes
Side thrust 221.5 67.54

Traction 101.7 11.92

100
Note that in the above summary for two cranes, the values for side thrust will be slightly conservative because the
maximum values for a single crane positioned for maximum effects were used. If a rigorous approach is used, the
designer may be faced with a formidable number of possibilities for the critical combination. From the summary
table, one crane will govern for strength calculations.

Investigate Deflection Due to Live Load

From a computerized moving load analysis using Ixx =14.5 × 109 mm4, maximum deflection due to live load not
including impact, is as follows. Deflection for two cranes is shown for information only.

Maximum Deflection, mm Span/800, mm

One crane 23.6 19.1
Two cranes 25.8 19.1
Therefore, for deflection ≤ 19.1 mm,
Ixx minimum = 23.6 # 14.5 # 10 9 = 17.9 # 10 9 mm 4
19.1

Pick Trial Section

1230

‘d’
*
30 1010x10

‘c’ ‘e’
500x30 207x10.9

‘f’
w=8.9

W 530x72
1500 mm

‘b’ Note: the 10 mm Apron Plate is considered

1440x16 adequate for local foot traffic. No other live
load need be included for this design.

* 30 is a minimum dimension and should

be increased if possible to limit distortion-
‘a’
induced fatigue stresses.
500x30

Figure A17
Trial Section

101
Class of Section for Bending x-x, Grade of Steel 350W

b 250 8.33 > 145

Flanges t = 30 = Fy Class 2

h 1440 90 > 1 700

w = 16 = Fy Class 2
Web
< 83 000 OK (14.3.1)
Fy

However, since the composite section, including a portion of the apron plate, will not have an axis of symmetry
in the plane of bending (see S16-01, Clause 11.1.3), the section will be considered Class 3.
Therefore, in accordance with S16-01, Clause 11.2, Table 2;

b # 200
Projecting flanges t = 10.69
Fy

b # 340
Stems of Tee Sections t = 18.17
Fy

h # 1 900
Webs w = 101.6
Fy

The maximum slenderness ratio of a web > 83 000 = 237.1 (Clause 14.3.1)
Fy

h > 1 900 ,
If the web slenderness ratio w
Mf
zS
then the moment resistance must be required in accordance with clause 14.3.4

Consider Eccentricity of Loads Due to Side Thrust (Css) in the Horizontal Direction

HT = Css # 1 631 = 1.094 6 Css

1490
HB = 0.094 6 Css

Referring to the moments due to side thrust, increase the bending moments and shears in the horizontal beam
by a factor of 1.0946, and apply a bending moment to the bottom flange of the plate girder = 0.094 6 times the
calculated lateral moment due to side thrust. The bending moment y-y in the bottom flange is
0.094 6 # 221.5 = 20.96 kN$m
2
Mry bottom flange = 0.9 # 350 # 30 # 500 # 10 - 6 = 591 kN$m
4
Note: Resilient pad not included above. Effect is small and can be neglected.

102
Calculate Section Properties x-x

136.9
‘c’ ‘d’

10.69x10=106.9 mm

‘b’
yB=769 mm

‘a’

Figure A18
Section Properties of Girder with Apron Plate, About x-x Axis

A yb Ayb Ay b2 I0
Element
(mm 2) (mm) (10 3 mm 3) (10 6 mm 4) (10 mm 4)
6

a 15 000 15 225 3.4 –

b 23 040 750 17 280 12 960 3 981
c 15 000 1 485 22 280 33 080 –
d 1 369 1 505 2 060 3 101 –
Σ 54 410 41 850 49 140 3 981

yB =
! Ayb = 41 850 # 10 3 = 769.2 mm and yT = 1510 - 769.2 = 740.8 mm
!A 54 410

103
Ixx = ! I + ! Ay b2 - y B2 ! A
O

= 3 981 # 10 6 + 49 140 # 10 6 - 54 410 ^769.2h

2

= 20 940 # 10 6 mm 4 > 17 900 # 10 6

Css Reaction from Horizontal Beam

HT

115146

115005
631

490

Reaction from Horizontal Beam

HB

Figure A19
Side Thrust

span
Therefore vertical deflection due to crane load will be less than and will be 1.79 # 19.1 = 16.3 mm
800 2.094
6
I
Sx Bottom = xx = 20 940 # 10 = 27 220 # 10 3 mm 3
yB 769.2

