STANDARD INFORMATIVE DOC No.

:CI-USD-391
WRITE-UP ON Rev. : R0
MONORAILS AND CRANES
Uhde India Limited Page : 1 of 9

Contents

Page

0.0 Cover Page: Contents, checking and approval of 1st edition and
Revision…………………………………………………………………………………..1

1.0 Introduction …………………………………………………………………………….. 2

2.0 Monorails & monorail beams..……………………………………………………….. 2

3.0 Overhead travelling cranes & crane girders..…….………………………………... 3

4.0 Information required from other groups for design of crane girders...………….. . 5

5.0 Design of crane girders ….………………………………………………………….. .6

6.0 Load Combinations with other loads....................................................................8

7.0 Typical commonly used crane girder sections..……………………………….….. .8

8.0 Limiting Vertical deflection ................................................……………………… .9

9.0 Crane buffer stops…………………………………………………………………… .9

10.0 Classification of Cranes ………………............……………………………………. .9

11.0 Co-ordination................................................................................................... 9

Enclosure :

Sketches

1. Fig.1 for overhead travelling crane – clearance diagram 1 Page

2. Sketch for gantry girder details 1 Page

CONTROLLED COPY NO:

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition:
Prepared: Checked: Approved:

K.R. Parulekar H.M. Doshi M.H. Joshi

Date: Date: Date:

Floppy No. : UCI-3H-99-03575 Server:\Dir:KUMUS201\Z:\DAT\STANDARD\DOC.

File Name : CRANES.DOC
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1.0 INTRODUCTION:
The purpose of this document is to describe the types and functioning of hoists – cranes
and monorails which we come across in our plant buildings and the design philosophy of
supporting beams, girders and structures for the same.

This information will be useful in making reasonable assumptions at the beginning of the
project when complete information is not available.

This document will also help in collecting information from concerned departments, and
in estimation of RCC and structural quantities.

This document covers monorails, cranes and supporting structurals and does not cover
elevators, lifts and conveyors.

2.0 M0NORAILS & MONORAIL BEAMS:

The monorail beams (by CI) are supporting monorail blocks which are travelling trolleys
or pulley blocks geared or ungeared, hand operated or electrically operated, used for
lifting / lowering and movements of equipments / parts with loads ½ to 10 T.

The monorail capacity and location is furnished by PI. The head room required i.e. the
elevation of the bottom of monorail beam is to be confirmed by MQ, depending on the
type of monorail blocks of the MQ vendor’s supply.

These monorail beams are supported by main framing beams spanning from column to
column in plant buildings.

In shed type buildings 1 monorail of 2 T capacity in the centre or 2 monorails of 1 T

capacity at critical locations are generally considered to be supported from truss.
Monorails of capacities higher than 5 T are not advisable to be supported from truss in
order to avoid undue deflections in truss and undesirable cracking of sheets.

Design forces to be considered and information required for the monorail beams are:
i) lifting capacity of monorail as furnished by PI / MQ.
ii) DL of the monorail block including chain pulley block and motor is considered
as 5% of monorail capacity in our design of monorail beams.
iii) Horizontal longitudinal force along the monorail beam is considered as 5% of
capacity of monorail as per IS-875.
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iv) Horizontal lateral force transverse to the monorail beam is considered as 5% of

capacity of monorail as per IS-875.
v) Monorails are designed for allowable deflection of span / 750.
vi) Location of monorail stops

Originating departments PI / MQ shall indicate the capacities of monorails and location

and extent required for monorail beams. CI will then indicate structurally required
member sizes of monorail beams.

MQ will then confirm from trolley vendors, the B.O.S. and sectional sizes (depths, width,
thickness etc.) of monorail beams, from the point of view of various dimensional
clearances required.

Our standard Drawing CI-USD-0025 shall be referred for sizes of monorail beams for
various monorail capacities along with connection details to main (steel or RCC) beams
or to bottom chord of truss etc.

