DESIGN CALCULATION OF STRUCTURAL

COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 1 of 48

Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
1. Description
Hoist Capacity = 60.0 T
Crowd Load = 500 kg/m
2

Weight of Chequered Plate = 55 kg/m

2

Impact Factor = 1.32

BDT Factor = 2.4

2. Mechanical Strength of Proposed Materials

Material Y.P U.T.S

Material
Specification (Kg/cm2) (Kg/cm2)
Structural Steel
upto 20th. 2548
IS:2062, E250,Gr.-A
Over 20 upto 40th. 2446 4179
Over 40th. 2344
IS:1570 40C8 3873 6116
Carbon Steel IS:1570 50C4 5504 8154
IS:1570 55C8 5504 9174

a. Material for Structure IS:2062 Gr.-A

Allowable Bending stress == 2344/1.5 = 1699 Kg/cm2
Allowable shear stress == 2344/1.5 = 1699 Kg/cm2
Allowable Bearing stress == 2344/1.5 = 1699 Kg/cm2
BDT Condition = 0.8X2344/1.5 = 1359.2 Kg/cm2
( Reference IS: 800 / 2007 and Duty factor as per IS :807 = 0.95 )

b. Material of Pin for Wheel Bogie IS:1570 55C8

Allowable bending stress=0.56X9174 = 5137.44 Kg/cm2
Allowable torsional shear stress=0.66X5504 = 3632.64 Kg/cm2
Combined stresses in Normal Condition=0.24X9174 = 2201.76 Kg/cm2
Stresses under BDT Condition=0.8X5504 = 4403.2 Kg/cm2

3. Loads considered for design of structural components

As per IS: 807:2006
i) 6.1.1 : Principal Loads
ii) 6.1.2 : Lifted Loads
iii) 6.1.3.1 : Inertia Force
iv) 6.1.3.4 : Transverse reaction due to rolling action
v) 7.1.1 : Wind Action
vi) 8.1 : Loads carried by Platforms
vii) 8.2 : Sesmic Load
Other loads indicated in the IS:807;2006 are not applicable for design of structural components of
Gantry crane
As per IS: 3177:1999
7.3.1 : All the loads considered for design of structural components of gantry crane except
load Rd as the same is not applicable.
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 2 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
4. Layout of the Hoisting Arrangement of the Gantry Crane
Wheel Boggie-I
Beam : FF

600
E2

400
F1 E E2 E F2
B1 C1 D1 C1 B1
D D
2490 160 Beam : DD Beam : CC

400
Beam : BB
Beam : AA Balancing
Sheave F
865

C A
B A C L
A1 A2 A2
A1 O
1550

375 W

Top Beam : EE
815

815
Sheave

450
E1 B2 C2 D2 C2 B2 E1
G1 G2
2650 725 750 1125 1125 750 725 2650

550
Beam : GG

Wheel Boggie-II 1450

10500
LAYOUT
5. Loads at different locations
Normal Condition BDT Condition With Impact
A = 11479.94 kg A = 27273.1 kg A = 15153.52 kg
B = 3850 kg B = 3850.00 kg B = 5082 kg
C = 16180.0 kg C = 38514.9 kg C = 21357.6 kg
D = 7092.56 kg D = 16883 kg D = 9362.18 kg
E = 7092.56 kg E = 16883 kg E = 17022.14 kg
Self Weight
Hoist Helical Gearbox = 3850 kg
Hoist EM Brake with Coupling = 120 kg
Hoist Thruster Brake with coupling = 112 kg
Hoist Motor = 334 kg
CT Vertical Helical Gearbox with coupling &
Floating shaft = 1214.58 kg
CT Horizontal Helical Gearbox with coupling = 165 kg
CT EM Brake = 40 kg
CT Thruster Brake = 33 kg
CT Hoist Motor = 17 kg
Balancing Pulley = 70 kg
Top Pulley = 146 kg
Coupling on Drum = 2360 kg
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 3 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
6. Description
Design of Beam :AA
630.13 kg/m
A
A1 A2
375 375
750
Reaction due to self weight
Self Weight of Beam AA = 200 kg/m
Load due to self weight of chequered plate and crowd load = 1X(500+55)X(0.775)
= 430.13 kg/m
Total UDL Load = 200+430.13
= 630.13 kg/m
Balancing Pulley = 70 kg
Reaction at A1 & A2 due to self weight = 630.13x750/2000+70/2
= 271.3 kg
Reaction at A1 & A2 due to self weight for load transfer = 200x750/2000+70/2
= 110 kg
Reaction due to live load with Impact
Reaction at A1 = (15153.52X375)/750
= 7576.76 kg
= 7.58 T
Reaction at A2 = 15153.52-7576.76
= 7576.76 kg = 7.58 T
Reaction due to self weight & live load with Impact
Total Reaction at A1 = 271.3+7576.76
= 7848.06 kg
Total Reaction at A2 = 271.3+7576.76
= 7848.06 kg
Moment due to self weight & live load with Impact
Maximum bending moment = 7848.06X37.5-630.13X0.375X18.75
= 289871.65 kgcm
Section of Beam 316
12

Area= 165.84 cm 146

2

Ixx= 55665.58 cm
4

Zxx= 2348.76 cm 10
3
450

Iyy= 11794 cm
4

Zyy= 746.46 cm
3

rx= 18.32 cm
ry= 8.43 cm 316
Area Web = 90 cm2
Le= 0.85x750/10 cm
= 63.75 cm
Le/ry= 63.75/8.43
= 7.56
D/T = (450+2X12)/12
= 39.5 < 85
Hence stiffners are not required
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 4 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Y =
26.5  10 5 f cb  f y
 Le 
2 f bc  0.66 
 r  (f 1.4
 f y1.4 )1 1.4
 y 
cb

= 26.5X10^5/(7.56^2) = 0.66X250X46366.28/((250^1.4+46366.28^1.4)^(1/1.4))
= 46366.28 Mpa = 164.92 Mpa
fcb = 46366.28 Mpa = 1681.14 kg/cm
2

fy = 250 Mpa

Stress due to self weight & live load with Impact

Bending Stress on Beam AA = 289871.65/2348.76
= 123.41 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam AA = 7848.06/90
= 87.2 kg/cm2 < 1699 kg/cm2 SAFE

Deflection of the Beam AA due to impact load

d= (75^3/(2.1X10^6X55665.6))X((5X630.1X0.75/384)+(15153.5/48)X(3X375/750-4X(375/750)^3))
d= 0.0012 cm
L/d = 64569.66 > 900 SAFE
L/900 = 0.08 cm > 0.0012 cm SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 750 mm
E = 2140672.78 kg/cm 2
Thermal Expansion of the beam = 0.225 mm

Reaction & Stress in beam AA under BDT Condition

Reaction at A1 = (27273.08X375)/750
= 13636.5 kg = 13.64 T
Reaction at A2 = 27273.08-13636.54
= 13636.54 kg = 13.64 T
Total Reaction at A1 = 13636.54+271.3
= 13907.84 kg
Total Reaction at A2 = 13636.54+271.3
= 13907.84 kg
Maximum bending moment = 13907.84X37.5-630.13X0.375X18.75
= 506939.65 kgcm

Bending Stress on Beam AA= 506939.65/2348.76

= 215.83 kg/cm2 < 1359.2 kg/cm2 SAFE

Shear Stress on Beam AA = 13907.84/90

= 154.53 kg/cm2 < 1359.2 kg/cm2 SAFE
Welding :-
Shear Force on the Beam = 13907.84 kg
Fillet size is 6 mm , shear area = 45X0.6X0.707X2+31.6X0.6X0.707X2 = 64.99 cm
2

Stress = 13907.84/64.99
= 214 kg/cm2 < 1699 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 5 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
7. Description
Design of Beam : BB
534.31 kg/m
A1
B1 B2
865 685
1550
Reaction due to self weight
Self Weight of Beam BB = 125 kg/m
Load due to self weight of chequered plate and crowd load = 0.5X(500+55)X(1.475)
= 409.31 kg/m
Total UDL Load = 125+409.31 = 534.31 kg/m
Reaction at B1 due to self weight = 534.31x1550/2000+685x110/1550
= 462.7 kg
Reaction at B2 due to self weight = 534.31x1550/2000+865x110/1550
= 475.48 kg
Reaction at B1 due to self weight for load transfer = 125x1550/2000+685x110/1550
= 145 kg
Reaction at B2 due to self weight for load transfer = 125x1550/2000+865x110/1550
= 158 kg
Reaction due to live load with Impact
Reaction at B1 = (7576.76X685)/1550
= 3348.44 kg = 3.35 T
Reaction at B2 = 7576.76-3348.44
= 4228.32 kg = 4.23 T
Reaction due to self weight & live load with Impact
Total Reaction at B1 = 462.7+3348.44
= 3811.14 kg
Total Reaction at B2 = 475.48+4228.32 = 4703.80 kg
Moment due to self weight & live load with Impact
Maximum bending moment = 4703.8X68.5-534.31X0.685X34.25
= 309674.72 kgcm
Section of Beam 274
12

Area= 165.76 cm 230

2

Ixx= 63937.7 cm
4

Zxx= 2440.37 cm 10
3
500

Iyy= 18522.5 cm
4

Zyy= 1352.01 cm
3

rx= 19.64 cm
ry= 10.57 cm 274
Area Web = 100 cm
2

Le= 0.85x1550/10 cm
= 131.75 cm
Le/ry= 131.75/10.57
= 12.46
D/T = (500+2X12)/12
= 43.66667 < 85
Hence stiffners are not required
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 6 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
26.5  10 5
Y = f cb  f y
 Le 
2
f bc  0.66 
 r  (f 1.4
 f y1.4 )1 1.4
 y 
cb

= 26.5X10^5/(12.46^2) = 0.66X250X17069.07/((250^1.4+17069.07^1.4)^(1/1.4))
= 17069.07 Mpa = 164.68 Mpa
fcb = 17069.07 Mpa = 1678.7 kg/cm
2

fy = 250 Mpa
Stress due to self weight & live load with Impact
Bending Stress on Beam BB= 309674.72/2440.37
= 126.9 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam BB= 4703.8/100
= 47.04 kg/cm2 < 1699 kg/cm2 SAFE
Deflection of the Beam BB due to impact load
d= (155^3/(2.1X10^6X63937.7))X((5X534.3X1.55/384)+(7576.8/48)X(3X685/1550-4X(685/1550)^3))
d= 0.0046 cm
L/d = 33755.72 > 900 SAFE
L/900 = 0.17 cm > 0.0046 cm SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 1550 mm
E = 2140672.78 kg/cm2
Thermal Expansion of the beam = 0.465 mm
Reaction & Stress in beam BB under BDT Condition
Reaction at B1 = (13636.54X685)/1550
= 6026.47 kg
= 6.03 T
Reaction at B2 = 13636.54-6026.47
= 7610.07 kg
= 7.61 T
Total Reaction at B1 = 6026.47+462.7
= 6489.17 kg
Total Reaction at B2 = 475.48+7610.07
= 8085.55 kg
Maximum bending moment = 7610.07X68.5-534.31X0.685X34.25
= 508754.21 kgcm
Bending Stress on Beam BB= 508754.21/2440.37
= 208.47 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam BB= 8085.55/100
= 80.86 kg/cm2 < 1359.2 kg/cm2 SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 1550 mm
E = 2140672.78 kg/cm2
Thermal Expansion of the beam = 0.465 mm
Welding :-
Shear Force on the Beam = 8085.55 kg
Fillet size is 6 mm , shear area = 50X0.6X0.707X2+27.4X0.6X0.707X2 = 23.25 cm
2

Stress = 8085.55/23.25
= 347.77 kg/cm2 < 1699 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 7 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
8. Description
Design of Beam : CC
630.31 kg/m
A2
C1 C2
865 685
1550
Reaction due to self weight
Self Weight of Beam CC = 110 kg/m
Load due to self weight of chequered plate and crowd load = 0.5X(55+500)X(1.875)
= 520.31 kg/m
Total UDL Load = 110+520.31 = 630.31 kg/m
Self weight of motor & Brakes = 566 kg
Reaction at C1 due to self weight = 630.31x1550/2000+685x110/1550+566/2
= 961.58 kg
Reaction at C2 due to self weight = 630.31x1550/2000+865x430.13/1550+566/2
= 1011.53 kg
Reaction at C1 due to self weight for load transfer = 110x1550/2000+685x430.13/1550+566/2
= 558.34 kg
Reaction at C2 due to self weight for load transfer = 110x1550/2000+865x430.13/1550+566/2
= 608.29 kg
Reaction due to live load with Impact
Reaction at C1 = (7576.76X685)/1550
= 3348.44 kg = 3.35 T
Reaction at C2 = 7576.76-3348.44
= 4228.32 kg = 4.23 T
Reaction due to self weight & live load with Impact
Total Reaction at C1 = 961.58+3348.44 = 4310.02 kg
Total Reaction at C2 = 1011.53+4228.32 = 5239.85 kg
Moment due to self weight & live load with Impact
Maximum bending moment = 5239.85X68.5-630.31X0.685X34.25
= 344141.86 kgcm
Section of Beam 274
12

