MONORAIL DESIGN( As per Euro Code)

Simply Support Span, L = 4.2 m

Overhang Span, Lo = 1.0 m
Member Size = 200x200
Yield strength, Fy = 355.0 N/mm² NV A36 Material

A. SECTIONAL PROPERTIES: Properties of Rolled Section; H 200x200

Self weight, w = 49.90 kg/m

= 0.50 kN/m
Area, A = 63.53 cm²
Depth of section, d = 20.0 cm
Width of flange, bf = 20.0 cm
Thickness of flange, tf = 1.2 cm
Thickness of web, tw = 0.8 cm
Moment of inertia about major axis, Iyy = 4720.0 cm4
Moment of inertia about minor axis, Izz = 1600.0 cm4
Section modulus about major axis, Zyy = 472.0 cm³
Section modulus about minor axis, Zzz = 160.0 cm³
Plastic Section Modulus abt major axis Wply = 513.15 cm³
Plastic Section Modulus abt minor axis Wplz = 480.0 cm³
Radius of gyration, rx = 8.62 cm
Radius of gyration, ry = 5.02 cm
Radius of fillet, r = 1.30 cm

B. CLASS CLASSIFICATION:

є = √(235/fy) = 0.81

a. Class Identification For Web:

α = 0.5
Ψ = -2
For Class 1;
If; α <= 0.5: c/t<= 36є/α
α>0.5: c/t<= 396є/(13α-1) ; Hence c/t = 58.58
For Class 2;
If; α <= 0.5: c/t<= 41.5є/α
α>0.5: c/t<= 456є/(13α-1) ; Hence c/t = 67.53
For Class 3;
If; Ψ<= -1 ; c/t<= 62є(1-Ψ) √(-Ψ)
Ψ> -1 ; c/t<= 42є/(0.67+0.33Ψ) ; Hence c/t = 214.02

Web Property: c = (h-2tf-2r) = 15.00 cm

c/tw = 18.75
Hence; Web is in CLASS 1

b. Class Identification For Flange:

Stree type in flange = 1.0
Stress Ratio,Ψ = 0.6
α = 1.0
kσ = 0.615
For Class 1;
Tip is in compression; c/t<=9є/α;
Tip is in tension; c/t<=9є/(α√α); Hence c/t = 7.32
For Class 2;
Tip is in compression; c/t<=10є/α;
Tip is in tension; c/t<=10є/(α√α); Hence c/t = 8.14
For Class 3;
Tip is in compression or tension; c/t<=21є√kσ ; Hence c/t = 13.40

Flange Property: c = (b-tw-2r)/2 = c 8.3 cm

c/tf = c/tf 6.92
Hence; Flange is in CLASS 1

Therefore overall Cross-Section is in Class 1

1 of 19
 C. LOAD CALCULATION for ULS - A :

4.2 1.0

0.11

200x200

20.0 kN

Capacity, P = 10.0 kN
Hoist Weight, Wh = 10.0 kN (Assumed)
Dynamic Load Factor,D f = 1.5 %
Lateral Load,Hh = 10 %
Load Factor,DL = 1.3
Axial Load, Va = 10 %
Wheel Spacing = 0.11 m (Assumed)
Wheels, Nw = 2 Pairs
Material factor; ý = 1.15 Ref: EC-3

LOADS:
Vertical Point Load; Pv = (P*Df+Wh)*DL
= (10 * 1.5 + 10) * 1.3 = 32.5 kN
Vertical Point Load per Trolley Axle = 32.5 / 2 = 16.25 kN
TotalAxial Load = (10+10)*1.3*10% = 2.60 kN
Total Lateral Load = (10+10)*1.3*10% = 2.60 kN

1.0 Loading Condition - Trolley placed at Simply Supported Span :

Acceleration Values:

Accelerations 1yr Factor

ax = 1.1538 0.7
ay = 2.0812 0.7
az = 2.8941 0.7

Note: Max bending moment occurs when centre line of trolley and first wheel consides with centre line of member.

Axial Load acceleration coefficient, Aa = 2.0812*0.7 / 9.81 = 0.1485 Considering the maximum of ax &
ay for different oriantation of
Lateral Load acceleration coefficient, A h = 2.0812*0.7 / 9.81 = 0.1485 Runway Beam.
Vertical Load acceleration coefficient, A v = 2.8941*0.7 / 9.81 = 0.2065
Effective vertical load per axle, P wa = (P+Wh)/Nw = 10.0 kN

Total Axial Load, Pa + Aa*2Pwa = 5.57 kN

Total Lateral Point Load per axle, P h + Ah*Pwa = 4.09 kN
Total Vertical Point Load per axle, P w + Av*Pwa = 18.32 kN

Reactions & Moments due to Vertical Loads:

cL of trolley
18.32 18.32 0.75

cL of beam

A C D B
2.0175 0.11 2.0725
e f g
4.2 1.0

Self Weight of Beam (UDL) = 0.50 kN/m

Total Vertical UDL (Selfweight of Beam), (D L + Av)* Self wt. = 0.75 kN/m
Lateral UDL due to selfweight of beam, A v* Self wt. = 0.07 kN

