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Industrial Designer & BOX TYPE GIRDER

Engineer Association
Date :

1. GENERAL.
The art of load determines the form of girder. Here, the box girder for overhead crane is discussed.
The box girder is made form plate sections, which are welded together. The box girder has the advantages as follow :
 It is rigid against torsion
 The dimensions of box can be designed to the actual need, so to achieve minimum weight.
 The manufacturing of box girder is relatively simple, automatic welding is possible.
 The preparation of groove is improved to achieve lesser notch effect class, so that higher allowable stress can be applied.

1.1. MONORAIL BOX GIRDER TYPE 1

Thickness of bottom plate = t1 mm b4
Width of bottom plate = b1 mm y 4

t4
Thickness of web plate = t2 mm
Height of web plate = h2 mm

h5
3
t2 d2 t2

y
Thickness of top plate = t4 mm
Width of top plate = b4 mm t5
h2

R R 2
Thickness of wing plate = t5 mm
Height of wing plate = h5 mm

ys
9
t1

x
i
1
s
b1

Section Area Gravity center Ai * yi Moment of inertia Ixi Moment of inertia Iyi
mm2 mm mm3 mm4 mm4

A1 b1 * t1 y1 = 0,5 * t1 A1 * y1 b1 * t13 t1 * b13

 A1*  y1 - ys 2
12 12

A2 h2 * t2 y2 = 0.5 * h2 + t1 A2 * y2 t 2 * h2 3 h2 * t2 3
 A2 *  y2 - ys 2  A2 *  0.5 * ( d2  t2 )2
12 12

A3 h2 * t2 y3 = 0.5 * h2 + t1 A3 * y3 t 2 * h2 3 h2 * t2 3
 A3 *  y3 - ys 2  A3 *  0.5 * ( d2  t2 )2
12 12

A4 b4 * t4 y4 = 0.5 * t4 + h2 + t1 A4 * y4 b4 * t 4 3 t 4 * b4 3
 A4 *  y4 - ys 2
12 12

A5 2 * h5 * t5 y5 = t1 + h2 - 0.5 * h5 A5 * y5 2 * t 5 * h5 3 h5 * t5 3
 A5 *  y5 - ys 2  A5 *  0.5 * ( b4  t5 )2
12 12

 Ai  Ai * yi Ix =  Ixi Iy =  Iyi
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1.1.1. PROPERTIES
Sectional area As =  Ai mm2
 Ai * yi
Center of gravity ys = mm
 Ai

y = t1 + h2 + t4 - ys mm
Moment of inertia Ix =  Ixi mm4
Moment of inertia Iy =  Iyi mm4

1.1.2. Modulus of section Wx , Wy and moment of area Sx

Point 1 Point 2 Point 3 Point 4 Point 9

Ix Ix Ix Ix Ix
Wx1 = Wx2 = Wx3 = Wx4 = Wx9 =
ys ys  t1 y  t4 y ys  t1

Iy Iy Iy Iy Iy
Wy1 = Wy2 = Wy3 = Wy4 = Wy9 =
0.5 * b1 0.5 * d2  t 2 0.5 * d2  t 2 0.5 * b 4 0.5 * b1  i

Sx1 = Ai * ( ys - y1 ) Sx2 = A2 * ( y2 - ys ) Sx3 = A3 * ( y3 - ys ) Sx4 = A4 * ( y4 - ys ) Sx9 = Sx2

1.2. MONORAIL BOX GIRDER TYPE 2

Thickness of bottom plate = t1 mm b4
Width of bottom plate = b1 mm y
t4

4
Thickness of lower web plate = t2 mm
Height of lower web plate = h2 mm
3
Thickness of intermediate plate = t3 mm t2 d3 t2
y

Width of intermediate plate = b3 mm

h3

Thickness of upper web plate = t2 mm

t3

Height of upper web plate = h3 mm

Thickness of intermediate plate = t4 mm t2 d2 t2

ys

2
h2

Width of intermediate plate = b4 mm R R

9
t1

x
i
1
s
b1
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Section Area Gravity center Ai * yi Moment of inertia Ixi Moment of inertia Iyi
mm2 mm mm3 mm4 mm4

b1 * t13 t1 * b13
A1 b1 * t1 y1 = 0,5 * t1 A1 * y1  A1*  y1 - ys 2
12 12

A2 h2 * t2 y2 = 0.5 * h2 + t1 A2 * y2 t 2 * h2 3 h2 * t2 3
 A2 *  y2 - ys 2  A2 *  0.5 * ( d2  t2 )2
12 12

A3 b4 * t4 y3 = 0.5 * t4 + h2 + t1 A3 * y3 t 2 * h2 3 h2 * t2 3
 A3 *  y3 - ys 2  A3 *  0.5 * ( d2  t2 )2
12 12

A4 h4 * t2 y4 = 0.5 * ( h4 + t4 ) + A4 * y4 b4 * t 4 3 t 4 * b4 3
 A4 *  y4 - ys 2
y3 12 12

A5 b4 * t4 y5 = 0.5 * ( t4 + h4 ) + A5 * y5 2 * t 5 * h5 3 h5 * t5 3
 A5 *  y5 - ys 2  A5 *  0.5 * ( b4  t5 )2
y4 12 12

 Ai  Ai * yi Ix =  Ixi Iy =  Iyi

1.2.1. PROPERTIES
Sectional area As =  Ai mm2
 Ai * yi
Center of gravity ys = mm
 Ai

y = t1 + h2 + t4 - ys mm
Moment of inertia Ix =  Ixi mm4
Moment of inertia Iy =  Iyi mm4

1.2.2. Modulus of section Wx , Wy and moment of area Sx

Point 2 Point 3 Point 4 Point 9

Point 1

Ix Ix Ix Ix Ix
Wx1 = Wx2 = Wx3 = Wx4 = Wx9 =
ys ys  t1 y  t4 y ys  t1

Iy Iy Iy Iy Iy
Wy1 = Wy2 = Wy3 = Wy4 = Wy9 =
0.5 * b1 0.5 * d2  t 2 0.5 * d4  t 2 0.5 * b 4 0.5 * b1  i

Sx1 = Ai * ( ys - y1 ) Sx2 = A2 * ( y2 - ys ) Sx3 = A3 * ( y3 - ys ) Sx4 = A4 * ( y4 - ys ) Sx9 = Sx2

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1.3. Flange factor

s s s

R R R
i i i

b t1 b* t1 b t1

0 1 2 0 1 2 0 1 2
I - cross section, Box girder I - cross section,
parallel flange cross section inclined flange

R
R

0 1 2

The bottom plate of the monorail girder is the railway for the trolley wheel. The wheel loads produce two-dimensional local
stresses in the contact point between the wheel and the bottom plate, in the edge of flange and in the joint between bottom plate
and web plate. The local stresses are experimentally determined, but they can be approximated by the following factors :
i
Auxiliary factor  =
s

Longitudinal factor Transversal factor

cx1 = 0,73 - 1,58 . + 2,91 * e ( - 6  cy1 = 0

cx2 = 0,05 - 0,58 . + 0,148 * e ( 3,015 . ) cy2 = - 2,11 + 1,977 . + 0,0076 * e ( 6,53 . )

cx9 = 2,23 - 1,49 . + 1,39 * e ( - 18,33 . ) cy9 = 10,108 - 7,408 . - 10,108 * e ( - 1,364 . )
 IDEA IDEA – WORK STANDARD Page : 5
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1.4. DOUBLE RAIL BOX GIRDER

Thickness of bottom plate = t1 mm b4
Width of bottom plate = b1 mm R

hr
y 4

t4
Thickness of web plate = t2 mm
Height of web plate = h2 mm
3

y
Thickness of top plate = t4 mm
t2 d2 t2
Width of top plate = b4 mm

h2
2

ys
x

t1
b1 1

Section Area Gravity center Ai * yi Moment of inertia Ixi Moment of inertia Iyi
mm2 mm mm3 mm4 mm4

A1 b1 * t1 y1 = 0,5 * t1 A1 * y1 b1 * t13 t1 * b13

 A1*  y1 - ys 2
12 12

A2 h2 * t2 y2 = 0.5 * h2 + t1 A2 * y2 t 2 * h2 3 h2 * t2 3
 A2 *  y2 - ys 2  A2 *  0.5 * ( d2  t2 )2
12 12