Sx Top =
Ixx 20 940 # 10 6 28 270 10 3 mm 3
yT = 740.8 = #

104
Calculate Section Properties y-y

1230

1010x10 207x10.9
470

‘a’
‘b’
18.17x8.9
=161.7 mm
500x30 18.17x16
=290.7 mm

‘X’ from point ‘a’ = 604.8 mm 978.7 mm

Figure A20
Section Properties of Girder with Apron Plate, About y-y Axis

A x 'a' A x'a' 2
A x'a' I0
Element (mm 2) (mm) (10 3 mm 3) (10 mm 4)
6
(10 6 mm 4)

500 × 30 15 000 250 3 750 938 313

290.7 × 16 4 651 250 1 163 290.8 –
1 010 × 10 10 100 975 9 848 9 602 859
207 × 10.9 2 256 1 480 3 339 4 942 81
161.7 × 8.9 1 439 1 480 2 130 3 152 –
Σ 33 450 20 230 18 920 1 253

x=
! Ax'a' = 20 230 # 10 3 = 604.8 mm and x' = 1583.5 - 604.8 = 978.7 mm
!A 33 450
Iyy = ! I0 + ! Ax '2a' - x 2 ! A
= 1 253 # 10 + 18 920 # 10 - 33 450 ^769.2h
6 6 2

6 4
= 7 945 # 10 mm
I 6
Sy 'a' = yy = 7 945 # 10 = 13 140 # 10 3 mm 3
x 604.8

105
 Iyy 7 945 # 10 6 8118 10 3 mm 3
Sy'b' = = = #
x' 978.7

Calculate Lateral Deflection Due to Side Thrust

1.094 6 # 0.080 5 # 20.94 # 10 9 # 16.3 3.8 mm
= =
7.945 # 10 9
Span 15 240
38.1 mm > 3.5 mm OK
400 = 400 =
Check Shear – OK by quick check.

Calculate Factored Moment Resistance Mrx = zSx Fy (Clause 13.5)

at top flange 6 6
= 0.9 # 28.27 # 10 # 350 # 10 - = 8 905 kN$m
at bottom flange 2.722
= 2.827 # 8 905 = 8 574 kN$m

Calculate Factored Moment Resistance Mry = zSy Fy (Clause 13.5)

at rail side 6 6
= 0.9 # 13.14 # 10 # 350 # 10 - = 4139 kN$m
at back side 8.118 4139 2 557 kN$m
= # =
13.14

Check for Reduction in Moment Resistance Mrx Due to a Slender Web (14.3.4)
Factored Moment M fx is approximately ^1.2 # 200h + ^1.5 # 3500h = 5 490 kN$m

then 1 900 ( min ) = 1 900

= 126.9 > 90 OK
M fx 5 490 # 10 6
zS x 0.9 # 27.22 # 10 6

Check for Reduction in Moment Resistance Mry Due to a Slender Web

Factored Moment M fy is approximately 1.5 # 221.5 = 332 kN$m

then 1 900 ]ming = 1 900 876

= 281 > 10 OK
M fy 332 # 10 6
zS y 0.9 # 8.118 # 10 6

Calculate Shear Capacity of the Unstiffened Plate Girder Web (Clause 13.4)
Vrf = zAw Fs
Fs is calculated in accordance with the web slenderness ratio h
w

Go to the CISC Handbook of Steel Construction, where the factored ultimate shear stress zFs is given for girder
webs.
h
For grade 350, w = 90 , no intermediate stiffeners zFs = 106 MPa

then Vrf = 106 # 1440 # 16 = 2 442 kN

1000

106
Check for Possibility of a Thinner Web
Capacity seems to be more than adequate, try 12 mm plate (flanges will have to be increased to maintain Ix min ),
h 1440 120 > 1 900 , therefore bending strength is calculated (S16-01, Clause 14).
w = 12 = Fy

From CISC Handbook zFs = 60 MPa ; therefore Vrf = 60 # 1440 # 12 = 1036 kN

1000

Factored Shear Force . 1.5 ^839 + 209 + 11.9h = 1590 kN plus Dead load > 1 036, therefore stiffeners would
be required.