3.0 OVERHEAD TRAVELLING CRANES & CRANE GIRDERS:

3.1 References:
Cranes and Hoists IS:807 - 1976 -
Amendment 1 Reaffirmed in 1990
Overhead travelling cranes and gantry girders – IS:3177- 1977 -
Amendment 1 Reaffirmed in 1990
Crane rail sections IS:3443 - 1980 -
Amendment 1 Reaffirmed in 1987
Structural steel design and fabrication IS:800-1984 –
Amendment 1 to 3 – Reaffirmed in 1991
Loading standard (5 parts) IS:875– 1987 Amendment 1 -
Reaffirmed in 1992

3.2 The overhead travelling cranes are used industrial structures such as warehouses,
workshops, boiler house, compressor house etc., to lift heavy equipments and their
parts, materials etc. and to carry them from one place to another. The crane consists of
bridge spanning the bay of the shop. A trolley or crab is mounted on the bridge. The
trolley moves along the bridge. The bridge as a whole moves longitudinally on rails
provided at the ends. The gantry rails on either side of the bridge rest on crane gantry
girders.
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As defined in IS 807, a crane is a specially designed structure equipped with

mechanical means for moving a load by raising or lowering by electrical or manual
operation and, whilst the load is in such a state of motion or suspension, transporting it.

3.3 Rated lifted load or capacity

As per IS-807, the rated lifted load from the mechanism design consideration shall mean
the external load lifted and handled by the crane and shall include in addition to the safe
working load, weight of rope and lifting tackles such as magnets, grabs, lifting beams,
hook blocks but shall exclude wind loads.

3.4 Dead Load (ref. IS:807)

The weight of the crane structural steel moving on crane runway girders with all material
fastened thereto and supported by it permanently is the dead load of the crane gantry.

3.5 Live Load (ref. IS:807)

The external static load variable in magnitude, position or direction, with reference to the
member (crane girder) of the structure under consideration, is called working load.

The weight of the trolley (crab) changes its position with respect to the members of the
structure and shall therefore, be considered as live load.

3.6 Dynamic effect (ref. IS:807)

The dynamic effects on the structure are caused by inertia or sudden load application
such as acceleration, deacceleration, breaking, impact and bumping, during movement
of cranes. The impact allowances (ref. 5.1) shall take care of the dynamic effects.

Suitable clearances shall be provided for the safe operation of the crane.

3.7 Ratio of carriage wheel base to crane span (ref. IS:807 Cl.11)

The wheel base i.e. centre-to-centre distance between the two wheels shall be:

a) for cranes upto and including 20 M span, not less than 1/5 of the span.
b) for cranes over 20 M span and upto 25 M, not less than 4 M.
and
 STANDARD INFORMATIVE DOC No. :CI-USD-391
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c) for cranes of 25 M span and over, not less than 1/6 th of the span.

4.0 INFORMATION REQUIRED FROM OTHER GROUPS FOR DESIGN OF

CRANE GIRDERS:

Overhead travelling crane consists essentially of a girder (or girders) attached at each
end to carriages, travelling along elevated tracks fixed in location, and a trolley or crab
equipped with hoisting mechanism travelling along such girder (or girders). These
cranes are either electrically operated travelling (EOT) or hand operated travelling
(HOT)cranes.

We need the following information from PI/MQ/Vendor, for the overhead travelling
cranes to be supported on structures from. (Refer Fig. 1 copy enclosed).

i) No. of cranes operating, main, auxiliary = __________ Nos.

ii) Type of crane EOT or HOT = __________Type
For each crane
iii) Capacity of crane/s = __________ MT
iv) DL of crane = __________ MT
v) Crab weight
vi) Wheel base i.e. c/c distance between the two wheels = __________ M
vii) Total No. of wheels = __________ No.
viii) On each side, Max. load per wheel = __________ MT
Min. load per wheel = __________ MT
ix) Crane rail section scope of supply and dimension B = ___________M
x) Crane span or distance between centrelines of gantry
track rails S = ___________ M
xi) Side clearance or distance from centre of gantry track
rails to nearest side obstruction e.g. column face A1 = __________ M
A2 = __________ M
xii) Vertical clear distance from top of gantry rail to:
a) lowest overhead obstruction C = __________ M
b) floor level D = ___________M
xiii) Min. hook approach i.e. Nearest position
Of hook to centre line of gantry rail.
Cabin end, E = ___________M
Other end , F = ___________M
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xiv) Information about the requirement of maintenance

walkway platform if any, with width(W), length/
Extent with Live load. W = ___________M
LL = ___________Kg/M2

xv) Location of crane stops

5.0 DESIGN OF CRANE GIRDERS

5.1 Impact Allowance:

a) The modern cranes are quick-acting to handle loads rapidly, therefore the
stresses produced in the crane girders are instantaneous. Hence, an impact
allowance of 25% of maximum static loads with EOT cranes and 10% with HOT
cranes is considered as specified in Cl. 6.3 of IS-875 Part 2, for the design of
crane girders and supporting structures such as columns etc.

