JOB No. Rev. No.

Page
DQ.No. Date
CLIENT Designed By
DESCRIPTION Checked By

Design of 3-Plate Run Way Beam (RWB) as per IS 800:1984

1) Crane Data
Crane Capacity 10 tons
98.1 kN
No of crane 1
Distance between cranes 1 m
Bride Weight 6.72 tons
65.9232 kN

12.503 m
Bridge Span i.e c/c of Rails
Trolley Weight 1.9 tons
18.64 kN
Wheel Load 6.67 tons
65.43 kN
Wheel Base 3.6 m
Vertical Impact factor 1.25
Lateral Impact factor 0.20
Lateral Wheel load 5.84 kN
Rail Weight 15.7 kg/m
50 x 40 bar 0.15 kN/m

2) Run Way Beam Data

Span 7.188 m
Grade of Steel Fy 345 kPa
Deflection Limit
Vertical L/ 750
Lateral L/ 400
Detail of 3pl RWB
Top Flange Width 300 mm
Top Flange thk 12 mm
Bottom Flange Width 300 mm
Bottom Flange thk 10 mm
Web thk 6 mm
Web Depth 497 mm
Overall Depth 519 mm
Self Weight of Beam 0.77 kN/m

300
12

244

cg
519

6
275

10
300

3) Propeties of 3-Plate RWB

Area of Top Flange 3600 sq.mm
Area of Bottom Flange 3000 sq.mm
Area of Web 2982 sq.mm
Total Area 9582 sq.mm
CG from Top Flange 244 mm
Ixx gross 484879583 mm4
Iyy gross 49508946 mm4
Iyy top flg 27000000 mm4
Zxx top 1985171 mm3
Zxx bottom 1764808 mm3
rxx 224.95 mm
ryy 71.88 mm
 JOB No. Rev. No. Page
DQ.No. Date
CLIENT Designed By
DESCRIPTION Checked By

DESIGN OF RUNWAY BEAM :

4) Design Forces

Vertical Bending Moment

81.79 81.79

2694 3600 894

900

3594 3594

cL
L = 7188

LHS Reaction = 61.31 kN RHS Reaction = 102.3 kN

Maximum Vertical Bending Moment = 165.17 kN-m

due to wheel loads

Maximum Vertical Bending Moment = 5.95 kN-m

due to self wt of rails + RWB

Net Max Vertical Bending Moment = 171.11 kN-m

Lateral Bending Moment

5.84 5.84

2694 3600 894

900

3594 3594

cL
L = 7188

LHS Reaction = 4.38 kN RHS Reaction = 7.3 kN

Maximum Lateral Bending Moment = 11.79 kN-m

Max Shear from wheel loads

81.79 81.79

3600

L = 7188

LHS Reaction = 122.62 kN RHS Reaction = 41.0

kN
Max Shear from wheel loads = 122.62 kN

Max Shear from self wt of rails + RWB = 4.60 kN

Net Max Shear = 127.22 kN

5) Calculation of Actual Stress

Bending Stress due to Vertical loading

Actual Bending Compressive stress for Vertical loading

σbcx cal = 86.20 Mpa

Actual Bending Tensile stress for Vertical loading

σbtx cal = 96.96 Mpa

Bending Stress due to Lateral loading

Actual Bending Compressive stress for Lateral loading

(Bottom flange is neglected)
σbcy cal = 65.48 Mpa

6) Calculation of Allowable Stress

For beams with Iy smaller than Ix, the elastic critical stress fcb is calculated using the formula

fcb = k1 [ X + k2 Y ] C2 /C1

k1 = 1.0 since no reduction in thk or breadth

ω = Iyy of Compression flange

Iyy of built up

= 0.55
From IS 800 1984,
k2 = 0.05

L / ryy = 100.0

D/T = 43.25

Y = 26.5 x 100000
[L / ryy]2

= 265.01 Mpa

X = Y sqrt (1 +[ 1/20 x {L / ryy} / {D/T} ]2 )

= 298.33 Mpa

fcb = 350.48 Mpa

σbc = 139.88 Mpa

> 86.20 Mpa Safe

7) Check for Combined Bending Compressive stress in Extreme fibre

σbcx cal + σbcy cal = 151.68 Mpa

σbc = 153.87 Mpa

σbcx cal + σbcy cal < σbc Safe

8) Check for Shear

Actual Shear stress for Vertical loading

ζv cal = 42.66 Mpa

Allowable Shear stress for Vertical loading

ζv allowable = 138.00 Mpa Safe

9) Check for Web Buckling

B = 0.5 x Web Depth + Bottom flange thk

= 258.5 mm

R = Shear at suppport
= 127.22 kN

Compression at support = R / B x tw
= 82.03 Mpa

Effective Slenderness ratio of web = d 3 / tw

tw

= 143.47

Allowable Compression σc = 51.50 Mpa Provide Bearing Stiffeners at

Support
9) Check for Fatigue

Minimum Wheel load = 31.7 kN

Number of Repetitons = 1x108 Cycles

Class of Construction detail = B

a.Vertical Bending Moment due to minimum Wheel Load

31.70 31.70

2694 3600 894

900

3594 3594

cL
L = 7188

LHS Reaction = 23.76 kN RHS Reaction = 39.6 kN

Maximum Vertical Bending Moment = 64.01 kN-m

due to wheel loads

Maximum Vertical Bending Moment 4 5.95 kN-m

due to self wt of rails + RWB

Net Max Vertical Bending Moment = 69.96 kN-m

b.Bending Stress due to Minimum Vertical loading

Actual Bending Compressive stress for Vertical loading

σbcx cal = 35.24 Mpa

Actual Bending Tensile stress for Vertical loading

σbtx cal = 39.64 Mpa

c.Check for Tensile Fatigue Stress

fmax = 96.96 Mpa

fmin = 39.64 Mpa

fmin/fmax = 0.409

Maximum allowable stress f = 150 Mpa

> 96.96 Mpa Hence Safe

d.Check for Compressive Fatigue Stress

fmax = 86.20 Mpa

fmin = 35.24 Mpa

fmin/fmax = 0.409

Maximum allowable stress f = 390.43 Mpa

> 86.2 Mpa Hence Safe
 JOB No. Rev. No. Page
DQ.No. Date
CLIENT Designed By
DESCRIPTION Checked By