Reaction at A = 20.13 kN
Reaction at B = 19.65 kN
Moment at D = Pg(f+2e)/L+wL2/8 = 39.12 kNm
Moment at C = Pe(f+2g)/L+wL2/8 = 39.09 kNm

2 of 19
 Reactions & Moments due to Lateral Loads:

cL of trolley

4.09 4.09 0.07

`

cL of beam

A C D B
2.0175 0.11 2.0725
e f g
4.2 1.0

Reaction at A = 4.294 kN
Reaction at B = 4.187 kN
Moment at D = Pg(f+2e)/L+wL2/8 = 8.52 kNm
Moment at C = Pe(f+2g)/L+wL2/8 = 8.51 kNm

1.0 A Stress Check 1 :- Capacity check

Check for Combine Stresses :

For Axial Force:

Axial Force, Af.Ed = 5.57 kN
Axial stress, σf.Ed = 0.88 N/mm2
Axial Resistance of Section, Af.Rd = 1961.14 kN
Unity Check Ratio = 0.003 < 1 hence OK

For Bending Moment about Minor axis:

Maximum Moment abt Minor axis,M z.Ed = 8.52 kNm
Bending stresses (minor axis), σ z.Ed = 53.24 N/mm2
Moment Resistance of Section(Minor Axis), M z.Rd = 148.17 kNm
Unity Check Ratio = 0.06 < 1 hence OK

For Bending Moment about Major axis:

Unity Check Ratio Moment abt Major axis,M y.Ed
Maximum = 39.12 kNm
Bending Stresses (major axis), σ y.Ed = 82.88 N/mm2
Moment Resistance of Section(Major Axis), M y.Rd = Calculated below

The designed buckling resistance moment for laterally unrestrained beam is given as:

Mb.Rd = XLTWply fy/ý

Where; Wply = Plastic Section Modulas abt major axis (For Class 1 & 2 Sections)
Elastic Section Modulas abt major axis (For Class 3 Section)
= 513.15 cm3
XLT = Reduction Factor for lateral-torsional buckling
= 1/(ФLT+√(ФLT2-ÝLT2)) = 0.80
ФLT = 0.5(1+áLT(ÝLT-0.2)+ÝLT2) = 0.88
Imperpection factor; áLT = 0.21 (Table 6.1 EC-3)

Non-dimensional slenderness Ý LT, for rolled section;

ÝLT = √(Wplyfy/Mcr) = 0.79
L= Length between unsupported points = 4.2 m
Iz = Moment of inertia abt minor axis = 1600.00 cm4
Iw = Warping Constant, Iyy (d-tf)2/4 = 365516.8 cm6
It = Torsional Constant = 26.04 cm4
C1 = 1.88-1.4Ψ+0.52Ψ (but C1<=2.7)
2
= 1.000
Ψ = Correction factor for the effects of any change
of moment along the length L
For constant moment b/t points C 1 may be taken as 1.001
Mcr C1pi()2EIz/Lcr2√(Iw/Iz+Lcr2GIt/pi()2EIz) = 290.97 kNm

Moment resistance of section about major axis;

My.Rd = 126.83 kNm
Unity Check Ratio = 0.31 < 1 hence OK

3 of 19
 Combine U/C Ratio:
Af.Ed/Af.Rd+My.Ed/My.Rd+Mz.Ed/Mz.Rd For Class 1 & Class 2 Sections

√((σf.Ed/(Fy/ý))2+(σy.Ed/(Fy/ý))2+(σz.Ed/(Fy/ý))2-(σf.Ed/(Fy/ý))(σy.Ed/(Fy/ý))-(σy.Ed/(Fy/ý))
For Class 3 Sections
(σz.Ed/(Fy/ý))-(σf.Ed/(Fy/ý))(σz.Ed/(Fy/ý))+3(σs.Ed/(Fy/ý))

Combined Unity Check Ratio = 0.37 < 1 hence OK

Check for Vertical Shear Force :
Maximum shear forces,τEd = 20.13 kN
shear stresses, σs.Ed = 14.30 N/mm2
Shear resistance of section , τ Rd = (Fy/√3)/ý*Aw = 250.94 kN
Unity Check Ratio = 0.08 < 1 hence OK

Slenderness Check:
KL/r = 83.67
Allowable Value of Slenderness Ratio = 100 > KL/r hence OK

Deflection Check:
Deflection due to Point Loads P1 at Centre = PL3(3e/L-4(e/L)3)/48EI = 2.85 mm
Deflection due to Point Loads P2 at Centre = PL3(3g/L-4(g/L)3)/48EI = 2.85 mm
Deflection due to UDL = 5wl4/384EI = 0.31 mm

Total Deflection = 6.00 mm

Allowable Deflection = L/500
= 8.4 mm Actual def. < Allowable, hence OK

1.0 B Stress Check 2 :- Beam stress check @ Bottom flange Ref:EC-3, part 6

The design resistance of bottom flange,

Ff.Rd = leff tf2 fy/ý/4m [1-(σf.Ed/fy/ý)2] = 42.42 kN

Where;
tf = Flange Thickness = 1.2 cm
σf.Ed = Stress at the flange due to moment = 82.88 N/mm2
e = 0.000 M
m = 0.086 M
xw = wheel spacing = 0.11 M
Effective length: =
if the wheel spacing xw=> 4√2 (m+e)
leff = 4√2 (m+e) = 484.23 mm
if the wheel spacing xw< 4√2 (m+e)
leff = 2√2 (m+e)+0.5xw = 352.11 mm
Total wheel load = 9.16 kN
U/C ratio = 0.22 < 1 hence OK