Area= 165.76 cm 230

2

Ixx= 63937.7 cm
4

Zxx= 2440.37 cm 10
3
500

Iyy= 18522.5 cm
4

Zyy= 1352.01 cm
3

rx= 19.64 cm
ry= 10.57 cm 274
Area Web = 100 cm
2

Le= 0.85x1550/10 cm
= 131.75 cm
Le/ry= 131.75/10.57
= 12.46
D/T = (500+2X12)/12
= 43.66667 < 85
Hence stiffners are not required
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 8 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Y =
26.5  10 5 f cb  f y
f bc  0.66 
 Le   f y1.4 )1 1.4
2

 r  (f 1.4
cb
 y 
= 26.5X10^5/(12.46^2) = 0.66X250X17069.07/((250^1.4+17069.07^1.4)^(1/1.4))
= 17069.07 Mpa = 164.68 Mpa
fcb = 17069.07 Mpa = 1678.7 kg/cm
2

fy = 250 Mpa
Stress due to self weight & live load with Impact
Bending Stress on Beam CC= 344141.86/2440.37
= 141.02 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam CC= 4310.02/100
= 52.4 kg/cm2 < 1699 kg/cm2 SAFE
Deflection of the Beam CC due to impact load
d= (155^3/(2.1X10^6X63937.7))X((5X630.3X1.55/384)+(7576.8/48)X(3X685/1550-4X(685/1550)^3))
d= 0.0046 cm
L/d = 33365.26 > 900 SAFE
L/900 = 0.17 cm > 0.0046 cm SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 1550 mm
E = 2140672.78 kg/cm 2
Thermal Expansion of the beam = 0.465 mm
Reaction & Stress in beam CC under BDT Condition
Reaction at C1 = (13636.54X685)/1550
= 6026.47 kg
= 6.03 T
Reaction at C2 = 13636.54-6026.47
= 7610.07 kg = 7.61 T
Total Reaction at C1 = 961.58+6026.47
= 6988.05 kg
Total Reaction at C2 = 1011.53+7610.07
= 8621.60 kg
Maximum bending moment = 8621.6X68.5-630.31X0.685X34.25
= 575791.74 kgcm
Bending Stress on Beam CC= 575791.74/2440.37
= 235.94 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam CC= 8621.6/100
= 86.22 kg/cm2 < 1359.2 kg/cm2 SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 1550 mm
E = 2140672.78 kg/cm2
Thermal Expansion of the beam = 0.465 mm
Welding :-
Shear Force on the Beam = 8621.60 kg
Fillet size is 6 mm , shear area = 50X0.6X0.707X2+27.4X0.6X0.707X2 = 23.25 cm
2

Stress = 8621.6/23.25
= 370.82 kg/cm2 < 1699 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 9 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
9. Description
Design of Beam :DD
859.38 kg/m
B
D1 D2
865 685
1550
Reaction due to self weight
Self Weight of Beam DD = 235 kg/m
Load due to self weight of chequered plate and crowd load = 1X(500+55)X(1.125)
= 624.38 kg/m
Total UDL Load = 235+624.38 = 859.38 kg/m
Self Weights
Hoist Helical Gearbox = 3850 kg
Total = 3850 kg
Reaction at D1 due to self weight = 859.38x1550/2000+3850/2
= 2591.02 kg
Reaction at D2 due to self weight = 859.38x1550/2000+3850/2
= 2591.02 kg
Reaction at D1 due to self weight for load transfer = 235x1550/2000+3850/2
= 2107.13 kg
Reaction at D2 due to self weight for load transfer = 235x1550/2000+3850/2
= 2107.13 kg
Reaction due to live load with Impact
Reaction at D1 = (5082X685)/1550 = 2245.92 kg = 2.25 T
Reaction at D2 = 5082-2245.92 = 2836.08 kg = 2.84 T
Reaction due to self weight & live load with Impact
Total Reaction at D1 = 2591.02+2245.92 = 4836.94 kg
Total Reaction at D2 = 2591.02+2836.08 = 5427.10 kg
Moment due to self weight & live load with Impact
Maximum bending moment = 4836.94X68.5-859.38X0.685X34.25
= 311168.26 kgcm
Section of Beam 680
12

Area= 267.84 cm 380

2

Ixx= 98483.19 cm
4

Zxx= 4281.88 cm 12
3
436

Iyy= 103097.46 cm
4

Zyy= 3032.28 cm
3

rx= 19.18 cm
ry= 19.62 cm 680
Area Web = 104.64 cm2
Le= 0.85x1550/10 cm
= 131.75 cm
Le/ry= 131.75/19.62 = 6.72
D/T = (436+2X12)/12
= 38.33 < 85
Hence stiffners are not required
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 10 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
26.5  10 5
Y = f cb  f y
 Le 
2
f bc  0.66 
 r  (f 1.4
 f y1.4 )1 1.4
 y 
cb

= 26.5X10^5/(6.72^2) = 0.66X250X58682.33/((250^1.4+58682.33^1.4)^(1/1.4))
= 58682.33 Mpa = 164.94 Mpa
fcb = 58682.33 Mpa = 1681.35 kg/cm
2

fy = 250 Mpa
Stress due to self weight & live load with Impact
Bending Stress on Beam DD = 311168.26/4281.88
= 72.67 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam DD = 5427.1/104.64
= 51.86 kg/cm2 < 1699 kg/cm2 SAFE

Deflection of the Beam DD due to impact load

d= (155^3/(2.1X10^6X98483.2))X((5X859.4X1.55/384)+(8932/48)X(3X685/1550-4X(685/1550)^3))
d= 0.0036 cm
L/d = 43082.61 > 900 SAFE
L/900 = 0.17 cm > 0.0036 cm SAFE (As per IS:800 CL. No.-3.3.4)
Thermal Expansion of the beam = 0.000012XDTXL
DT = 25
L = 1550 mm
E = 2140672.78 kg/cm
2

Thermal Expansion of the beam = 0.465 mm

Reaction & Stress in beam DD under BDT Condition

Reaction at D1 = (3850X685)/1550
= 1701.45 kg = 1.70 T
Reaction at D2 = 3850-1701.45
= 2148.55 kg = 2.15 T
Total Reaction at D1 = 1701.45+2591.02
= 4292.47 kg
Total Reaction at D2 = 2148.55+2591.02
= 4739.57 kg

Maximum bending moment = 4292.47X68.5-859.38X0.685X34.25

= 127013.55 kgcm

Bending Stress on Beam DD= 127013.55/4281.88

= 29.66 kg/cm2 < 1359.2 kg/cm2 SAFE

Shear Stress on Beam DD = 4739.57/104.64

= 45.29 kg/cm2 < 1359.2 kg/cm2 SAFE

Welding :-
Shear Force on the Beam = 4739.57 kg = 94.68 cm
2

Fillet size is 6 mm , shear area = 43.6X0.6X0.707X2+68X0.6X0.707X2

Stress = 4739.57/94.68 SAFE
= 50.06 kg/cm 2
< 1699 kg/cm 2
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 11 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
10. Description
Design of Beam :EE
1136.56 kg/m
C
E1 E2
815 735
1550

Reaction due to self weight

Self Weight of Beam EE = 200 kg/m
Load due to self weight of chequered plate and crowd load = 1X(500+55)X(1.6875)
= 936.56 kg/m
Total UDL Load = 200+936.56
= 1136.56 kg/m
Weight of Pulley = 200 kg
Reaction at E1 due to self weight = 1.13656x1550x735/1550+200x735/1550
= 930.21 kg
Reaction at E2 due to self weight = 1136.56x1.55+200-930.21 = 1031.46 kg
Reaction at E1 due to self weight for load transfer = 0.2x1550x735/1550+200x735/1550
= 241.84 kg
Reaction at E2 due to self weight for load transfer = 200x1.55+200-241.84 268.16 kg
Reaction due to live load with Impact
Reaction at E1 = (21357.6X735)/1550
= 10127.6 kg
= 10.13 T
Reaction at E2 = 21357.6-10127.64
= 11229.96 kg = 11.23 T
Reaction due to self weight & live load with Impact
Total Reaction at E1 = 930.21+10127.64
= 11057.85 kg
Total Reaction at E2 = 930.21+11229.96
= 12160.17 kg
Moment due to self weight & live load with Impact
Maximum bending moment = 11057.85X81.5-1136.56X0.815X40.75
= 863468.2 kgcm
Section of Beam 400
12

Area= 276 cm 270

2

Ixx= 321130.08 cm
4

Zxx= 6950.87 cm 10
3
900

Iyy= 48095 cm
4

Zyy= 2404.75 cm
3

rx= 34.11 cm
ry= 13.2 cm 400
Area Web = 180 cm2
Le= 0.85x1550/10 cm
= 131.75 cm
Le/ry= 131.75/13.2
= 9.98
D/T = (900+2X12)/12
= 77 < 85
Hence stiffners are not required
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 12 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Y =
26.5  10 5 f cb  f y
 Le 
2 f bc  0.66 
 r  (f 1.4
 f y1.4 )1 1.4
 y 
cb

= 26.5X10^5/(9.98^2) = 0.66X250X26606.32/((250^1.4+26606.32^1.4)^(1/1.4))
= 26606.32 Mpa = 164.83 Mpa
fcb = 26606.32 Mpa = 1680.22 kg/cm
2

fy = 250 Mpa

Stress due to self weight & live load with Impact

Bending Stress on Beam EE = 863468.2/6950.87
= 124.22 kg/cm2 < 1680.22 kg/cm2 SAFE
Shear Stress on Beam EE = 12160.17/180
= 67.56 kg/cm2 < 1699 kg/cm2 SAFE

Deflection of the Beam EE due to impact load

d= (155^3/(2.1X10^6X321130.1))X((5X1136.6X1.55/384)+(21357.6/48)X(3X735/1550-4X(735/1550)^3))
d= 0.0026 cm
L/d = 60216.96 > 900 SAFE
L/900 = 0.17 cm > 0.0026 cm SAFE
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 1550 mm
E = 2140672.78 kg/cm2
Thermal Expansion of the beam = 0.465 mm

Reaction & Stress in beam EE under BDT Condition

Reaction at E1 = (38514.92X735)/1550
= 18263.5 kg = 18.26 T
Reaction at E2 = 38514.92-18263.53
= 20251.39 kg = 20.25 T
Total Reaction at E1 = 18263.53+930.21
= 19193.74 kg
Total Reaction at E2 = 20251.39+930.21
= 21181.60 kg
Maximum bending moment = 19193.74X73.5-1136.56X0.735X36.75
= 1457777.26 kgcm

Bending Stress on Beam EE= 1457777.26/6950.87

= 209.73 kg/cm2 < 1359.2 kg/cm2 SAFE

Shear Stress on Beam EE = 21181.6/180

= 117.68 kg/cm2 < 1359.2 kg/cm2 SAFE
Welding :-
Shear Force on the Beam = 21181.60 kg
Fillet size is 6 mm , shear area = 90X0.6X0.707X2+40X0.6X0.707X2 = 110.29 cm
2

