Calculations Bracket

Design Calculations
Cradle Runways (I) Pvt Ltd

Prepared By SK Prep Date 4-Jul-14
Checked By SJ Rev 0
Approved By RKS Rev Date 4-Jul-14
Project - Worli Mixed Use Development

Project No - C4281PMU
Aim
To calculate the size of component used in façade access system.
Reference Code
1 EN1808-1999+A1:2010 - Safety requirement on suspended access equipments-
Design, calculation, stability criteria and test
2 IS 800- 2007 - Code of practice for general construction in Steel
3 IS2062 - 2010 - Hot rolled low, medium, and high tensile steel structure
4 IS 806- 1968 - Code of practice for use of steel tubes in General Building construction.
5 IS 816:1969 -code of practice for metal arc welding for general construction in mild steel.
6 BS 8118 -Part-1 - 1991 - Structural use of Alunimum - Part 1 - code of Practice for design
7 BS EN 10210-2:2006 - Hot finished structural hollow sections of non-alloy and fine grain steel-
- Part 2: Tolerances, dimensions and sectional properties.
8 BS EN ISO 3506-1:1998 Mechanical properties of corrosion resistant stainless steel fasteners -
Part 1: Bolts, screws, and studs
Material Specifications :-
Mild Steel- E250(fe410) as per IS 2062-2010
Density of steel ρ = 7,250.00 Kg/M3
Modulus of elasticity E = 206,000.00 MPa
Tensile strength σR = 410.00 MPa
Yeild Strength σE = 250.00 MPa
for plate thickness <=20mm
Bolts, screw and Studs

A2-70gr, Austenitic steel BS EN 3506-1:1998
Grade A2
Property Class 70.00
Tensile strength σRB = 700.00 MPa
Stress at 0.2% permanent strain σEB = 450.00 MPa
Aluminum alloy track profile sections

Al Alloy - 6351, T6 temper As per BS 8118-1 : 1998
Limiting stress for bending and overall yeilding σR = 255.00 MPa
Limiting stress for local capacity of section in tension σE = 275.00 MPa
For extrusion upto 20mm
file:///conversion/tmp/scratch/492979148.xlsx
Design Calculations
Calculations Methodology :-
The monorail with soffit mounted bracket are installed at Front and rear reveal areas.
The rear reveal area is accessed by using single man power cradle while front reveal area is accessed
by using Two man power cradle.
There has been provision of extra roller along with glass lifting hoist given for lifting glass panel.
The calculation is done for mororail using two man power cradle services as this is the worst case
condition.
As per EN1808:1999+A1:2010, the maximum allowable stress σa is defined by table 2
Load case-1 Load case-II Load case -III

Value of safety factor VE 1.5 1.33 1
Allowable stress = σa = σE / 1.5 σE / 1.33 σE / 1.0
Allowable stress = σa = 166.67 MPa 187.97 MPa 250.00 MPa
The value of calculated stress is compared with allowable stress value calculated above.
Based on table -10 of EN1808:1999+A1:2010, the factor for load case is expressed as
Factor for WLL 1.5 1.5 2.5
Data
Rated load of cradle RL 250.00 Kg Safe Working load
Dead weight of cradle including hoist, wire rope SWP 600.00 Kg

Total Suspened Load - RL + SWP = WLL 850.00 Kg
Dead weight of glass hoist GRU 60.00 Kg
Maximum weight of glass GRL 300.00 Kg
Building Height 215.00 Mt
Maximum distance between bracket BKTmax 2,000.00 mm
Maximum length of bracket BLmax 400.00 mm
Hanging centre of cradle CCTC 2,185.00 mm
Distance of GRU fixing from track suspension point BGRU 425.00 mm

Partial Factory of safety for materials - Shop weld γmw = 1.25 From IS800:2007 table 5
Partial Factory of safety for materials - field weld γmw = 1.50 From IS800:2007 table 5
Design Calculations
Calulation methodology
The design of design of glass lifting hoist unit is carried out first. The reaction from this
member is transferred to bracket load reaction.
The bracket design is considered as a combination of load cases due to C130 track load
and load due to material lifting hoist.
Since there are different lengths of brackets, the longest bracket size is calculated
and the small bracket size are assumed safe for the given load conditions.
The brackets at 88,050Mt level which is used for abseiling system, doesn’t take the material
lifting hoist fixing bracket arrangement.
Material lifting Hoist Member size Calculations

The glass repalcement hoist is suspended between two brackets. The member is designed as
simply supported member at both ends and vertical load acting at centre.
Maximum distance between brackets = BKTmax 2000 mm

Load Acting at centre = Wd = GRU + GRL
360.00 Kg
Free body digram for the material lifting hoist 2000
MLH Member
360 Kg
R1 R2
Reaction on brackets
R1G = R2G = 1.25*Wd/2
R1G = R2G = 225 Kg
R1G = R2G = 2250.00 N
This load is considered on the bracket design due to GRU fixing.
Glass replacement unit Member design.

Glass replacement member design is based on the values to calculate minimum Ixx & Zxx values from
bending and deflection calculations.
The maximum length of system is considered as the maximum bracket support distance.
Maximum length of member = BKTmax 2000 mm
Maximum deflection limitation = δmax= L/350
Maximum deflection limitation = δmax= 5.71 mm
Design Calculations
Maximum bending stress = σmax = 166.67 MPa From LC1

Bending stress = σmax = W*L/4*Zxx
Zxx = 1.25*W*L/4*σmax
Zxx min = 8437.50 mm3
Maximum deflection = δmax= WL^3 / 48EIxx

Ixx = 1.25WL^3 / 48Eδmax
Ixx = 398209.95 mm4
Hence the minimum properties of the section for GRU unit is as follows
Moment of Inertia Ixx = 398209.95 mm4
Section Modulus Zxx min = 8437.50 mm3
From the standard pipe section as per BS EN 10210-2

following are the dimensions of the pipe section
Outside diameter - OD - 88.90 mm
Thickness - Thk - 4.50 mm
Moment of Inertia Ixx = 105.54 cm4
Section Modulus Zxx = 23.74 cm3
Calculating bending stress for the 3 load cases as above

LC-1 LC-2 LC-3
Bending stress = σmax = 1.25W*L/4*Z xx
1.5W*L/4*Z xx
2.5W*L/4*Zxx
Bending stress = σmax = 59.24 71.08 118.47
Comparing with permissible value of stress = Pass Pass Pass
Actual Maximum deflection = δmax= WL^3 / 48EIxx

δmax= 1.72 mm
Pass
Design Calculations
Design Calculations

Load on bracket calculations
The two man power cradle is suspended on two rollers. These rollers are attached to track system and
move on the track system.
The total load of cradle is equally distributed on two rollers. The maximum load on each bracket is
calculated based on maximum shear load condition.
Free body diagram for track & cradle load system
RB1 RB2
BKTmax
CCTC
WLL
Total suspended load = WLL 850 Kg

Load on each suspension point of roller =0.5*WLL 425.00 Kg
Maximum distance between bracket BKTmax 2000 mm