2.0 Loading Condition - Trolley placed at Overhang :

Reactions & Moments due to Vertical Loads:

0.75 18.32 18.32

A B
4.2 1.0

Reaction at B = 37.38 kN
Moment at B = P1L1+P2(L1-xw)+wL2/2 = 34.99 kNm

Reactions & Moments due to Lateral Loads:

0.07 4.09 4.09

`
A B

4 of 19
 4.2 1.0

Reaction at B = 8.24 kN
Moment at B P1L1+P2(L1-xw)+wL2/2 = 7.76 kNm

2.0 A Stress Check 1 :- Beam stress check @ Top flange

Check for Combine Stresses :

For Axial Force:

Axial Force, Af.Ed = 5.57 kN
Axial stress, σf.Ed = 0.88 N/mm2
Axial Resistance of Section, Af.Rd = 1961.14 kN
Unity Check Ratio = 0.003 0.002840237

For Bending Moment about Minor axis:

Maximum Moment abt Minor axis,M z.Ed = 7.76 kNm
Bending stresses (minor axis), σ z.Ed = 48.49 N/mm2
Moment Resistance of Section(Minor Axis), M z.Rd = 148.17 kNm
Unity Check Ratio = 0.05 0.157068298

For Bending Moment about Major axis:

Maximum Moment abt Major axis,M y.Ed = 34.99 kNm
Bending Stresses (major axis), σ y.Ed = 74.13 N/mm2
Moment Resistance of Section(Major Axis), M y.Rd = Calculated below

The designed buckling resistance moment for laterally unrestrained beam is given as: Ref:EC-3

My.Rd = XLT Wply fy/ý

Where; Wply = Plastic Section Modulas abt major axis (For Class 1 & 2 Sections)
Elastic Section Modulas abt major axis (For Class 3 Section)
= 513.15 cm3
XLT = Reduction Factor for lateral-torsional buckling
= 1/(ФLT+√(ФLT2-ÝLT2)) = 0.96
ФLT = 0.5(1+áLT(ÝLT-0.2)+ÝLT2) = 0.59
Imperfection factor; áLT = 0.21 (Table 6.1 EC-3)

5 of 19
 Non-dimensional slenderness Ý LT, for rolled section;
ÝLT = √(Wplyfy/Mcr) = 0.38
L= Length between unsupported points. = 2.0 m
Iz = Moment of inertia abt minor axis = 1600 cm4
Iw = Warping Constant, Iyy (d-tf)2/4 = 365516.8 cm6
It = Torsional Constant = 26.04 cm4
C1 = 1.88-1.4Ψ+0.52Ψ2 (but C1<=2.7) = 1.0
Ψ = Correction factor for the effects of any change
of moment along the length L
For constant moment b/t points C 1 may be taken as 1.0
Mcr = C1pi()2EIz/Lcr2√(Iw/Iz+Lcr2GIt/pi()2EIz) = 1260.02 kNm

Moment resistance of section about major axis;

My.Rd = 151.74 kNm
Unity Check Ratio = 0.23 0.240153620919
Combine U/C Ratio:
Af.Ed/Af.Rd+My.Ed/My.Rd+Mz.Ed/Mz.Rd For Class 1 & Class 2 Sections

√((σf.Ed/(Fy/ý)) +(σy.Ed/(Fy/ý)) +(σz.Ed/(Fy/ý)) -(σf.Ed/(Fy/ý))(σy.Ed/(Fy/ý))-(σy.Ed/(Fy/ý))

2 2 2
For Class 3 Sections
(σz.Ed/(Fy/ý))-(σf.Ed/(Fy/ý))(σz.Ed/(Fy/ý))+3(σs.Ed/(Fy/ý))

Combined Unity Check Ratio = 0.29 OK

Check for Vertical Shear Force :

Maximum shear forces,τEd = 37.382 kN
shear stresses, σs.Ed = 26.550 N/mm2
Shear resistance of section , τ Rd = (Fy/√3)/ý*Aw = 250.94 kN
Unity Check Ratio = 0.15 OK

Deflection Check:
Deflection due to Point Loads P1 at Centre = PL3(3e/L-4(e/L)3)/48EI = 0.62 mm
Deflection due to Point Loads P2 at Centre = PL3(3g/L-4(g/L)3)/48EI = 0.05 mm
Deflection due to UDL = 5wl4/384EI = 0.01 mm