Stress = 21181.6/110.29
= 192.05 kg/cm2 < 1699 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 13 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
11. Description
Design of Beam : FF
1045 kg/m
C1 D1 C1 B1 E+E2 D
D E+E2 B1
F1 F2
3215 160 750 1125 1125 750 160 3215
10500
Reaction due to self weight
Self Weight of Beam FF = 490 kg/m
Load due to self weight of chequered plate and crowd load = (500+55)X1
= 555 kg/m
Coupling on Drum = 2360 kg
Reaction at D & E due to self weight = 1180 kg
Total UDL Load = 490+555 = 1045 kg/m
Reaction at F1= (1180X7285+145.5X7125+558.3X6375+2107.1X5250+558.34X4125+145.49X3375+
1180X3215+1045X10.5X2625)/10500
= 5680.52 kg = 5.68 T
Total Reaction on wheel boggie at F1 & D due to self weight = 5680.52+1180
= 6860.52 kg
Reaction at F2 = 1180+145.49+558.34+2107.13+558.34+145.49+1180+1.045X10500-5680.52
= 5680.52 kg = 5.68 T 1274
Total Reaction on wheel boggie at F2 & D due to self weight = 5680.52+1180
= 6860.52 kg
Moment due to self weight
Maximum bending moment = 6860.52X525-462.7X203.5-961.58X187.5-1180X112.5-1180X525
= 2575067.3 kgcm
Reaction due to live load
Reaction at F1= (28252.1X7285+3348.44X7125+3348.44X6375+2245.92X5250+3348.44X4125+
3348.44X3375+28252.1X3215)/10500
= 36071.9 kg = 36.07 T
Total Reaction on wheel boggie at F1 & D due to Live Load = 36071.94+9362.18
= 45434.12 kg
Reaction at F2= (28252.1+3348.44+3348.44+2245.92+3348.44+3348.44+28252.1-36071.94
= 36071.94 kg = 36.07 T
Total Reaction on wheel boggie at F2 & D due to Live Load = 36071.94+9362.18
= 45434.12 kg
Moment due to Live Load
Maximum bending moment = 45434.12X525-28252.1X203.5-3348.4X187.5-3348.4X112.5
17099090.65 kgcm
Total moment due to self weight & live load = 2575067.3+17099090.65
= 19674157.95 kgcm
Section of Beam 400
20

Area= 448 cm 352

2

Ixx= 941013.33 cm
4
1200

Zxx= 15177.63 cm 12
3

Iyy= 116765.01 cm
4

Zyy= 5838.25 cm
3

rx= 45.83 cm
ry= 16.14 cm 400
Area of Web = 288 cm2
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 14 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Le= 0.85x10500/10 cm
= 892.5 cm
Le/ry= 892.5/16.14
= 55.3
D/T = (1200+2X20)/20 f cb  f y
= 62 > 85 f bc  0.66 
Hence stiffners are required (f 1.4
cb  f y1.4 )1 1.4

Y = 26.5  10 5 = 0.66X866.55X250/((866.55^1.4+250^1.4)^(1/1.4))
 Le 
2 = 147.01 Mpa
 r  = 1498.57 kg/cm
2

=
 y 
26.5X10^5/(55.3^2)
= 866.55 Mpa
fcb = 866.55 Mpa
fy = 250 Mpa

Distance between Stiffeners

Maximum distance = 1.5d d= Clear disance between flanges
= 1.5X1200 = 1800 mm
Maximum distance provided between stiffeners = 592 mm
Minimum moment of Inertia of the pair of stiffeners(I) = 1.5Xd3Xt3/c2
Where,
t = Thickness of the Web
c = Maximum clearance distance between vertical stiffener
I = (1.5X119^3X1^3)/59.2^2
= 721.25 cm
4

Proposed moment of Inertia of Pair of Stiffeners 20 592

I = 10800 cm > 721.25 cm 582

4 4

SAFE 10
###

Bending Stress on Beam FF= 19674157.95/15177.63 1200

= 1296.26 kg/cm2 < 1498.57 kg/cm2 SAFE
Shear Stress on Beam FF = 52294.64/288
= 181.58 kg/cm2 < SAFE 1699 kg/cm2
Deflection of the Beam FF
d= (1050^3/(2.1X10^6X941013.3))X((5X1045X10.5/384)+(18202.1/48)X(3X3215/10500-4X(3215/10500)^3
+(3811.1/48)X(3X3375/10500-4X(3375/10500)^3)+(4310/48)X(3X4125/10500-4X(4125/10500)^3
+(4836.9/48)X(3X5250/10500-4X(5250/10500)^3)+(4310/48)X(3X6375/10500-4X(6375/10500)^3
+(3811.1/48)X(3X7125/10500-4X(7125/10500)^3)+(18202.1/48)X(3X7285/10500-4X(7285/10500)^3))
d= 0.660 cm
L/d = 1590.76 > 900 SAFE
L/900 = 1.17 cm > 0.6601 cm SAFE (As per IS:800 CL. No.-3.3.4)
Thermal Expansion of the beam = 0.000012XDTXL
DT = 25
L = 10500 mm
E = 2140672.78 kg/cm
2

Thermal Expansion of the beam = 3.15 mm

 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 15 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Load & Stress in beam FF under BDT Condition
Reaction at F1 = (37134.54X7285+6026.47X7125+6026.47X6375+1701.45X5250+6026.47X4125+
6026.47X3375+37134.54X3215)/10500
= 50038.2 kg = 50.04 T
Reaction at F2 = 37134.54+6026.47+6026.47+1701.45+6026.47+6026.47+37134.54-50038.205
= 50038.21 kg = 50.04 T
Maximum bending moment = 50038.205X525-37134.54X203.5-6026.5X187.5-6026.5X112.5
= 16905228.74 kgcm
Total bending moment due to BDT & Self weight = 16905228.74+2575067.3
= 19480296.04 kgcm
Bending Stress on Beam FF= 19480296.04/15177.63
= 1283.49 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam FF= 56898.73/288
= 197.57 kg/cm2 < 1359.2 kg/cm SAFE
2

12. Design of Beam : GG

1118.54 kg/m
C2 D2 C2 B2 E1
E1 B2
G1 G2
2650 725 750 1125 1125 750 725 2650
10500
Reaction due to self weight
Self Weight of Beam GG = 490 kg/m
Load due to self weight of chequered plate and crowd load = (500+55)X1.1325
= 628.54 kg/m
Total UDL Load = 490+628.54 = 1118.54 kg/m
Self Weight of CT M/c = 1469.58 kg (Acting at B2 location on left side only)
Total Load at B2 = 475.48+1469.58 = 1945.06 kg
Reaction at G1= (930.2X7850+158.3X7125+608.29X6375+2107.13X5250+608.29X4125+1627.8X3375+
930.21X2650+1118.54X10.5X2625)/10500
= 6158.86 kg = 6.16 T
Reaction at G2 = 930.21+158.26+608.29+2107.13+608.29+1627.8+930.21+1.11854X10500-6158.86
= 6683.71 kg = 6.68 T 1274
Moment due to self weight
Maximum bending moment = 6158.9X525-930.2X260-475.5X187.5-1011.5X112.5-1118.54X10500X0.13125
= 1247109.34 kgcm
Reaction due to live load
Reaction at G1= (10127.64X7850+4228.32X7125+4228.32X6375+2836.08X5250+4228.32X4125+
4228.32X3375+10127.64X2650)/10500
= 20002.3 kg = 20.00 T
Reaction at G2= (10127.64+4228.32+4228.32+2836.08+4228.32+4228.32+10127.64-20002.32)
= 17166.24 kg = 17.17 T
Moment due to Live Load
Maximum bending moment = 20002.32X525-10127.64X260-4228.3X187.5-4228.3X112.5
= 6599541.6 kgcm
Total moment due to self weight & live load = 1247109.34+6599541.6
= 7846650.94 kgcm
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 16 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Section of Beam 400
20

Area= 448 cm 352

2

Ixx= 941013.33 cm
4

1200
Zxx= 15177.63 cm 12
3

Iyy= 116765.01 cm
4

Zyy= 5838.25 cm
3

rx= 45.83 cm
ry= 16.14 cm 400
Area of Web = 288 cm2
Le= 0.85x10500/10 = 892.5 cm
Le/ry= 892.5/16.14
= 55.3
D/T = (1200+2X20)/20
= 62 > 85
Hence stiffners are required

Y = 26.5  10 5 f cb  f y
f bc  0.66 
 Le   f y1.4 )1 1.4
2

 r  (f 1.4

 y 
cb

= 26.5X10^5/(55.3^2) = 0.66X866.55X250/((866.55^1.4+250^1.4)^(1/1.4))
= 866.55 Mpa = 147.01 Mpa
fcb = 866.55 Mpa = 1498.57 kg/cm
2

fy = 250 Mpa
Maximum distance = 1.5d d= Clear disance between flanges
= 1.5X1200 = 1800 mm
Maximum distance provided between stiffeners = 592 mm
Minimum moment of Inertia of the pair of stiffeners(I) = 1.5Xd3Xt3/c2
Where,
t = Thickness of the Web
c = Maximum clearance distance between vertical stiffener
I = (1.5X119^3X1^3)/59.2^2
= 721.25 cm
4

Proposed moment of Inertia of Pair of Stiffeners 20 592

I = 10800 cm > 721.25 cm 582

4 4

SAFE 10
###

1200

Bending Stress on Beam GG= 7846650.94/15177.63

= 516.99 kg/cm2 < 1498.57 kg/cm2 SAFE
Shear Stress on Beam GG = 26161.18/288
= 90.84 kg/cm2 < 1699
SAFE kg/cm2
Deflection of the Beam GG
d= (1050^3/(2.1X10^6X941013.3))X((5X1118.5X10.5/384)+(10127.6/48)X(3X2650/10500-4X(2650/10500)^3
+(4703.8/48)X(3X3375/10500-4X(3375/10500)^3)+(5239.9/48)X(3X4125/10500-4X(4125/10500)^3
+(5427.1/48)X(3X5250/10500-4X(5250/10500)^3)+(5239.9/48)X(3X6375/10500-4X(6375/10500)^3
+(4703.8/48)X(3X7125/10500-4X(7125/10500)^3)+(10127.6/48)X(3X7850/10500-4X(7850/10500)^3))
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 17 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
d=
Description
0.524 cm
L/d = 2003.79 > 900 SAFE
L/900 = 1.17 cm > 0.5240 cm SAFE (As per IS:800 CL. No.-3.3.4)
Thermal Expansion of the beam = 0.000012XDTXL
DT = 25
L = 10500 mm
E = 2140672.78 kg/cm
2

Thermal Expansion of the beam = 3.15 mm

Load & Stress in beam GG under BDT Condition

Reaction at G1 = (18263.53X7850+7610.07X7125+7610.07X6375+2148.55X5250+7610.07X4125+
7610.07X3375+18263.53X2650)/10500
= 34557.9 kg = 34.56 T
Reaction at G2 = (18263.53+7610.07+7610.07+2148.55+7610.07+7610.07+18263.53-34557.945
= 34557.95 kg = 34.56 T
Maximum bending moment = 34557.945X525-18263.53X260-7610.1X187.5-7610.1X112.5
= 11111373.33 kgcm
Total bending moment due to BDT & Self weight = 11111373.33+1247109.34
= 12358482.67 kgcm
Bending Stress on Beam GG= 12358482.67/15177.63
= 814.26 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam GG= 41241.66/288
= 143.2 kg/cm2 < 1359.2 kg/cm SAFE
2

13. Design of C. T. Wheel Boggie-I

Reaction due to self weight = 6860.52 kg
Reaction due to live load = 45434.12 kg
325 kg/m
F1 D
X Y
400 400
800
Reaction due to self weight
Self Weight of Beam = 325 kg/m
Load due to self weight of chequered plate and crowd load = (500+55)X0.625
= 346.88 kg/m
Total UDL Load = 325+346.88 = 671.88 kg/m
Reaction at X due to self weight = (6860.52X400+0.67188X800^2/2)/800
= 3699.01 kg = 3.70 T
Reaction at Y due to self weight = 6860.52+0.67188X800-3699.01
= 3699.01 kg = 3.70 T
Maximum bending moment = 3699.01X40-671.88X0.4X20
= 142585.36 kgcm
Reaction due to live load
Reaction at X /Y due to live load = 45434.12/2
= 22717.1 kg = 22.72 T
Maximum bending moment = 22717.06x40
= 908682.4 kgcm
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Total moment due to self weight & live load = 142585.36+908682.4
= 1051267.76 kgcm
400
Section of Beam
12
Area= 176 cm 210
2

Ixx= 51416.75 cm
4

400
Zxx= 2425.32 cm 10
3

400
Bending Stress on Beam XY= 1051267.76/2425.32
= 433.46 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam XY= 26416.07/176
= 150.09 kg/cm2 < 1699 kg/cm2 SAFE
Ratio of D/t of the Beam = 400/10
= 40 < 85
Hence stiffners are not required
Reaction due to BDT load
Reaction at X/Y = 66921.355/2
= 33460.7 kg = 33.46 T
Maximum bending moment = 33460.6775x40 = 1338427.1 kgcm
Total bending moment due to BDT & Self weight = 142585.36+1338427.1
= 1481012.5 kgcm
Bending Stress on Beam XY= 1481012.46/2425.32
= 610.65 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam XY= 37159.6875/176
= 211.13 kg/cm2 < 1359.2 kg/cm SAFE
2

