Centre-to-centre distance between columns (i.e., span of the gantry girder) = 7.

5 m
Crane capacity = 200 kN
Self-weight of the crane girder excluding trolley = 200 kN
Self-weight of trolley, electrical motor, hook, etc. = 40 kN
Minimum hook approach = 1.2 m
Distance between wheel centres= 3.5 m
Centre-to-centre distance between gantry rails (i.e., span of the crane) = 15 m
Self-weight of the rail section = 300 N/m
Yield stress of steel = 250 MPa

1. Load and bending moment calculations

(a) Load
(i) Vertical loading
Calculation of maximum static wheel load
Maximum static wheel load due to the weight of the crane = 200/4 = 50 kN
Maximum static wheel load due to crane load
WI = [W1(Lc- LI)]/(2Lc)
= (200 + 40)(15 - 1.2)/(2 X 15)
= 110.4 kN

Total load due to the weight of the crane and the crane load= 50+ llOA = 160.4 kN
To allow for impact, etc., this load should be multiplied by 25% (see
Table 12.3).
Design load = 160.4 x 1.25 = 200.5 kN
:. Factored wheel load on each wheel,
We= 200.5 X 1.5 = 300.75 k:N
(ii) Lateral (horizontal) surge load
Lateral load (per wheel) = 1 0%(hook + crab load)/4
= 0.1 X (200 + 40)/4
=6k:N
Factored lateral load = 1.5 x 6 = 9 kN
(iii) Longitudinal (horizontal) braking load
Horizontal force along rails (Table 12.3) = 5% of wheel load
= 0.05 X 200.5 = 10.025 kN
Factored load Pg = 1.5 x 10.025 = 15.04 kN
(b) Maximum bending moment
(i) Vertical maximum bending moment
Without considering the self-weight,
M1 = WcL/4 = 300.75 x 7.5/4 = 563.90 k:Nm
M2 = 2Wc(L/2- c/4)2/L
= 2 X 300.75(7.5/2- 3.5/4)217.5
= 662.90 k:Nm
Hence M = 662.90 k:Nm.
Assume that the self-weight of the gantry girder is 1.6 k:N/m.
Total dead load= 1600 + 300 (self-weight of rail)= 1.9 k:N/m
Factored DL = (1.9 x 1.5) = 2.85 k:N/m
BM due to dead load = w/2/8 = ( 2.85 x
7t)
= 20.04 k:Nm
(ii) Horizontal bending moment
Moment due to surge load= 2 x 9(7.5/2- 3.5/4)217.5
My= 19.84 k:Nm
(iii) Bending moment due to drag (assuming the rail height as 0.15 m and depth of
girder as 0.6 m)
Reaction due to drag force= Pge/L = 15.04(0.3 + 0.15)17.5 = 0.903
M3 = R(L/2- c/4) = 0.903(7.5/2- 3.5/4) :;:: 2.59 k:Nm
Total design bending moment Mz = 662.9 + 20.04 + 2.59 = 6~5.53 k:Nm
(c) Shear force (for maximum shear force, one of the wheel loads should be very
close to the supports)
(i) Vertical shear force
Shear force due to wheel load
WL(2- elL)= 300.75(2- 3.517.5) = 461.15 kN
wl 7.5
Shear force due to DL = T = 2.85 x 2 = 10.69 kN
Maximum ultimate shear force
Vz = 10.94 + 461.15 = 472.09 kN
(ii) Lateral shear force due to surge load Vy = 9(2- 3.517.5) = 13.8 kN
Reactions due to drag force = 0.903 kN
and maximum ultimate reaction
Rz = 472.09 kN + 0.903
= 472.99 or 473 kN
2. Preliminary selection of the girder
Since L/12 = 7500/12 = 625, we choose the depth as 600 mm. Therefore,
Approximate width of beam = L/30 = 250 mm
Since deflection governs the design, choose I, using the deflection limit of L/750,
I= 15.6W(L- c) [2L2 + 2Lc- c2]
LE
= 15.6 X 200.5 X 103 X (7500- 3500)
X [2 X 75002 + 2 X 7500 X 3500 - 35002]/(2 X 105
X 7500)
= 1.274 x 109 mm4
Required ZP = 1.4 x Mlf;, = 1.4 x 685.53 x106/250 = 3.83 x 106 mm3
Choose ISMB 600 @ 1230 N/m with a channel ISMC 300 @ 363 N/m @ the
top (see Fig. 12.27).
a. Properties of the sections
ISMB 600 @ 1.23 kN/m
A= 15600 mm2
t1=20.3 mm
~ . = 12 mm
B=210mm
lzz = 91800 X 104 mm4
I = 2650 x 104 mm4
yy
R=20mm
(i) Elastic properties of the combined section
ISMC 300 @ 0.363 kN/m
A =4630mm2