Calculate Dead Load Supported by the Plate Girder

Section Area, mm 2 # 0.785 = kg/m # 0.009 81 = kN/m

Plate Girder 53.04 # 10 3 416.3
50% of Apron Plate 5 175 40.6
135# Rail 66.96
Misc. (allowance) 50.0

Σ 573.8 5.629 kN/m

Calculate the Unfactored Bending Moment Mx Due to Dead Load

15.240 2 163.4 kN$m
= 5.629 # 8 =

Calculate the Unfactored Maximum Bending Moment Mx Due to Live Loads

= 2 751 + 687.8 + 101.7 = 3 541 kN$m

Calculate the Unfactored Maximum Bending Moment My due to Live Loads (side thrust)
= 1.094 6 * # 221.5 = 242.5 kN$m
* Amplified due to eccentricity of loads due to side thrust

Calculate M fx
M fx = ^1.25 # 163.4h + ^1.5 # 3 541h = 5 516 kN$m (see previous calculations)
If the unloaded crane has been weighed (CDL) knowing the lifted load (CLL), the factored vertical crane load
would be 1.25CDL +1.5CLL.

Calculate M fy at Top
M fy = 1.5 # 242.5 = 363.7 kN$m

107
Calculate M fy at Bottom
M fy = 1.5 # 0.094 6 # 221.5 = 31.4 kN$m

Check Trial Section for Biaxial Bending, Top corner, Rail Side.
This is the Yielding Limit State (Strength) Check.
M fx M fy
# 1.0
Mrx + Mry
5 516 363.7 0.691 0.088 0.779 # 1.0 OK
+ = + =
8 905 4139

Check for Lateral-Torsional Buckling

Limit State (Stability) is not required because the section is laterally supported by the horizontal beam.

Check for Bending Strength Top Corner, Back Side

M fy
# 1.0
Mry
363.8
= 0.142 < 1.0 OK
2 557.2

Check for M fx and M fy in Bottom Flange

5 516 20.96
+ 591 = 0.643 + 0.035 = 0.678 < 1.0 OK
8 574

Calculate Factored Shear in the Vertical Direction

= b1.25 # 5.629 # 2 l + 1.5 ^839.0 + 209.8 + 11.92h

15.24

= 53.61 + 1591 = 1 665 kN

Check Shear Strength in the Vertical Direction

1 665
= 0.682 < 1.0 OK
2 442

A check for combined bending moment and shear is not required because the section is not transversely stiffened.
See S16-01, Clause 14.6.

108
Check Local Wheel Support
(a) Check Web Crippling and Yielding (Clause 14.3.2)

Factored Wheel Load = 1.5 x 1.25 x 276 = 517.5 kN

Rail, 146 mm deep

1
1 Flange, t =30 mm
2.5:1

Fillet Weld, 8mm

Web, t =16 mm

N = (2 x 146) + (5 x 38) = 482 mm

Figure A21
Web Crippling Under Crane Wheel

Check Interior
(i) Br = 0.8 # 16 ^482 + 300h 350 = 3 503 kN 14.3.2(i)
1000
2
(ii) Br = 1.45 # 0.8 # 16 350 # 200 000 = 2 485 kN 14.3.2(ii) Governs
1000

the factored resistance of 2 485 kN > 517.5 kN OK

A check at the ends is not necessary because bearing stiffeners will be used.
(b) Check torsional effects on web under a wheel load including rail eccentricity and side thrust.
Factored Vertical Load = 1.5 # 1.25 # 276 = 517.5 kN , including impact
Factored moment due to eccentricity = 1.5 # 1.25 # 276 # 12 = 6.21 kN$m
1000
Factored moment due to side thrust = 1.5 # 22.21 # 184
= 6.13 kN$m
1000
M f = 6.21 + 6.13 = 12.34 kN$m