Hanging centre of cradle CCTC 2185 mm
0.5*WLL
Maximum load on each bracket = +(0.5∗𝑊𝐿𝐿∗(𝐵𝐾𝑇𝑚𝑎𝑥−𝐶𝐶𝑇𝐶))/𝐵𝐾𝑇𝑚𝑎𝑥
Maximum load on each bracket = Rbmax = 385.69 Kg

Rbmax = 3856.88 N
This load is taken at the track suspension point with bracket for design of bracket system.
Design Calculations

Holding Down unit calculations
Hexagonal headed M16* 180 long bolts are casted in-situ for fixing the bracket on parapet wall. The
design of HDU [holding down unit] is based on maximum bracket length used for project.
Each HDU comprises of two bolts which are separated by plates for ease of erection purpose.
The material of the holding down unit bolt is A2-70 grade, austenitic steel, cold worked, minimum 700MPa
tensile strength. 400
Free Body diagram of load for HDU / anchor

250
-25 425
R1G Rbmax
The maximum load on the HDU will be combined load condition due to glass replacement unit and load
due to the cradle suspension at front.
The top bolts of anchors / HDU will be under tensile load and bottom bolts of anchor will be under
compression load conditions. The vertical distance between top and bottom bolts will be moment arm.
Number of bolts in holding down unit Nb = 2.00 No
Gross Diameter of bolt Bdia = 16.00 mm
Maximum length of bracket BLmax 400 mm
orking load Distance between top & bottom bolt CTC BCTC 250 mm
Load on front due to cradle suspension Rbmax = 3856.88 N
Load on bracket due to GRU = R1G 2250.00 N
Shear load on the bolt = ζb = =R1G + Rbmax
Shear load on the bolt = Rshear = 6106.88 N
this is the shear load acting on the bolt in combination with tensile load due to moment
Moment reaction acting on centre of anchors = Manc = Moment due to GRU +
Moment due to Cradle Load
Manc = =R1G*(BLmax - BGRU) + Rbmax*BLmax
Manc = 1486500.00 N-mm
Tensile reaction on the top anchors / HDU = Ranc = 1.25 *Manc / BCTC
Ranc = 7432.50 N
Net Tensile diameter of bolt = 0.85*B dia = Btens = 13.6 mm
Tensile area for bolt = Bta = =PI* Btens^2 / 4
Tensile area for bolt = Bta = 145.27 mm2

Permissible tensile strength of bolt σE = 450 MPa
√( 〖𝑅𝑠ℎ𝑒𝑎𝑟 〗 ^2+ 〖𝑅
𝑎𝑛𝑐〗 ^2 )
Design Calculations

√( 〖𝑅𝑠ℎ𝑒𝑎𝑟〗 ^2+ 〖𝑅
𝑎𝑛𝑐〗 ^2 )
Combined load acting due to shear & tensile on bolt = Rbolt -T =
Rbolt -T = 9619.56 N
The above load is taken by two bolts.
Tensile stress acting on single bolt = σT = Rbolt -T / Bta* Nb
σT = 33.11 MPa
Factor of safety for bolts = Cwr = σEB / σT =
13.59
As per EN1808:1999, clause 6.5.3.4, the anchor/ bolt is safe for the given load condition.
Face mounted Bracket Member size & Design Calculations

The brackets are designed for the maximum length to be used in the project. The face mounted brackets
are made of MS plates with welded construction. The plates are checked for bending stress and bolts
used for connection between track and bracket is checked for tensile load.
400
the bracket is basically divided in 3 parts Pl
at
Plate - A - front plate e
C
250 Plate B
Plate B - Vertical plate
Plate C - Base Plate
P-A
-25 425
Design of Plate A R1G Rbmax

The load on plate A is due to cradle Load R bmax. This load is trasferred from track by means of hex bolts.
Dimension of Plate A
Plate width = PAW = 100.00 mm
Plate length = PAL = 250.00 mm
Plate thickness PAT = 12.00 mm
Number of bolts for fixing track = PANB = 2.00 No
Gross Bolt Diameter = PABD = 16.00 mm
Distance between bolt CTC = PABCTC = 180.00 mm
Load on front due to cradle suspension Rbmax 3856.88 N
250 100
12
180
Section modulus of plate = ZXXP = PAw* PAT2 / 6
Section modulus of plate = ZXXP = 2400.00 mm3

Since the load on the member is taken by two bolts, the load on each bolt =
Load on each bolt = RbA = 1928.44 N
Moment at the centre of plate = MPA = RbA * (0.5*PABCTC)
Design Calculations

Moment at the centre of plate = MPA = 173559.38 N-mm
Cheking the bending stress for the plate

LC-1 LC-2 LC-3
Bending stress = σmax = 1.25MPA/*ZxxP 1.5MPA/*ZxxP 2,5MPA/*ZxxP

Hence the plate is safe for the given load.
Welding Check for Plate A

Plate A is welded to plate B by using fillet weld. All the welding is done in factory.
Minimum weld size = 5.00 mm
Permissible stress in fillet weld = fwd = fwn/γmw
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3)
Ultimate strength of parent material = fu = 410 MPa
fwn = 236.71 MPa
189.37 MPa
Effective Weld length = PAW * 2 = 200.00 mm
Weld area = PAAW = = 0.707*Weld size * weld length
Weld area = PAAW = 707.00 mm2
Welding stress for plate A with load = σw = 1.25 *Rbmax / PAAW
Welding stress for plate A with load = σw = 6.82 MPa

Factor of safety for fillet welding = fe / σw = 27.77
Pass
Hence the weld is safe for the given load.
Bolt Check between Plate A & track

The track is connected with bracket by using two hexagonal headed bolts of M16*50mm.
Bolt grade is A2-70, stainless steel 304 material.
Net Tensile diameter of bolt = 0.85*B dia = Btens = 13.6 mm

Tensile area for bolt = Bta = =PI* Btens^2 / 4

Considering the load acting on bracket taken by single bolt only,

Tensile stress acting on single bolt = σT = Rbmax / Bta
σT = 26.55 MPa
16.95
Design Calculations

Design Calculations

Design of Plate B
Plate B is a vertical plate with hole in between for fixing of glass changing unit.
Dimension of Plate B
Plate width = PBW = 200.00 mm
Plate length = PBL = 700.00 mm
Plate thickness PBT = 12.00 mm
Distance from front for GRU hole BGRU 425 mm
GRU Hole Diameter = PBBD = 92.9 mm
B A
Free body digram for plate B
200 Plate -B
B 275 12
A 700
R1G Rbmax
The bracket is analysed at two different locations. First at section A-A to check at location of hole in plate
and second at the base of the section at B-B
Member check at Section A-A = [shear load due to GRU] + [Bending due to cradle load]
Member check at Section B-B = [Bending due to GRU load]+ [Bending due to cradle load]
Analysis at Section A-A
Minimum area of plate at A-A with hole = APBmin = [PBW - PBBD] * PBT
APBmin = 1285.20 mm2
Section modulus of plate at A-A = ZXX A-A = PBT* (PBTW - PBBD)2 / 6
Section modulus of plate at A-A = ZXX A-A = 22940.82 mm3

Bending Moment due to cradle load at A-A = MPA-A = 1639171.88 N-mm
LC-1 LC-2 LC-3

