CLIENT :
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STEEL STRUCTURE CALCULATION For Hoists &
Crane - WORKSHOP BUILDING (10T)
IN-HOUSE REVISIONS
DOCUMENT REVISIONS
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B
B
A
Second Issue
S.K
S.K
S.A
S.A
8/15/2021
A
Second Issue
S.K
S.K
S.A
S.A
0
First Issue
S.K
S.K
S.A
S.A
7/23/2020
0
First Issue
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S.K
S.A
S.A 7/23/2020
REV.
DESCRIPTION
DESG DRAWN. CHK
APP.
DATE
REV.
DESCRIPTION
DESG DRAWN CHKD
APP.
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No.
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CHAPTER 1: GIRDER
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CALCULATION
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1-1- INTRODUCTION
This chapter applies to design structure of main girder in accordance with CMAA, FEM and DIN
standards.
Calculations in this chapter is considered as a basis for structural design and COSMOS analysis in
chapter 2 is only for overview.
1-2- Design Load
First step is find of the external forces and their combination that act on the structure. According
to CMAA standard, follow Loads to be considered:
Principal loads
Dead Load (DL)
Trolley Load (TL)
Lifted Load (LL)
Vertical Inertia Forces
Dead Load Factor (DLF)
Hoist Load Factor (HLF)
Inertia Forces From Drives
Additional loads
Operating wind load (WLO)
Forces Due to Skewing (SK)
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Extraordinary loads
Collision Forces (CF)
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1-3- Girder Calculation
L = 10.8m
Q = 10000kg
Span
Hoisting capacity
Wtrolley = 1410kg
Trolley weight
WBridge = 2024kg
Weight of bridge
V = 2.5 / 12
m
min
Bridge speed
Crane Girder dimension
H = 600mm
b = 350mm
t 1 = 8mm
t 2 = 8mm
t 3 = 30mm
t 4 = 10mm
h1 = 330mm
h 2 = 310mm
EA60 X 60 X 6
Longitudinal stiffener
T Diaphragm = 8mm
Diaphragm thickness
Material :St37
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1-4- Girder Section Properties
Moment of inertia:
I x = 3565329.985mm4
I z = 1555116.952mm 4
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Elastic section modulus:
Point 1:
Wx = 3565330mm3
Wz = 1555117 mm3
Point 2:
Wx = 3655611mm3
Wz = 2267879mm3
Point 3:
Wx = 3655611mm3
Wz = 2267879mm3
Point 4:
Wx = 6141005mm3
Wz = 1555117 mm3
1-5- General Check of Dimensions
L
 25
H
L 10800
=
= 18.33  25
H
600
L
 65
B
L 11000
=
= 31.42  65
B
350
CMAA
Ok.
CMAA
Ok.
1-6- Load Combination
For moving concentrated loads, the maximum bending moment will occur when the centerline of
the span is midway between the center of gravity of loads and the nearest concentrated load.
Based on the above rule, the distance from the runway support to the nearest trolley wheel for
maximum live load moment will be as follows for equal wheel loads (AISC):
4 wheel trolley:
a
2
L d
L =
−
2 2
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d =
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R 1 = FL (1 −
a
)
2L
R1 = 6759 N
Fig (1-1) Bridge Girder Loading
6 wheel trolley:
a 2a1
−
3
3
L d
L =
−
2 2
3 2a1
R1 = FL ( +
)
2
L
d =
Fig (1-2) Bridge Girder Loading
8 wheel trolley:
a
− a1
2
L d
L =
−
2 2
d =
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R 1 = 2FL (1 +
d
a 2a1
− +
)
L L
L
Fig (1-3) Bridge Girder Loading
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Dead Load (Girder Weight)
PDL
L
WL2
M DL =
8
W =
PDL = 2024 kg
M DL = 27730 N .m
Trolley Load (Trolley Weight)
wheel load =
MTL =
PTL
n
PTL :Trolley load, n : Number of wheel
Fig (1-1), Fig (1-2), Fig (1-3)
PTL L
4
PTL = 1410 kg
MTL = 38775N.m
Lifting Load (Crane Capacity)
wheel load =
M LL =
PLL
n
PLL : Lifting Load, n : Number of wheel
Fig (1-1), Fig (1-2), Fig (1-3)
PLL L
4
PLL = 10000kg
M LL = 275000 N.m
1-7- Inertia Forces From Drives (IFD)
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The inertia forces occur during acceleration or deceleration of crane motions and depend on the
driving and braking torques applied by the drive units and brakes during each cycle.
Exact solution:
M Horz =
a
(M LL + M TL + M DL )
g
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M Horz = 8702.98 N .m
There is also various approximate method for calculating of horizontal bending moment.