A3 h2 * t2 y3 = 0.5 * h2 + t1 A3 * y3 t 2 * h2 3 h2 * t2 3
 A3 *  y3 - ys 2  A3 *  0.5 * ( d2  t2 )2
12 12

A4 b4 * t4 y4 = 0.5 * t4 + h2 + t1 A4 * y4 b4 * t 4 3 t 4 * b4 3
 A4 *  y4 - ys 2
12 12

 Ai  Ai * yi Ix =  Ixi Iy =  Iyi

1.4.1. PROPERTIES
Sectional area As =  Ai mm2
 Ai * yi
Center of gravity ys = mm
 Ai

y = t1 + h2 + t4 - ys mm
Moment of inertia Ix =  Ixi mm4
Moment of inertia Iy =  Iyi mm4
Polar modulus of section Wt = ( d2 + t2 ) * ( h2 + 0.5 * ( t1 + t4 )) * 2 * t2 mm3
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1.4.2. Modulus of section Wx , Wy and moment of area Sx

Point 1 Point 2 Point 3 Point 4

Ix Ix Ix Ix
Wx1 = Wx2 = Wx3 = Wx4 =
ys ys  t1 y  t4 y

Iy Iy Iy Iy
Wy1 = Wy2 = Wy3 = Wy4 =
0.5 * b1 0.5 * d2  t 2 0.5 * d2  t 2 0.5 * b 4

Sx1 = Ai * ( ys - y1 ) Sx2 = A2 * ( y2 - ys ) Sx3 = A3 * ( y3 - ys ) Sx4 = A4 * ( y4 - ys )

1.4.3. SECONDARY PROPERTIES

100
The secondary bending moment occurs on the load-carrying web of double girder crane
t4

system, when the wheel passes the section between two adjacent diaphragms.

L1 = L4 is normally taken 100 mm

h2
t1

Section Area ( mm2 ) Gravity center ( mm ) Aai * yi ( mm3 ) Moment of inertia Ixxi ( mm4 )

Aa1 L1 * t1 y1 = 0,5 * t1 Aa1 * y1 L1 * t13

 A1*  y1 - ys 2
12

Aa2 h2 * t2 y2 = 0.5 * h2 + t1 Aa2 * y2 t 2 * h2 3

 A2 *  y2 - ys 2
12

Aa4 L4 * t4 y4 = 0.5 * t4 + h2 + t1 Aa4 * y4 L4 * t 4 3

 A4 *  y4 - ys 2
12

 Ai  Aai * yi Ixx =  Ixxi

1.4.3.1. PROPERTIES
Sectional area As =  Aai mm2
 Aai * yi
Center of gravity yss = mm
 Aai
yy = t1 + h2 + t4 - ys mm
Moment of inertia Ixx =  Ixxi mm4
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1.4.3.2. Modulus of section Wxx ,

Point 1 Point 2 Point 3 Point 4

Ixx Ixx Ixx Ixx

Wxx1 = Wxx2 = Wxx3 = Wxx4 =
yss yss  t1 yy  t 4 y

1.5. NOTES ON WEB STIFFENERS

The web stiffeners, both horizontally and vertically, are provided to limit the web buckling. A box girder is normally stiffened
horizontally and vertically. The British standard and American standard specify the location of web stiffeners and its dimensions,
whereas the German standard gives the freedom for the manufacturer, how to stiffen its girder.

1.5.1 STIFFENER DIMENSIONING ACCORDING TO DIN 4114.

1.5.1.2. WEB PLATE WITH STIFFENER AT NEUTRAL AXIS

Length of panel a = mm
 c
Height of panel b = mm
diaphragm

diaphragm

H = Height of web

Thickness of panel t2 = mm
b

Stiffener a
Dimension ratio  = > 1
Neutral axis b
Compression stress c = N / mm2
Tensile stress t = 0 N / mm2
t
a Shear stress  = N / mm2
t
Stress ratio  = - = 0 -
c

1.5.1.2.1. Dimension of stiffener

Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
As
h

x Auxiliary factor  = -
web b* t
t

2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia of stiffener Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
Required moment of inertia of stiffener Jr = 2 * b * t 3 ( BS 2573 ) mm4
Condition Ja > Jr
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1.5.1.3. WEB PLATE WITH ONE STIFFENER AT HALF DISTANCE OF FLANGE TO NEUTRAL AXIS

 c Length of panel a = mm
Height of panel b = mm

diaphragm

H = Height of web
diaphragm

Stiffener Thickness of panel t2 = mm

b
b/2
a
Stiffener Dimension ratio  = > 1
b
Neutral axis Compression stress c = N / mm2
Tensile stress t = 0 N / mm2
t Shear stress  = N / mm2
a t
Stress ratio  = - = 0 -
c

1.5.1.3.1. Dimension of stiffener

Thickness of stiffener t = mm
h Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
As
Ratio of area  = -
h

x b * t2
web
Auxiliary factor  = 1 + 2* -
t
2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia of stiffener Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 

  2 * 16 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =  0.53 
0.47 *   *   if < 8*  - 1
 2 
  8 *  - 1  2   
" =  0.53  0.47 *   *   if > 8*  - 1
 2 
" * b * t 3
Required moment of inertia of stiffener Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr
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1.5.1.4. WEB PLATE WITH 2 STIFFENER AT EQUAL DISTANCE FROM FLANGE TO NEUTRAL AXIS
Length of panel a = mm
 c
Height of panel b = mm

b/3
Stiffener

diaphragm

H = Height of web
diaphragm

Thickness of panel t2 = mm

b/3
b
Stiffener
a
Dimension ratio  = > 1

b/3
Stiffener
b
Neutral axis Compression stress c = N / mm2
Tensile stress t = 0 N / mm2
Shear stress  = N / mm2
t t
a Stress ratio  = - = 0 -
c

1.5.1.4.1. Dimension of stiffener

Thickness of stiffener t = mm
h Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
As
h

Ratio of area  = -
x b * t2
web
t Auxiliary factor  = 1 + 3* -

2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia of stiffener Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
  3 * 36 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =   if < 18 *  - 1
 3 
  18 *  - 1  2   
" =   if > 18 *  - 1
 3 
" * b * t 3
Required moment of inertia of stiffener Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr
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1.5.1.5. TOP PLATE WITH ONE STIFFENER IN THE MIDDLE

Length of panel a = mm
c Height of panel d2 = mm
Thickness of panel t4 = mm
diaphragm

diaphragm
Stiffener

d2
a
Dimension ratio  = > 1
d2
c Compression stress c = N / mm2
Shear stress  = N / mm2
a t  c
Stress ratio  = =1 -
c

1.5.1.5.1. Dimension of stiffener

Thickness of stiffener t = mm
h Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
As
h

Ratio of area  = -
x d2 * t2
web
t Auxiliary factor  = 1 + 2* -

2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia of stiffener Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
  2 * 16 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =  0.53  0.47 *   *   if < 8*  - 1
 2 

 0.53  0.47 *   *   8 *  - 1    
 2 
" = if > 8*  - 1
 2 
" * b * t 3
Required moment of inertia of stiffener Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr
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1.5.1.6. TOP PLATE WITH 2 STIFFENER AT EQUAL DISTANCE

Length of panel a = mm
c Height of panel d2 = mm
Stiffener Thickness of panel t2 = mm
diaphragm

diaphragm
a

d2
Stiffener Dimension ratio  = > 1
d2
c Compression stress c = N / mm2
Shear stress  = N / mm2
a
Stress ratio  = 1 -

1.5.1.6.1. Dimension of stiffener

Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
h

As
web
x Ratio of area  = -
d2 * t2
t
Auxiliary factor  = 1 + 3* -

2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia of stiffener Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 

  3 * 36 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =   if < 18 *  - 1
 3 
  18 *  - 1  2   
" =   if > 18 *  - 1
 3 
" * b * t 3
Required moment of inertia of stiffener Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr
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1.6. EFFICIENT GIRDER

Every girder must fulfill the following requirements :
 Sufficient strength, as measured by its modulus of section W
 Sufficient stiffness, as measured by its moment of inertia I.
 Ability to carry shear force, as measured by its web area Aw.
 Ability to withstand web buckling, as indicated by empirical relationship of web depth to web thickness
H
K = . In some cases, the depth H must be held within a certain minimum.
tw
 An efficient girder must satisfy the above requirements with the minimum weight.
In order to simplify the derivation of the efficient girder, it is assumed that the depth of the web plate H is also the distance
between the center gravity of the two flange plates, as well as the overall depth of the girder. In the case where the thicknesses of
the flange plates are small compared to the girder depth, the assumption does not introduce very much error while simplifying the
procedure and the resulting formula.