Deflection of the Beam XY

d= (80^3/(2.1X10^6X51416.8))X((5X671.9X0.8/384)+(52294.6/48)X(3X400/800-4X(400/800)^3))
d= 0.00520 cm
L/d = 15386.78 > 900 SAFE
L/900 = 0.09 cm > 0.0052 cm SAFE (As per IS:800 CL. No.-3.3.4)
Thermal Expansion of the beam = 0.000012XDTXL
DT = 25
L = 800 mm
E = 2140672.78 kg/cm
2

Thermal Expansion of the beam = 0.24 mm

Section at the Wheel
400
12

Area= 95.4 cm 210

2

Ixx= 4530.25 cm
4
157

Zxx= 724.94 cm 10
3

16
105
50
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Maximum bending moment = 26416.07X10.5
= 277368.74 kgcm
Bending Stress on Beam XY= 277368.74/724.94
= 382.61 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam XY= 26416.07/95.4
= 276.9 kg/cm2 < 1699 kg/cm2 SAFE

Stress in beam XY under BDT Condition

Maximum bending moment = 37159.6875X10.5
= 390177 kgcm
Bending Stress on Beam XY= 390176.71875/724.94
= 538.22 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam XY= 37159.6875/95.4
= 389.51 kg/cm2 < 1359.2 kg/cm SAFE
2

Max. wheel Reaction of wheel boggie-I with impact = 26416.07 kg

Max. wheel Reaction of wheel boggie-I with BDT = 37159.69 kg
Min. wheel Reaction of wheel boggie-I with self weight = 3699.01 kg
14. Design of C. T. Wheel Boggie-II
Reaction due to self weight = 6683.71 kg
Reaction due to live load = 20002.32 kg

375 kg/m
G1
U V
450 550
1000

Reaction due to self weight

Self Weight of Beam = 375 kg/m
Load due to self weight of chequered plate and crowd load = (500+55)X0.625
= 346.88 kg/m
Total UDL Load = 375+346.88
= 721.88 kg/m
Reaction at U due to self weight = (6683.71X550+0.72188X1000^2/2)/1000
= 3863.54 kg = 3.86 T
Reaction at V due to self weight = 6683.71+0.72188X1000-3863.54
= 3542.05 kg
= 3.54 T
Maximum bending moment = 3542.05X55-721.88X0.55X27.5
= 183894.32 kgcm
Reaction due to live load
Reaction at U due to live load = 20002.32x550/1000
= 11001.3 kg
= 11.00 T
Reaction at V due to live load = 20002.32-11001.276
= 9001.04 kg
Maximum bending moment = 11001.276x45
= 495057.42 kgcm
Total moment due to self weight & live load = 183894.32+495057.42
= 678951.74 kgcm
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description 400
Section of Beam
12

Area= 176 cm 210

2

Ixx= 51416.75 cm
4

400
Zxx= 2425.32 cm 10
3

400
Bending Stress on Beam UV= 678951.74/2425.32
= 279.94 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam UV= 14864.816/176
= 84.46 kg/cm2 < 1699 kg/cm SAFE
2

Ratio of D/t of the Beam = 400/10

= 40 < 85
Hence stiffners are not required
Reaction due to BDT load
Reaction at U = 34557.945x550/1000
= 19006.9 kg = 19.01 T
Reaction at V = 34557.945-19006.87
= 15551.08 kg
Maximum bending moment = 19006.87x45
= 855309.15 kgcm
Total bending moment due to BDT & Self weight = 183894.32+855309.15
= 1039203.5 kgcm
Bending Stress on Beam UV= 1039203.47/2425.32
= 428.48 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam UV= 19006.87/176
= 107.99 kg/cm2 < 1359.2 kg/cm SAFE
2

Deflection of the Beam UV

d= (100^3/(2.1X10^6X51416.8))X((5X721.9X1/384)+(26686/48)X(3X550/1000-4X(550/1000)^3))
d= 0.00516 cm
L/d = 19394.18 > 900 SAFE
L/900 = 0.11 cm > 0.00516 cm SAFE (As per IS:800 CL. No.-3.3.4)
Thermal Expansion of the beam = 0.000012XDTXL
DT = 25
L = 1000 mm
E = 2140672.78 kg/cm
2

Thermal Expansion of the beam = 0.3 mm

Section at the Wheel 400
12

Area= 95.4 cm 210

2

Ixx= 4530.25 cm
4
157

Zxx= 724.94 cm 10
3

16
105
50
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
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Description
Maximum bending moment = 14864.82X10.5
= 156080.57 kgcm
Bending Stress on Beam UV= 156080.57/724.94
= 215.3 kg/cm2 < 1699 kg/cm2 SAFE
Shear Stress on Beam UV= 14864.82/95.4
= 155.82 kg/cm2 < 1699 kg/cm2 SAFE
Stress in beam UV under BDT Condition
Maximum bending moment = 22870.41X10.5
= 240139 kgcm
Bending Stress on Beam UV= 240139.305/724.94
= 331.25 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam UV= 22870.41/95.4
= 239.73 kg/cm2 < 1359.2 kg/cm2 SAFE
Max. wheel Reaction of wheel boggie-II with impact = 14864.82 kg
Max. wheel Reaction of wheel boggie-II with BDT = 22870.41 kg
Min. wheel Reaction of wheel boggie-II with self weight = 3863.54 kg

15. Design of Portal Frame/Beam HH

15.1 Load Condition - I : Normal Service without wind
Beam HH

H1 H2

###
N P
6000

Section of Beam HH 400

12

Area= 360 cm 352

2

Ixx= 562982.08 cm
4
1100

Zxx= 10017.47 cm 12
3

Iyy= 100279.04 cm
4

Zyy= 5013.95 cm
3

rx= 39.55 cm
ry= 16.69 cm 400
Web Area = 264 cm
2

Le= 0.85x6000/10 cm = 510 cm

Le/ry= 510/16.69 f cb  f y
= 30.56 f bc  0.66 
(f 1.4
 f 1.4 )1 1.4
D/T = (1100+2X12)/12 = 0.66X2837.5X250/((2837.5^1.4+250^1.4)^(1/1.4))
y cb

= 94 > 85 = 161.18 Mpa

Hence stiffners are required = 1643.02 kg/cm
2
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
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Description
Y = 26.5  10 5
 Le 
2

 r 
 y 
= 26.5X10^5/(30.56^2)
= 2837.5 Mpa
fcb = 2837.5 Mpa
fy = 250 Mpa
Maximum distance = 1.5d d= Clear disance between flanges
= 1.5X1100 = 1650 mm
Maximum distance provided between stiffeners = 1065 mm
Minimum moment of Inertia of the pair of stiffeners(I) = 1.5Xd3Xt3/c2
Where,
t = Thickness of the Web
c = Maximum clearance distance between vertical stiffener
I = (1.5X109^3X1^3)/106.5^2
= 171.27 cm
4

Proposed moment of Inertia of Pair of Stiffeners 12 1065

I = 1584133 cm > 171.27 cm 1055

4 4

SAFE 10

###

1100
Girder diaphragms:
Maximum wheel load = 26416.07 kg
Bending moment in diaphragm = 26416.07x35.2/6 = 154974.28 Kg-cm
Thickness of diaphragm = 10.00 mm
Height of diaphragm = 250.00 mm
Section modulus of diaphragm = 1x25^2/6 = 104.17 cm
3

Stress = 154974.28/104.17
= 1487.71 kg/cm2 < 1643.02 kg/cm2 SAFE
Section of Portal (Column) 12 400

Area= 276 cm
2

Ixx= 321130.08 cm 10 360 10

4

Zxx= 6950.87 cm
3
900

Iyy= 74420 cm
4

Zyy= 3721 cm 12
3

rx= 34.11 cm
ry= 16.42 cm
Le= 814.3 cm f cb  f y
f bc  0.66 
Le/rx= 814.3/34.11 = 23.87 (f 1.4
cb  f y1.4 )1 1.4
D/T = (900+2X12)/12 = 0.66X4650.9X250/((4650.9^1.4+250^1.4)^(1/1.4))
= 77 < 85 = 163.06 Mpa
Hence stiffners are not required = 1662.18 kg/cm2
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
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Description
Y = 26.5  10 5

Le 
2

26.5X10^5/(23.87^2)
r 
=  x 
= 4650.9 Mpa
fcb = 4650.9 Mpa
fy = 250 Mpa
Considering frame(as per Steel Designer's Manual)
I2  h
k
I1  L
I2 = 562982.08 cm
4

I1 = 321130.08 cm
4

h = 814.3 cm
L = 600 cm
k= 562982.08x814.3/(321130.08x600) = 2.38
N= 2x2.38+3 = 7.76
15.1.1 Case-I : When C. T is on extream left side
Reaction due to self weight
475 kg/m
X Y U V
H1 H2
558 800 700 1000 2942
6000
Self Weight of Beam HH = 475 kg/m
Reaction at H1 = (3699X5442+3699X4642+3863.5X3942+3542.1X2942+0.475X6000^2/2)/6000
= 11916.92 kg
= 11.92 T
Reaction at H2 = 3699.01+3699.01+3863.54+3542.05+0.475X6000-11916.92
= 5736.69 kg
= 5.74 T

Bending moment = 5736.69x294.2-0.475x2942x147.1

= 1482169.3 kgcm

Moment and recation on Portal Frame due to self weight

H1
- - H2
+
Due to UDL
MH1SW1 = MH2SW1 = -4.75x600^2/(4x600)
-712.5 Kg-cm
- -
MSW1MAX = MH1SW1 + wL
2

8
= 712.5+4.75x600^2/8
= 214462.5 Kg-cm

VXSW1 = VYSW1 = wL HXSW X Y HYSW

2 VYSW
= 4.75x600/2 VXSW
= 1425 kg
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
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Description
HXSW1 = HYSW1 = MH1SW1
= -712.5/814.3
h
= -0.87 kg
Due point load
( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 3699.01 kg P3 = U = 3863.54 kg
P2 = Y = 3699.01 kg P4 = V = 3542.05 kg
L = 600 cm h = 814.3 cm
a1 = 55.8 cm b1 = 544.2 cm
a2 = 135.8 cm b2 = 464.2 cm
a3 = 205.8 cm b3 = 394.2 cm
a4 = 305.8 cm b4 = 294.2 cm
MH1sw2 = MH2sw2 = -3x(3699.01x55.8x544.2+3699.01x135.8x464.2+3863.54x205.8x394.2
+3542.05x305.8x294.2)/(600x7.76x2)
= -314950.15 Kg-cm

VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
L
VXsw2 = (3699.01x544.2+3699.01x464.2+3863.54x394.2+3542.05x294.2)/600
= 10491.9 kg
VYsw2 = P1 a 1  P 2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (3699.01x55.8+3699.01x135.8+3863.54x205.8+3542.05x305.8)/600
= 4311.68 kg
HXsw2 = HYsw2= MH1 NL

h
= -386.77 kg
Total moment due to self weight MH1SW & MH2SW = -712.5+-314950.15
= -315662.65 Kg-cm
Vertical & horizontal reaction
VXsw = 11916.93 kg
Vysw = 5736.68 kg
HXSW = HYSW = -387.64 kg
Reaction due to Live Load

X Y U V
H1 H2
558 800 700 1000 2942
6000

Self Weight of Beam HH = 475 kg/m

Reaction at H1 = (11001.3X5442+11001.3X4642+11001.3X3942+9001X2942)/6000
= 49821.22 kg
= 49.82 T
Reaction at H2 = 22717.06+22717.06+11001.276+9001.044-49821.22
= 15615.22 kg
= 15.62 T
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
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Description
Deflection of the Beam HH
d= (600^3/(2.1X10^6X321130.1))X((5X475X6/384)+(26416.1/48)X(3X558/6000-4X(558/6000)^3)
+(26416.07/48)X(3X1358/6000-4X(1358/6000)^3)+(14864.82/48)X(3X2058/6000-4X(2058/6000)^3
+(12543.09/48)X(3X3058/6000-4X(3058/6000)^3))
d= 0.3417 cm
L/d = 1755.83 > 900 SAFE
L/900 = 0.67 cm > 0.34 cm SAFE
Bending moment = 15615.22x294.2
= 4593997.72 kgcm
( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 22717.10 kg P3 = U = 11001.28 kg
P2 = Y = 22717.06 kg P4 = V = 9001.04 kg
L = 600 cm h = 814.3 cm
a1 = 55.8 cm b1 = 544.2 cm
a2 = 135.8 cm b2 = 464.2 cm
a3 = 205.8 cm b3 = 394.2 cm
a4 = 305.8 cm b4 = 294.2 cm
MH1sw2 = MH2 sw2 = -3x(22717.1x55.8x544.2+22717.06x135.8x464.2+11001.276x205.8x394.2
+9001.044x305.8x294.2)/(305.8x7.76x2)
= -1232012.4 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
L
VXsw2 = (22717.1x544.2+22717.06x464.2+11001.276x394.2+9001.044x294.2)/600
= 49821.2 kg