109
 Wheel load = 276 kN

eccentricity = 0.75x16 = 12 mm

Side thrust = 22.21 kN per wheel

Note: The procedure below is conserva-

146+30+8 = 184 mm
tive, neglecting torsional restraint pro-
vided by the rail and flange. Refer to
Reference 1 for information on a more
exact method established by Cornell Uni-
8 versity. Australian Standard A5 1418.18-
GTSM
2001 also includes a procedure using
limit states methods.
8

Figure A22
Stability and Strength of Web Under Combined Loads

For length of web = 482 mm, as previously calculated

2 2
Z = bd = 482 # 16 = 30 848 mm 3
4 4

Mr = 0.9 # 30 848 # 350 # 10 - 6 = 9.717 kN < 12.34 kN$m, No Good

Since the torsional resistance of the rail and flange was not included in the above approximation, check using a
more exacting method such as the Australian Standard A5 1418.18. Using this method:

Factored bending moment = 15 000 N·mm/mm length of weld

2
Factored resistance = 0.9 # 16 # 350 = 20 160 N$mm/mm length of weld OK
4

No need to check at ends because bearing stiffeners have been used.

110
Design Bearing Stiffeners

GTSM

Bearing Stiffener

A A

GTSM or Grind to
bear and fillet weld

Support Factored Reaction = 1665 kN

b=232 mm 240 mm

16 mm web

12 mm
12t =192 mm

Section A-A

Figure A23
Bearing Stiffeners

For stiffeners, bt # 200 = 10.69 Clause 11.2

Fy

therefore minimum t = 232 = 21.7 mm

10.69
Try 25 mm thick stiffeners

111
Check column action
A = ^2 # 232 # 25h + ^16 # 192h = 14 672 mm 2
3
^ h 3
I = 25 # 480 + 192 - 25 # 16 = 230.5 # 10 6 mm 4
12 12
6
r = 230.5 # 10 = 125.3 mm
14 672
L = 3 of the length of the stiffeners
4
= 0.75 # 1440 = 1080 mm
KL 1 # 1080 8.61
r = 125.3 =

Using Table 4-4 of the CISC Handbook, the factored resistance for 350 MPa stiffeners is
314 # 14 672 = 4 607 kN > 1 665 kN OK
1000

Check Bearing (Clause 13.10)

Fit to Bear, Minimum welds to be provided

25

207 mm

Figure A24
Bearing of Bearing Stiffener
Check one side
Factored load = 1 665 = 832.5 kN
2

Clause 28.5 states that at least 75% of the area must be in contact. To guard against fillet welds supporting the
load, check for 0.75 × 207 = 155 mm in contact.
The factored bearing resistance, to clause 13.10

1.55 OK
= 1.5 # 0.9 # 350 # # 25 = 1831 kN > 832.5
1000

Design welds to web

1 665
2 # 1350 ^sayh
Factored load per weld = = 0.617 kN/mm

From Table 3-24, CISC Handbook, need 5 mm for strength, use minimum = 8 mm (50% loaded)

112
Design Bottom Flange Fillet Welds For Strength
Maximum Factored Shear Vfx = 1 665 kN

A3
A2

701 mm

731 mm
N.A.

769 mm

754 mm

‘a’
A1

Figure A25
Factored Shear Flow at Web-to-Flange Junction 'a'

VAy
Calculate Shear Flow
I
Factored shear flow at web-to-flange junction 'a'
1 665 # 10 3 # 15 000 # 754 899.3 N/mm
= =
20.94 # 10 9

The minimum fillet weld is 8 mm (Page 6-172 of the CISC Handbook). Using an E49XX electrode and Table
3-24 in the CISC Handbook, the factored shear resistance for a pair of 8 mm fillet welds is
2 # 1.24 = 2.48 kN/mm > 0.8993 OK
Continuous welds would be used to 0.899 = 0.36 capacity
2.48

Design Upper welds for Strength

Maximum Factored Shear due to side thrust Vfy = 1.5 # 67.54 # 1.094 6 = 110.9 kN

113
 Weld ‘c’ Weld ‘f’

266x30

Weld ‘d’ Weld ‘e’