The required moment of inertia of the girder and its respective modulus of sections are :
2 2 * tw * 3 Af * H2
H H H4
Ix = 2 * Af *    = 
2 12 2 6*K
2 * Ix H3
Wx = = Af * H 
H 3*K

Wx H2
Hence : the flange area Af = -
H 3*K
H2
the web area Aw = tw . H =
K

2 * Wx 2 * H2 2 * H2 2 * Wx 4 * H2
The total girder area At = 2 . ( Af + Aw ) = -  = 
H 3*K K H 3*K

Now differentiate the equation with respect to H and set equal to zero :

dAt - 2 * Wx 8*H Wx 4 * H2
  = 0 --> 
dH H 2 3*K H 3*K

H2
The flange area becomes Af = = Aw
K
The efficient girder has half its weight in the web and half in flanges.

2 * H4 4 * H3
Hence : Moment of inertia : Ix = and Modulus of section : Wx =
3*K 3*K

It is seen that the larger value of K results in lower weight and increase the depth of girder. Conversely, lower value of K will
produce heavier and shallower girders.

Reference value for steel SS 400 : no stiffener K < 60

with transverse stiffeners K < 170
with longitudinal and transverse stiffeners K < 340
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Bending moment and deflection of girder

1. GENERAL SYSTEM
1.1. BENDING MOMENT DUE TO TRAVELLING LOAD
P
 Mb = 0  A*L - P*b = 0
x y
J1 P*b
A =
L
Mp
A B
P*a
a b B =
L
L

P *  L * a - a 2 
P*b*a P*(L-a)* a  
Bending moment M(a) = A*a = = =
L L L
Mp L
Maximum bending moment   0  L - 2*a = 0  a =
a 2
L L
P* *
L 2 2
Maximum bending moment Mp = A* = 
2 L
P*L
Mp =
4

1.2. DEFLECTION DUE TO TRAVELLING LOAD

P
1.2.1. Deflection at maximum bending moment (classic )  Supporting force A = B =
2
 P* x
E * J1 * " = - Mx =
2

 P* x  P* x2
E * J1 * ' =   * dx =  C1
 2  4

 P* x2  - P * x3
E* J1 *  =    C1  * dx =  C1 * x  C2
4  12
 
Condition (0) = 0  C2 = 0 and

- P * L2 P * L2
' ( L/2 ) = 0   C1  0  C1 =
16 16

- P * x3 P * L2 * x
Equation for deflection becomes E * J1 *  ( x ) = 
12 16

- P * L3 P * L2 * L - P * L3 3 * P * L3
Deflection in the middle of girder  ( L / 2 ) =  = 
12 * 8 * E * J1 16 * 2 * E * J1 96 * E * J1 96 * E * J1

P * L3
 =
48 * E * J1
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1.2.2. Deflection at maximum bending moment using Castigliano method

P 1

x y x y
J1 J1
Mp Mp1
A B A B
L/2 L/2 L/2 L/2

L L

P
Supporting force A = B =
2

Section M
("1" )
P* x x
x A*x =
2 2
L P* y P*L P*L-y  Ly
y A*y - P*(y- ) = - P* y  =
2 2 2 2 2

L/2
L / 2 P * x  x L / 2  P * x2   P * x3  P * L3
E * J1 * 1 =    * * dx =    * dx

=   =
0  2  2 0  4
  12 
0
96

 2 
L  P *  L - 2 * L * y  y  
2
L  P *  L - y 2 
   * dy
E* J1 * 2 =    * dy

=  
L/2  4 
L/2  4 

 
L
P  y 3  P * L3  1 1 1 1  P * L3
= 2 2
 * L *y - L*y   = * -  -  =
 4  3 
 L / 2
4  3 2 4 24  96

1  2 2 * P * L3 P * L3
Total deflection  = =   =
E * J1 96 * E * J1 48 * E * J1

1.2.3. Calculation using  Mk * Mi * dx table

P*L L
With Mp = and Mp1 =
4 4

1 L 1 L L P*L L P * L3
E * J1 *  = * * Mp * Mp1  * * Mp * Mp1 = 2* * * =
3 2 3 2 6 4 4 48

P * L3
Deflection  =
48 * E * J1
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1.3. BENDING MOMENT DUE TO OWN WEIGHT

x L
 Mb = 0  A * L - q*L*
2
q q*L
A =
J1 2
Mq
A B q*L
B =
2
L

q * x2 q * L * x q * x2 q 
Bending moment M(x) = A*x - = - = *  L * x - x 2 
2 2 2 2  
Mp L
Maximum bending moment   0  L - 2*x = 0  x =
x 2

q  L L 
2
q  L 2 L 2 
Maximum bending moment Mp = * L* -    = * -
2  2 2  2  2 4 
   

q * L2
Mp =
8

1.4. DEFLECTION DUE TO OWN WEIGHT

1.4.1. Deflection at maximum bending moment
q*L
Supporting force A = B =
2

q * x2 q * L * x
E * J1 * " = - Mx = -
2 2
 q * x2 q * L * x  q* x3 q * L * x2
E * J1 * ' =   -  * dx =   C1
2 2  6 4
 

 q* x3 q * L * x2  q * x4 q * L * x3
E* J1 *  =     C1 * dx =   C1 * x  C2
6 4  24 12
 
Condition (0) = 0  C2 = 0 and

q * L3 q * L3 q * L3
' ( L/2 ) = 0    C1  0  C1 =
6* 8 4* 4 24

q * x4 q * L * x3 q * L3 * x
Equation for deflection becomes E * J1 *  ( x ) = - 
24 12 24

q * L4 q * L4 q * L4
Deflection in the middle of girder  ( L / 2 ) =   =
24 * 16 * E * J1 12 * 8 * E * J1 24 * 2 * E * J1

5 * q * L3
 =
384 * E * J1
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1.4.2. Deflection at maximum bending moment using Castigliano method

1
x y

q x y
J1
Mq1 J1 Mp1
A B A B
L/2 L/2
L/2 L/2
L
L

q*L
Supporting force A = B =
2

Section M
("1" )
q * x2 q*L* x q * x2 x
x A*x - = -
2 2 2 2
L/2 q x L/2 q
E * J1 * 1 =  *  L * x - x 2  * * dx =  *  L * x 2 - x 3  * dx
  2  
0 2 0 4

L/2
 q  L * x 3 x 4  q * L4  1 1  q * L 4  16 6
=  *  -   = * -  = * - 
 4  3 4 
 0
4  3 * 8 4 * 16  16  96 96 


5 * q * L4 5 * q * L4
=  1 =
768 768 * E * J1

5 * q * L4
Due to symmetry, total deflection  = 2 * 1   =
384 * E * J1

1.4.3. Calculation using  Mk * M1 * dx table

q * L2 L
With Mp = and Mp1 =
8 4

5 L 5 L 5 * L q * L2 L 5 * q * L4
E * J1 * 1 = * * Mp * Mp1  * * Mp * Mp1 = 2* * * =
12 2 12 2 24 8 4 384

5 * P * L4
Deflection 1 =
384 * E * J1
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1.5. BENDING MOMENT DUE TO TWO TRAVELING LOAD WITH FIXED DISTANCE

 Mb = 0 
b
P P A*L - P*(L-x) - P*(L-x-b) = 0
x y A*L - 2*P*(L-x) - P*b = 0
J1
2*P*(L- x) P* b
A = -
Mamax Mbmax L L
A B
A - line B - line P*2*L - b  - 2* x 
=
L
b/4 b/4
L/2 L/2
L