Total Deflection = 0.68 mm

Allowable Deflection = L/500
= 2.0 mm OK

2.0 B Stress Check 2 :- Beam stress check @ Bottom flange Ref:EC-3, part 6

The design resistance of bottom flange,

Ff.Rd = leff tf2 fy/ý/4m [1-(σf.Ed/fy/ý)2] = 54.65 kN

Where;
tf = Flange Thickness = 1.2 cm
σf.Ed = Stress at the flange due to moment = 16.44 N/mm2
e = 0.000 M
m = 0.086 M
xw = wheel spacing = 0.11 M
xe = Distance from end stoper = 0.25 M
Effective length for a wheel adjacent to an end stop;
if the wheel spacing xw=>2√2 (m+e)+xe
leff = 2(m+e)( xe/m+√(1+(xe/m)2) = 1028.50 mm
but leff = 2√2 (m+e)+xe = 492.11 mm

if the wheel spacing xw<2√2 (m+e)+xe

leff = 2(m+e)( xe/m+√(1+(xe/m)2) = 1028.50 mm
but leff = 2√2 (m+e)+(xe+xw)/2 = 422.11 mm
Total wheel load = 9.16 kN

U/C ratio = 0.17 OK

Check of Web Bending

6 of 19
 Y

60⁰
La

At mid span
La = d - 2*tf - r = 163.00 mm
Y = X + 2*Tan60⁰*(La+Bf) = 1367.47 mm
Section Modulus Y*tf2/6 = 14586.33 mm3
Plastic Modulus Y*tf2/4 = 21879.50 mm3
Moment = 665.86 kNm
Bending Stress = 30.43 N/mm²
U/C ratio = 0.10 < 1 hence OK
At the end
Y = X + Tan60⁰*(La+Bf) = 738.73 mm
Section Modulus Y*tf2/6 = 7879.83 mm3
Plastic Modulus Y*tf /4
2
= 11819.75 mm3
Bending Stress = 56.33 N/mm²
U/C ratio = 0.18 < 1 hence OK

7 of 19
DESIGN OF HANGERS

Section Properties H 200x200

Height 0.7 m
fy 355 N/mm2
Weight 49.90 kg/m
Area 63.53 cm2
Iyy 4720.00 cm4
Izz 1600.00 cm4
Zyy 472.00 cm3
Zzz 160.00 cm3
ryy 8.62 cm
rzz 5.02 cm
Design Load

Vertical Load Qv = 37.382 kN

Lateral Load
Perpendicular to Monorail Qh1 = 8.24 kN
Along Monorail Axis Qh2 = 5.57 kN

Bending Moment
Due to Lateral load perpebndicular to monorail = 5.77 kNm
Due to Lateral load along the axis of monorail = 3.90 kNm

Section Resistance

Axial resistance of Section = 1961.14 kN

Moment Resistance of Section abt Major axis = 145.70 kNm

Moment Resistance of Section abt Minor axis = 49.39 kNm

U/C Ratio = 0.16 OK

8 of 19
DESIGN OF BOLTS Ref: EC-3 part 1-8

Bolt Class = 4.6

Material factor, ým2 = 1.25 Ref: EC-3
Yield Strength fyb = 240 N/mm2
Ultimate Tensile Strength f ub = 400 N/mm2
BOLT Classification = M22
Diameter of Bolt, d = 22.00 mm
Diameter of Hole, do = 24.00 mm
Edge distance from centre of a fastner hole to the adjacent edge of any part in line of load,e 1 =
100 mm
Edge distance from centre of a fastner hole to the adjacent edge of any part at right angle to load,e 2 =
100 mm
Spacing between centres of fastners in line of load, P 1 = 100 mm
Spacing between centres of fastners perpendicular to load, P2 100 mm
Area of Bolt, A = 380.13 mm2
No of Bolts per connection = 4 nos

Axial Load for Bolt Design,Ft.Ed = 37.382 kN

Shear Force perpendicular to monorail , Fv.Ed = 8.244 kN
Shear Force along the monorail,Fv.Ed = 5.570 kN

Shear Resistance per shear plane:

FvRd = avfub A/ ým2 = 72.99 kN
where
av Constant = 0.6

Tension Resistance of bolt:

Ft,Rd = k2fubAs/ ým2 = 109.48 kN
where
k2 Constant = 0.63 for countersunk bolt
0.9 otherwise

Combine U/C ratio FvEd/ FvRd + FtEd/(1.4FtRd) = 0.10 OK

Bearing Resistance:
Ultimate Strength of Steel = 400 N/mm2

Fb,Rd = k1abfudt/ ým2 = 211.20 kN end Bolts

k1abfudt/ ým2 = 211.20 kN inner bolts
where
ab is smallest of ad ; fub/fu; 1

ad = e1/3d0 1.39 for end bolts

p1/3do-1/4 1.14 for inner bolts
fub/fu = 1
k1 = 2.8*e2/do-1.7 9.97 for end bolts
1.4p2/do-1.7 4.13 for inner bolts
or 2.5 Smaller Value

Unity Check FvEd/FbRd = 0.05 OK

Punching Shear Resistance:

Bp.Rd = 0.6πdmtpfu/ ým2 = 188.19 kN

where
dm bolt head dimension = 26 mm
tp Thikness of plate under bolt = 12 mm

Unity check Ft.Ed/Bp.Rd = 0.20 OK

9 of 19
 MONORAIL DESIGN( As per Euro Code)

Simply Support Span, L = 4.2 m

Overhang Span, Lo = 1.0 m
Member Size = 200x200
Yield strength, Fy = 355.0 N/mm² NV A36 Material