Bending stress due to cradle load = σmax = 1.25MPA/*ZxxP 1.5MPA/*ZxxP 2,5MPA/*ZxxP
Bending stress = σmax =

89.32 107.18 178.63
Direct shear Stress due to GRU load = ζGRU = 1.25R1G/APBmin 1.5R1G/APBmin 2.5R1G/APBmin
Direct shear Stress due to GRU load = ζGRU = 2.19 2.63 4.38
Combined stress at section A-A = σa-a = 91.50 109.80 183.01
Design Calculations

Analysis at section B- B
Section modulus of plate at B-B = ZXX B-B = PBT* (PBTW )2 / 6
Section modulus of plate at B-B = ZXX B-B = 80000.00 mm3

Bending Moment due to cradle load at B-B = MPC B-B = =Rbmax*PBL
2699812.50 N-mm
Bending Moment due to GRU load at B-B = MPG B-B = =R1G*( PBL-BGRU )
618750.00 N-mm
Total Bending Moment at B-B = M T B-B = = MPC B-B + MPG B-B
Total Bending Moment at B-B = M T B-B = 3318562.50 N-mm
LC-1 LC-2 LC-3

Bending stress = σmax = 1.25MTB/*ZxxB 1.5MTB/*ZxxB 2.5MTB/*ZxxB

Welding Check for Plate B
Plate B is welded to plate B by using fillet weld. All the welding is done in factory.
Welding is checked for the moment load due to cradle & GRU. The moment of inertia is calculated for
welding. There are two rows of weld on either side of plate.
Minimum weld size = Ws 6.00 mm

Throat thickness of weld = Wbs = 0.707*Ws
Wbs = 4.24 mm 200
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3) 4.24
fwn = 236.71 MPa
Permissible stress in fillet weld = fwd = 189.37 MPa
Equivalent Weld length = PBW = 200.00 mm

Section modulus of weld at B-B = ZXX W = WS* (PBW )2 / 6
ZXX W = 28280.00 mm3
Since the welding is there on both sides of plates, the total section modulus of welding is
Section modulus of weld at B-B = ZXX TW = = ZXX W *2
Section modulus of weld at B-B = ZXX TW = 56560.00 mm3
Bending Stress in weld at B-B = σw = 1.25* MT B-B / Z xx TW

Bending Stress in weld at B-B = σw = 73.34 MPa
Shear Stress on weld at B-B = = ζwd = =(Rbmax+ R1G)/(throat thick*length)
Shear Stress on weld at B-B = = ζwd = 3.60 MPa
Design Calculations
Combined Shear & bending stress in weld = fe = = sqrt(σW2 +3* ζwd2)

Combined Shear & bending stress in weld = fe = 73.61 MPa
Factor of safety of weld at B-B = FOS = fwd / fe

FOS = 2.57
Pass
Hence the welding of plate B is okay !!
Design of Base Plate - Plate C
Plate C is a base plate with hole for fixing anchors / HDU. The moment load due to cradle and GRU is
acting at the centre of plate.
Dimension of Plate C
Plate width = PCW = 310.00 mm
Plate length = PCL = 350.00 mm
Plate thickness PCT = 16.00 mm
Distance between top & bottom bolt CTC BCTC 250 mm
Edge distance between top plate and hole = PCED = 50 mm
Total Moment acting on plate C = M T B-B = 3318562.50 N-mm
310
350
16
Maximum tension at top HDU of plate= PCT = M T B-B / BCTC
Maximum tension at top HDU of plate= PCT = 13274.25 N
Bending moment in the plate = MCT = =tension * edge distance

= PCT * PCED
Bending moment in the plate = MCT = 663712.50 N-mm

Section modulus of top of plate = ZXXP-T = PCw* PCT2 / 6
Section modulus of top of plate = ZXXP-T = 13226.67 mm3
Checking the bending stress for the plate

LC-1 LC-2 LC-3
Design Calculations

Face mounted Bracket Member size & Design Calculations- II
This bracket is the second bracket to be used in the project. The face mounted brackets
1100
the bracket is basically divided in 3 parts Pl
at
Plate - A - front plate e
250C Plate B
Plate C - Base Plate
P-A
675 425
R1G Rbmax
Maximum length of bracket BLmax 1,100.00 mm
Distance between top & bottom bolt CTC BCTC 250.00 mm
Distance of GRU fixing from track suspension point BGRU 425 mm
Design of Plate A
The load on plate A is due to cradle Load R bmax. This load is trasferred from track by means of hex bolts.
250 100
12
180

Since the load on the member is taken by two bolts, the load on each bolt =

LC-1 LC-2 LC-3
Design Calculations

[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3)
fwn = 236.71 MPa
189.37 MPa

Net Tensile diameter of bolt = 0.85*Bdia = Btens = 13.6 mm

2
Tensile area for bolt = Bta = =PI* Btens^ / 4

σT = 26.55 MPa
16.95
Design Calculations
Design of Plate B
Plate B is a vertical plate with hole in between for fixing of glass changing unit.
Plate length = PBL = 1,100.00 mm
Plate thickness PBT = 12.00 mm
Distance from front for GRU hole BGRU 425 mm
GRU Hole Diameter = PBBD = 92.9 mm
B A
200 Plate -B
B 675 12
A 1100
R1G Rbmax
The bracket is analysed at two different locations. First at section A-A to check at location of hole in plate
and second at the base of the section at B-B
Member check at Section A-A = [shear load due to GRU] + [Bending due to cradle load]
Member check at Section B-B = [Bending due to GRU load]+ [Bending due to cradle load]
Analysis at Section A-A
Minimum area of plate at A-A with hole = APBmin = [PBW - PBBD] * PBT
APBmin = 1285.20 mm2
Section modulus of plate at A-A = ZXX A-A = PBT* (PBTW - PBBD)2 / 6
Section modulus of plate at A-A = ZXX A-A = 22940.82 mm3

Bending Moment due to cradle load at A-A = MPA-A = 1639171.88 N-mm
LC-1 LC-2 LC-3

Bending stress due to cradle load = σmax = 1.25MPA/*ZxxP 1.5MPA/*ZxxP 2,5MPA/*ZxxP
Direct shear Stress due to GRU load = ζGRU = 1.25R 1G
/APB min
1.5R 1G
/APB min
2.5R 1G
/APBmin
Direct shear Stress due to GRU load = ζGRU = 2.19 2.63 4.38
Combined stress at section A-A = σa-a = 91.50 109.80 183.01
Design Calculations

Bending Moment due to cradle load at B-B = MPC B-B = =Rbmax*PBL
4242562.50 N-mm
Bending Moment due to GRU load at B-B = MPG B-B = =R1G*( PBL-BGRU )
1518750.00 N-mm
Total Bending Moment at B-B = M T B-B = = MPC B-B + MPG B-B

LC-1 LC-2 LC-3


Plate B is welded to plate B by using fillet weld. All the welding is done in factory.
Welding is checked for the moment load due to cradle & GRU. The moment of inertia is calculated for
Minimum weld size = Ws 6.00 mm

Wbs = 4.24 mm 200
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = 236.71 MPa

ZXX W = 28280.00 mm3

Shear Stress on weld at B-B = = ζwd = =(Rbmax+ R1G)/(throat thick*length)
Design Calculations