10) Deflection

For Single Crane - 2 Wheel Loads :

Vertical Deflection

P CL P
65.43 kN 65.43 kN
= =

a a
1.794 3.6 m 1.794

L = 7.188 m

Actual Deflection (@ Centre of Beam) d(actual) = P * a * (3 * L2 - 4 * a2) / 24 E Ixx

Here P = 65432.7 N
a = 1794 mm
L = 7188 mm
E = 200000 N/mm2
Ixx gross = 4.85E+08 mm4

d(actual) = 7.17 mm

Allowable Deflection d(allow) = L / 600 mm

= 11.98 mm

d(actual) < d(allow) Safe

Lateral Deflection

P CL P
5.84 kN 5.84 kN
= =

a a
1.794 3.6 m 1.794

L = 7.188 m

Actual Deflection (@ Centre of Beam) d(actual) = P * a * (3 * L2 - 4 * a2) / 24 E Ixx

Here P = 5836.95 N
a = 1794 mm
L = 7188 mm
E = 200000 N/mm2
Iyy top flg = 27000000 mm4

d(actual) = 11.48 mm

Allowable Deflection d(allow) = L / 400 mm

= 17.97 mm

d(actual) < d(allow) Safe

 JOB No. Rev. No. Page
DQ.No. Date
CLIENT Designed By
DESCRIPTION Checked By

10) Deflection

For Double Crane - 4 Wheel Loads :

81.79 81.79 81.79 81.79

-506 3600 1000 3600 -506

500

3594 3594

cL
L = 7188

Vertical Deflection

Actual Deflection due to Wheel loads = P * [ a * (3 * L2 - 4 * a2) ] + [ b * (3 * L2 - 4 * b2) ] / 24 E Ixx

dv1 (actual) ( @ Centre of Beam)

Here P = 81.8 KN
a = -506 mm
b = 1000 mm
L = 7188 mm
E = 200000 N/mm2
Ixx gross = 4.85E+08 mm4

dv1(actual = 2.57 mm

Actual Deflection -self wt of rails + RWB = 5 w L4 / 384 E Ixx

Here w = 0.9 kN/m

L = 7188 mm
E = 200000 N/mm2
Ixx gross = 4.85E+08 mm4

dv2(actual = 0.33 mm

Actual Deflection dvactual = dv1 + dv2 = 2.90 mm

Allowable Deflection dv (allow) = L / 1000 mm

= 7.19 mm

dvactual < dv (allow) Safe

Lateral Deflection

Actual Deflection dL(actual) = P * [ a * (3 * L2 - 4 * a2) ] + [ b * (3 * L2 - 4 * b2) ] / 24 E Iyy

( @ Centre of Beam)

Here P = 2.9 KN
a = -506 mm
b = 1000 mm
L = 7188 mm
E = 200000 N/mm2
Iyy gross = 27000000 mm4

dL (actual) = 1.65 mm

Allowable Deflection dL (allow) = L / 400 mm

= 17.97 mm

dL (actual) < dL (allow) Safe

 JOB No. Rev. No. Page
DQ.No. Date
CLIENT Designed By
DESCRIPTION Checked By

10) Deflection

For Single Crane - 4 Wheel Loads :

81.79 81.79 81.79 81.79

-1806 3600 3600 3600 -1806

1800

3594 3594

cL
L = 7188

Vertical Deflection

Actual Deflection due to Wheel loads = P * [ a * (3 * L2 - 4 * a2) ] + [ b * (3 * L2 - 4 * b2) ] / 24 E Ixx

dv1 (actual) ( @ Centre of Beam)

Here P = 81.8 KN
a = -1806 mm
b = 3600 mm
L = 7188 mm
E = 200000 N/mm2
Ixx gross = 4.85E+08 mm4

dv1(actual = 4.04 mm

Actual Deflection -self wt of rails + RWB = 5 w L4 / 384 E Ixx

Here w = 0.9 kN/m

L = 7188 mm
E = 200000 N/mm2
Ixx gross = 4.85E+08 mm4

dv2(actual = 0.33 mm

Actual Deflection dvactual = dv1 + dv2 = 4.37 mm

Allowable Deflection dv (allow) = L / 1000 mm

= 7.19 mm

dvactual < dv (allow) Safe

Lateral Deflection

Actual Deflection dL(actual) = P * [ a * (3 * L2 - 4 * a2) ] + [ b * (3 * L2 - 4 * b2) ] / 24 E Iyy

( @ Centre of Beam)

Here P = 5.84 KN
a = -1806 mm
b = 3600 mm
L = 7188 mm
E = 200000 N/mm2
Iyy gross = 27000000 mm4

dL (actual) = 5.18 mm

Allowable Deflection dL (allow) = L / 400 mm

= 17.97 mm

dL (actual) < dL (allow) Safe