A. SECTIONAL PROPERTIES: Properties of Rolled Setion H 200x200

Self weight, w = 49.90 kg/m

= 0.50 kN/m
Area, A = 63.53 cm²
Depth of section, d = 20.0 cm
Width of flange, bf = 20.0 cm
Thickness of flange, tf = 1.2 cm
Thickness of web, tw = 0.8 cm
Moment of inertia about major axis, Iyy = 4720.0 cm4
Moment of inertia about minor axis, Izz = 1600.0 cm4
Section modulus about major axis, Zyy = 472.0 cm³
Section modulus about minor axis, Zzz = 160.0 cm³
Plastic Section Modulus abt major axis Wply = 513.15 cm³
Plastic Section Modulus abt minor axis Wplz = 480.0 cm³
Radius of gyration, rx = 8.62 cm
Radius of gyration, ry = 5.02 cm
Radius of fillet, r = 1.30 cm

B. CLASS CLASSIFICATION:

є = √(235/fy) = 0.81

a. Class Identification For Web:

α = 0.5
Ψ = -2
For Class 1;
If; α <= 0.5: c/t<= 36є/α
α>0.5: c/t<= 396є/(13α-1) ; Hence c/t = 58.58
For Class 2;
If; α <= 0.5: c/t<= 41.5є/α
α>0.5: c/t<= 456є/(13α-1) ; Hence c/t = 67.53
For Class 3;
If; Ψ<= -1 ; c/t<= 62є(1-Ψ) √(-Ψ)
Ψ> -1 ; c/t<= 42є/(0.67+0.33Ψ) ; Hence c/t = 214.02

Web Property: c = (h-2tf-2r) = 15.00 cm

c/tw = 18.75
Hence; Web is in CLASS 1

b. Class Identification For Flange:

Stree type in flange = 1.0
Stress Ratio,Ψ = 0.6
α = 1.0
kσ = 0.615
For Class 1;
Tip is in compression; c/t<=9є/α;
Tip is in tension; c/t<=9є/(α√α); Hence c/t = 7.32
For Class 2;
Tip is in compression; c/t<=10є/α;
Tip is in tension; c/t<=10є/(α√α); Hence c/t = 8.14
For Class 3;
Tip is in compression or tension; c/t<=21є√kσ ; Hence c/t = 13.40

Flange Property: c = (b-tw-2r)/2 = c 8.3 cm

c/tf = c/tf 6.92
Hence; Flange is in CLASS 1

Therefore overall Cross-Section is in Class 1

10 of 19
 D. LOAD CALCULATION for ULS - B :

4.2 1.0

0.11

200x200

20.0 kN

Capacity, P = 10.0 kN
Hoist Weight, Wh = 10.0 kN (Assumed)
Dynamic Load Factor,D f = 1.5 %
Lateral Load,Hh = 10 %
Load Factor,DL = 1.0
Axial Load, Va = 10 %
Wheel Spacing = 0.11 m (Assumed)
Wheels, Nw = 2 Pairs
Material factor; ý = 1.15 Ref: EC-3

LOADS:
Vertical Point Load; Pv = (P*Df+Wh)*DL
= (10 * 1.5 + 10) * 1 = 25 kN
Vertical Point Load per Trolley Axle = 25 / 2 = 12.5 kN
TotalAxial Load = (10+10)*1*10% = 2.00 kN
Total Horizontal Load = (10+10)*1*10% = 2.00 kN

1.0 Loading Condition - Trolley placed at Simply Supported Span :

Acceleration Values:

Accelerations 1yr Factor

ax = 1.1538 1.3
ay = 2.0812 1.3
az = 2.8941 1.3

Note: Max bending moment occurs when centre line of trolley and first wheel consides with centre line of member.

Longitudinal Load acceleration coefficient, A a = 2.0812*1.3 / 9.81 = 0.2758 Considering the maximum of ax &
ay for different oriantation of
Lateral Load acceleration coefficient, A h = 2.0812*1.3 / 9.81 = 0.2758 Runway Beam.
Vertical Load acceleration coefficient, A v = 2.8941*1.3 / 9.81 = 0.3835
Inertia for acceleration load per axle, P wa = (P+Wh)/Nw = 10.0 kN

Total Longitudinal Load, Pa + Aa*2Pwa = 7.52 kN

Total Lateral Point Load per axle, P h + Ah*Pwa = 4.76 kN
Total Vertical Point Load per axle, P w + Av*Pwa = 16.34 kN

Reactions & Moments due to Vertical Loads:

cL of trolley
16.34 16.34 0.69

cL of beam

A C D B
2.0175 0.11 2.0725
e f g
4.2 1.0

Self Weight of Beam (UDL) = 0.50 kN/m

Total Vertical UDL (Selfweight of Beam), (D L + Av)* Self wt. = 0.69 kN/m
Lateral UDL due to selfweight of beam, A v* Self wt. = 0.14 kN

Reaction at A = 18.00 kN
Reaction at B = 17.57 kN
Moment at D = Pg(f+2e)/L+wL2/8 = 34.93 kNm
Moment at C = Pe(f+2g)/L+wL2/8 = 34.91 kNm