t1= 13.6mm
~ . =7.8mm
B=90mm
!== = 6420 x 104 mm4
I = 313 x 104 mm4
JY
Cv=23.5 mm
(i) Elastic properties of the combined section
ISMC 300 @ 0.363 kN/m
A =4630mm2
t1= 13.6mm
~ . =7.8mm
B=90mm
!== = 6420 x 104 mm4
I = 313 x 104 mm4
JY
Cv=23.5 mm
Total area A =As+ Ach = 15,600 + 4630 = 20,230 mm2
The distance of NA of the built-up section from the extreme fibre of tension
flange,
y = [15,600 x 600/2 + 4630 x (600 + 7:8- 23'.5)]/20,230 = 365.07 mm
h1 = y - hs/2 = 365.07 - 600/2 = 65.07 mm
h2 = (hs + tch)- y- cy = (600 + 7.8)- 365.07-23.5 = 219.23 mm
h3 = 607.8-365.07-7.8 = 234.93 mm
I z = Izs + Ashf + (Iy)ch + Ach X hi
= 91,800 X 104 + 15,600 X 65.072 + 313 X 104 + 4630 X 219.232
= 1.2097 x 109 mm4 "" 1.274 x 109 (required for deflection control)
Zzb = 1.2097 x 109/(365.07) = 3.31 x 106 mm3
Z=t = 1.2097 X 109/(242.73) = 4.98 X 106 mm3
lyy combined = 2650 x 104 + 6420 x 104 = 9070 x 104 mm4
ly for tension flange about the y-y axis
ltf= 20.3 X 2103/12 = 1566.6 X 104 mm4
For compression flange about the y-y
axis
/cf = 1566.6 X 104 + 6420 X 104 =
7986.6 x 104 mm4
Zy (for top flange alone)= 7986.6 x
104/150 = 532,443 mm3
b. Calculation of plastic modulus (see
Section 12.4.2 and Fig. 12.15)
The plastic neutral axis divides the area
into two equal areas, i.e., 10,115 mm2
dP = 4630/(2 x 12) = 193 mm
Ignoring fillets, the plastic section
modulus below the equal-area axis is
LAy= 20.3 X 210 X (493-
20.3/2) + (493- 20.3) X 12 X (493- 20.3)/2
= 3399.1 x103 mm3
Above the equal-area axis
300
210 \ . )ol
y=
ISMS 600
Fig. 12.28
ISMC300
LAy= 4630 X (114.8- 23.5) + 210 X 20.3 X (114.8- 7.8- 10.15)
+ 86.7 X 12 X 86.7/2 = 880.692 X 103 mm3
Zpz= 3399.1 X 103 + 880.692 X 103 = 4279.792 X 103 mm3
For the top flange only
ZPJ, = 20.3 X 2102/4 + (300- 2 X 13.6i X 7.8/4 + 2 X 90 X 13.6
x (150- 13.6/2) = 719,479.8 mm3
3. Check for moment capacity
Check for plastic section
bit of the flange of the I-beam = [(210- 12)/2]/20.3 = 4.87 < 9.4
bit of the flange of the channel= (90- 7.8)/13.6 = 6.04 < 9.4
dlt of the web of the I-section = (600 - 2 x 20.3)112 = 46.6 < 84
Hence the section is plastic.
a. Local moment capacity
1.2Ze.f;,/1.1 = 1.2 X 3.31 X 106
X (250/1.1) X 10-6 = 902.72 kNm
Md:: = .{yZ/1.1 = (250/1.1) X 4279.792 X 10-3 = 972.68 kNm > 902.72 kNm
Hence take Mctz = 902.72 kNm
Md:: = (/y/1.1) X Zp(top flange)= (250/1.1) X 719,479.8 X 10-6 = 163 kNm
1.2Z.J;,Il.I = 1.2 X 532,443 X (250/1.1) X 10-6 = 145.2 kNm <163 kNm
Hence take Mdy = 145.2 kNm.
b. Combined local capacity check
685.53/902.72 + 19.84/145.2 = 0.759 + 0.137 = 0.896 < 1
Hence the chosen section is the right choice.
4. Check for buckling resistance
As per IS 800 (Clause 8.2.2), the design bending strength
Md = f3bZpfbd

We have
f3b = 1.0
h = 600 + 7.8 = 607.8 mm
KL=7500mm
E = 2 x 105 N/mm2
~= 20.3 + 7.8 = 28.1 mm
ry= ~lyyiA
/yy = (2650 X 104
) + (6420 X 104
) = 9070 X 104 mm4
A= 15,600 + 4630 = 20,230 mm2
9070x104
ry = 20
,
230 = 66.96 mm
According to clause 8.2.2.1 of (IS 800), elastic lateral buckling moment

C1 = 1.132 (from Table 42 ofiS 800 : 2007)

Note The above formula is valid for !-sections only. For more accurate values of Mer
for a compound section, the formula given in E 1.2 (Annex E) ofthe code may be used.
Non-dimensional slenderness ratio

Along the z-direction

Note Since the channel will normally be connected by intermittent welds to the
!-section, au value has been taken as 0.21. If heavy welding is involved, take. au as 0.49.