Weld ‘b’

y=179 mm
291x16

N.A.
605 979

A=12363 mm2
(7980x133)+(4656x258)
y=
12636
=179.1 mm

Figure A27
Upper Welds

For weld 'b', Ayr = 12 636 # ^605 - 179h = 5.383 # 10 6 mm 3

For welds 'e', and 'd' (Calculate 'c', use for both)
Ayr = 19 651 # ^605 - 250h = 6.976 # 10 6 mm 3
For welds 'e'
A = ^103.5 # 10.9h + ^161.7 # 8.9h + ^103.5 # 10h = 1128 + 1439 + 1035 = 3 602 mm 2
^2567 # 103.5h + ^1035 # 51.8h
N.A. = = 88.6 mm (118.4 from RHS)
3 602
Ayr = 3 602 # ^979 - 118.4h = 3.10 # 10 6 mm 3
For weld 'f'
A = ^103.5 # 10.9h + ^161.7 # 8.9h = 1128 + 1439 = 2 567 mm 2
^1128 # 51.8h + ^1439 # 103.5h
N.A. = = 80.8 mm (from RHS)
2 567
Ayr = 2 567 # ^979 - 80.8h = 2.306 # 10 6 mm 3
For weld 'b'
A = 1500 + 1369 = 2 869 mm 2 Weld ‘c’
^1500 # 15h + ^1369 # 35h 500x30 136.9x10
N.A. = = 24.5 mm
2 869
^725.5 from NA of entire sectionh
‘b’ ‘d’

Ayr = 2 869 # 725.5 = 2.081 # 10 6 mm 3

For weld 'c'
A = 1369 mm 2
yr = 741 - 5 = 736 mm
^from NA of entire sectionh
Ayr = 1369 # 736 = 1.008 # 10 6 mm 3
N.A.

Figure A26
Welds 'b','c' and 'd'

114
Calculate Factored Shear Flows

166 5 # 10 3 # 2.081 # 10 6 110.9 # 10 3 # 5.383 # 10 6

weld 'b ' = +
20.94 # 10 9 7.945 # 10 9
= 165.5 + 75.1 = 240.6 N/mm ^2 weldsh

3
weld 'c' and 'd' = 1 665 # 10 # 1.008 # 10 6 + 110.9 # 10 3 # 6.976 # 10 6
9
20.94 # 10 7.945 # 10 9
= 80.1 + 97.4 = 177.5 N/mm ^2 weldsh

weld 'e' 110.9 # 10 3 # 3.10 # 10 6 43.3 N/mm

= =
7.945 # 10 9

weld 'f' 110.9 # 10 3 # 2.306 # 10 6 32.2 N/mm

= =
7.945 # 10 9

For fillet welds, refer to the CISC Handbook, Table 3-24, and page 6-172.

Factored Shear Flow, N/mm Minimum Fillet, mm

Weld
x-x y-y Combined Strength Thickness

a 449.7 - 5 (58%) 8 (36%)

b 82.8 37.6 120.4 5 8

c 40.1 48.7 88.8 5 8 (7%)

d 40.1 48.7 88.8 5 8 (7%)

e * 43.3 43.3 5 (3%) 5

f * 32.2 32.2 5 (2%) 5

* No significant gravity loads for purpose of this example. (%) means % of strength provided.

Regarding weld 'a', a complete-joint-penetration groove weld with reinforcing will be provided. No further
evaluation.
Simplify Fatigue Loading
The criterion for vertical loading is 1 000 000 passes of a crane, maximum wheel loads.
The criterion for side thrust is 500 000 cycles of loading at 50% side thrust.
Find the level of side thrust that for 1 000 000 cycles, will cause the same damage.
Fatigue life is inversely proportional to the value of the stress range for values above constant amplitude
threshold.*
Stress range is proportional to load.

* Does not include consideration of low stress cycles, not significant for these calculations.

115
 =d n = Load Ratio 3
3
life 1 load range 2
life 2 load range 1

then Load Ratio = 3 0.5 = 0.794

i.e. use 0.794 # 50% = 39.7% of specified side thrust in calculations for strength.