11 of 19
 Reactions & Moments due to Lateral Loads:

cL of trolley

4.76 4.76 0.14

`

cL of beam

A C D B
2.0175 0.11 2.0725
e f g
4.2 1.0

Reaction at A = 5.109 kN
Reaction at B = 4.985 kN
Moment at D = Pg(f+2e)/L+wL2/8 = 10.04 kNm
Moment at C = Pe(f+2g)/L+wL2/8 = 10.03 kNm

1.0 A Stress Check 1 :- Capacity check

Check for Combine Stresses :

For Axial Force:

Axial Force, Af.Ed = 7.52 kN
Axial stress, σf.Ed = 1.18 N/mm2
Axial Resistance of Section, Af.Rd = 1961.14 kN
Unity Check Ratio = 0.004 < 1 hence OK

For Bending Moment about Minor axis:

Maximum Moment abt Minor axis,M z.Ed = 10.04 kNm
Bending stresses (minor axis), σ z.Ed = 62.72 N/mm2
Moment Resistance of Section(Minor Axis), M z.Rd = 148.17 kNm
Unity Check Ratio = 0.07 < 1 hence OK

For Bending Moment about Major axis:

Unity Check Ratio Moment abt Major axis,M y.Ed
Maximum = 34.93 kNm
Bending Stresses (major axis), σ y.Ed = 74.01 N/mm2
Moment Resistance of Section(Major Axis), M y.Rd = Calculated below

The designed buckling resistance moment for laterally unrestrained beam is given as:

Mb.Rd = XLTWply fy/ý

Where; Wply = Plastic Section Modulas abt major axis (For Class 1 & 2 Sections)
Elastic Section Modulas abt major axis (For Class 3 Section)
= 513.15 cm3
XLT = Reduction Factor for lateral-torsional buckling
= 1/(ФLT+√(ФLT2-ÝLT2)) = 0.80
ФLT = 0.5(1+áLT(ÝLT-0.2)+ÝLT2) = 0.88
Imperpection factor; áLT = 0.21 (Table 6.1 EC-3)

Non-dimensional slenderness Ý LT, for rolled section;

ÝLT = √(Wplyfy/Mcr) = 0.79
L= Length between unsupported points = 4.2 m
Iz = Moment of inertia abt minor axis = 1600.00 cm4
Iw = Warping Constant, Iyy (d-tf)2/4 = 365516.8 cm6
It = Torsional Constant = 26.04 cm4
C1 = 1.88-1.4Ψ+0.52Ψ (but C1<=2.7)
2
= 1.000
Ψ = Correction factor for the effects of any change
of moment along the length L
For constant moment b/t points C 1 may be taken as 1.001
Mcr C1pi()2EIz/Lcr2√(Iw/Iz+Lcr2GIt/pi()2EIz) = 290.97 kNm

Moment resistance of section about major axis;

My.Rd = 126.83 kNm
Unity Check Ratio = 0.28 < 1 hence OK

12 of 19
 Combine U/C Ratio:
Af.Ed/Af.Rd+My.Ed/My.Rd+Mz.Ed/Mz.Rd For Class 1 & Class 2 Sections

√((σf.Ed/(Fy/ý))2+(σy.Ed/(Fy/ý))2+(σz.Ed/(Fy/ý))2-(σf.Ed/(Fy/ý))(σy.Ed/(Fy/ý))-(σy.Ed/(Fy/ý))(σz.Ed/
For Class 3 Sections
(Fy/ý))-(σf.Ed/(Fy/ý))(σz.Ed/(Fy/ý))+3(σs.Ed/(Fy/ý))

Combined Unity Check Ratio = 0.35 < 1 hence OK

Check for Vertical Shear Force :
Maximum shear forces,τEd = 18.00 kN
shear stresses, σs.Ed = 12.78 N/mm2
Shear resistance of section , τ Rd = (Fy/√3)/ý*Aw = 250.94 kN
Unity Check Ratio = 0.07 < 1 hence OK

Slenderness Check:
KL/r = 83.67
Allowable Value of Slenderness Ratio = 100 > KL/r hence OK

Deflection Check:
Deflection due to Point Loads P1 at Centre = PL3(3e/L-4(e/L)3)/48EI = 2.54 mm
Deflection due to Point Loads P2 at Centre = PL3(3g/L-4(g/L)3)/48EI = 2.54 mm
Deflection due to UDL = 5wl4/384EI = 0.28 mm

Total Deflection = 5.36 mm

Allowable Deflection = L/500
= 8.4 mm Actual def. < Allowable, hence OK

1.0 B Stress Check 2 :- Beam stress check @ Bottom flange Ref:EC-3, part 6

The design resistance of bottom flange,

Ff.Rd = leff tf2 fy/ý/4m [1-(σf.Ed/fy/ý)2] = 43.09 kN

Where;
tf = Flange Thickness = 1.2 cm
σf.Ed = Stress at the flange due to moment = 74.01 N/mm2
e = 0.000 M
m = 0.086 M
xw = wheel spacing = 0.11 M
Effective length: =
if the wheel spacing xw=> 4√2 (m+e)
leff = 4√2 (m+e) = 484.23 mm
if the wheel spacing xw< 4√2 (m+e)
leff = 2√2 (m+e)+0.5xw = 352.11 mm
Total wheel load = 8.17 kN
U/C ratio = 0.19 < 1 hence OK