Shear Stress on weld at B-B = = ζwd = 3.60 MPa
Design Calculations

Combined Shear & bending stress in weld = fe = = sqrt(σW2 +3* ζwd2)

FOS = 1.49
Pass
Design Calculations

Plate C is a base plate with hole for fixing anchors / HDU. The moment load due to cradle and GRU is
Plate thickness PCT = 16.00 mm
Distance between top & bottom bolt CTC BCTC 250 mm
Total Moment acting on plate C = M T B-B = 5761312.50 N-mm
taken from Plate B design - Total moment acting on plate B
350
350
16
Maximum tension at top HDU of plate= PCT = M T B-B / BCTC
Maximum tension at top HDU of plate= PCT = 23045.25 N

= PCT * PCED
Bending moment in the plate = MCT = 1152262.50 N-mm

Section modulus of top of plate = ZXXP-T = 14933.33 mm3

LC-1 LC-2 LC-3
Worli Mixed Use Project - PS17/E - BMU
Cradle Runways (India) Pvt. Ltd

Calculation of Wire Rope
Date: #REF! Project No #REF!
Initials RKS Region Mumbai
(A) Wire rope calculations

Material :- M. S. Galvanized
Construction :- 6*19, Preformed
8.3mm nominal diameter wire rope is used for suspension of cradle
The cradle is supported by 4 No of wire rope
From the test certificates enclosed for wire rope,
Minimum Break load = 40.5 kN
Total Suspended load = 740 Kg
As per BS EN1808:1999+A1:2010, clause 6.6.2, for platform mounted hoist,

Force S = WLL
Nr
Where, WLL = Rated load of hoist = 500 Kg
Nr = Number of steel wire ropes = 2
used in that hoist
S= 250
Co-efficent Zp for steel wire rope as per BS EN1808:1999+A1:2010, clause 6.6.1

Zp = Fo
S
Where, Fo = Minimum guarenteed breaking load of wire rope
S= Maximum static force in the wire rope
Fo = 40.5 kN
S= 250 Kg
Zp = 16.2
For single active rope suspension system, Zp shoul be equal to or greater than 8
Since, 16.2 > 8,
Wire rope is safe for use and satisfies the BS EN1808:1999+A1:2010 condition.
492979148.xlsx
Prepared By SK Prep Date 14-Jan-16
Checked By SJ Rev 0
Approved By ADK Rev Date 14-Jan-16
Project - EMBASSY LAKE TERRACES

Project No - C4406PBL
Aim
Calculate the size of face mounted bracket (800mm OR )used to install Aluminum C130 track
Reference Shop Drawing
Reference Code
Material Specification
Grade = A2
Property Class = 70.00
Tensile strength σ RB
= 700.00 MPa

Density of Aluminum ρ= 2,710.00 Kg/M3
Modulus of elasticity E= 70,000.00 MPa

Data
Rated load of cradle = RL 180.00 Kg Safe Working load
Dead weight of cradle including hoist, wire rope = SWP 545.60 Kg
Total Suspened Load - RL + SWP = WLL 7256.00 N
Building Height = HB = 85.00 Mt
Maximum distance between bracket = BKTmax = 2,000.00 mm
Maximum length of bracket = BLmax = 800.00 mm
Distance between top & bottom bolt CTC = BCTC = 200.00 mm
Hanging centre of cradle = CCTC = 1,700.00 mm
Partial Factory of safety for materials - Shop weld = γmw = 1.25 From IS800:2007 table 5
Partial Factory of safety for materials - field weld = γmw = 1.50 From IS800:2007 table 5
The monorail with Face mounted bracket are installed at Level-11 & Level-22 (below Helipad).
The façade is accessed by using two man cradle.
condition.
Considering the law of super position for the beams,
The beam is suppoted at two points
Case-I RB1 RB2
2000
Taking Moment about RB2,
MRB1 = 0
1700
3628 3628
RB1 = 3628.00 N
RB1 RB2
Case-II 2000
MRB1 = 0
1700
3628 3628
RB1 = 4172.20 N
Maximum Load on the bracket (RB1 )= Rb max = 4172.20 N

The load Rb is the maximum load acting on the bracket. Hence, every bracket is designed for Rbmax. = 4172.20
800
the bracket is basically divided in 3 parts
Plate - A - front plate
200 Plate B
Plate C - Base Plate Plate A
P-A
Plate C Pd
Design of Plate A
The load on plate A is due to Spiderman design Load Pd. This load is trasferred from track by means of hex bolts.
Load on front due to cradle suspension = Rbmax = 4172.20 N
250 110
12
180
Rbmax
Since the load on the member is taken by two bolts, the load on each bolt is,

LC-1 LC-2 LC-3
Bending stress = σmax = 1.25M PA
/*Z xxP
1.5M PA
/*ZxxP 2,5MPA/*ZxxP

[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3)
fwn = 236.71 MPa
189.37 MPa


2

Permissible tensile strength of bolt = σE = 450 MPa

σT = 28.72 MPa
15.67 MPa
Design of Plate B
Plate B is a vertical plate welded from front plate at one end & base plate on the other end.
Plate thickness = PBT = 12.00 mm
Maximum Load = Rb max = 4172.20 N
B
150 Plate -B
B 12
800
Pd
The bracket is analysed at at the base of the section at B-B
Member check at Section B-B =[Bending due to Cradle load]

Bending Moment due to Cradle load at B-B = MPC B-B = =Pd*PBL
3337760.00 N-mm
Total Bending Moment at B-B = M T B-B = = MPC B-B
Bending stress = σmax = MTB/*ZxxB = 74.17 MPa
LC-1 LC-2 LC-3

Plate B is welded to plate C by using fillet weld. All the welding is done in factory.
Welding is checked for the moment load due to Cradle load. The moment of inertia is calculated for
welding around the plate.
Minimum weld size = Ws = 6.00 mm

Wbs = 4.24 mm 150
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3) 12
fwn = 236.71 MPa

Section modulus of weld at B-B = ZXX W = Wbs* [ (PBw * PBT)+ PBW 2 / 3]
ZXX W = 39450.60 mm3
Bending Stress in weld at B-B = σw = 1.25* MT B-B / Z xx W

Shear Stress on weld at B-B = ζwd = Pd/(throat thick*length)

Shear Stress on weld at B-B = ζwd = 3.28 MPa
Combined Shear & bending stress in weld = fe = sqrt(σW2 +3* ζwd2)
FOS = 1.79
Pass


Plate C is a base plate with hole for fixing anchors / HDU. The moment load due to cradle is
Plate thickness = PCT = 16.00 mm
Distance between top & bottom bolt CTC BCTC = 200.00 mm
Edge distance between top plate and hole = PCED = 62.5 mm
Total Moment acting on plate C = M T B-B = Rbmax * BLmax
M T B-B = 3337760.00 N-mm
250
325
16
Maximum tension at top anchor of plate = Tmax. = M T B-B / BCTC

