CT4125 Steel instruction

This
instruction
includes
the
design,
dimensioning, checking and drawing of an
industrial steel hall with a hoisting installation.
The roof of and the fronts consist of thin-walled
trapezoid steel plates and has the following
outward measurements.
The facades are provided all around with a glass
strip and big doors in the end wall. One of the
end walls can be opened entirely by means of
sliding doors. (These sliding doors do not have
to be detailed extensively.)
Photo Hall Corus Ijmuiden

This instruction is meant for students who have followed cie4115 Steel Structures 2 as well as
one of the coarses cie3211 Constructions of Buildings 1, cie4121 Steel Structures 3 or ie5126
Fatigue.
Because not all students have followed lectures on these subjects, new knowledge may have
to be applied to carry out the instruction. Emphasis is put on weighing of factors and arriving
at a certain construction, the form and the dimensioning of elements and verification of the
construction as to the constructive safety, the ultimate limit states and the serviceability limit
states.
80
m
18
m
7
m

m
200
kN
m/s
8

Lengte gebouw

Breedte
gebouw

Data:
- Length building
- Width building
- Free hoisting height
- Frame spacing
- Hoisting load
- Hoisting speed
- Crane group
- Floor load

kN/m2

Instruction:
- Determine the definite plan measurements and measurements of the hall, including a grid
- Determine the stability system for discharging the forces in various directions
- Dimension and verify the crane gantry girder (not the crane girder)
- Dimension and verify the bearing system (girders, trusses, intermediate columns,
connections, etc.
- Verify the crane gantry girder on fatigue
- Draw the bearing construction of the building with some details (the details in
deliberation with the lecturer).
Standards:
The Eurocode standards are used for this exercise. These standards are freely available in
Dutch or English for students of the TU-Delft and can be downloaded from internet from:
www.tudelft.nl, library, date-bases and so on (NEN-connect).
General data crane girder, etc.
If the data of the crane girder, as supplied by crane manufacturers, are not at your disposal,
then these are to be determined with the aid of literature.

For the determination of weight, the following can be assumed:

- Web height spacing distance between the crane gantry girders E/20
- Flange width spacing distance between the crane gantry girders E/40
From literature on existing cranes it appears that the rad position increases in proportion to
the span E and also depends a bit on the lifting capacity L:
D = [2000 + 2,00 L + 50 E] [in mm] [L in kN, E in m].
Explanation
To determine the cross-section of the building as well as the crane girder load, the required
data (see table I) are as follows:
As
= half width wheel box
B
= extreme position of hoisting hook
Bcage = ditto, when using hoisting crane
with cage ("kooi")
C
= height difference rails
D
= spacing distance crane travelling
wheels
E
= span in width direction

Table I
Hoisting
Load L [kN]
100
150
200
250
300
350
400
450

As
[mm]
300
300
300
350
350
350
380
380

B
[mm]
1000
1000
1000
1000
1150
1150
1350
1350

Bcage
[mm]
1500
1500
1500
1500
1700
1700
2000
2000

C
[mm]
800
800
800
800
1000
1000
1100
1100

Diameter
wheel [mm]
710
710
710
710
900
900
1000
1000

Traversing crab weight

This weight varies with the crab rail distance, which reduces or increases the crab frame
weight, but the weight mainly depends on the lifting capacity and the hoisting equipment. The
following data are sufficient:
Table II
Hoisting Load L
[kN]
100
150
200
250

Dead load Crab

[kN]
38
46
56
68

Hoisting Load L
[kN]
300
350
400
450

Dead load Crab

[kN]
75
80
85
95

Weight crane without crab

Basis is a crane consisting of 2 welded tube girders:
- Girder height E/20
- Flange width E/40
- Minimum plate thickness 10 mm
Table III
Hoisting
Load L
[kN]
100
150
200
250
300
350
400
450