VYsw2 = P1 a 1  P 2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (22717.1x55.8+22717.06x135.8+11001.276x205.8+9001.044x305.8)/600
=15615.29 kg
HXsw2 = HYsw2= MH1 NL
h
= -1512.97 kg
Total moment due to self weight & SWL MH1SW & MH2SW = -315662.65+-1232012.4
= -1547675.05 Kg-cm
Vertical & horizontal reaction due to self weight & SWL
VXsw = 60313.13 kg
Vysw = 19926.97 kg
HXSW = HYSW = -1900.62 kg
15.1.2 Case-II : When C. T is at center
475 kg/m
X Y U V
H1 H2
1750 800 700 1000 1750
6000
Reaction due to self weight
Reaction at H1 = (3699X4250+3699X3450+3863.5X2750+3542.1X1750+0.475X6000^2/2)/6000
= 8975.93 kg
= 8.98 T
Reaction at H2 = 3699.01+3699.01+3863.54+3542.05+0.475X6000-8975.93
= 8677.68 kg
= 8.68 T
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
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Description
Bending moment = 8975.93x255-3699.01x80-0.475x2550x127.5
= 1838506.98 kgcm

( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 3699.01 kg P3 = U = 3863.54 kg
P2 = Y = 3699.01 kg P4 = V = 3542.05 kg
L = 600 cm h = 814.3 cm
a1 = 175 cm b1 = 425 cm
a2 = 255 cm b2 = 345 cm
a3 = 325 cm b3 = 275 cm
a4 = 425 cm b4 = 175 cm
MH1sw2 = MH2sw2 = -3x(3699.01x175x425+3699.01x255x345+3863.54x325x275
+3542.05x425x175)/(600x7.76x2)
= -389587.03 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
VXsw2 L
= (3699.01x425+3699.01x345+3863.54x275+3542.05x175)/600
= 7550.95 kg
VYsw2 = P1 a 1  P2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (3699.01x175+3699.01x255+3863.54x325+3542.05x425)/600
= 7252.66 kg

HXsw2 =
MH1 NL
HYsw2=

=
h
-478.43 kg
Total moment due to self weight MH1 & MH2 = -712.5+-389587.03
SW SW
= -390299.53 Kg-cm
Vertical & horizontal reaction
VXsw = 8975.95 kg
Vysw = 8677.66 kg
HXSW = HYSW = -479.30 kg
Reaction due to Live Load

X Y U V
H1 H2
1750 800 700 1000 1750
6000

Reaction at H1 = (22717.1X4250+22717.1X3450+11001.3X2750+9001X1750)/6000
= 36821.17 kg
= 36.82 T
Reaction at H2 = 22717.06+22717.06+11001.276+9001.044-36821.17
= 28615.27 kg
= 28.62 T
Bending moment = 36821.17x255-22717.06x80/20
= 9298530.11 kgcm
Deflection of the Beam HH
d= (600^3/(2.1X10^6X321130.1))X((5X475X6/384)+(26416.1/48)X(3X1750/6000-4X(1750/6000)^3)
+(26416.07/48)X(3X2550/6000-4X(2550/6000)^3)+(14864.82/48)X(3X3250/6000-4X(3250/6000)^3
+(12543.09/48)X(3X4250/6000-4X(4250/6000)^3))
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
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d=
Description
0.4763 cm
L/d = 1259.84 > 900 SAFE
L/900 = 0.67 cm > 0.48 cm SAFE

( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 22717.10 kg P3 = U = 11001.28 kg
P2 = Y = 22717.06 kg P4 = V = 9001.04 kg
L = 600 cm h = 814.3 cm
a1 = 175 cm b1 = 425 cm
a2 = 255 cm b2 = 345 cm
a3 = 325 cm b3 = 275 cm
a4 = 425 cm b4 = 175 cm
MH1sw2 = MH2sw2 = -3x(22717.1x175x425+22717.06x255x345+11001.276x325x275
+9001.044x425x175)/(600x7.76x2)
= -1720621.57 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
VXsw2 L
= (22717.1x425+22717.06x345+11001.276x275+9001.044x175)/600
= 36821.1 kg
VYsw2 = P1 a 1  P2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (22717.1x175+22717.06x255+11001.276x325+9001.044x425)/600
=28615.34 kg
HXsw2 = HYsw2=
MH1
NL
=
h
-2113.01 kg
Total moment due to self weight & SWL MH1SW & MH2SW = -390299.53+-1720621.57
= -2110921.1 Kg-cm
Vertical & horizontal reaction due to self weight & SWL
VXsw = 45797.09 kg
Vysw = 27179.63 kg
HXSW = HYSW = -2592.31 kg
15.1.3 Case-III : When C. T is on extream right side
475 kg/m
X Y U V
H1 H2
3,258 800 700 1000 242
6000

Reaction at H1 = (3699X2742+3699X1942+3863.5X1242+3542.1X242+0.475X6000^2/2)/6000
= 5255.30 kg
= 5.26 T
Reaction at H2 = 3699.01+3699.01+3863.54+3542.05+0.475X6000-5255.3
= 12398.31 kg
= 12.40 T
Bending moment = 5255.3x325.8-0.475x3258x162.9
= 1460080.85 kgcm

( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 3699.01 kg P3 = U = 3863.54 kg
P2 = Y = 3699.01 kg P4 = V = 3542.05 kg
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
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Description
L = 600 cm h = 814.3 cm
a1 = 325.8 cm b1 = 274.2 cm
a2 = 405.8 cm b2 = 194.2 cm
a3 = 475.8 cm b3 = 124.2 cm
a4 = 575.8 cm b4 = 24.2 cm
MH1sw2 = MH2sw2 = -3x(3699.01x325.8x274.2+3699.01x405.8x194.2+3863.54x475.8x124.2
+3542.05x575.8x24.2)/(600x7.76x2)
= -289827.26 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
VXsw2 L
= (3699.01x274.2+3699.01x194.2+3863.54x124.2+3542.05x24.2)/600
= 3830.31 kg
VYsw2 = P1 a 1  P 2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (3699.01x325.8+3699.01x405.8+3863.54x475.8+3542.05x575.8)/600
= 10973.3 kg

HXsw2 =
MH1 NL=
HYsw2= -355.92 kg

h
Total moment due to self weight MH1 & MH2 SW SW =
=
-712.5+-289827.26
-290539.76 Kg-cm
Vertical & horizontal reaction
VXsw = 5255.309 kg
Vysw = 12398.3 kg
HXSW = HYSW = -356.79 kg
Reaction due to Live Load

X Y U V
H1 H2
3,258 800 700 1000 242
6000

Reaction at H1 = (22717.1X2742+22717.1X1942+11001.3X1242+9001X242)/6000
= 20374.79 kg = 20.37 T
Reaction at H2 = 22717.06+22717.06+11001.276+9001.044-20374.79
= 45061.65 kg
= 45.06 T
Deflection of the Beam HH
d= (600^3/(2.1X10^6X321130.1))X((5X475X6/384)+(26416.1/48)X(3X3258/6000-4X(3258/6000)^3)
+(26416.07/48)X(3X4058/6000-4X(4058/6000)^3)+(14864.82/48)X(3X4758/6000-4X(4758/6000)^3
+(12543.09/48)X(3X5758/6000-4X(5758/6000)^3))
d= 0.3089 cm
L/d = 1942.66 > 900 SAFE
L/900 = 0.67 cm > 0.31 cm SAFE
Bending moment = 20374.79x325.8
= 6638106.58 kgcm
( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 22717.10 kg P3 = U = 11001.28 kg
P2 = Y = 22717.06 kg P4 = V = 9001.04 kg
 DESIGN CALCULATION OF STRUCTURAL
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Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
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Description
L = 600 cm h = 814.3 cm
a1 = 325.8 cm b1 = 274.2 cm
a2 = 405.8 cm b2 = 194.2 cm
a3 = 475.8 cm b3 = 124.2 cm
a4 = 575.8 cm b4 = 24.2 cm
MH1sw2 = MH2sw2 = -3x(22717.1x325.8x274.2+22717.06x405.8x194.2+11001.276x475.8x124.2
+9001.044x575.8x24.2)/(600x7.76x2)
= -1480413.51 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
VXsw2 L
= (22717.1x274.2+22717.06x194.2+11001.276x124.2+9001.044x24.2)/600
= 20374.8 kg
VYsw2 = P1 a 1  P 2 a 2  P3 a 3  P4 a 4

L
VYsw2 =(22717.1x325.8+22717.06x405.8+11001.276x475.8+9001.044x575.8)/600
= 45061.7 kg
HXsw2 = HYsw2=
MH1 NL
= -1818.02 kg

h
Total moment due to self weight & SWL MH1SW & MH2SW =
=
-290539.76+-1480413.51
-1770953.27 Kg-cm
Vertical & horizontal reaction due to self weight & SWL
VXsw = 25630.09 kg
Vysw = 12398.3 kg
HXSW = HYSW = -2174.81 kg
Max. Bending Moment on beam HH = 11137037.09 Kg-cm
Max. vertical reaction = 61738.14 kg
Max. horizontal reaction = 2592.31 kg
Horizontal bending moment on beam HH = 11137037.09/20
= 556851.85 Kg-cm
Bending Stress on Beam HH= 11137037.09/10017.47
= 1111.76 kg/cm2 < 1643.02 kg/cm2 SAFE
H. Bending Stress on Beam HH= 556851.8545/5013.95
= 111.06 kg/cm2 < 1643.02 kg/cm2 SAFE
Shear Stress on Beam HH= 61738.14/360
= 171.49 kg/cm2 < 1699 kg/cm SAFE
2

15.2 Design of Column

Self Weight of the Column = 2000 kg
Reaction on Column due to Self weight & SWL = 61738.14 kg
Total load on column = 63738.14 kg
Self weight of the wheel boogie = 2000.00 kg (approx.)
Self weight of the tie beam & counter weight = 14574.00 kg (approx.)
Total reaction on wheel bogie due to Self weight & SWL = 63738.14+2000+14574/2
= 73025.14 kg
Wheel reaction = 36512.6 kg
Horizontal motion : Traverse or Travel
Lateral load on wheel due to Inertia Force due to L. T. Motion
b= 0.01 = v 0.01
Lateral Load on wheel bogie = 0.01X73025.14 = 730.25 kg
Bogie Skew Load
SF = l X R
l/a = (6000+320)/10500 = 0.6
l = 0.025
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 30 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
SF = 0.025X73025.14 = 1825.63 kg
Section of Column
Area= 276 cm
2
12 400
Ixx= 321130.1 cm
4

Zxx= 6950.87 cm
3

Iyy= 74420 cm
4

Zyy= 3721 cm 10 360 10

3

rx= 34.11 cm

900
ry= 16.42 cm
Le= 814.3 mm 12
Le/rx= 81.43/34.11
= 2.39 < 180
D/T = 900/12 = 75 < 85 f cb  f y
f bc  0.66  1.4
Hence stiffners are not required (f  f 1.4 )1 1.4
 10
cb y

Y = 26.5 5
= 0.66X463927.5X250/((463927.5^1.4+250^1.4)^(1/1.4))

Le 
2 = 165 Mpa
  = 1681.96 kg/cm
2

= r
26.5X10^5/(2.39^2)
x  = 463928 Mpa
fcb = 463927.5 Mpa
fy = 250 Mpa
Allowable compressive stress on the column = 125.73 Mpa = 1281.65 kg/cm
2

Compressive Stress =63738.14/276= 230.94 kg/cm <

2
1281.65 kg/cm 2

Bending moment due to fixed end moment

Bending Stress =2110921.1/6950.87= 303.69 kg/cm2
< 1681.96 kg/cm2 SAFE
15.3 Design of Tie Beam
Section of Horizontal Tie Beam
Area= 176 cm
2