Calculate Fatigue Loads and Stress Ranges

For Mx , criterion is 1 000 000 crane passages, maximum wheel load without impact.
Mx specifed = 2751 kN$m, no reversal
Vx specified = 839 kN
For My , criterion is 1 000 000 cycles of side thrust, including reversal, at 0.397 × full load

M ytopspecified = ! 0.397 # 242.5 = 96.27 kN$m

M ybottom 31.4 8.31 kN$m

specified = ! 0.397 # =
1.5

Vy specified = ! 0.397 # 110.9 = 29.35 kN

1.5
At welded rail clips, check if net tension exists under minimum wheel loads (trolley at other side) and 50%
side thrust. Wheel loads . 106 600 + b 0.1 # 29 500 l + b 0.1 # 45 000 l = 15 187 kg = 149.0 kN
8 4 4
149 2 751 10 6
# #
fsv =+ 276 = 52.53 MPa
28.27 # 10 6
6
^ h
fsh = ! 96.27 # 10 # 6059 - 100 = 6.12 MPa < 52.53 No Tension, OK
7.945 # 10

Before proceeding further with a check on base metal, weld details need to be addressed. Referring to strength
calculations, intermittent fillet welds would be adequate at welds a, c, d, e and f.
Use of intermittent fillet welds in tension areas is not advisable. These welds should be continuous fillets. Bolted
connections would be considered for the apron plate, but welds will be used for purposes of this example.
Evaluation for continuous fillet welds of the same size at a, b, c, d, e, f and g.

Calculate Stress Ranges in Base Metal

(+) means tension
6
base metal at bottom flange fsr =+ 2 751 # 10 6 =+ 101.1 MPa
27.22 # 10

6
at ‘a' fsr =+ 2 751 # 10 # 9739 =+ 97.09 MPa
20.94 # 10
=- 0.0

fsr =- d 2 751 # 10 # 9731 n ! d 96.27 # 10 # 9355 n

6 6
at 'b' 20.94 # 10 7.945 # 10
=- 96.04 ! 4.30 =- 100.3 or - 91.7
^ No Tensionh

116
 5 3 - 100
5 2 - 100

8 7 - 100
8 7 - 100
GTSM

GTSM

8 50 - 100
8 50 - 100
One Stiffener detailed.
Other Stiffener is the same.

See
8 36 - 100
Figure
8 36 - 100
A24

Figure A28
Minimum Welds Required for Factored Loads (Except GTSM weld) Minimum Effective Welds
and Fatigue Considerations not Included

fsr =- d 2 751 # 10 # 9731 n ! d 96.27 # 10 # 9175 n

6 6
at 'c' and 'd'
20.94 # 10 7.945 # 10
=- 96.22 ! 2.12 =- 98.34 or - 94.1 MPa
^ No Tensionh

^Reversalh
6
at 'e' fsr = ! 96.27 # 10 # 9772 = ! 9.35 MPa = 18.71 MPa
7.945 # 10

^Reversalh
6
at 'f fsr = ! 96.27 # 10 # 9875 = ! 10.60 MPa = 21.20 MPa
7.945 # 10
Calculate Ranges of Shear Flow in Weld Metal

3 6
at 'a' Vr = 839 # 10 # 11.319 # 10 = 453.1 N/mm
20.94 # 10

117
 100 welded rail clips
‘f’

‘c’ , ‘d’ ‘e’

‘h’
‘b’

Note: Stiffeners are at bearings only.

‘g’

‘a’

Base Metal

Figure A29
Locations of Fatigue Checks on Cross Section

3 6 3
at 'b' Vr =+ 839 # 10 # 2.0819 # 10 ! 29.35 # 10 # 5.383 # 10 6
9
20.94 # 10 20.18 # 10
=+ 833.8 ! 7.83 =+ 841.6 or + 826.0 N/mm

3 6 3
at 'c', 'd' Vr =+ 839 # 10 # 1.0089 # 10 ! 29.35 # 10 # 6.976 # 10 6
20.94 # 10 20.18 # 10 9
=+ 40.39 ! 10.15 =+ 50.54 or 30.24

3 6
at 'e' Vr = ! 29.35 # 10 # 3.109 # 10 = ! 4.51 = 9.02 N/mm (Reversal)
20.18 # 10

3
at 'f' Vr = ! 29.35 # 10 # 2.306 # 10 6 = ! 3.35 = 6.70 N/mm (Reversal)
20.18 # 10 9