Maximum tension at top anchor of plate = Tmax. = 16688.80 N

= Tmax. * PCED
1043050.00 N-mm
ZXXP-T = 10666.67 mm3
LC-1 LC-2 LC-3
Fixing Anchor/Bolt Calculations
The design of Anchor/Bolt is based on maximum bracket length used for project.
Face Mounted Brackets are fixed with the concrete structure using 4 No. M16 chemically grouted threaded rod.
Fischer chemical is used for grouting threaded rods.
The top anchor bolts will be under tensile load and bottom bolts of anchor will be under compression load.
The vertical distance between top and bottom bolts will be moment arm.
Anchor grade is A2-70, stainless steel 304 material. 800
Free Body diagram of load for Anchor/Bolt,
200
Rbmax
Number of Anchor = Nb = 4.00 No

Gross Diameter of bolt = Bdia = 16.00 mm
Maximum load acting on top / bottom anchors = Tmax = Rbmax* BL max /BCTC
Tmax = 16688.80 N (Un-factored load)
This is maximum load acting on top anchors as a tensile load & on bottom anchors as a compressive load.
Maximum load acting on each anchor = Tmax/2=Tmax-E = 8.34 kN (Un-factored load)
Please refer attached sheet showing Fischer - Chemical anchor calculations as per the given loading details.
Checked By SJ Rev 0

Aim
Calculate the size of face mounted bracket used to install Aluminum C130 track

1
2
3
4
5
Reference Code
Grade = A2
= 700.00 MPa


Data
condition.
Case-I RB1 RB2
2000
MRB1 = 0
1700
3628 3628
RB1 = 3628.00 N
RB1 RB2
Case-II 2000
MRB1 = 0
1700
3628 3628
RB1 = 4172.20 N

800
250 Plate B
P-A
Plate C Pd
Design of Plate A
250 110
12
180
Rbmax

LC-1 LC-2 LC-3

[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3)
fwn = 236.71 MPa
189.37 MPa


2


σT = 28.72 MPa
15.67 MPa
Design of Plate B
B
180 Plate -B
B 10
800
Pd
Member check at Section B-B =[Bending due to Spiderman load]

Bending Moment due to Spiderman load at B-B = MPC B-B = =Pd*PBL
3337760.00 N-mm
LC-1 LC-2 LC-3

Welding is checked for the moment load due to Spiderman load. The moment of inertia is calculated for

Wbs = 4.24 mm 180
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = 236.71 MPa

ZXX W = 22906.80 mm3

FOS = 2.08
Pass


M T B-B = 3337760.00 N-mm
300
350
12


= Tmax. * PCED
667552.00 N-mm
ZXXP-T = 7200.00 mm3
LC-1 LC-2 LC-3
Anchor grade is A2-70, stainless steel 304 material. 800
250
Rbmax

Maximum load acting on each anchor = Tmax/2=Tmax-E = 6675.52 N (Un-factored load)
As per fischer specification,recommended load carrying capacity for treaded rod with RM 16 capsule is as follows.
Please refer attached sheet showing loading details.
σanchor = 19.80 kN
Factor of Safety = FOS = 2.97

Hence, anchor is safe for given loading conditions.
Checked By SJ Rev 0

Aim
Calculate the size of face mounted bracket used to install Aluminum C130 track

1
2
3
4
5
Reference Code
Grade = A2
= 700.00 MPa


Data
Maximum length of bracket = BLmax = 1,000.00 mm
condition.
Case-I RB1 RB2
2000
MRB1 = 0
1700
3628 3628
RB1 = 3628.00 N
RB1 RB2
Case-II 2000
MRB1 = 0
1700
3628 3628
RB1 = 4172.20 N

1000
250 Plate B
P-A
Plate C Pd
Design of Plate A
250 110
12
180
Rbmax

LC-1 LC-2 LC-3

[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3)
fwn = 236.71 MPa
189.37 MPa


2


σT = 28.72 MPa
15.67 MPa
Design of Plate B
Plate length = PBL = 1,000.00 mm
B
200 Plate -B
B 10
1000
Pd
Member check at Section B-B =[Bending due to Spiderman load]

Bending Moment due to Spiderman load at B-B = MPC B-B = =Pd*PBL
4172200.00 N-mm
LC-1 LC-2 LC-3

Welding is checked for the moment load due to Spiderman load. The moment of inertia is calculated for

Wbs = 4.24 mm 200
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = 236.71 MPa

ZXX W = 28280.00 mm3

FOS = 2.05
Pass


M T B-B = 4172200.00 N-mm
300
350
16


= Tmax. * PCED
834440.00 N-mm
ZXXP-T = 12800.00 mm3
LC-1 LC-2 LC-3
Anchor grade is A2-70, stainless steel 304 material. 1,000
250
Rbmax

Maximum length of bracket = BLmax = 1,000.00 mm
Maximum load acting on each anchor = Tmax/2=Tmax-E = 8344.40 N (Un-factored load)
As per fischer specification,recommended load carrying capacity for treaded rod with RM 16 capsule is as follows.
Please refer attached sheet showing loading details.
σanchor = 19.80 kN
Factor of Safety = FOS = 2.37

Hence, anchor is safe for given loading conditions.
Extension Bracket bolted to the Face Mounted Bracket-
Due to variation in the RCC beam level between the buildings/blocks joints, extension brackets are designed
for maintaining the track level at FL-11.
Extension brackets are bolted to the face mounted brackets using 2No. M16 hex. Bolts.
Brackets are made of MS plates, SHS with welded construction. The plates are checked for bending stress and
bolts used for connection between track and bracket is checked for tensile strength criteria.
P-A Plate C
P-A
Plate A Part B -SHS

P-A
Rbmax
Design Calculations for Member Size -
Design of Plate-A
The Rbmax is the maximum load acting on the bracket.
Dimension of Plate A Plate A
Plate thickness = PAT = 12.00 mm
Load on front due to cradle suspension = Rbmax = #REF! N
250 100
12
180
Rbmax

Since the load on the member is taken by two bolts, the load on each bolt
Load on each bolt = RbA = #REF! N
Moment at the centre of plate = MPA = #REF! N-mm
LC-1 LC-2 LC-3
Bending stress = σmax = #REF! #REF! #REF!
Comparing with permissible value of stress = #REF! #REF! #REF!
Checking for tension capacity of plate A

The plate size, used for connection between bracket & C130 track.
Min. plate size = wxt= 1200.00 mm2
Net plate size(Area) (After bolt deduction)= A= 768.00 mm2
The load acting on the bracket = R bmax = #REF! N
Consider load cases based on EN1808-2015, table 13.

Load Case-1 Load Case-2 Load Case-3
Force(N) F1=1.25*Rbmax F2=1.5*Rbmax F3 =2.5*Rbmax
#REF! #REF! #REF!
Tensile stress = F/A F1/A F2/A F3/A
2
Actual Stress (N/mm ) = #REF! #REF! #REF!
As the actual tensile stress calculated above is less than allowable tensile stress(A) , therefore system
is safe for the given load condition.
(Note : The same size plate is used as plate-C, hence plate-C is also considered as safe as per the given
loading conditions.
Part B Checking for SHS 80x80x4.8 thk.under tension.

SHS 80x80x4.8 thk is welded on one side to the plate A and other side it is welded to plate C.
Properties of SHS 80x80x4.8 thk.
Cross sectional area of tube = 1,385.00 mm2
Table 1 Reference IS 4923 : 1997
Consider load cases based on EN1808:2015, table 13.