Ixx= 51416.75 cm
4

Zxx= 2425.32 cm
3
12 400
Iyy= 39597.87 cm
4

Zyy= 1979.89 cm
3

rx= 17.09 cm
ry= 15 cm 10 356 10
Le= 1050 cm
400

Le/rx= 1050/17.09
= 61.44 < 180 12
D/T= (400+2X12)/12 = 35 < 85
Hence stiffners are not required
f cb  f y
Y = 26.5  10 5
f bc  0.66 
(f 1.4
 f y1.4 )1 1.4
Le 
2 cb

 r  = 0.66X702X250/((702^1.4+250^1.4)^(1/1.4))
=  x 
26.5X10^5/(61.44^2) = 141.86 Mpa
= 702 Mpa = 1446.08 kg/cm2
fcb = 702 Mpa
fy = 250 Mpa
Direct tensile load on the beam =
730.25+1825.63+2592.31
=
5148.19 kg
Load on tie beam with counter weight = 750 kg/m
Maximum bending moment due to self weight= 7.5X1050^2/8 = 1033593.75 kgcm
Bending Stress =1033593.75/2425.32= 426.17 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 31 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Allowable compressive stress on tie beam= 141.86 Mpa = 1446.08 kg/cm2
Tensile Stress =5148.19/176= 29.25 kg/cm2 < 1446.08 kg/cm2
Load on the bolts = 3937.50 kg
Number of Bolts = 16
Load on each bolt = 3937.5/16 = 246.09 kg

Proposed M24 Bolts as per IS:1367, Part-3

Grade of Bolt = 4.6
Ultimate Tensile Load = 98000 N
UTS = 4077 kg/cm 2
YP = 2445 kg/cm 2
Cross sectional area = 4.52 cm 2
Allowable shear stress = 2445X0.3 = 734 kg/cm 2
Shear stress in bolt = 246.09/4.52 = 54 kg/cm2 < 733.5 kg/cm2
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 10500 mm
E = 2140672.78 kg/cm 2
Thermal Expansion of the beam = 3.15 mm

15.4 Design of Pin for L.T Wheel Bogie & Leg Connection
X X
A B
207
260

Vertical Load on Pin

Load at X/Reaction at A or B = 14574/4+63738.14/2 = 35512.57 kg

Horizontal Load on Pin

Load at X/Reaction at A or B = 2574.10 kg
Resultant Load on Pin
Load at X/Reaction at A or B = (35512.57^2+2574.1^2)^0.5 = 35605.74 kg
Bending Moment on Pin
Bending Moment at X = 35605.74X2.65 = 94355.21 kg-cm
Pin dia. = 100
Zxx = (3.14X10^3)/32 = 98.17 cm
3

Area = (3.14X10^2)/4 = 78.5 cm

2

Bending stress=94355.21/98.17 = 961.14 kg/cm2 < 5137.44 kg/cm2 SAFE

Direct Shear stress=35605.74/78.5 = 453.58 kg/cm < 3633 kg/cm
2 2
SAFE

Proposed Pin of Diameter : 100 mm, Length : 349 mm

Nos. Required : 4 , Material of Pin : IS:1570 55C8

15.5 Design of L. T. Wheel Bogie

Maximum Load on the column = 73025.14 kg
C
X Y
582 582
1164

Reaction at X & Y= 73025.14/2 = 36512.6 kg = 36.51 T

 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 32 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Maximum bending moment = 36512.57X58.2 = 2125031.574 kgcm
Section of Beam XY 400
12

Area= 231 cm 250

2

Ixx= 164541.9 cm
4

Zxx= 4707.92 cm 10
3

675
rx= 26.69 cm
Le= 116.4 cm
Le/rx= 116.4/26.69 400
= 43.61
D/T = 675/12 = 56 < 85
Hence stiffners are not required

Y = 26.5  10 5
f cb  f y
f bc  0.66 
Le 
2

  (f  f y1.4 )1 1.4
1.4

 r x 
cb
= 26.5X10^5/(43.61^2)
= 1393.4 Mpa = 0.66X1393.4X250/((1393.4^1.4+250^1.4)^(1/1.4))
fcb = 1393.4 Mpa = 155.13 Mpa
fy = 250 Mpa = 1581.35 kg/cm2
Bending Stress on Beam XY= 2125031.574/4707.92
= 451.37 kg/cm2 < 1581.35 kg/cm2 SAFE

Shear Stress on Beam XY = 36512.57/231

= 158.06 kg/cm2 < 1699 kg/cm2 SAFE

Deflection of the Beam XY

d= (116.4^3/(2.1X10^6X164541.9))X((36512.6/48)X(3X582/1164-4X(582/1164)^3))
d= 0.00347 cm
L/d = 33526.51 > 900 SAFE
L/900 = 0.13 cm > 0.0035 cm SAFE

Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 1164 mm
E = 2140672.78 kg/cm2

Thermal Expansion of the beam = 0.3492 mm

Section at the Wheel 400

12

Area= 144.6 cm2 258

Ixx= 20648.59 cm4
Zxxtop= 1472.56 cm3 10
258

Zxxbottom= 1334.08 cm3

1 90 165
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 33 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Maximum bending moment = 36512.57X16.5 = 602457.41 kgcm

Bending Stress on Beam XY= 602457.405/1334.08

= 451.59 kg/cm2 < 1699 kg/cm2 SAFE

Shear Stress on Beam XY= 36512.57/144.6

= 252.51 kg/cm2 < 1699 kg/cm2 SAFE

15.6 Design Connecting bolt of Column and Girder

Load on the column in X direction = 60313.13 kg

Load on the column in Y direction = 2592.31 kg

Proposed Cl. 8.8 M 24 fit bolts as per IS3640 with shank dia. 25 mm, shank area= 4.91 cm2
Number of bolts provided = 34

Zxx = 4X(100+400+900+1600+2500+3X3600)X4.91/60
= 5335.53 cm
3

Bending Stress on Bolt in X Direction= 2110921.1/5335.53

= 395.63 kg/cm2 < 1376.1468 kg/cm2 SAFE
Shear Stress on Bolt in X Direction = 60313.13/(34x4.91)
= 361.29 kg/cm < 1301.321 kg/cm SAFE
2 2

Shear Stress on Bolt in Y Direction = 2592.31/(34x4.91)

= 15.53 kg/cm < 1301.321 kg/cm SAFE
2 2
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 34 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
16 Description
Load Case - II : Normal Service with wind
16.1 Moment and recation on Portal Frame due to Wind Load parallel to flow 61.2
Area Distance Moment of
Form
from Rail Area about Rail Normal Wind
Nos. Factor (m )X
2
Wind Load on L/B H Level
NosX Level Load(kg) 61.2kg/m 2
(FF)
FF (m) (m )
3

Hoist Components = 11.7 1.3 1 1.3 19.8 10.12 200.10276 1210.11

Horizontal Girder = 1.5 0.5 2 1.3 1.95 8.6 16.77 119.34
Lifting Beam = 9.5 1.1 1 1.4 14.6 6 87.78 895.36
Column = 7 0.4 4 1.6 17.9 4.5 80.64 1096.7
Top horizontal Girder = 10 0.5 2 1.6 16 8.2 131.2 979.2
Tie Beam = 10 0.6 2 1.6 17.6 1.4 24.64 1077.12
Cabin = 1.5 2.2 1 1.3 4.29 6.8 29.172 262.55
Bogies & L.T. M/c = 3.5 1.5 4 1.3 27.3 0.8 21.84 1670.76
Total= 119.463 46.42 592.14 7311.14
Moment and recation on Portal Frame due to Normal Wind Load
Distance of C.G. from Rail Level= 592.14/119.463
= 4.96 m
P = 7311.14/2 a= 496 cm
= 3655.57 kg L= 600 cm

MH1NWIND = MH2NWIND = Pa H1 - H2

= -3655.57x496 + -
= -1813163 Kg-cm

VXNWIND = - VYNWIND =  2  P  a
L
Y
=
2x3655.57x496/600 HXNWIND X HYNWIND
=
6043.88 kg
HXNWIND =
HYNWIND = P VXNWIND VYNWIND
= 3655.57 kg
Total bending moment due to self weight, SWL & Wind

Max. Bending Moment on beam HH = 11137037.09+1813162.72 Kg-cm

= 12950199.81 Kg-cm
Max. vertical reaction = 61738.14+6043.88
= 67782.02 kg
Max. horizontal reaction = 2592.31+3655.57
= 6247.88 kg
Horizontal bending moment on beam HH = 12950199.81/20
= 647509.99 Kg-cm

Bending Stress on Beam HH= 12950199.81/10017.47

= 1292.76 kg/cm2 < 1662.18 kg/cm2 SAFE
H. Bending Stress on Beam HH= 647509.9905/5013.95
= 129.14 kg/cm2 < 1662.18 kg/cm2 SAFE
Shear Stress on Beam HH= 67782.02/360
= 188.28 kg/cm2 < 3632.64 kg/cm SAFE
2

16.2 Design of Column

Self Weight of the Column = 2000 kg
Reaction on Column due to Self weight & SWL = 67782.02 kg
Total load on column = 69782.02 kg
Self weight of the wheel boogie = 2000.00 kg (approx.)
Self weight of the girder, tie beam & counter weight = 14574.00 kg (approx.)
Total reaction on wheel bogie due to Self weight & SWL = 69782.02+2000+14574/2
= 79069.02 kg
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 35 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Wheel reaction = 39534.5 kg

Horizontal motion : Traverse or Travel

Lateral load on wheel due to Inertia Force due to L. T. Motion
b= 0.01 v = 0.01
Lateral Load on wheel bogie = 0.01X79069.02 = 790.69 kg
Bogie Skew Load
SF = l X R
l/a = (6000+320)/10500 = 0.6
l = 0.025
SF = 0.025X79069.02 = 1976.73 kg
Allowable compressive stress on the column = 125.73 Mpa = 1281.65 kg/cm
2

Compressive Stress =77069.02/276= 279.24 kg/cm2 < 1281.65 kg/cm2

Bending moment due to fixed end moment
Bending Stress =1813162.72/6950.87= 260.85 kg/cm 2
< 1681.96 kg/cm2 SAFE
16.3 Design of Tie Beam
Direct tensile load on the beam = 790.69+1976.73+6247.88
= 9015.30 kg
Load on tie beam with counter weight = 750 kg/m
Maximum bending moment due to self weight= 7.5X1050^2/8 = 1033593.75 kgcm
Bending Stress =1033593.75/2425.32= 426.17 kg/cm2 SAFE
Allowable compressive stress on tie beam= 141.86 Mpa = 1446.08 kg/cm2
Tensile Stress =9015.3/176= 51.22 kg/cm <
2
1446.08 kg/cm 2
Load on the bolts = 3937.50 kg
Number of Bolts = 16
Load on each bolt = 3937.5/16 = 246.09 kg
Proposed M24 Bolts as per IS:1367, Part-3
Grade of Bolt = 4.6
Ultimate Tensile Load = 98000 N
UTS = 4077 kg/cm 2
YP = 2445 kg/cm 2
Cross sectional area = 4.52 cm 2
Allowable shear stress = 2445X0.3 = 734 kg/cm2
Shear stress in bolt = 246.09/4.52 = 54 kg/cm 2 < 733.5 kg/cm2
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 10500 mm
E = 2140672.78 kg/cm2
Thermal Expansion of the beam = 3.15 mm
16.4 Design of Pin for L.T Wheel Bogie & Leg Connection
X X
A B
207
260

Vertical Load on Pin

Load at X/Reaction at A or B = 14574/4+69782.02/2 = 38534.51 kg
Horizontal Load on Pin
Load at X/Reaction at A or B = 4507.65 kg
Resultant Load on Pin
Load at X/Reaction at A or B = (38534.51^2+4507.65^2)^0.5 = 38797.26 kg
Bending Moment on Pin
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 36 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Bending Moment at X = 38797.26X2.65 = 102812.7 kg-cm
Pin dia. = 100
Zxx = (3.14X10^3)/32 = 98.17 cm
3