XLTz =

fbd = hXLriYmo
Ymo = 1.10 (from Table 5 of the code)
fbd = 0.7967 X 250/1.1 = 181.07 N/mm2
Mdz = f3bZpzfbd
= 1.0 X 181.07 X 4279.792 X 10-3
Mdz = 774.9 kNm > 685.53 kNm

Thus the beam is satisfactory under vertical loading. Now it is necessary to check
it under biaxial bending.
For top flange only
Mdy = (/y/1.1) x Zyt
= (250/1.1) X 719,479 X 10:..() = 163.5 kNm > 1.2 X 532,433 X 250/
(1.1 x 106) = 145.2 kNm
Hence Mdy = 145.2 kNm
a. Check for biaxial bending
In order to check for biaxial bending, we substitute the terms with their value~ in
the following equation:
Mz My
M+M:l>l.O
dz dy
We have
~7~~: + ~~5~~ = 0.884 + 0.137 = 1.021 = 1.0'
. Hence the beam is safe.
Slightly bigger size of top channel may be selected.

5. Check for shear capacity

For vertical load,
vz = 472.09 kN
Shear capacity = Avf.ywl( .J3 X 1.1 0)
= (600 X 12) X 250/(.J3 X 1.10) X 10-3
= 944.75 kN > 472.09 kN
The maximum shear force is 472.09 kN, which is less than 0.6 times the shear
capacity, i.e.,
0.6 X 944.75 = 566.85 kN
Hence it is safe in vertical shear and there is no reduction in the moment capacity.
a. Weld design
The required shear capacity of the weld is given by
q = VAYflz
y = h3 = 234.93
A = 4630 mm2
, V = 472.09 kN
I z = 1.2097 x 109 mm4
q = 472.09 X 103 X 4630 X 234.93/(1.2097 X 109) = 424 N/mm

This shear is taken by the welds. Hence use a minimum weld of 4 mm (442 N/mm
per weld) connecting the channel to th.e top flange of the I-beam.
For lateral shear force,
Fy = 13.8 kN
Shear capacity Vny = Avfywl( J3 X 1.1 0)
= 250/(J3 X 1.10) X (210 X 20.3 + 300 X 7.8) X 10-3
= 866.41 kN > 13.8 kN
Hence it is safe for resisting lateral shear.
6. Web buckling
At points of concentrated loads (wheel loads or reaction) the web of the girder
must be checked for local buckling (see Section 10.11)
The dispersion length under wheel (assuming it to be 150 mm and assuming an
angle of dispersion of 45). Also, assume shift bearing length at support =150 mm.
b1 = 150 mm
n1 = 600/2 + 7.8 = 307.8 mm
Web slenderness A.= 2.5d/t
= 2.5 X (600- 2(20.3 + 20)]/12 = 108.2
Stress reduction factor (from Table 8 of IS 800 : 2007) = 0.426
fca = 0.426 X 250/1.1 = 96.8 MPa

Bucklingresistance = (bl + n1)tfca

= (150 + 307.8)12 X 96.8 X 10-3 = 531.78 kN
Maximum reaction= 473 kN < 540.8 kN
Hence buckling resistance is satisfactory.
Under concentrated loads, the dispersion will be on two sides and hence buckling
resistance will be satisfactory. In addition web crippling due to wheel load at inner
points is to be checked. This is left as an exercise to students.
7. Web bearing (see Section 10.11)
Load dispersion at support with 1: 2.5 dispersion
Minimum stiff bearing= Rx/(tfyw/1.1)- n2
n2 = (20.3 + 20) x 2.5 = 100.75 mm
Rx = 473 kN (support reaction)
b1 = 473 X 103/(12 X 250/1.1)- 100.75 = 72.68 mm
Web bearing at support requires a minimum stiff bearing of 73 mm < 150 mm
8. Check for deflection at working load

Serviceability vertical wheel load excluding impact= 160.4 kN

Deflection at mid-span
Ll = WL3[(3a/4L)- (a3/L3)/(6El)
Where

(i) Vertical
Combined Izz = 1.2097 X 109 mm4
160.4 X 103 X 75003
.1 = [3 X 2000/(4 X 7500)- 20003/75003]
6 X 2 X 105 X 1.2097 X 109
= 8.43 mm <L/750 = 10 mm
(ii) Lateral
Only the compound top flange will be assumed to resist the applied surge load as
in the bending check.
I= (Iz)ch +IF= 7986.6 X 104 mm4
.1 = 6 X 10
3
X
75003
(3 X 2000/(4 X 7500)- 20003/75003]
6 X 2 X 105 X 7986.6 X 104
= 4. 78 < 10 mm (Table 6 ofiS 800 : 2007)