1.5.1. Bending moment A - line

P 
M(x) = A * x = *  2 * L - b  * x - 2 * x2 
L  

Mx 2*L - b L b
Maximum moment , if  0  (2*L - b) - 4*x = 0  hence, x = = -
x 4 2 4

Maximum bending moment

Mx =
P 
*   2 * L - b *
 2 * L - b - 2 *  2 * L - b 2 
=
P  1 
*   2 * L - b  2 - *  2 * L - b  2

L  4 16  4*L  2 

P 1 P  P  2 b 2 
= * *  2 * L - b 2 = *  4 * L 2 - 4 * L * b - b 2  = * L - L*b -
4*L 2 8*L   2*L  4 
 
2
P  b
Mx = * L - 
2*L  2

2
P  b 2*L - b
Idem Bending moment B - line My = * L -  at y =
2*L  2 4

1.5.2. BENDING MOMENT AT LOCATION BETWEEN THE LOAD

M(z) = A*z - P*(z-x) = (A-P)*z + P*x

b
P*2*L - b  - 2* x  P*L P
P P A-P = - = * L - b - 2* x 
L L L
P
x M(z) = * L - b - 2* x  * z + P * x
A B L
z
L Mz L-b
 0  L - b - 2*x = 0  x 
z 2
P  L-b   L-b 
Mzmax = * (L-b-L b)  P*   = P* 
L  2   2 
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1.6. DEFLECTION OF BEAM

1.6.1. Deflection at maximum bending moment , using  Mk * M1 * dx table

b
P P 1
x y
J1 J1
Mamax Mbmax Mb
A B 1/2 1/2
A - line B - line
b/4 b/4 b/4 b/4
L/2 L/2 L/2 L/2
L L

2
P  b 1  L b 1  b 
Mx = * L -  * -   * L- 
Mb =
2*L  2 2  2 4 4  2 
2
5 L 5 L P  b  1  b 
E * J1 *  = 2* * * Mamax * Mb = 2* * * * L-  * * L- 
12 2 12 2 2 * L  2  4  2 

3
5*P  b 
 = * L- 
96 * E * J1  2 

1.6.2. DEFELECTION OF BEAM

P P 1

Mb M1
A A 1/2 1/2

x x
L L

at point x  Mp = P*x Mb = x/2

at point L/2  Mp = P*x M1 = L/4
L- b
with x =  b = L - 2*x
2
 x b   x x b  x L 
E*J* = 2 *  * Mp * Mb  Mp *  Mb  M1  2 *  * P * x *
=  * P * x *    
 3 2 * 2   3 2 4  2 4 
 P * x3 P * x2 * b P * x * L * b   8 * x2 6* x*b 3 * L * b 
= 2*   = 2*P* x*  
 6 8 16   48 48 48 
  
=
P* x
24

* 8 * x2  6 * x * ( L - 2 * x )  3 * L * ( L - 2 * x ) =
P*L* x

24 * L
* 3 * L2 - 4 * x2  
P * L 3  x   4  x  
2 2
 = *  * 1 - *  
8*E* J  L   3  L  
 
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1.8. NATURAL FREQUENCY OF GIRDER ( JIS 8834 - 2010 )

The effect of flexibility of girder is shown as elastic deformation under load and as vibration induced by motion or force
transmission. Excessive flexibility of crane system ( structures and components ) can affect the safety of their use; therefore, the
elastic deformation and vibration should be limited so that they do not cause dangerous situation.
If the natural frequency of the crane is in the region of that of supporting structure, the crane must be build stiffer to avoid
resonant. The requirements concerning the elastic deformation and vibration depend very much on the configuration of crane and
from the required accuracy of load handling, type of control and location of control cabin. Therefore, no exact limits are given for
the deflection or the vibration.

 In order to avoid uncomfortable vibration for operator in the cabin, the natural frequency of the structure carrying the cabin
should not be less than 2 Hz for vertical vibration.
 For long span, this limit might be difficult to meet due to economical reason. Therefore, lower frequencies are permitted, but
amplitude and duration of vibration should be minimized by using smooth speed transitions.
 For gantry crane, the frequency of horizontal vibration should not be less than 0.5 Hz for vibration caused by main operating
movement of the crane ( e.g. trolley travel direction of container crane ).
 The effect of vibration on bridge structure and crane operation can be reduced by controlling the stiffness of the girder.
Damping at higher frequencies requires a greater effort than at lower ones.

1.8.1. GUIDELINES FOR MAXIMUM DEFLECTION

Is = stiffness index L = crane span s = deflection of girder due to traveling load

Stiffness index = Is  L Zone Description

s

1500 A Characteristic of cranes needing high positioning accuracy

1400
1300
1250

1000 B Characteristics of normal workshop cranes with medium positional accuracies, which
900 can use simple control system
800
750

600 C Suitable for low speed cranes and acceleration. Mainly for manually driven cranes,
500 or using step-less controllers.

400 D No specification
300

1.8.2. GUIDELINES FOR NATURAL FREQUENCY

Factors g = gravitation = 9.81 m /s2
L = span of girder = mm
E = modulus of elasticity = 210 000 N / mm2
c = spring constant = N / mm
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1.8.2.1. Vertical natural frequency

mv * g * L 3 v = deflection mm
Deflection v = 17
48 * E * Jx mv = SWL + Gc + * Gg kg
35
Spring force mv * g = cv * v SWL = lifted load kg
mv * g Gc = weight of trolley kg
Spring constant cv = Gg = weight of girder kg
v Jx = vertical moment of inertia of girder mm4

cv mv * g g
Circular frequency v = = =
mv mv * v v

1 g 1 9.81 * 1000 mm / s2 99.045

Vertical natural frequency fv = *  fv = * =
2*  v 2*  v mm 2* * v
15.76
fv =
v

1.8.2.2. Horizontal natural frequency

mh * g * L 3 h = deflection Mm
Deflection h = 17
48 * E * Jy mh = Gc + * Gg kg
35
ch mh * g g Gc = weight of trolley kg
h = = = Gg = weight of girder kg
mh mh * h h
Jy = horizontal moment of inertia of girder mm4

1 g 15.76
Horizontal natural frequency f = * =
2*  h h

1.8.2.3. Minimum values for fv and fh.

Vertical frequency fv For span L <= 25 m  fv = 2.4 Hz
For span L > 25 m  fh ~ - 0.02 * ( L - 22 ) + 2.4 Hz

Horizontal frequency fh For span L <= 50 m  fv = 1.8 Hz

For span L > 50 m  fh ~ - 0.02 * ( L - 46 ) + 1.8 Hz
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1. GENERAL DATA
Safe Working load SWL = = kg = N
Weight of crab Gc = = kg = N
Number of crab wheel nwc = = -
Width of crab wheel bwc = = -
Lifting speed vh = = m / min = m/s

Crane span L = = m = mm
Traveling speed vc = = m / min = m/s

1.1. CLASS OF UTILISATION

Working cycle / hour c = = c/h
Working hours / day h = = h/d
Working days / year d = = d/y
Service life sl = = years
Total working cycle Nc = c * h * d * sl = cycles
Class of utilisation Ui = f ( Nc ) = -

1.2. LOAD SPECTRUM

Girder capacity P = SWL + Gc = kg = N

Lifted load 100% SWL + Gc 75% SWL + Gc 50% SWL + Gc 25%SWL + Gc

m1 = m2 = m3 = m4 = N
Number of cycle n1 = n2 = n3 = n4 = cycle

3 3 3 3
m1  n1  m2  n2  m3  n3  m4  n4 
Spectrum factor kp = 3 *   *   *   *  = -
P  Nc  P  Nc  P  Nc  P  Nc 

Crane group Ai = f ( Ui , kp ) = -
Duty factor K = f ( Ai ) = -
0.6 * vh
Impact factor  = 1 , minimum  = 1.1 = -
60

1.3. PROPERTIES OF GIRDER MATERIAL

Material = -
Yield strength s = = N / mm2
s
Basic allowable stress a = = N / mm2
1.5
Modulus of elasticity E = = N / mm2
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1.3.1. GENERAL ALLOWABLE STRESS