Area = (3.14X10^2)/4
= 78.5 cm
2

Bending stress=102812.74/98.17 = 1047.29 kg/cm2 < 5137.44 kg/cm2 SAFE

Direct Shear stress=38797.26/78.5 = 494.23 kg/cm2 < 3633 kg/cm2 SAFE

16.5 Design of L. T. Wheel Bogie

Maximum Load on the column = 79069.02 kg
C
X Y
582 582
1164
Reaction at X & Y= 79069.02/2 = 39534.5 kg = 39.53 T
Maximum bending moment = 39534.51X58.2 = 2300908.482 kgcm
Bending Stress on Beam XY= 2300908.482/4707.92
= 488.73 kg/cm2 < 1581.35 kg/cm2 SAFE
Shear Stress on Beam XY = 39534.51/231
= 171.15 kg/cm2 < 1699 kg/cm2 SAFE
Section at the Wheel
Maximum bending moment = 39534.51X16.5 = 652319.42 kgcm
Bending Stress on Beam XY= 652319.415/1334.08
= 488.97 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam XY= 39534.51/144.6
= 273.41 kg/cm2 < 1699 kg/cm2 SAFE
16.6 Design Connecting bolt of Column and Boggie
Load on the column in X direction = 67782.02 kg
=
Load on the column in Y direction = 6247.88+1976.73+790.69
= 9015.30 kg
Bending Stress on Bolt in X Direction= 1813162.72/5335.53
= 339.83 kg/cm2 < 1376.15 kg/cm2 SAFE
Shear Stress on Bolt in X Direction = 67782.02/(34x4.91)
= 406.03 kg/cm2 < 1301.32 kg/cm2 SAFE
Shear Stress on Bolt in Y Direction = 9015.3/(34x4.91)
= 54 kg/cm2 < 1301.3208 kg/cm2 SAFE
17 Load Case - III : Crane Out of Service
17.1 Moment and recation on Portal Frame due to Wind Load parallel to flow 152.9
Area Distance
Form Moment of Area Storm Wind
(m 2
)X from Rail
Wind Load on L/B H Nos. Factor about Rail Level Pressure
NosX Level
(FF) (m) (m )
3
152.91kg/m2
FF
Hoist Components = 11.7 1.3 1 1.3 19.8 10.12 200.10276 3023.2917
Horizontal Girder = 1.5 0.5 2 1.3 1.95 8.6 16.77 298.155
Lifting Beam = 9.5 1.1 1 1.4 14.6 6 87.78 2236.927
Column = 7 0.4 4 1.6 17.9 4.5 80.64 2739.968
Top horizontal Girder = 10 0.5 2 1.6 16 8.2 131.2 2446.4
Tie Beam = 10 0.6 2 1.6 17.6 1.4 24.64 2691.04
Cabin = 1.5 2.2 1 1.3 4.29 6.8 29.172 655.941
Bogies & L.T. M/c = 3.5 1.5 4 1.3 27.3 0.8 21.84 4174.17
Total= 119 46.42 592.14 18265.89
Distance of C.G. from Rail Level= 592.14/119.46 = 4.96 m
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 37 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
P = 18265.89/2 a= 496 cm
= 9132.95 kg L= 600 cm

ME1NWIND = ME2NWIND = Pa D1 - D2

= 9132.95x496 + -
= 4529943 Kg-cm
VXNWIND = - VYNWIND = 2 Pa

L
= -2x9132.95x496/600 X Y HYNWIND
HXNWIND
= -15099.8 kg
HXNWIND = HYNWIND = P VXNWIND VYNWIND
= 9132.95 kg
Total bending moment due to self weight & Wind = 214462.5+4529943.2
= 4744405.7 Kg-cm
Reactions
VXsw = 16524.8 kg
Vysw = 16524.8 kg
HXSW = HYSW = 9133.82 kg
Bending Stress on Beam HH= 4744405.7/10017.47
= 473.61 kg/cm2 < 1643.02 kg/cm2 SAFE
Shear Stress on Beam HH= 16524.81/360
= 45.9 kg/cm2 < 1699 kg/cm2 SAFE
17.2 Design of Column
Self Weight of the Column = 2000 kg
Reaction on Column due to Self weight & Wind load= 16524.81 kg
Total load on column = 18524.81 kg
Self weight of the wheel boogie = 2000.00 kg (approx.)
Self weight of the tie beam & counter weight= 14574.00 kg (approx.)
Total reaction on wheel bogie due to Self weight & Wind = 18524.81+2000+14574/2
= 27811.81 kg
Wheel reaction = 13905.9 kg
Compressive Stress =18524.81/276= 67.12 kg/cm2 < 1359.2 kg/cm2
Bending moment in X direction
Bending moment due to fixed end moment
Bending Stress =4744405.7/6950.87
= 682.56 kg/cm2 < 1359.2 kg/cm2 SAFE
17.3 Design of Pin for L.T Wheel Bogie & Leg connection
Vertical Load on Pin
Load at X/Reaction at A or B = 14574/2+18524.81 = 25811.81 kg
Horizontal Load on Pin
Load at X/Reaction at A or B = 9133.82 kg
Resultant Load on Pin
Load at X/Reaction at A or B = (25811.81^2+9133.82^2)^0.5 = 27380.22 kg
Bending Moment on Pin
Bending Moment at X = 27380.22X2.65 = 68401.3 kg-cm
Bending stress=68401.3/98.17 = 696.76 kg/cm2 < 4403.2 kg/cm2 SAFE
Direct Shear stress=25811.81/78.5 = 328.81 kg/cm 2 < 4403.2 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 38 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
17.4 Description
Design of L. T. Wheel Bogie
Maximum Load on the column = 27811.81 kg
Reaction at X & Y = 27811.81/2
= 13905.91 kg = 13.91 T
Maximum bending moment = 13905.905X58.2
= 809323.671 kgcm
Bending Stress on Beam XY= 809323.671/4707.92
= 171.91 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam XY= 13905.905/231
= 60.2 kg/cm2 < 1359.2 kg/cm2 SAFE
At minimum section
Maximum bending moment = 13905.905X16.5
= 229447.4325 kgcm
Bending Stress on Beam XY= 229447.4325/1334.08
= 171.99 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam XY= 13905.905/144.6
= 96.17 kg/cm2 < 1359.2 kg/cm2 SAFE
17.5 Design Connecting bolt of Column and Boggie
Fixed End moment on column in X direction = 4744405.70 kgcm
Load on the column in X direction = 16524.81 kg
Load on the column in Y direction = 9133.82 kg
Bending Stress on Bolt in X Direction= 4744405.7/5335.53
= 889.21 kg/cm2 < 2446.48 kg/cm2 SAFE
Shear Stress on Bolt in X Direction = 16524.81/(34x4.91)
= 98.99 kg/cm2 < 1301.32 kg/cm2 SAFE
Shear Stress on Bolt in Y Direction = 16524.81/(34x4.91)
= 54.71 kg/cm2 < 1301.32 kg/cm2 SAFE
18 Load Case - IV : Exceptional Loading Condition
BDT Factor = 2.4
Load/Reaction due to BDT of Hoist Motor
18.1 Case-I : When C. T is on extream left side

X Y U V
H1 H2

558 800 700 1000 2942

6000

Reaction at H1 = (33460.7X5442+33460.7X4642+19006.9X3942+15551.1X2942)/6000
= 76349.04 kg
= 76.35 T
Reaction at H2 = 33460.6775+33460.6775+19006.87+15551.075-76349.04
= 25130.26 kg
= 25.13 T
Bending moment = 25130.26x294.2
= 7393322.49 kgcm
( P1a1b1  P2 a 2 b2  P3 a3 b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 33460.68 kg P3 = U = 19006.87 kg
P2 = Y = 33460.68 kg P4 = V = 15551.08 kg
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 39 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
L = 600 cm h = 814.3 cm
a1 = 55.8 cm b1 = 544.2 cm
a2 = 135.8 cm b2 = 464.2 cm
a3 = 205.8 cm b3 = 394.2 cm
a4 = 305.8 cm b4 = 294.2 cm
MH1sw2 = MH2sw2= -3x(33460.6775x55.8x544.2+33460.6775x135.8x464.2+19006.87x205.8x394.2
+15551.075x305.8x294.2)/(600x7.76x2)
= -1954386.92 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
L
VXsw2 = (33460.6775x544.2+33460.6775x464.2+19006.87x394.2+15551.075x294.2)/600
= 76349 kg

VYsw2 = P1 a 1  P 2 a  P3 a 3  P4 a 4
2

L
VYsw2 = (33460.6775x55.8+33460.6775x135.8+19006.87x205.8+15551.075x305.8)/600
= 25130.33 kg

HXsw2 = HYsw2= MH1 NL

h
= -2400.08 kg
Total moment due to self weight & BDT MH1SW & MH2SW = -315662.65+-1954386.92
= -2270049.57 Kg-cm
Vertical & horizontal reaction due to self weight & BDT
VXsw = 88265.90 kg
Vysw = 30867.01 kg
HXSW = HYSW = -2787.73 kg
18.2 Case-II : When C. T is at center

X Y U V
H1 H2

1750 800 700 1000 1750

6000

Reaction at H1 = (33460.7X4250+33460.7X3450+19006.9X2750+15551.1X1750)/6000
= 56188.47 kg
= 56.19 T
Reaction at H2 = 33460.6775+33460.6775+19006.87+15551.075-56188.47
= 45290.83 kg
= 45.29 T
Bending moment = 56188.47x255-33460.6775x80/20
= 14194217.14 kgcm
( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 33460.68 kg P3 = U = 19006.87 kg
P2 = Y = 33460.68 kg P4 = V = 15551.08 kg
L = 600 cm h = 814.3 cm
a1 = 175 cm b1 = 425 cm
a2 = 255 cm b2 = 345 cm
a3 = 325 cm b3 = 275 cm
a4 = 425 cm b4 = 175 cm
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 40 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
MH1 sw2 = MH2sw2 = -3x(33460.6775x175x425+33460.6775x255x345+19006.87x325x275
+15551.075x425x175)/(600x7.76x2)
= -2670003.61 Kg-cm
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
VXsw2 L
= (33460.6775x425+33460.6775x345+19006.87x275+15551.075x175)/600
= 56188.4 kg

VYsw2 = P1 a 1  P2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (33460.6775x175+33460.6775x255+19006.87x325+15551.075x425)/600
= 45290.88 kg

HXsw2 =
MH1 NL
HYsw2=

=
h
-3278.89 kg
Total moment due to self weight & BDT MH1 & MH2 = -390299.53+-2670003.61
SW SW
= -3060303.14 Kg-cm

Vertical & horizontal reaction due to self weight & BDT

VXsw = 65164.37 kg
Vysw = 39544.67 kg
HXSW = HYSW = -3758.20 kg

18.3 Case-III : When C. T is on extream right side

X Y U V
H1 H2
3,258 800 700 1000 242
6000

Reaction at H1 = (33460.7X2742+33460.7X1942+19006.9X1242+15551.1X242)/6000
= 30683.31 kg
= 30.68 T
Reaction at H2 = 33460.6775+33460.68+19006.87+15551.075-30683.31
= 70795.99 kg
= 70.80 T
Bending moment = 30683.31x325.8
= 9996622.4 kgcm
( P1 a1b1  P2 a 2 b2  P3 a3b3  P4 a 4 b4 ) 3
MH 1SW 2  MH 2 SW 2  
L 2N
P1 = X = 33460.68 kg P3 = U = 19006.87 kg
P2 = Y = 33460.68 kg P4 = V = 15551.08 kg
L = 600 cm h = 814.3 cm
a1 = 325.8 cm b1 = 274.2 cm
a2 = 405.8 cm b2 = 194.2 cm
a3 = 475.8 cm b3 = 124.2 cm
a4 = 575.8 cm b4 = 24.2 cm
MH1sw2 = MH2sw2= -3x(33460.6775x325.8x274.2+33460.68x405.8x194.2+19006.87x475.8x124.2
+15551.075x575.8x24.2)/(600x7.76x2)
= -2244199.65 Kg-cm
P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
L
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 41 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
VXsw2 = P1 b 1  P 2 b 2  P3 b 3  P 4 b 4
VXsw2 L
= (33460.6775x274.2+33460.68x194.2+19006.87x124.2+15551.075x24.2)/600
= 30683.3 kg

VYsw2 = P1 a 1  P2 a 2  P3 a 3  P4 a 4

L
VYsw2 = (33460.6775x325.8+33460.68x405.8+19006.87x475.8+15551.075x575.8)/600
= 70796.02 kg
HXsw2 = HYsw2= MH1 NL
= h kg
-2755.99
Total moment due to self weight & BDT MH1SW & MH2SW = -290539.76+-2244199.65
= -2534739.41 Kg-cm
Vertical & horizontal reaction due to self weight & BDT
VXsw = 35938.59 kg
Vysw = 12398.3 kg
HXSW = HYSW = -3112.78 kg
Max. Bending Moment on beam HH = 14194217.14 Kg-cm
Max. vertical reaction = 88265.90 kg
Max. horizontal reaction = 3758.20 kg
Horizontal bending moment on beam HH = 14194217.14/20
= 709710.86 Kg-cm
Bending Stress on Beam HH= 14194217.14/10017.47
= 1416.95 kg/cm2 < 1359.2 kg/cm2 Fail
H. Bending Stress on Beam HH= 709710.86/5013.95
= 141.55 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam HH= 88265.9/360
= 245.18 kg/cm2 < 1359.2 kg/cm SAFE
2