Accordance to AIST M Horz is calculated as follow (AIST):
M Horz = 0.2(M LL + M TL + M DL ) 
Number of Driven BridgeWheels
Total Number of BridgeWheels
1-8- Loads Factor
Dead Load Factor
This factor covers only the dead loads of the crane, trolley and its associated equipment and shall
be taken according to CMAA Revised 2000: (CMAA Revised 2000: sec 3.3.2.1.1.4.1, page 21)
DLF = 1.1  1.05 +
Travel Speed (FPM )
 1.2
2000
For this case: DLF = 1.1
Hoist Load Factor
This factor applies to the motion of the rated load in the vertical direction, and covers inertia
forces, the mass factor due to the sudden lifting of the hoist load and the uncertainties in
allowing for other influences. This factor shall be taken according to CMAA Revised 2000:
(CMAA)
HLF = 0.15  0.005  Hoist Speed (FPM )  0.5
For this case: HLF = 0.15
1-9- Load Combination
The combined stresses shall be calculated for the following design cases:
Case 1: Crane in regular use under principal loading (stress level 1)
DL (DLFBr ) +TL (DLFTr ) + LL (1 + HLF ) + IFD
Case 2: Crane in regular use under principal loading and additional loading:
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DL (DLFBr ) +TL (DLFTr ) + LL (1 + HLF ) + IFD +WLO + SK
Case 3: Extraordinary loads:
The highest of the following combinations shall be considered:
Crane subjected to out of service wind
DL + TL + WLS
Crane in collision
DL + TL + LL + CF
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125 percent of rated load.
Test load (CMAA)
NOTE: In the structure design, load case 1 is considered; therefore, wind load does not
need to calculate.
1-10- ALLOWABLE STRESSES
Allowable stresses are considered according CMAA standard: (CMAA)
Allowable Stress
STRESS
LEVEL
AND CASE
ALLOWABLE
ALLOWABLE
COMPRESSION
TENSION
STRESS
STRESS
ALLOWABLE
SHEAR
STRESS
1
0.60 yp
0.60 yp
0.35 yp
2
0.60 yp
0.60 yp
0.35 yp
3
0.75 yp
0.75 yp
0.43 yp
For carbon, steel of current manufacture ST-37 the yield stress  yp is conventionally considered
240 MPa .Hence, for case 1 load combination allowable stress is obtained as follow:
Allowable Stress for St-37
STRESS
LEVEL AND
CASE
1
ALLOWABLE
COMPRESSION
STRESS (  a )
ALLOWABLE
TENSION STRESS
( a )
ALLOWABLE
SHEAR STRESS
( a )
144 Mpa
144 Mpa
84 Mpa
1-11- Combined Stresses
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 t =  y2 +  x2 −  y  y + 3v2   a
CMAA
DL (DLFBr ) +TL (DLFTr ) + LL (1 + HLF ) + IFD Case 1 load combination
 x = Vertical +  Horizontal
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DLFBr (M DL ) + (DLFTr (M TL ) + (1 + HLF )M LL )
Sx
M
 horizontal = Horz
SZ
Vertical =
v (max) = vb + vt
maximum shear stress in the web
vb =
VQ
2I z t
Shear stress due to the torsional moment.
vt =
Mt
2A t
shear stress due to the resultant shear force
v (max) =
VQ M t
+
2I z t 2At
 t =  x2 + 3 v2 = 122MPa
Combined stress
1-12- Flange stresses
Local flange stresses are formed when a wheel loads the lower flange of an I-beam or a
box girder. The flange stresses is calculated:
 Fx =
k .F
t2
K: factor that can be retrieved from a curve
F: loading on one wheel
t: flange thickness
The flange stress is directly added to the general bending stress.
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 Fx = 107 MPa
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1-13- Deflection
No general rule can be found in the crane standards for the maximum Allowed crane deflection.
Deflection is according to client technical specification:
y max 
y =
1
L
1000
PL3
48EI x
ymax = 10.23 mm
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ymax 
1
L = 10.8mm 
1000
Ok.
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CHAPTER 2: SOFTWARE
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ANALYSIS
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2-1- Introduction
Calculations in chapter 1 is considered as a basis for structural design and COSMOS analysis in
this chapter is only for overview.
A complete box girder is modeled in SOLIDWORKS software and all dimension is according to
DWG of crane girder. Thickness of web, top flange, bottom flange and stiffener plates are 8mm,
12mm, 30mm and 8mm respectively. Width of top and bottom flange is 400mm and maximum
height of web plates is 730mm.
2-2- Boundary Conditions
Considering crane parked at one position and lifting the maximum load that is considered for crane
operation. Hence during finite element analysis, no horizontal force is considered to be acting on
the main girder. Main girder is fully fixed at the ends where it is joined to the end carriages. Trolley
is assume to be at the point that is explained in section 1-6 and the 19.5 ton (include hoist
capacity and dynamic load) is applied on the top of trolley plate.
2-3- Input Data of ANSYS Simulation
component
Description
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Material of
Girder structure
ST-37, E = 2.1e11 ,  = 0.3 ,  = 7850kg / m
Trolley Structure
E = 2.1e12 ,  = 0.3 ,  = 7850kg / m
3
3
Load
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Force on trolley
Trolley mass
1.3  10Ton = 13Ton
Bridge self-weight
g = 9.81m / s 2
1410 kg
2-4- Total Deflection
Comments
Maximum deflection (4.14mm) is less than calculated maximum deflection (6.8) in chapter 1.
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2-5- Von-Mises stress
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