Material Weldment
Welding test procedure - RT / UT / MPT / DPT -
Stress correction factor w = - w = f ( test ) = -
Tensile bending stress ba = baa = baw = w * a = N / mm2
Compression stress ca = ca = a = caw = w * 0.85 * a = N /mm2
Transversal stress ya = 0.85 * ba = yw = 0.85 * baw = N / mm2
a = a = a = aw = w * a = N / mm2
Shear stress 3 3

1.3.2. FATIGUE ALLOWABLE STRESS

Damaged influence factor b = fatigue damaged lead destruction of crane = -
Critically factor w = = -
Inspection factor i = difficult inspection on installed crane = -
Stress correction factor  = b * w * i = -

For normal stress Material Weldment

Fatigue strength grade fn = fnw = f ( test ) = -
Normal stress factor Co = f ( fn ) = Cow = f ( fn ) = -
Curve inclination factor m = m = -

Basic stress range  = m Co = w = m

Co
= N / mm2
Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 

For shear stress fs = fsw = f ( test ) = -

Factor for normal stress Do = f ( fs ) = Dow = f ( fs ) = -
Inclination factor n = n = -

Basic stress range  = n Do = w = n

Do
= N / mm2
Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 
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2. CRANE GIRDER
2.1. GIRDER TYPE.

b4

t4
4
t4

b4 4 3
t2 d3 t2
3
h5

h3
t2 t2

y
d2
t5
h2

b4
2 ys
9 t2 d2 t2 2

t4
h2
i 1 9
s
t1

b1 1
i
t1 s
Type 1
b1

Type 2

thickness width height distance

Bottom plate t1 = b1 = - - mm
Web plate t2 = - h2 = d2 = mm
Middle plate ( option 2 ) t4 = b4 = - - mm
Upper web ( option 2 ) t2 = - h3 = d3 = mm
Top plate t4 = b4 = - - mm
Top wing ( option 1 ) t5 = h5 = - b4 = mm

Weight of girder Gg = = kg = N

2.2. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12

Point 1 Point 2 Point 3 Point4 Point 9

Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = Wx9 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = Wy9 = mm3
Moment of area Sx1 = - - Sx4 = - mm3
Flange factor cx1 = cx2 = - - cx9 = -
Flange factor cy1 = cy2 = - - cy9 = -
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2.3. DEFLECTION OF GIRDER

5 * Gg * L3
Deflection due to DWT dg = = mm
384 * E * Ix

P * L3
Deflection due to SWL dp = = mm
48 * E * Ix
Allowable deflection dp,all = L / 800 = mm
5
Frequency of girder fg = > 2.5 Hz = Hz
( 0.78 * dg  dp ) / 10

2.4. LOAD OF GIRDER

Vertical static load Vg = K * Gg = N
Vertical dynamic load Vp = K**P = N
Vp
Crab wheel load Rc = = N
nwc
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N

Vertical bending moment

P
q

Mp Mq
A B A B
L L

Vg * L
due to DWT Mxg = = Nmm
8
Vp * L
due to SWL Mxp = = Nmm
4
Total bending moment Mx = Mxg + Mxp = Nmm

Hg * L Hp * L
Total horizontal moment My =  = Nmm
8 4
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1.3 * ( 1 - kx )
2.4.1. STRESS ON GIRDER
1.6 - kx
Point 1 Point 2 Point3 Point 4 Point 9
Mxg Mxg Mxg Mxg Mxg
Minimum longitudinal stress xmin = = = = = = N / mm2
Wx1 Wx 2 Wx 3 Wx 4 Wx 9
Mx My cx1 * Rw Mx My cx2 * Rw Mx My Mx My Mx My cx9 * Rw
Maximum longitudinal stress x =         N / mm2
Wx1 Wy1 t12 Wx 2 Wy2 t12 Wx 3 Wy3 Wx 4 Wy4 Wx 9 Wy9 t12
Allowable general stress x,all = ba > x1 baw > x2 caw > x3 ca > x4 ba > x9 N / mm2

x min x min x min x min x min

Stress ratio kx = x1 x2 x3 x 4 x9 -

1.3 * ( 1 - kx ) 1.3 * ( 1 - kx )
Stress ratio factor cr = - - 1.6 - kx 1.6 - kx - -

Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) cr3 * w1 > ( x3 - x3min ) cr4 * 1 > ( x4 - x4min ) 1 > ( x9 - x9min ) N / mm2

cy1 * Rw cy2 * Rw cy9 * Rw

Maximum transversal stress y = - - N / mm2
t12 t12 t12
Allowable general stress x,all = ya > y1 yaw > y2 - - ya > y9 N / mm2
Allowable fatigue stress fx,all = 1 > y1 w1 > y2 - - 1 > y9 N / mm2

Vp * Sx1 Vp * Sx4
Maximum shear stress  = - 2 * Ix * t2 2 * Ix * t2 - - N / mm2
Allowable general stress ,all = - aw > 2 aw > 3 - - N / mm2
Allowable fatigue stress f,all = - w2 > 3 w3 > 3 - - N / mm2

2 2 2 2
Combined stress c = x1 x 2  y - x * y  3 *  x12  3 *  x4 x12  y - x * y N / mm2
Allowable general stress c,all = ba > c1 baw > c2 caw > c3 ca > c4 ba > c9 N / mm2
Allowable fatigue stress fc,all = 1 > c1 w1 > c2 cr3 * w1 > c3 cr4 * 1 > c4 1 > c9 N / mm2
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2.5. BUCKLING STRESS

2.5.1. UNSTIFFENED WEB PLATE UNDER COMPRESSION STRESS
Length of panel a = mm
 c
Height of panel H = mm

H = Height of web
diaphragm
Thickness of panel t2 = mm
diaphragm

Neutral axis
a
Dimension ratio  = > 1
H
Compression stress c = N / mm2
t
a
Tensile stress t = N / mm2
Web plate
Shear stress  = N / mm2

2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * H2
 
t
Stress ratio  = - -
c
Normal stress factor ks = ( 1 +  ) * 7.636 -  * 23.9 + 10 *  * ( 1 +  ) -
4
Shear stress factor kt = 5.34 + -
2
Ideal buckling stress ki = ks * E N / mm2
Ideal buckling stress ki = kt * E N / mm2

c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 

If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
if vki < s  vk = vki

 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s

vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
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2.5..2. WEB PLATE WITH STIFFENER AT NEUTRAL AXIS

Length of panel a = mm
 c
Height of panel b = mm
diaphragm

diaphragm

H = Height of web
Thickness of panel t2 = mm

b
Stiffener a
Dimension ratio  = > 1
Neutral axis b
Compression stress c = N / mm2
Tensile stress t = 0 N / mm2
t
a Shear stress  = N / mm2
t
Stress ratio  = - = 0 -
c
2..5.2.1. Dimension of stiffener
Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
h

As
web
x Auxiliary factor  = -
b* t
t
2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
Required moment of inertia Jr = 2*b* t 3 ( BS 2573 ) mm4

Condition Ja > Jr

In case Ja cannot be bigger than Jr due to any restriction, then the buckling of the compression side must be checked :

2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * b 2
 
8.4
Normal stress factor ks = -
1.1  
4
Shear stress factor kt = 5.34 + -
2
Ideal buckling stress ki = ks * E N / mm2
Ideal buckling stress ki = kt * E N / mm2
c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki     4   ki    ki 

If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
if vki < s  vk = vki
 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s
vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
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2.5..3. WEB PLATE WITH ONE STIFFENER AT HALF DISTANCE OF FLANGE TO NEUTRAL AXIS

 c Length of panel a = mm
Height of panel b = mm

diaphragm

H = Height of web
diaphragm

Stiffener
Thickness of panel t2 = mm

b
b/2
Stiffener a
Dimension ratio  = > 1
Neutral axis b
Compression stress c = N / mm2

t Tensile stress t = 0 N / mm2

a
Shear stress  = N / mm2
t
Stress ratio  = - = 0 -
c
1.3.1. Dimension of stiffener
Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
h