118
Examine Base Metal
Refer to CSA S16-01, Clause 26, and Tables 9 and 10

Stress Range γ Frst Fatigue Life Cycles

Location Category Comment
fsr MPa MPa MPa nN = c fsr3
Base metal
bottom 101.1 A 8 190 × 109 165 > 1 × 106 OK
flange

a 97.1 B 3 930 × 109 110 > 1 × 106 OK

Special
b no tension OK
Case*

c, d no tension OK

e 18.71 B 3 930 × 109 110 > 1 × 106 OK

f 21.20 B 3 930 × 109 110 > 1 × 106 OK

* Detail is subject to 8 repetitions of load with each crane passage (nN ≈ 8 000 000 cycles). There is no category but this type
of weld detail is known to provide satisfactorily service.

Examine Weld Metal

Weld Throat γ Frst nN

Stress Range
Location Size Area Category Comment
fsr MPa MPa MPa
mm mm2/mm = c fsr3

453.1 ÷ 5.656 ÷ 2 5.619 × > 1 × 106

a 8 5.656
= 40.05 MPa
E 361 × 109 31
106 OK

> 1 × 106
b Full-Strength Groove Weld B 3930 × 109 110 See Note
OK

50.54 ÷ 5.659÷2 > 1 × 106

c, d 8 5.659
= 4.47 MPa
E 361 × 109 31 ˝ OK

9.02 ÷ 3.535 > 1 × 106

e 5 3.535
= 2.55 MPa
E 361 × 109 31 ˝ OK

6.70 ÷3.535 > 1 × 106

f 5 3.535
= 1.90 MPa
E 361 × 109 31 ˝ OK

Note: an examination of fsr compared with Fsrt and clause 26.3.4, Figure 1 shows that fatigue life is well above the
requirement of 1 000 000 cycles.

119
Consider Distortion-Induced Fatigue
The area of most vulnerability is at welds 'c' and 'd' where differential vertical deflection between the runway
beam and the W530 beam at the back of the apron plate may cause premature failure of these welds. In addition,
the fabricator/erector may prefer a bolted connected for ease of fabrication, shipping, and erection.
Provide a bolted connection, slip-critical, class A surfaces, 22 mm diameter A325 bolts. Table 3-11 of the CISC
Handbook provides a value Vs = 45.2 kN per bolt in single shear for slip resistance. Table 3-4 of the Handbook
provides a value of 88.9 kN factored shear resistance, threads included. OK for 10 mm plate.

Unfactored Shear Flow

1061 # 10 3 # 1.008 # 10 6 1.094 6 # 67.54 # 10 3 # 6.976 # 10 6 51.1 64.9 116.0 N/mm
= + = + =
20.94 # 10 9 7.945 # 10 9

Factored Shear Flow = 174.0 N/mm

Calculate minimum bolt spacing for shear flows

45.2 10 3 390 mm
= 116#.0 = (Slip) Governs

or 88.9 # 10 3 511 mm (Strength)

= 174.0 =

Determine minimum bolt spacing for built-up members in accordance with S16-01, Clause 19. Spacing for bolts,

not staggered, should not exceed 330 t = 330 # 10 = 176 mm > 300 mm
Fy 350

Since this provision governs over slip resistance, a smaller bolt diameter will do. M20 bolts provide 37.4 kN slip
resistance, therefore OK by inspection.

Check Fatigue at Stiffener Welds

Specified Shear 839.0 + 209.8 + 11.92 = 1 061 kN

fsr in 8 mm fillets 10 3
= 1061 # 4 # 8 # 0.707 # 1350 (4 welds)
= 34.7 MPa
For category E, c = 361 # 10 9 MPa, Fsrt = 31 MPa

c 361 # 10 9 8.64 10 6 cycles > 1.0 10 6 OK

nN = = = # #
fsr3 34.7 3
Examine Weld to Top Flange
No calculation is necessary here. CJP welds with reinforcing are recommended to reduce possibility of cracking
due to repeated stress due to loads from the crane rail. nN could be as high as 4 × 106 for this detail.

Conclusion
Crane runway beam design shown below is OK.
Could investigate use of a lighter section and alternative grade of steel.

120
121