2.0 Loading Condition Trolley placed at Overhang :

Reactions & Moments due to Vertical Loads:

0.69 16.34 16.34

A B
4.2 1.0

Reaction at B = 33.36 kN
Moment at B = P1L1+P2(L1-xw)+wL2/2 = 31.22 kNm

Reactions & Moments due to Lateral Loads:

0.14 4.76 4.76

13 of 19
 A B
4.2 1.0

Reaction at B = 9.65 kN
Moment at B P1L1+P2(L1-xw)+wL2/2 = 9.06 kNm

2.0 A Stress Check 1 :- Beam stress check @ Top flange

Check for Combine Stresses :

For Axial Force:

Axial Force, Af.Ed = 7.52 kN
Axial stress, σf.Ed = 1.18 N/mm2
Axial Resistance of Section, Af.Rd = 1961.14 kN
Unity Check Ratio = 0.004 0.003832418

For Bending Moment about Minor axis:

Maximum Moment abt Minor axis,M z.Ed = 9.06 kNm
Bending stresses (minor axis), σ z.Ed = 56.63 N/mm2
Moment Resistance of Section(Minor Axis), M z.Rd = 148.17 kNm
Unity Check Ratio = 0.06 0.183460592

For Bending Moment about Major axis:

Maximum Moment abt Major axis,M y.Ed = 31.22 kNm
Bending Stresses (major axis), σ y.Ed = 66.14 N/mm2
Moment Resistance of Section(Major Axis), M y.Rd = Calculated below

The designed buckling resistance moment for laterally unrestrained beam is given as: Ref:EC-3

My.Rd = XLT Wply fy/ý

Where; Wply = Plastic Section Modulas abt major axis (For Class 1 & 2 Sections)
Elastic Section Modulas abt major axis (For Class 3 Section)
= 513.15 cm3
XLT = Reduction Factor for lateral-torsional buckling
= 1/(ФLT+√(ФLT2-ÝLT2)) = 0.96
ФLT = 0.5(1+áLT(ÝLT-0.2)+ÝLT2) = 0.59
Imperfection factor; áLT = 0.21 (Table 6.1 EC-3)

14 of 19
 Non-dimensional slenderness Ý LT, for rolled section;
ÝLT = √(Wplyfy/Mcr) = 0.38
L= Length between unsupported points. = 2.0 m
Iz = Moment of inertia abt minor axis = 1600.00 cm4
Iw = Warping Constant, Iyy (d-tf)2/4 = 365516.8 cm6
It = Torsional Constant = 26.04 cm4
C1 = 1.88-1.4Ψ+0.52Ψ2 (but C1<=2.7) = 1.0
Ψ = Correction factor for the effects of any change
of moment along the length L
For constant moment b/t points C 1 may be taken as 1.0
Mcr = C1pi()2EIz/Lcr2√(Iw/Iz+Lcr2GIt/pi()2EIz) = 1260.02 kNm

Moment resistance of section about major axis;

My.Rd = 151.74 kNm
Unity Check Ratio = 0.21 0.214260688602
Combine U/C Ratio:
Af.Ed/Af.Rd+My.Ed/My.Rd+Mz.Ed/Mz.Rd For Class 1 & Class 2 Sections

√((σf.Ed/(Fy/ý)) +(σy.Ed/(Fy/ý)) +(σz.Ed/(Fy/ý)) -(σf.Ed/(Fy/ý))(σy.Ed/(Fy/ý))-(σy.Ed/(Fy/ý))(σz.Ed/

2 2 2
For Class 3 Sections
(Fy/ý))-(σf.Ed/(Fy/ý))(σz.Ed/(Fy/ý))+3(σs.Ed/(Fy/ý))

Combined Unity Check Ratio = 0.27 OK

Check for Vertical Shear Force :

Maximum shear forces,τEd = 33.361 kN
shear stresses, σs.Ed = 23.694 N/mm2
Shear resistance of section , τ Rd = (Fy/√3)/ý*Aw = 250.94 kN
Unity Check Ratio = 0.13 OK

Deflection Check:
Deflection due to Point Loads P1 at Centre = PL3(3e/L-4(e/L)3)/48EI = 0.55 mm
Deflection due to Point Loads P2 at Centre = PL3(3g/L-4(g/L)3)/48EI = 0.05 mm
Deflection due to UDL = 5wl4/384EI = 0.01 mm