As
web
x Ratio of area  = -
b * t2
t
Auxiliary factor  = 1 + 2* -

2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
  2 * 16 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =  0.53  0.47 *   *   if < 8*  - 1
 2 

  8 *  - 1  2   
" =  0.53  0.47 *   *   if > 8*  - 1
 2 
" * b * t 3
Required moment of inertia Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr

In case Ja cannot be bigger than Jr due to any restriction, then the buckling of the compression side must be checked :

2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * b 2
 
Ja * 12 *  1 -  2 
Actual auxiliary factor  =   -
b * t2 3
2
 1   2   2 * 
2
Normal stress factor ks = *   if  < 4 1 2 * 
0.95 *    1.1   * 1  2*  
2

4 1  1 2 * 
ks = * if  > 4 1 2 * 
0.95 *    1.1  1  2*  
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2 2 2
Auxiliary factors n =  1  2  ; p =  1  9 * 2  ; q =  9  2 
     
10.24 * n  3.16 * p  4.05 *  10.24 * n  0.41 * q  13.11 * 
x = 
n* p  2*  * n  2*  * p n * q  2 *  * q  162 *  * n

Shear stress factor kt =


4.93 * 1   2  -
3 * x

Ideal buckling stress ki = ks * E N / mm2

Ideal buckling stress ki = kt * E N / mm2

c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki     4   ki    ki 

If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
if vki < s  vk = vki

 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s

vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
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3. SADDLE
3.1. BOX SADDLE
t4

b4
4 Vp + Vg / 2

3
t2 d2 t2
h2

2
Rmax Rmax

b1 1 es
t1

thickness width height distance

Bottom plate tf = bf = - - mm
Web plate tw = - hw = d2 = mm
Top plate tf = bf = - - mm
Top reinforcement tr = d2 = - b4 = mm

Weight of saddle Gs = = kg = N
L
Wheel base es = = mm
6.3

3.1.1. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12

Polar modulus of section Wt = = mm3

Point 1 Point 2 Point 3 Point4

Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3

3.1.2. LOAD OF MIDDLE OF SADDLE

Vertical static load Vs = K * Gs = N
Vgs = Vg / 2 = N
Vertical dynamic load Vps = Vp = N
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N
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Vertical bending moment

Vs * es Vgs * es
due to DWT Mxg =  = Nmm
8 4
Vps * es
due to SWL Mxp = = Nmm
4
Total bending moment Mx = Mxg + Mxp = Nmm
Total horizontal moment My =  * Mx = Nmm
Torsion moment Mt = ( Vgs + Vps ) * ( d2 + tw ) / 2 = Nmm

3.1.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
Mxg Mxg
Minimum longitudinal stress xmin = = = N / mm2
Wx1 Wx 2
Mx My Mx My
Maximum longitudinal stress x =   N / mm2
Wx1 Wy1 Wx 2 Wy2
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
x min x min
Stress ratio kx = x1 x 2 -

Stress ratio factor cr = - - -

Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) N / mm2

Mt Vp * Sx1 Vps Mt
Maximum shear stress  =   N / mm2
Wt 2 * Ix * t2 2 * tw * hw Wt
Allowable general stress ,all = a > t1 aw > 2 N / mm2
Allowable fatigue stress f,all =  > t1 w2 > 3 N / mm2

2 2
Combined stress c = x 2  3 *  x 2  3 *  N / mm2
Allowable general stress c,all = ba > c1 baw > c2 N / mm2
Allowable fatigue stress fc,all = 1 > c1 w1 > c2 N / mm2

Moveable mass Mm = Gg + 2 * Gs + P = kg = N
Gg  2 * Gs P
Maximum wheel load Rmax =  = N
4 2
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3.1.4. SADDLE CONNECTION TO WHEEL SET

bf
tf

he
3 R
t2 d2 t2

he
he

2
Rmax
bf 1 eh
tf

thickness width height distance

Bottom plate tf = bf = - - mm
Web plate te = - he = d2 = mm
Top plate tf = bf = - - mm
Wheel distance eh = = mm

3.1.4.1. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12
Polar modulus of section Wt = = mm3
Point 1 Point 2 Point 3 Point4
Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3

Depth of cut t = hw - he = mm
Radius of cut R = = mm
Ratio x1 = R/t = -
Ratio x2 = R / he = -
1
Notch effect factor k = 1 = -
0.5 * X1  12 * X2 *  1  2 * X2 2

3.1.4.2. LOAD ON CONNECTION

Maximum wheel load Rmax = = N
Wheel distance eh = = mm
Bending moment Mxe = Rmax * eh = Nmm
Horizontal moment Mye = 0.15 * Mxe = Nmm
Torsion moment Mte = Mts = Nmm
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3.1.4.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
 Mxe Mye   Mxe Mye 
Maximum longitudinal stress x = k *    k *    N / mm2
 Wx1 Wy1   Wx2 Wy2 
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
Allowable fatigue stress fx,all = 1 > x1 w1 > x2 N / mm2

 Mt Rmax   Mt Rmax 
Maximum shear stress  = k *    k *    N / mm2
 Wt 2 * te * he   Wt 2 * te * he 

Allowable general stress ,all = a > 1 aw > 2 N / mm2

Allowable fatigue stress f,all = 1 > 1 w2 > 3 N / mm2

2 2
Combined stress c = x 2  3 *  x 2  3 *  N / mm2
Allowable general stress c,all = ba > c1 baw > c2 N / mm2
Allowable fatigue stress fc,all = 1 > c1 w1 > c2 N / mm2

3.2. PROFILE SADDLE

y
Vp + Vg/2

x x

Rmax Rmax
y
es
a

3.2.1. PROPERTIES
Moment of inertia Ix = 2 * Ixi = mm4
2
 a
Moment of inertia Iy = 2 * Iyi + 2 * As *   = mm4
 2
Point 1 Point 2 Point 3 Point4
Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3
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3.2.2. LOAD OF MIDDLE OF SADDLE

Vertical static load Vs = K * Gs = N
Vgs = Vg / 2 = N
Vertical dynamic load Vps = Vp = N
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N
Vertical bending moment
Vs * es Vgs * es
due to DWT Mxg =  = Nmm
8 4
Vps * es
due to SWL Mxp = = Nmm
4
Total bending moment Mx = Mxg + Mxp = Nmm
Total horizontal moment My =  * Mx = Nmm

3.2.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
Mxg Mxg
Minimum longitudinal stress xmin = = = N / mm2
Wx1 Wx 2
Mx My Mx My
Maximum longitudinal stress x =   N / mm2
Wx1 Wy1 Wx 2 Wy2
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
x min x min
Stress ratio kx = x1 x 2 -

Stress ratio factor cr = - - -

Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) N / mm2

Moveable mass Mm = Gg + 2 * Gs + P = kg = N
Gg  2 * Gs P
Maximum wheel load Rmax =  = N
4 2
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1. GENERAL DATA
Safe Working load SWL = = kg = N
Weight of crab Gc = = kg = N
Number of crab wheel nwc = = -
Width of crab wheel bwc = = -
Crab track gauge spw = = mm
Lifting speed vh = = m / min = m/s

Crane span L = = m = mm
Traveling speed vc = = m / min = m/s

1.1. CLASS OF UTILISATION

Working cycle / hour c = = c/h
Working hours / day h = = h/d
Working days / year d = = d/y
Service life sl = = years
Total working cycle Nc = c * h * d * sl = cycles
Class of utilisation Ui = f ( Nc ) = -

1.2. LOAD SPECTRUM

Girder capacity P = SWL + Gc = N

Lifted load 100% SWL + Gc 75% SWL + Gc 50% SWL + Gc 25%SWL + Gc

m1 = m2 = m3 = m4 = N
Number of cycle n1 = n2 = n3 = n4 = cycle

3 3 3 3
m1  n1  m2  n2  m3  n3  m4  n4 
Spectrum factor kp = 3 *   *   *   *  = -
P  Nc  P  Nc  P  Nc  P  Nc 

Crane group Ai = f ( Ui , kp ) = -
Duty factor K = f ( Ai ) = -
0.6 * vh
Impact factor  = 1 , minimum  = 1.1 = -
60

