Faculty Advisor: Dr. Han P. Bao
Group Leader: Parker Harding
Group Members: Christina Toroc
Hunter Hughes
Deborah C. McHugh
Introduction
“The goal of this project is to design a rack to store various
sized spools that contain expensive power cables.”
 Cables supply power to the ships
 Cable spools are currently stored on the ground
 They are getting damaged due to the sun, weather, &
waterfront activity
 Safety hazard
 Disorganized
 Spools in front are being used more than those in the back
Design Parameters
 Area 120’ x 84’
 Ground is relatively flat; an exception is where the
drain is located
 Maximum height forklift can handle 10-14 ft
 Blades 8’x 8” wide x 3” thick, 25K Forklift 15’ long x 8’
wide
Problem Definition
 Racks need to be
adaptable to different
sized spools
 Cables must be stored in
the allotted area
 Forklift will be used to
load & unload the rack
http://www.google.com/imgres?imgurl=http://chinadigitaltimes.net
Spools
Cables
Grey
Length (feet) Weight (lb/ft)
50
10
Diameter (in)
70
100
10
Outer width (in)
32.5
150
10
Inner width (in)
28.5
Yellow
50
28
31
Grey & Yellow Spools
Design Details
 Constructed of structural steel I-beams & square
tubing
 Welded connections
 2 levels of storage available
 Forklift accessible from both sides
 First in-last out or first in first out spools picking,
ensures all spools are utilized
Forklift Attachment
Single Unit Cell
2x2 Structure
Side View of 2x2
Environmental Protection
 Warehouse Storage
 Likely means of storage
 Portable Building
 Alternative means of storage
 Polyolefin Covered Shelters
 5-8 yr lifetime expectancy
 Bolted construction, to
http://1southerncomfortshelters.com/services.nxg
withstand up to 70 mph winds
 Can be manufactured to
withstand up to 110 mph winds
 Flame retardant, UV, & mildew
treated
 5 year pro-rated warranty
Materials Required
Cable Storage Rack:
Forklift Blades Accessory:
FEA – Bending Stress – Max: 6,720 psi
Factor of Safety: (P) 5.36 (H) 5.80
Connections
FEA - Plate Stress - Max: 14,200 psi
Factor of Safety: (P) 2.54
FEA - Displacement - Max: .0695 in
Material Analysis
Forklift Assembly:
Forklift Sleeve/Rectangular Tubing
Circular Rod
Triangular Brace (cut from Plate)
Size
Length Cut to
(in)
Size (in)
10 x 4 x
1/4
58
D=2.25
55
3x4
Total Cost for Forklift Assembly
$363.31
Component
Quantity
Needed
2
1
4
Each
Price (US Total Cost
$)
(US $)
$152.46
$58.39
$25.38
$304.92
$58.39
$101.52
Cost of Each Component for a 2 x
2 Modular Structure:
Each
Price (US Total Cost
$)
(US $)
Size
(in)
Length Cut to
Size (in)
Quantity
Needed
98
9
$248.76
$2,238.84
Plates
I-beams
4 x 4 x 1/2
10 x 10 x
1
8 x 15
76
9
24
$45.15
$105.08
$406.35
$2,521.92
Spool Support
Triangular Brace (cut from Plate)
4 x 4 x 1/2
3x4
79.75
16
36
$203.50
$25.38
$3,256.00
$913.68
Total Cost for 2 x 2 Structure
$9,336.79
Component
HSS Column
Labor Analysis
Man day rate
(loaded rate)
$374.00
# of
workers
needed
3
# of days for
Project
Completion
2
Total Cost
of Labor
$2,244.00
Grand Total
Grand Total Cost of Project
(for 2x2 modular structure)
Components
Spool & Cable Value
$11,944.10
Total Cost for
Cost for a Cost for # of Spools with
New Spool Cable Spools
Cables
$700.00 $20,000
8
$165,600.00
Gantt Chart
References

"A992 Hot Rolled Wide Flange I-beam." OnlineMetalStore.com. N.p., 2011. Web. 23 Mar 2011.
<http://www.onlinemetalstore.com/items/A992_Hot_Rolled_Steel_Wide_Flange_I_Beam.cfm?item_id=194&size_no=1>.

"American Standard Steel Channels." The Engineering Toolbox. The Engineering Toolbox, n.d. Web. 21 Mar 2011.
<http://www.engineeringtoolbox.com/american-standard-steel-channels-d_1321.html>.

Budynas, Richard G., and J. Keith Nisbett. Shigley's Mechanical Engineering Design. 9th ed. New York, NY: McGraw-Hill, 2011.
Print.

"Galvanized Steel Channel." OnlineMetalStore.com. N.p., 2011. Web. 23 Mar 2011.
<http://www.onlinemetalstore.com/items/Galvanized_Steel_Channel.cfm?item_id=168&size_no=4>.

"Mechanical/Structural Steel Tubing." OnlineMetalStore.com. N.p., 2011. Web. 23 Mar 2011.
<http://www.onlinemetalstore.com/items/Structural_Mechanical_Steel_Square_Tube.cfm?item_id=206&size_no=78>.

"Services." Southern Comfort Shelters. Southern Comfort Shelters, n.d. Web. 21 Mar 2011.
<http://1southerncomfortshelters.com/services.nxg>.

"Structural Steel Tubing." Saginaw Pipe. Saginaw Pipe, n.d. Web. 21 Mar 2011.
<http://www.saginawpipe.com/square_rectangular_tube.htm>.

"Wide Flange Steel Beams." Saginaw Pipe. Saginaw Pipe, n.d. Web. 21 Mar 2011.
<http://www.saginawpipe.com/steel_i_beams.htm>.
Questions?