Total Deflection = 0.60 mm

Allowable Deflection = L/500
= 2.0 mm OK

2.0 B Stress Check 2 :- Beam stress check @ Bottom flange Ref:EC-3, part 6

The design resistance of bottom flange,

Ff.Rd = leff tf2 fy/ý/4m [1-(σf.Ed/fy/ý)2] = 54.59 kN

Where;
tf = Flange Thickness = 1.2 cm
σf.Ed = Stress at the flange due to moment = 19.20 N/mm2
e = 0.000 M
m = 0.086 M
xw = wheel spacing = 0.11 M
xe = Distance from end stoper = 0.25 M
Effective length for a wheel adjacent to an end stop;
if the wheel spacing xw=>2√2 (m+e)+xe
leff = 2(m+e)( xe/m+√(1+(xe/m)2) = 1028.50 mm
but leff = 2√2 (m+e)+xe = 492.11 mm

if the wheel spacing xw<2√2 (m+e)+xe

leff = 2(m+e)( xe/m+√(1+(xe/m)2) = 1028.50 mm
but leff = 2√2 (m+e)+(xe+xw)/2 = 422.11 mm
Total wheel load = 8.17 kN

U/C ratio = 0.15 OK

15 of 19
Check for Web Bending

60⁰
La

At mid span
La = d - 2*tf - r = 163.00 mm
Y = X + 2*Tan60⁰*(La+Bf) = 1367.47 mm
Section Modulus Y*tf2/6 = 14586.33 mm3
Plastic Modulus Y*tf /4
2
= 21879.50 mm3
Moment = 775.55 kNm
Bending Stress = 35.45 N/mm²
U/C ratio = 0.11 < 1 hence OK
At the end
Y = X + Tan60⁰*(La+Bf) = 738.73 mm
Section Modulus Y*tf2/6 = 7879.83 mm3
Plastic Modulus Y*tf2/4 = 11819.75 mm3
Bending Stress = 65.61 N/mm²
U/C ratio = 0.21 < 1 hence OK

16 of 19
DESIGN OF HANGERS

Section Properties H 200x200

Height 0.7 m
fy 355 N/mm2
Weight 49.90 kg/m
Area 63.53 cm2
Iyy 4720.00 cm4
Izz 1600.00 cm4
Zyy 472.00 cm3
Zzz 160.00 cm3
ryy 8.62 cm
rzz 5.02 cm
Design Load

Vertical Load Qv = 33.361 kN

Horizontal Load
Perpendicular to Monorail Qh1 = 9.65 kN
Along Monorail Axis Qh2 = 7.52 kN

Bending Moment
Due to horizontal load perpebndicular to monorail = 6.76 kNm
Due to horizontal load along the axis of monorail = 5.26 kNm

Section Resistance

Axial resistance of Section = 1961.14 kN

Moment Resistance of Section abt Major axis = 145.70 kNm

Moment Resistance of Section abt Minor axis = 49.39 kNm

U/C Ratio = 0.19 OK

17 of 19
DESIGN OF BOLTS Ref: EC-3 part 1-8

Bolt Class = 4.6

Material factor, ým2 = 1.25 Ref: EC-3
Yield Strength fyb = 240 N/mm2
Ultimate Tensile Strength f ub = 400 N/mm2
BOLT Classification = M22
Diameter of Bolt, d = 22.00 mm
Diameter of Hole, do = 24.00 mm
Edge distance from centre of a fastner hole to the adjacent edge of any part in line of load,e 1 =
100 mm
Edge distance from centre of a fastner hole to the adjacent edge of any part at right angle to load,e 2 =
100 mm
Spacing between centres of fastners in line of load, P 1 = 100 mm
Spacing between centres of fastners perpendicular to load, P2 100 mm
Area of Bolt, A = 380.13 mm2
No of Bolts per connection = 4 nos

Axial Load for Bolt Design,Ft.Ed = 33.361 kN

Shear Force perpendicular to monorail , Fv.Ed = 9.654 kN
Shear Force along the monorail,Fv.Ed = 7.516 kN

Shear Resistance per shear plane:

FvRd = avfub A/ ým2 = 72.99 kN
where
av Constant = 0.6

Tension Resistance of bolt:

Ft,Rd = k2fubAs/ ým2 = 109.48 kN
where
k2 Constant = 0.63 for countersunk bolt
0.9 otherwise

Combine U/C ratio FvEd/ FvRd + FtEd/(1.4FtRd) = 0.10 OK

Bearing Resistance:
Ultimate Strength of Steel = 400 N/mm2

Fb,Rd = k1abfudt/ ým2 = 211.20 kN end Bolts

k1abfudt/ ým2 = 211.20 kN inner bolts
where
ab is smallest of ad ; fub/fu; 1

ad = e1/3d0 1.39 for end bolts

p1/3do-1/4 1.14 for inner bolts
fub/fu = 1
k1 = 2.8*e2/do-1.7 9.97 for end bolts
1.4p2/do-1.7 4.13 for inner bolts
or 2.5 Smaller Value

Unity Check FvEd/FbRd = 0.06 OK

Punching Shear Resistance:

Bp.Rd = 0.6πdmtpfu/ ým2 = 188.19 kN

where
dm bolt head dimension = 26 mm
tp Thikness of plate under bolt = 12 mm

Unity check Ft.Ed/Bp.Rd = 0.18 OK

18 of 19
no. dia area capacity axial shear
4 12 452.3893 10 0.18 0.09 0.23
4 20 1256.637 20 0.10 0.05 0.13
4 20 1256.637 30 0.13 0.06 0.17
4 24 1809.557 50 0.13 0.07 0.18
4 27 2290.221 100 0.19 0.10 0.25
4 30 2827.433 150 0.23 0.11 0.30