Force(N) F1 =1.25*Rbmax F2 =1.5*Rbmax F3 = 2.5*Rbmax
#REF! #REF! #REF!
Tensile stress = F/A F1/A F2/A F2/A
Actual Stress (N/mm2) #REF! #REF! #REF!
Actual stress is less than allowable stress (A), hence the sq. tube is safe.
Bolt Check between Plate A & C130 track
The plate A is connected with the track by using two square headed bolts of M16*50mm.
Refer the same calculation for M16 bolt between plate -A of face mounted bracket & extension bracket
as calculated above.
Welding Check for Plate A/Plate C and SHS -

Plate A is welded to the SHS from one & plate C is welded from the other end by using fillet weld all round.
All the welding is done in factory.
Permissible stress in fillet weld = fwd = #REF! MPa
SHS size = 80.00 mm

Effective Weld length = 4*L= 320.00 mm
Welding stress for plate A with load = σw = 1.25 *(Rbmax) / PAAW )
Welding stress for plate A with load = σw = #REF! MPa
Factor of safety for fillet welding = fe / σw = #REF!
Hence,the weld is safe for the given load.
The same welding is followed on other side of SHS i.e to weld SHS and plate C
therefore the welding in that case is also safe.
CLIENT - : BRAMHA BUILDER
PROJECT ARCHITECT : REZA KABUL
FAÇADE CONSULTANT : JW CONSULTANTS LLP
PROJECT : SKY UZURI, Proposed Bldg At PIMPRI, PUNE
BMU VENDOR : LEOFAB
CALCULATIONS FOR BRACKET OF MONORAIL.
A AIM:
To calculate the size of the face Mounted bracket used to install ISMB Track for façade access.
These tracks are installed at terrace level for rigging and de-rigging process.
B Material Specification
Acceleration due to gravity= g= 9.81 m/s^2
Partial Factory of safety for materials - Shop weld γmw = 1.25 From IS800:2007 table 5
Partial Factory of safety for materials - field weld γmw = 1.50 From IS800:2007 table 5
Partial Factory of safety for materials γm = 1.10 From IS800:2007 table 5
As per IS 800:2007, clause 2.2.4.1
Upto 20 mm thick plates; Table 2 Mechanical properties IS 2062:2011

Material Properties E250
Density of steel ρ= 7850 Kg/m^3
Modulus of elasticity E= 200000 MPa
Tensile strength σTp = 410 MPa
Yield Strength σYp = 250 MPa
Allowable stress σap = σap = σy/ γm 227 MPa
Ratio of Yield to Tensile Strength σYp / σTp 0.6
Since ratio is less than 0,7, the factors are by Table 2
As per EN1808:2015, the maximum allowable stress σa is defined by table 2 for Mild steel.
52 of 62
Material properties for SHS & RHS, as per Tata brochure (IS 4923:1997)
Material Properties Yst 240
Density of steel ρ= 7850 Kg/m^3
Modulus of elasticity E= 200000 MPa
Tensile strength σTh = 410 MPa
0.2% Yield Strength σYh = 240 MPa
Allowable stress σap = σah =σyh/ γm 218 MPa
Bolts, screw and Studs : BS EN ISO 3506-1:2009

Grade & Property class A4-70
Tensile strength σRB = 700 MPa
Proof Stress at 0.2% permanent strain σEB = 450 MPa
Allowable stress= σab = σEB / γm 409 MPa
C REFERENCE STANDARDS VALUES FOR CALCULATIONS

As per EN1808:2015, the maximum allowable stress σa is defined by table 2
Value of safety factor VE 1.5 1.33 1.1
Allowable stress of SHS/RHS material = σa = 160.00 MPa 180.45 MPa 218.18 MPa
Allowable stress for plate = = σaplate = 166.67 MPa 187.97 MPa 227.27 MPa
The system that is being used is single man power cradle
Hence the maximum load that is considered is rated load of the winches.
Total maximum load on the track is the maximum winch capacity of the cradle.
53 of 62
Rated load of std cradle = RL = 250.00 Kg Safe Working load
Dead load of 2M 2 man cradle= SWP = 400.00 Kg
Working Height (maximum rope length)= H= 40.00 Mt
Weight of wire rope+electrical cable= Mwr + Mc= 51.60 Kg
Total Suspended Load = RL + SWP = TSL = 702.00 Kg
Total Suspended Load = RL + SWP = TSL = 6886.62 N
Work load limit [max rated load of each hoist] = WLL= 4,000.00 N
Cradle Winch C/C= Cw= 2,000.00 mm
Minimum CTC of rollers Cwmin = 500.00 mm
Load eccentricity= Lo= 0.00 mm
Self weight of manual ISMB trolley= SWRM= 30.00 Kg
Unit weight of ISMB track= ISMB 5.85 Kg/mt
Self weight of track= SWRT= 12.00 Kg
Weld size= Ws= 6.00 mm
D DESIGN CALCULATIONS
The monorail with face munted brakets are installed on terrace level. Considering the worst case is when load
is acting at the suspension point of cradle is directly below the cradle.
Based on table -13 of EN1808:2015, the factor for load case is expressed as
D1 Loading conditions -1
Bracket position and abseiling supsension point
The bracket is being designed based on the EN1808. There are three load cases with various factor of safety.
Bkt-1 Bkt-2 Bkt-3

2000 mm 2000 mm
Rollers
2,000.00
WLL WLL
54 of 62
Load description based on table 13 Case 1 Case II Case III
rk load limit [max rated load of each hoist] = WLL= 4000 N 1.25 1.5 2.5 1.25
Self weight of track= SWRT= 12 Kg 1 1 1
Self weight of manual ISMB trolley= SWRM= 30 Kg 1.25 1 1
Horizontal Force 0.1 0 0
WLL [N] 5000 6000 10000

Weight of Monorail [N] 117.72 117.72 117.72
Weight of Trolley [x1] [N] 367.875 294.3 294.3
For rollers with position -1
Total Vertical Force [N] 5486.00 N 6413.00 N 10413.00 N
Rollers
Second case of the trolley at equidistance from both the brackets is not considered due to fact that load
will be divided between the two brackets.
The maximum forces from the single roller conditions are used for the bracket analysis. Hence the summary of
forces which are used for loading conditions are given below.
Total Vertical Force [N] 5486.00 N 6413.00 N 10413.00 N
Horizontal Force [N] 400.00 N 0.00 N 0.00 N

E PLATE DIMENSIONS
E1 Connection plate
Dimensions of Connection plate
Plate thickness = PAT = 12.00 mm
Hole dimension for bolting PAHole = 14.00 mm
Tensile area of M12 hexagonal/bolt Bta= 84.3 mm2
E2 Baseplate
Dimensions of base plate
Number of bolts for fixing track = PCNB = 2.00 No
Gross Bolt Diameter = PCBD = 16.00 mm
Lateral CTC distance between bolt= PCvCTC = 200.00 mm
Longitudinal CTC distance between bolt= PChCTC = 200.00 mm
E3 Mid Plate
Dimensions of Mid plate
Maximum bracket length PCNB = 550.00 No
F Calculation:-
F.1 Design calculation for Plate- A
vertical load acting on the plate is considered for bending stress on plate and horizontal force considered is
acting as a shear load on the area. The area considered for shear is minimum area of plate after deducting the hole dimensions.
55 of 62
Horizontal load acting on the plate for shear load.
Hor. Load 400.00 N