1.3. PROPERTIES OF GIRDER MATERIAL

Material = -
Yield strength s = = N / mm2
s
Basic allowable stress a = = N / mm2
1.5
Modulus of elasticity E = = N / mm2
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1.3.1. GENERAL ALLOWABLE STRESS

Material Weldment
Welding test procedure - RT / UT / MPT / DPT -
Stress correction factor w = - w = f ( test ) = -
Tensile bending stress ba = baa = baw = w * a = N / mm2
Compression stress ca = ca = a = caw = w * 0.85 * a = N /mm2
Transversal stress ya = 0.85 * ba = yw = 0.85 * baw = N / mm2
a = a = a = aw = w * a = N / mm2
Shear stress 3 3

1.3.2. FATIGUE ALLOWABLE STRESS

Damaged influence factor b = fatigue damaged lead destruction of crane = -
Critically factor w = = -
Inspection factor i = difficult inspection on installed crane = -
Stress correction factor  = b * w * i = -

For normal stress Material Weldment

Fatigue strength grade fn = fnw = f ( test ) = -
Normal stress factor Co = f ( fn ) = Cow = f ( fn ) = -
Curve inclination factor m = m = -

Basic stress range  = m Co = w = m Co = N / mm2

Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 

For shear stress fs = fsw = f ( test ) = -

Factor for normal stress Do = f ( fs ) = Dow = f ( fs ) = -
Inclination factor n = n = -

Basic stress range  = n Do = w = n Do = N / mm2

Nc Nc
 
Corrected stress range 1 = = w1 = = N / mm2
 
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2. CRANE GIRDER
2.1. GIRDER TYPE.

b4
spw
t4

tr

3
t2 d2 t2
h2

b1 1
t1

thickness width height distance

Bottom plate t1 = b1 = - - mm
Web plate under rail t2 = - h2 = d2 = mm
Web plate opposite rail t3 = - h2 = d2 = mm
Top plate t4 = b4 = - - mm
Crab rail tr = hr = - - mm
Longitudinal distance of diaphragm ld = = mm
Weight of girder Gg = = kg = N

2.2. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12
Moment of inertia Ixx = = mm4
Polar modulus of section Wt = = mm3
Point 1 Point 2 Point 3 Point4
Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Modulus of section Wxx1 = Wxx2 = Wxx3 = Wxx4 = mm3
Moment of area Sx1 = - - Sx4 = mm3

2.3. DEFLECTION OF GIRDER

5 * Gg * L3
Deflection due to DWT dg = = mm
384 * E * Ix
0.56 * P * L 3
Deflection due to SWL dp = = mm
48 * E * Ix
Allowable deflection dp,all = L / 800 = mm
5
Frequency of girder fg = > 2.5 Hz = Hz
( 0.78 * dg  dp ) / 10
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2.4. LOAD AT THE MIDDLE OF GIRDER

Vertical static load Vg = K * Gg = N
Vertical dynamic load Vp = 0.56 * K *  * P = N
2 * Vp
Crab wheel load Rc = = N
nwc
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N
Vertical bending moment

P
q

Mp Mq
A B A B
L L

Vg * L
due to DWT Mxg = = Nmm
8
Vp * L
due to SWL Mxp = = Nmm
4
Total bending moment Mx = Mxg + Mxp = Nmm

Hg * L Hp * L
Total horizontal moment My =  = Nmm
8 4
Vp * Ld
Secondary bending moment Mxx = = Nmm
5
Vp * ( d2  t2 )
Torsion moment Mt = = Nmm
2
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2.4.1. STRESS ON MIDDLE OFGIRDER

Point 1 = 4 Point 2 = 3
Mxg Mxg
Minimum longitudinal stress xmin = = = N / mm2
Wx1 Wx 3
Mx My Mxx Mx My Mxx
Maximum longitudinal stress x =     N / mm2
Wx1 Wy1 Wxx1 Wx 3 Wy3 Wxx3
Allowable general stress x,all = ba > x1 caw > x3 N / mm2
x min x min
Stress ratio kx = x1 x 3 -

1.3 * ( 1 - kx ) 1.3 * ( 1 - kx )
Stress ratio factor cr = 1.6 - kx 1.6 - kx -

Allowable fatigue stress fx,all = cr1 > ( x1 - x1min ) cr * cr3 * w1 > ( x3 - x3min ) N / mm2

Rc
Maximum transversal stress y = -
( 2 * ( hr  t4  t2 )  50 ) * t2 N / mm2
Allowable general stress x,all = - ya > y1 N / mm2
Allowable fatigue stress fx,all = - 1 > y1 N / mm2

Mt Vp * Sx1 Mt
Maximum shear stress  =   0.2 * y N / mm2
Wt 2 * Ix * t2 Wt
Allowable general stress ,all = a > 1 aw > 3 N / mm2
Allowable fatigue stress f,all = 1 > 1 w3 > 3 N / mm2

2 2 2
Combined stress c = x12  3 *  x 2  y - x * y  3 *  N / mm2
Allowable general stress c,all = ba baw N / mm2
Allowable fatigue stress fc,all = 1 w1 N / mm2
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2.5. BUCKLING STRESS

2.5.1. UNSTIFFENED WEB PLATE UNDER COMPRESSION STRESS
Length of panel a = mm
 c
Height of panel H = mm

H = Height of web
diaphragm
Thickness of panel t2 = mm
diaphragm

Neutral axis
a
Dimension ratio  = > 1
H
Compression stress c = N / mm2
t
a
Tensile stress t = N / mm2
Web plate
Shear stress  = N / mm2

2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * H2
 
t
Stress ratio  = - -
c
Normal stress factor ks = ( 1 +  ) * 7.636 -  * 23.9 + 10 *  * ( 1 +  ) -
4
Shear stress factor kt = 5.34 + -
2
Ideal buckling stress ki = ks * E N / mm2
Ideal buckling stress ki = kt * E N / mm2

c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 

If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
if vki < s  vk = vki

 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s

vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
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2.5.2. WEB PLATE WITH STIFFENER AT NEUTRAL AXIS

Length of panel a = mm
 c Height of panel b = mm
Thickness of panel t2 = mm
diaphragm

diaphragm

H = Height of web
a

b
Dimension ratio  = > 1
Stiffener b
Neutral axis Compression stress c = N / mm2
Tensile stress t = 0 N / mm2
Shear stress  = N / mm2
t t
a Stress ratio  = - = 0 -
c

2.5.2.1. Dimension of stiffener

Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
h

As
web
x Auxiliary factor  = -
b* t
t
2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 
Required moment of inertia Jr = 2*b* t 3 ( BS 2573 ) mm4

Condition Ja > Jr

In case Ja cannot be bigger than Jr due to any restriction, then the buckling of the compression side must be checked :

2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * b 2
 
8.4
Normal stress factor ks = -
1.1  
4
Shear stress factor kt = 5.34 + -
2
Ideal buckling stress ki = ks * E N / mm2
Ideal buckling stress ki = kt * E N / mm2
c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki    4   ki   ki 

If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
if vki < s  vk = vki
 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s
vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
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2.5.3. WEB PLATE WITH ONE STIFFENER AT HALF DISTANCE OF FLANGE TO NEUTRAL AXIS

 c Length of panel a = mm
Height of panel b = mm

diaphragm

H = Height of web
Thickness of panel t2 = mm
diaphragm

Stiffener

b
a


b/2
Stiffener Dimension ratio = > 1
b
Neutral axis Compression stress c = N / mm2
Tensile stress t = 0 N / mm2
Shear stress  = N / mm2
t
a t
Stress ratio  = - = 0 -
c

2.5.3.1. Dimension of stiffener

Thickness of stiffener t = mm
h
Height of stiffener h = mm
h1
Sectional area As = 2*t*h mm2
As
h


t

Ratio of area = -
x b * t2
web
t Auxiliary factor  = 1 + 2* -

2 2
t * h3  h ( h - t ) * t3  t 
Actual moment of inertia Ja =  t * h*     (h- t )* t *  h-  mm4
12  2 12  2 

  2 * 16 *  - 2  -  4   
Auxiliary factor ( DIN 4114 ) " =  0.53  0.47 *   *   if < 8*  - 1
 2 