18.4 Design of Column

Self Weight of the Column = 2000 kg
Reaction on Column due to Self weight & SWL = 88265.90 kg
Total load on column = 90265.90 kg
Self weight of the wheel boogie = 2000.00 kg (approx.)
Self weight of the tie beam & counter weight = 14574.00 kg (approx.)
Total reaction on wheel bogie due to Self weight & SWL = 90265.9+2000+14574/2
= 99552.90 kg
Wheel reaction = 49776.5 kg
Horizontal motion : Traverse or Travel
Lateral load on wheel due to Inertia Force due to L. T. Motion
b= 0.01 v = 0.01
Lateral Load on wheel bogie = 0.01X99552.9 = 995.53 kg
Bogie Skew Load
SF = l X R
l/a = (6000+320)/10500 = 0.6
l = 0.025
SF = 0.025X99552.9 = 2488.82 kg
Compressive Stress =90265.9/276= 327.05 kg/cm 2 < 1359.2 kg/cm2
Bending moment due to fixed end moment
Bending Stress =2670003.61/6950.87
= 384.13 kg/cm2 < 1359.2 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 42 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
18.5 Description
Design of Tie Beam
Direct tensile load on the beam = 995.53+2488.82+3758.2 = 7242.55 kg
Load on tie beam with counter weight = 750 kg/m
Maximum bending moment due to self weight= 7.5X1050^2/8 = 1033593.80 kgcm
Bending Stress =1033593.8/2425.32= 426.17 kg/cm2
Tensile Stress =7242.55/176= 41.15 kg/cm2 < 1359.2 kg/cm2 SAFE
Load on the bolts = 3937.50 kg
Number of Bolts = 16
Load on each bolt = 3937.5/16 = 246.09 kg
Proposed M24 Bolts as per IS:1367, Part-3
Grade of Bolt = 4.6
Ultimate Tensile Load = 98000 N
UTS = 4077 kg/cm 2
YP = 2445 kg/cm 2
Cross sectional area = 4.52 cm 2
Allowable shear stress = 2445X0.3 = 734 kg/cm2
Shear stress in bolt = 246.09/4.52 = 54 kg/cm 2 < 733.5 kg/cm2
Thermal Expansion of the beam = 0.000012XDTXL (As per IS:800 CL. No.-3.3.4)
DT = 25
L = 10500 mm
E = 2140672.78 kg/cm2
Thermal Expansion of the beam = 3.15 mm
18.6 Design of Pin for L.T Wheel Bogie & Leg Connection
X X
A B
207
260
Vertical Load on Pin
Load at X/Reaction at A or B = 14574/4+90265.9/2 = 48776.45 kg
Horizontal Load on Pin
Load at X/Reaction at A or B = 3621.28 kg
Resultant Load on Pin
Load at X/Reaction at A or B = (48776.45^2+3621.28^2)^0.5 = 48910.69 kg
Bending Moment on Pin
Bending Moment at X = 48910.69X2.65 = 129613.3 kg-cm
Pin dia. = 100
Zxx = (3.14X10^3)/32 = 98.17 cm
3

Area = (3.14X10^2)/4 = 78.5 cm

2

Bending stress=129613.33/98.17 = 1320.29 kg/cm 2 < 4403.2 kg/cm2 SAFE

Direct Shear stress=48910.69/78.5 = 623.07 kg/cm2 < 4403 kg/cm 2 SAFE
Proposed Pin of Diameter : 100 mm, Length : 349 mm
Nos. Required : 4 , Material of Pin : IS:1570 55C8
18.7 Design of L. T. Wheel Bogie
Maximum Load on the column = 99552.90 kg
C
X Y
582 582
1164

Reaction at X & Y= 99552.9/2 = 49776.5 kg = 49.78 T

Maximum bending moment = 49776.45X58.2 = 2896989.39 kgcm
Bending Stress on Beam XY= 2896989.39/4707.92
= 615.34 kg/cm2 < 1359.2 kg/cm2 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 43 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description
Shear Stress on Beam XY = 49776.45/231
= 215.48 kg/cm2 < 1359.2 kg/cm2 SAFE
Maximum bending moment = 49776.45X16.5 = 821311.43 kgcm
Bending Stress on Beam XY= 821311.425/1334.08
= 615.64 kg/cm2 < 1359.2 kg/cm2 SAFE
Shear Stress on Beam XY= 49776.45/144.6
= 344.24 kg/cm2 < 1359.2 kg/cm2 SAFE

18.8 Design Connecting bolt of Column and Boggie

Load on the column in X direction = 88265.90 kg
Load on the column in Y direction = 7242.55 kg
Fixed End moment on column in X direction = 2670003.61 kgcm
Shear Stress on Bolt in X Direction = 88265.9/(34x4.91)
= 528.73 kg/cm < 1301.32 kg/cm SAFE
2 2

Shear Stress on Bolt in Y Direction = 7242.55/(34x4.91)

= 43.38 kg/cm < 1301.32 kg/cm SAFE
2 2

19 Stability of Crane
19.1 Self Weight of Crane Parts
Components Weight(T) Nos. Total Weight(T)
1 Hoist Components 41.000 X 1 = 41
2 Top Horizontal Girder 3.300 X 2 = 6.6
3 Horizontal beam 2.300 X 2 = 4.6
4 Bottom tie Girder 2.300 X 2 = 4.6
5 Column 1.800 X 4 = 7.2
6 Idle Wheel Bogies 1.500 X 2 = 3
7 Drive Wheel Bogies 2.000 X 2 = 4
8 Wt. of Cabin 0.900 X 1 = 0.9
9 Wt. of Ladder 0.287 X 1 = 0.287
10 Weight of Lifting Beam 4.460 X 1 = 4.46
11 Counter Weight 5.495 X 2 = 10.99
Total = 87.6 61.2

19.2 Service Wind Load parallel to flow

Area Distance Moment of
Form
from Rail Area about Rail Normal Wind
Nos. Factor (m )X
2
Wind Load on L/B H
NosX Level Level Load(kg) 61.2kg/m 2
(FF)
FF (m) (m )
3

Hoist Components = 11.7 1.3 1 1.3 19.8 10.12 200.10276 1210.11

Horizontal Girder = 1.5 0.5 2 1.3 1.95 8.6 16.77 119.34
Lifting Beam = 9.5 1.1 1 1.4 14.6 6 87.78 895.36
Column = 7 0.4 4 1.6 17.9 4.5 80.64 1096.7
Top horizontal Girder = 10 0.5 2 1.6 16 8.2 131.2 979.2
Tie Beam = 10 0.6 2 1.6 17.6 1.4 24.64 1077.12
Cabin = 1.5 2.2 1 1.3 4.29 6.8 29.172 262.55
Bogies & L.T. M/c = 3.5 1.5 4 1.3 27.3 0.8 21.84 1670.76
Total= 119.463 46.42 592.14 7311.14
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 44 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
19.3 Description
Storm Wind Load parallel to flow
Area Distance Moment of Area Storm Wind
Form
from Rail
Nos. Factor (m )X
2
Wind Load on L/B H about Rail Level Pressure
NosX Level
(FF) (m3) 152.91kg/m2
FF (m)
Hoist Components = 11.7 1.3 1 1.3 19.8 10.12 200.10276 3023.2917
Horizontal Girder = 1.5 0.5 2 1.3 1.95 8.6 16.77 298.155
Lifting Beam = 9.5 1.1 1 1.4 14.6 6 87.78 2236.927
Column = 7 0.4 4 1.6 17.9 4.5 80.64 2739.968
Top horizontal Girder = 10 0.5 2 1.6 16 8.2 131.2 2446.4
Tie Beam = 10 0.6 2 1.6 17.6 1.4 24.64 2691.04
Cabin = 1.5 2.2 1 1.3 4.29 6.8 29.172 655.941
Bogies & L.T. M/c = 3.5 1.5 4 1.3 27.3 0.8 21.84 4174.17
Total= 119 0 592.14 18265.89

As the gate is guide in the groove wind load on the gate has not been consider.
19.4
Stability of gantry crane with gate under normal operating condition with steady wind pressure of 61.2kg/cm 2
on exposed area. The stability factor shall be at least 1.5.
19.4.1 Case-I : When C. T is on extream left side

2
3 1 C. G. of Gate

D
C
1683 1317 3000 9

10 8
F L O W

5 5
4
4
11
0 11

6
6
7
7

A B
6000
Tilting moment= 1210.1x10.12+119.34x8.6+895.36x6+1096.7x4.5+979.2x8.2+1077.12x1.4+262.55x6.8
+1670.76x0.8
= 36239.30 kgm
= 36239.30 Tmm
Stabilising Moments= 41x4317+6.6x3000+2.3x6000+(2.3+1.8+1.5+2+5.495)x6000+4.46x4317
= 308421 Tmm
Stability Factor= 308420.82/36239.3032
= 8.5 > 1.5 SAFE
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 45 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
19.4.2 Description
Case-II : When C. T is at Center

3 1 C. G. of Gate

D
C
3000 3000 9

10 8
F L O W
5
5
4
4
11
0 11

6
6
7 7

A B
6000
Tilting moment= 1210.11x10.12+119.34x8.6+895.36x6+1096.7x4.5+979.2x8.2+1077.12x1.4+262.55x6.8
+1670.76x0.8
= 36239.30 kgm = 36239.30 Tmm
Stabilising Moments= 41x3000+6.6x3000+2.3x3000+(2.3+1.8+1.5+2+5.495)x6000+4.46x3000
= 241650 Tmm
Stability Factor= 241650/36239.3032
= 6.67 > 1.5 SAFE
19.4.3 Case-III : When C. T is on extream Right side
2 C. G. of Gate

3 1

D
C
3000 1557 1443 9
F L O W
10 8

5 5
4
4
11
11

6
6
7
7

A B
6000
Tilting moment= 1210.11x10.12+119.34x8.6+895.36x6+1096.7x4.5+979.2x8.2+1077.12x1.4+262.55x6.8
+1670.76x0.8
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 46 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description = 36239.30 kgm = 36239.30 Tmm

Stabilising Moments= 41x1443+6.6x3000+2.3x6000+(2.3+1.8+1.5+2+5.495)x6000+4.46x1443

= 177769 Tmm
Stability Factor= 177768.78/36239.3032
= 4.91 > 1.5 SAFE

19.5 Stability of gantry crane without load and not operating with storm wind pressure of 152.91kg/cm2 on exposed
area. The stability factor shall be at least 1.25.
19.5.1 Case-I : When C. T is on extream left side
2
3 1 C. G. of Gate
F L O W D
C
1683 1317 3000 9

10 8

5 5
4
4
11
11
0
6
6
7
7

A B
6000
Tilting moment= 3023.3x10.12+298.155x8.6+2236.927x6+2739.968x4.5+2446.4x8.2+2691.04x1.4+655.9x6.8
+4174.17x0.8

= 90538.93 kgm = 90538.93 Tmm

Stabilising Moments= 41x4317+6.6x3000+2.3x6000+(2.3+1.8+1.5+2+5.495)x6000+4.46x4317

= 308421 Tmm
Stability Factor= 308420.82/90538.933804

= 3.41 > 1.25 SAFE

 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 47 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
19.5.2 Description
Case-II : When C. T is at center
2
3 1 C. G. of Gate

3000 3000 D
C
9

10 8
F L O W
5
5
4
4
11
11

6
6
7 7

A 6000 B
Tilting moment= 3023.3x10.12+298.2x8.6+2236.927x6+2739.968x4.5+2446.4x8.2+2691.04x1.4+655.941x6.8
+4174.17x0.8
= 90538.93 kgm = 90538.93 Tmm
Stabilising Moments= 41x3000+6.6x3000+2.3x3000+(2.3+1.8+1.5+2+5.495)x6000+4.46x3000
= 241650 Tmm
Stability Factor= 241650/90538.933804
= 2.67 > 1.25 SAFE
19.5.3 Case-III : When C. T is on extream right side

2
C. G. of Gate
3 1
3000 1557 1443 D
C
9

10 8
F L O W

5 5
4
4
11
11

6
6
7 7

A 6000 B
Tilting moment= 3023.3x10.12+298.2x8.6+2236.927x6+2739.968x4.5+2446.4x8.2+2691.04x1.4+655.941x6.8
+4174.17x0.8
= 90538.93 kgm
= 90538.93 Tmm
Stabilising Moments= 41x1443+6.6x3000+2.3x6000+(2.3+1.8+1.5+2+5.495)x6000+4.46x1443
 DESIGN CALCULATION OF STRUCTURAL
COMPONENTS FOR 60T CAP. GANTRY CRANE Page: 48 of 48
Om Metals Infra Projects Ltd. FOR OPERATION OF SPILLWAY STOPLOG
Kothari Bhawan, W-3/3, Western Avenue,
Sanik Farms, Khanpur, New Delhi – 110 005 VYASI H. E. PROJECT Rev.:R2
Description = 177769 Tmm
Stability Factor= 177768.78/90538.93
= 1.96 > 1.25 SAFE