Thk = 12
180
For Horizontal load, as per table 12, is only for Load case 1
F1.1 Checking the plate for Shear Stress
Shear Area of plate = PAars = ( Paw- PAHOLE)* PAT
= (100 - 14 )x 12
PAars = 1032.00 mm2
LC-1
Shear stress = σmax = Horz/PAars
400/ 1032
Shear stress = σmax [Mpa]= 0.39
Comparing with permissible value of stress = Pass
For vertical load as per table above,

F.1.2 Checking the plate for bending stress,
The total load acting on the track from roller is transferred through two bolts.
Modulus of the front plate Ixx-A =PAW *PAT^3/12 mm4
14400.00 mm4
Section modulus of the front plate Zxx-A = Ixx-A/(Paw/2)
2400.00 mm4
Maximum moment acting on plate = Vert*PA BCTC /4 246870.00 288585.00 468585.00 N-mm
Bending Stress on the plate = M/Zxx-A 102.86 MPa 120.24 MPa 195.24 MPa Mpa
Permissible Stress value from above 166.67 MPa 187.97 MPa 227.27 MPa
F.1.3 Checking Weld strength between Part A (Front plate) & Part D (SHS Tube)
Weld length
100
Plate A is welded to SHS tube all around. All welding is done in factory.
56 of 62
[As per IS 800:2007, clause 10.5.7,1,1]
fwn = fu/sqrt(3)
Ultimate strength of parent material = fu = 410.00 MPa
fwn = 236.71 MPa
189.37 MPa
Effective Weld length = HTB*2= 100.00 mm

Tensile stress is considered acting on the welds.
Welding stress for Part A with load = σw = L3/ PAAW
Welding stress for Part A with load = σw = 24.55 MPa
Factor of safety for fillet welding = fwd / σw = 7.71
Since top and bottom plates are both welded with same size of weld, Hence, the weld is safe for the given load.
F.1.4 Bolt Check between Part A & track

TheISMB is connected with bracket by using four hexagonal headed bolts of M12
Permissible tensile strength of bolt = σEB /γm = 409.09 MPa
Considering the load acting on bracket taken by one bolt only,

The Load case III is taken into consideration in order to determine tensile load carrying capacity of bolt
Tensile stress acting on single bolt = σT = F1/ Bta = 10413 / 84.3

σT = 123.52 MPa
Factor of safety for bolts = Cwr = σEB / σT
= 3.31
G Design of Mid plate

Dimension of Mid plate
Plate length PCvCTC = 540.00 mm
Bending load acting point - Moment load - 550.00 mm
Section modulus of plate 30000.00 mm3
Shear area of plate 1200.00 mm2
Moment load
150.00
Shear Load
550.00
57 of 62
8.00
540.00
Load Case-1 Load Case-2Load Case-3

Bending moment acting on plate = (Force* bracket length
Bending moment acting on plate 3017300.00N-mm 3527150.00N-mm 5727150.00N-mm
Bending stress in X axis = σPCA = BMA/ZxxPC BMB/ZxxPC BMC/ZxxPC
Bending stress in X axis = σPCA = 3017300 / 30000 3527150 / 30000 5727150 / 30000
Bending stress in X axis (Mpa)= σPCA = 100.58 117.57 190.91
Shear Stress = Load / Area 5486 / 1200 6413 / 1200 10413 / 1200
Shear Stress = Load / Area 4.57 MPa 5.34 MPa 8.68 MPa
Resultant Stress 100.89 MPa 117.94 MPa 191.50 MPa
H Design of Base plate

Base plate with hole is used for fixing bolts. The bending moment load due to the cleaning system is acting at the center
of plate.
Dimension of End plate
Lateral CTC distance between bolt= PCvCTC = 200.00 mm
Load eccentricity due to bolt CTC= Lo= 0.5*PCvCTC 100.00 mm
Area of plate= APC= =PCW*PCT 3600.00 mm2
Edge distance from hole center=PCED= (PCW-PCvCTC)/2 = 50.00 mm
Section modulus of Base plate C= Zxx PC= PCW*PC /6 =
T
2 7200.00 mm3
200.00
300.00
200.00
300
12
Bending stress on base plate due to loads= (Load*bracket dist/Bolt CTC)*Edge distance

Bending moment acting on plate = (L1*Lo/PCvCTC)*PCED
58 of 62
Bending moment acting on plate 754325 881787.5 1431787.5
Bending stress in X axis = σPCA = BMA/ZxxPC BMB/ZxxPC BMC/ZxxPC
Bending stress in X axis = σPCA = 754325 / 7200 881787.5 / 7200 1431787.5 / 7200
Bending stress in X axis (Mpa)= σPCA = 104.77 122.47 198.86
Maximum Shear stress due to load L3= σPCB=L3/A 2.89 Mpa
Actual stress due to load L3= σMax= Ö((σPCA^2)+(3.σPCB^2))

198.92 Mpa
I Anchor design
END OF CALCULATION
59 of 62
492979148.xlsx Page 60
CLIENT - : BRAMHA BUILDER

BMU VENDOR : LEOFAB
1. AIM:
To calculate the strength of ISMB 150 track used for façade access system.
2. INFORMATION:
Project Title SKY UZURI, Proposed Bldg At PIMPRI, PUNE
3. CROSS-REFERENCE STANDARDS:
1 EN1808:2015 - Safety requirement for suspended access equipments- Design calculations, stability
criteria, Construction. Examinations and test
7 BS EN 10210-2:2006 - Hot finished steel structural hollow sections. Tolerances, dimensions and sectional
properties.
8 BS EN ISO 3506-1:1998 Mechanical properties of corrosion resistant stainless steel fasteners - : Bolts,
screws, and studs
4. LOAD INFORMATION:
Description Value
Power Cradle (RL) - Safe working Load 250 Kg
Dead weight of cradle (SWP) 450 Kg
Weight of trolley (SWR) 30 Kg
Spacing of bracket (Bracket A and Bracket B) (L1) 2000 mm
Winch centre (L2) 2000 mm
Weight of track (ISMB) 15.00 Kg/M
Dead Weight of track (SWR2) = WISMB x L1 30.00 Kg
Total Suspended Load(TSL) = RL+SWP+SWR+SWR2 = 760.00 Kg
= 7600.00 N
Working Load Limit WLL = 4000.00 N
Based on IS : 800 - 2007, Table 6
Allowable deflection = L/240
= 8 mm
Spacing of bracket (maximum) (L1) = 2000 mm
Hanging centre of cradle (L2) = 2000 mm
Distance between track and bracket (Worst Case) - (a) = (2 *L1 - L2 ) /4
= 500.00 mm
Track Profile ISMB 150

Weight of track (WISMB) 15.00 Kg/M
Profile height 150 mm
Profile width 75 mm
Profile crossection 1910.00 mm^2
Moment of Inertia Ixx 7180000 mm^4

Moment of Inertia Iyy 468000 mm^4
492979148.xlsx Page 61
Sectional Moment Sxx 95733 mm^3

Sectional Moment Syy 12480 mm^3
Grade of steel track E250
Elastic Yeild Limit of track (ζ) 250 N/mm^2
Modulus of Elasticity (E) 200000 N/mm^2
In service conditions , access equipment with Rated load is affected by wind.