 0.53  0.47 *   *   8 *  - 1    
 2 
" = if > 8*  - 1
 2 
" * b * t 3
Required moment of inertia Jr = mm4
12 *  1 -  2 
 
Condition Ja > Jr

In case Ja cannot be bigger than Jr due to any restriction, then the buckling of the compression side must be checked :

2 * E * t2 2
Euler stress E = N / mm2
12 *  1 -  2  * b 2
 
Ja * 12 *  1 -  2 
Actual auxiliary factor  =   -
b * t2 3
2
 1   2   2 * 
2
Normal stress factor ks = *   if  < 4 1 2 * 
0.95 *    1.1   * 1  2*  
2

4 1  1 2 * 
ks = * if  > 4 1 2 * 
0.95 *    1.1  1  2*  
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2 2 2
Auxiliary factors n =  1  2  ; p =  1  9 * 2  ; q =  9  2 
     
10.24 * n  3.16 * p  4.05 *  10.24 * n  0.41 * q  13.11 * 
x = 
n* p  2*  * n  2*  * p n * q  2 *  * q  162 *  * n

Shear stress factor kt =


4.93 * 1   2  -
3 * x

Ideal buckling stress ki = ks * E N / mm2

Ideal buckling stress ki = kt * E N / mm2

c 2  3 *  2
Ideal combined stress vki = N / mm2
2 2
  1     c     3 -    c     
  *      *     
  4   ki     4   ki    ki 

If the ideal combined stress vki is bigger than yield strength s, it must be reduced to vk.
if vki < s  vk = vki

 s 
if 0.6 * s < vki < 2.04 * s  vk = s *  1.474 - 0.677 * 
 vki 
 
if vki > 2.04 * s  vk = s

vk
Safety against buckling Sb = > 1.5
c 2  3 * 2
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3. SADDLE
3.1. BOX SADDLE

( Vp + Vg ) / 2 ( Vp + Vg ) / 2
t4

b4
4

3
t2 d2 t2
h2

spw + d2 + t2
2
Rmax Rmax

b1 1 es
t1

thickness width height distance

Bottom plate tf = bf = - - mm
Web plate tw = - hw = d2 = mm
Top plate tf = bf = - - mm
Top reinforcement tr = d2 = - b4 = mm

Weight of saddle Gs = = kg = N
Girder distance eg = spw + d2 + t2 = mm
L
Wheel base es = max ( spw + 2 * d2 + 1000, ) = mm
6.3

3.1.1. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12

Polar modulus of section Wt = = mm3

Point 1 Point 2 Point 3 Point4

Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3

3.1.2. LOAD OF MIDDLE OF SADDLE

Vertical static load Vs = K * Gs = N
Vgs = Vg / 2 = N
Vertical dynamic load Vps = Vp = N
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N
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Vertical bending moment

Vs * es Vgs * es
due to DWT Mxg =  = Nmm
8 4
Vps * ( es - eg )
due to SWL Mxp = = Nmm
2
Total bending moment Mx = Mxg + Mxp = Nmm
Total horizontal moment My =  * Mx = Nmm
Torsion moment Mts = ( Vgs + Vps ) * ( d2 + tw ) / 2 = Nmm

3.1.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
Mxg Mxg
Minimum longitudinal stress xmin = = N / mm2
Wx1 Wx 2
Mx My Mx My
Maximum longitudinal stress x =   N / mm2
Wx1 Wy1 Wx 2 Wy2
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
x min x min
Stress ratio kx = x1 x 2 -

Stress ratio factor cr = - - -

Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) N / mm2

Vps * Sx1 Vps

Maximum shear stress  = -  N / mm2
2 * Ix * t2 2 * tw * hw
Allowable general stress ,all = - aw > 2 N / mm2
Allowable fatigue stress f,all = - w2 > 3 N / mm2

2
Combined stress c = x1 x 2  3 *  N / mm2
Allowable general stress c,all = ba baw N / mm2
Allowable fatigue stress fc,all = 1 w1 N / mm2

Moveable mass Mm = 2 * ( Gg + Gs ) + P = kg = N
2 * ( Gg  Gs ) P
Maximum wheel load Rmax =  = N
4 2
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3.1.4. SADDLE CONNECTION TO WHEEL SET

bf
tf

he
3 R
t2 d2 t2

he
he

2
Rmax
bf 1 eh
tf

thickness width height distance

Bottom plate tf = bf = - - mm
Web plate te = - he = d2 = mm
Top plate tf = bf = - - mm
Wheel distance eh = = mm

3.1.4.1. PROPERTIES
Moment of inertia Ix = = mm4
Moment of inertia Iy = = mm4
Ratio k = Iy / Ix = > 0.12
Polar modulus of section Wt = = mm3
Point 1 Point 2 Point 3 Point4
Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3

Depth of cut t = hw - he = mm
Radius of cut R = = mm
Ratio x1 = R/t = -
Ratio x2 = R / he = -
1
Notch effect factor k = 1 = -
0.5 * X1  12 * X2 *  1  2 * X2 2

3.1.4.2. LOAD ON CONNECTION

Maximum wheel load Rmax = = N
Wheel distance eh = = mm
Bending moment Mxe = Rmax * eh = Nmm
Horizontal moment Mye = 0.15 * Mxe = Nmm
Torsion moment Mte = Mts = Nmm
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3.1.4.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
 Mxe Mye   Mxe Mye 
Maximum longitudinal stress x = k *    k *    N / mm2
 Wx1 Wy1   Wx2 Wy2 
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
Allowable fatigue stress fx,all = 1 > x1 w1 > x2 N / mm2

 Mt Rmax   Mt Rmax 
Maximum shear stress  = k *    k *    N / mm2
 Wt 2 * te * he   Wt 2 * te * he 

Allowable general stress ,all = a > 1 aw > 2 N / mm2

Allowable fatigue stress f,all = 1 > 1 w2 > 3 N / mm2

2 2
Combined stress c = x 2  3 *  x 2  3 *  N / mm2
Allowable general stress c,all = ba > c1 baw > c2 N / mm2
Allowable fatigue stress fc,all = 1 > c1 w1 > c2 N / mm2

3.2. PROFILE SADDLE

y ( Vp + Vg ) / 2 ( Vp + Vg ) / 2

x x

spw + d2 + t2
Rmax Rmax
y
es
a

3.2.1. PROPERTIES
Moment of inertia Ix = 2 * Ixi = mm4
2
 a 
Moment of inertia Iy = 2 * Iyi + 2 * As *   = mm4
 2 
Point 1 Point 2 Point 3 Point4
Modulus of section Wx1 = Wx2 = Wx3 = Wx4 = mm3
Modulus of section Wy1 = Wy1 = Wy3 = Wy4 = mm3
Moment of area Sx1 = - - Sx4 = mm3
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3.2.2. LOAD OF MIDDLE OF SADDLE

Vertical static load Vs = K * Gs = N
Vgs = Vg / 2 = N
Vertical dynamic load Vps = Vp = N
Horizontal static load Hg =  * Vg = N
Horizontal dynamic load Hp = *K*P = N

Vertical bending moment

Vs * es Vgs * es
due to DWT Mxg =  = Nmm
8 4
Vps * ( es - eg )
due to SWL Mxp = = Nmm
2
Total bending moment Mx = Mxg + Mxp = Nmm
Total horizontal moment My =  * Mx = Nmm

3.2.3. STRESS ON MIDDLE OF SADDLE

Point 1 = 4 Point 2 = 3
Mxg Mxg
Minimum longitudinal stress xmin = = N / mm2
Wx1 Wx 2
Mx My Mx My
Maximum longitudinal stress x =   N / mm2
Wx1 Wy1 Wx 2 Wy2
Allowable general stress x,all = ba > x1 baw > x2 N / mm2
x min x min
Stress ratio kx = x1 x 2 -

Stress ratio factor cr = - - -

Allowable fatigue stress fx,all = 1 > ( x1 - x1min ) w1 > ( x2 - x2min ) N / mm2

Moveable mass Mm = 2 * ( Gg + Gs ) + P = kg = N
2 * ( Gg  Gs ) P
Maximum wheel load Rmax =  = N
4 2