20

22

Dead load crane girder exclusive dead load crab in kN

24
26
28
30
40
44
48
52

56

60

166
175
184
194
203
214
224
243

189
199
209
219
229
241
253
264

213
224
235
246
256
269
282
295

930
936
943
949
955
962
968
974

1052
1059
1066
1073
1079
1086
1093
1099

240
252
264
276
287
302
316
330

269
281
294
306
319
335
351
367

300
313
326
340
354
372
390
407

521
526
532
537
542
548
553
558

612
617
623
629
634
640
646
651

710
716
722
728
734
740
746
752

815
821
827
833
839
845
851
857

Choice rail profile

The choice for the crane rail profile depends, given a dynamic pressure F, from the wheel
diameter D, the net railhead width L and the allowable contact tension. The contact tension
follows from the Hertz equation, which reads, for a cylinder on a plane:
F
=
2 0, 75 105
2r
F
r

rad pressure in kN
beam cylinder in mm
length contact area in mm

The matter is rather complex and limitation of the contact tension suffices. The wheel gives a
wheel impression on the rail. This impression, a surface, depends on the strength en hardness
of the two materials contacting each other, the rail and the wheel. Current values for the
allowable Hertz-tension for S235 = 650 N/mm2, cast steel = 850 N/mm2, forged steel =
950 N/mm2.
Application of this Hertz equation gives allowable rad pressures that are twice as high as
those that are normal with crane rails from S235, which leads to too rapid rail wear. To limit
wear and thus maintenance, the contact tension is substantially reduced. For a value of 70%
of the ultimate tensile strength of = 0.7 x 850 = 595 N/mm2, the following practical
calculation rule is found from the Hertz equation:
=
F

=
D 0, 005 D [kN ] D is the diameter and is rail width in mm
0, 75 108
For heavy and frequent traffic F = 0.04 D is maintained.
For little loaded crabs F = 0.06 D is maintained.
So, at a rad pressure F = 320 kN and a wheel diameter of D = 900 mm, at least an A100 is
required. As shown in the graph, this is already a heavy rail profile with little wear, because
the Hertz tension is kept low.

The above practical equation is represented in the graph shown below for a number of usual
rail profiles. In reality, the calculation is much more complex. In fact, per wheel, two
eccentric forces are directly coupled, namely a vertical and a horizontal force. Both
eccentricities lead to a torsional moment. Both forces lead to bending moments in the rail.
Moreover, both forces can locally lead to high tensions due to force inleidingen. The force
distribution greatly depends on the construction the rail is attached to, in this case the crane
gantry girder. In case of railways the basis is often an uniform rail bed constant. With a crane
gantry girder the stiffness is not uniform. In this exercise, using the table shown below
suffices.
A45

A55

A65

250

300

1200

200

1300
A75

A100

A120

1100
1000
900

D [mm]

800
700
600
500
400
300
200
100
700

650

600

550

500

450

400

350

150

100

50

F [kN]

Graph determination rail type related to the diameter travelling wheel, in mm, and the rad pressure in kN, based
on F = 0.005 Dl and a tension of 600 N/mm2.

For an overview of the normal A-rails and strips of hardwearing S600 see attachment, copied
from Stahl im Hochbau. The following remarks can be made about the choice between rails
and strips. The strip is cheap and (in case of non-frequent crane usage) can be easily attached
to the crane gantry by means of welding. If the crane is not used very often, a crane gantry
with a welded profile suffices. In case of heavy use, the clack welds will tear. The strip rail
then requires a lot of maintenance and replacing it will be expensive. In such a case it is
preferred to choose a rail profile with a footing, which is clamped onto the gantry with
eccentric clamps. This clamped foot rail construction is not only more expensive, but does not
contribute to the strength and stiffness of the gantry. This solution, however, favourably
influences the fatigue behaviour.
Self-weight crane gantry
Normally, for the weight of one crane gantry girder with rail and associated platform, the
following can be maintained:
- For a hoisting capacity of 100 kN - weight crane gantry, etc.: 3.5 kN/m
- For a hoisting capacity of 500 kN - weight crane gantry, etc.: 5.5 kN/m