Horizontal force Fh considered is more than the wind load factor of 200Kpa
5. Service Condition (Load Case: 1)
Based on Table 8, BS EN1808 : 2015, load cases for trolley, Load case 1, factor of 1,25*WLL
Minimum allowable safety factor (S1)
As per BS EN1808 : 2015, Table 2, limiting stress factor for load case 1
Safety Coefficent compared to elastic yeild limit = 1.5
Maximum load on trolley (F ) =1.25*WLL
max V
= #REF!
Horizontal force (Fh) = 0.1 * WLL
= 400.00 N
Maximum Moment Vertical (Mb max V) = a*(2*Fmax V – ((Fmax V *a)+(Fmax V *(a+ L2))/ L1))
= #REF!
Maximum Moment Sideways (Mb max S) = a* (2*Fh- (Fh*a+Fh*(a+L2))/L1))
= 100000.00N-mm
Maximum Stress Vertical (σ v) = Mb max V / Sxx
= #REF!
Maximum Stress Horizontal (σ h) = Mb max S / Syy
= 8.01 N/mm^2
Maximum stress for Case -1 (σ T) =σV+σh
= #REF!
Actual Factor of safety (S1) =ζ/σT
= #REF!
Deflection of track (δ) =[ Fmax V * a^2*(1,5(L1 – 2*a)+a) / 3EI] +
[ Fmax V * (L1 – 2*a)^2 * a / 8EI]
= #REF!
Hence, track is OK
6. Occational Condition (Load Case: 2)
Based on Table 8, EN1808, load cases for trolley, Load case 2, factor of 1,5* WLL
Minimum allowable safety factor (S ) 2
As per En1808, Table 2, limiting stress factor for load case 2
Safety Coefficent compared to elastic yeild limit = 1.33
Maximum load on trolley (Fmax 2) = 1,5*(WLL) + 0,5* (SWR + SWR2)
= #REF! N
Maximum Moment (Mb max) = a*(2*Fmax 2 – ((Fmax 2 *a +Fmax 2 *(a+L2))/L1))
= #REF!
Maximum Stress (σ) = Mb max / Sxx
= #REF!
Actual Factor of safety (S2) =ζ/σ
= #REF!
Hence, track is OK
7. Extreme Condition (Load Case: 3)
492979148.xlsx Page 62
Load condition occurring due to operation of safety devices, out of service & wind conditions
Based on Table 8, EN1808, load cases for trolley, Load case 3, factor of 2,5* WLL
Minimum allowable safety factor (S )3
As per En1808, Table 2, limiting stress factor for load case 3
Safety Coefficent compared to elastic yeild limit = 1
Maximum load on trolley (Fmax 3) = 2,5*(WLL ) + 0,5* (SWR + SWR2)
= #REF!
Maximum Moment (Mb max) = a*(2*Fmax 3 – ((Fmax 3 *a+ Fmax 3 *(a+L2))/L1))
= #REF!
Maximum Stress (σ) = Mb max / Sxx
= #REF!
Actual Factor of safety (S3) =ζ/σ
= #REF!
Hence, track is OK
8. CONCLUSION
Load Case Minimum Actual Result

7. Service Condition (Load Case :1) 1.5 #REF! #REF!
8. Occational Condition (Load case :2) 1.33 #REF! #REF!
9. Extreme Conditions (Load Case: 3) 1 #REF! #REF!
Maximum Actual Result

DEFLECTION OF TRACK(mm) 8 #REF! #REF!
END OF CALCULATION

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Design Calculations

Cradle Runways (I) Pvt Ltd

Project - Worli Mixed Use Development

Bolts, screw and Studs

Aluminum alloy track profile sections

Cradle Runways (I) Pvt Ltd

As per EN1808:1999+A1:2010, the maximum allowable stress σa is defined by table 2

Load case-1 Load case-II Load case -III

Dead weight of cradle including hoist, wire rope SWP 600.00 Kg

Distance of GRU fixing from track suspension point BGRU 425.00 mm

Cradle Runways (I) Pvt Ltd

Material lifting Hoist Member size Calculations

Maximum distance between brackets = BKTmax 2000 mm

Free body digram for the material lifting hoist 2000

Glass replacement unit Member design.

Cradle Runways (I) Pvt Ltd

Maximum bending stress = σmax = 166.67 MPa From LC1

Maximum deflection = δmax= WL^3 / 48EIxx

From the standard pipe section as per BS EN 10210-2

Calculating bending stress for the 3 load cases as above

Actual Maximum deflection = δmax= WL^3 / 48EIxx

Cradle Runways (I) Pvt Ltd

Cradle Runways (I) Pvt Ltd

Free body diagram for track & cradle load system

Total suspended load = WLL 850 Kg

Maximum distance between bracket BKTmax 2000 mm

Maximum load on each bracket = Rbmax = 385.69 Kg

Cradle Runways (I) Pvt Ltd

Free Body diagram of load for HDU / anchor

Tensile area for bolt = Bta = 145.27 mm2

Cradle Runways (I) Pvt Ltd

Face mounted Bracket Member size & Design Calculations

Design of Plate A R1G Rbmax

Section modulus of plate = ZXXP = PAw* PAT2 / 6

Section modulus of plate = ZXXP = 2400.00 mm3

Cradle Runways (I) Pvt Ltd

Cheking the bending stress for the plate

Bending stress = σmax = 90.40 108.47 180.79

Welding Check for Plate A

Welding stress for plate A with load = σw = 6.82 MPa

Bolt Check between Plate A & track

Net Tensile diameter of bolt = 0.85*B dia = Btens = 13.6 mm

Tensile area for bolt = Bta = 145.27 mm2

Considering the load acting on bracket taken by single bolt only,

Cradle Runways (I) Pvt Ltd

Cradle Runways (I) Pvt Ltd

Section modulus of plate at A-A = ZXX A-A = 22940.82 mm3

LC-1 LC-2 LC-3

Bending stress = σmax =

Cradle Runways (I) Pvt Ltd

Section modulus of plate at B-B = ZXX B-B = PBT* (PBTW )2 / 6

Section modulus of plate at B-B = ZXX B-B = 80000.00 mm3

Total Bending Moment at B-B = M T B-B = 3318562.50 N-mm

LC-1 LC-2 LC-3

Bending stress = σmax = 51.85 62.22 103.71

Minimum weld size = Ws 6.00 mm

Equivalent Weld length = PBW = 200.00 mm

Section modulus of weld at B-B = ZXX TW = 56560.00 mm3

Bending Stress in weld at B-B = σw = 1.25* MT B-B / Z xx TW

Cradle Runways (I) Pvt Ltd

Combined Shear & bending stress in weld = fe = = sqrt(σW2 +3* ζwd2)

Factor of safety of weld at B-B = FOS = fwd / fe

Maximum tension at top HDU of plate= PCT = 13274.25 N