b) Longitudinal (Traction) force (along rails) on crane girders

When the brakes are applied suddenly the frictional resistance to the sliding of
locked wheels upon the rail is supplied by the crane girder and therefore a
longitudinal traction force is induced in the girder. 5% of static wheel loads is
considered as the breaking longitudinal force or traction for both EOT & HOT
cranes as specified in IS 875 Part 2 Cl.6.3.

c) Lateral (surge) force (transverse to rails) on crane girders

This is caused by sudden stopping of the crab or by dragging of the loads
along the floor of the shop. Therefore, Lateral horizontal (surge) force of 10%
[of weight of the crab plus weight lifted by the crane] is considered for EOT
cranes and 5% for HOT cranes. In case of I-Section gantry girder, the lateral
force is resisted entirely by the compression flange strengthened by channel
or suitably as the web is very flexible in lateral direction. The tension flange is
also not effective as it cannot be pushed sideways by the web which is itself
ineffective. The surge force is acting on any crane track rail, acting in either
direction and equally distributed amongst all wheels on one side of the rail
track (refer IS-875 Cl.6.4).

Sometimes an additional surge girder is provided to resist the heavy lateral

surge force.
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5.2 Crane load combinations:

In case of provision of more than one crane in single or multiple bay frames the following
crane combinations for vertical loads and lateral / longitudinal forces shall be considered
(Refer IS-875 Part 2, Clause 3.4.2 of IS-800).

5.2.1 Vertical Loads

In an aisle, where more than one crane is in operation, or has provision for more than
one crane in future, the following load combinations shall be taken for vertical loading:

a) two adjacent cranes working in tandem with full load with the above mentioned
appropriate impact allowance (ref. 5.10).
b) For long span gantries, where more than one crane can come in the span, the
girder shall be designed for one crane fully loaded with above mentioned
appropriate impact allowance (as per 5.10), plus as many loaded cranes as
can be accommodated on the span but without impact allowance to give the
max. effect.
c) DL & LL on maintenance walkway platform (with railings) shall be added
appropriately.

5.2.2 Lateral Surge

For design of crane girders and supporting columns and foundations the following
crane combinations shall be considered:
a) For single bay frames – Effect of one crane in the bay giving the critical effect
shall be considered for calculation of surge force, and
b) For multiple bay frames – Effect of two cranes working one each in any of two
bays in the cross section to give the critical effect shall be considered for
calculation of surge force.

5.2.3 Longitudinal Traction

a) where one crane is in operation with no provision for future crane, tractive
force from only one crane shall be taken.
b) Where more than one crane is in operation or there is provision for future
crane, tractive force from two cranes giving the maximum effect shall be
considered.
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Note:- Lateral (surge) force and longitudinal (traction or drag) force acting transverse and along
the crane rail respectively, shall not be assumed to act simultaneously. However, if there
is only one crane in the bay, the lateral and longitudinal forces may act together
simultaneously with vertical loads (clause 6.4 IS-875 Part 2).

5.3 Permissible stresses:

5.3.1 As per Clause 3.9.3 of IS-800, while considering the simultaneous effects of vertical
loads of crane and horizontal surge loads, the permissible stresses may be increased by
10%.

5.3.2 For repeated loads and consequent fluctuations of stresses, the permissible stresses are
reduced (to avoid fatigue) as per Clause 3.10 (IS-800) for ratio f min/f max.

6.0 LOAD COMBINATIONS WITH OTHER LOADS:

The crane loads shall be considered under imposed loads IL and combination with other
loads DL, WL, EL, TL etc. shall be considered. The load combination whichever
produces the most unfavourable effect in the building, foundation or structural member
shall be adopted. It should also be recognized in load combinations that the
simultaneous occurrence of max. values of wind, earthquake and imposed loads is not
likely. Ref. IS 875 (Part 2), Cl.6 & IS 875 (Part 5), Cl.8.

7.0 TYPICAL COMMONLY USED CRANE GIRDER SECTIONS ARE:

a) Rolled beams strengthened by channels at top with or without plates at bottom

and top if required.
b) Plate girders with double angles and plates at top.
The strengthened top flange provides effective resistance to:
i) Instability of the compression flange.
ii) Horizontal bending moment
iii) Torsion due to crane surges
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8.0 LIMITING VERTICAL DEFLECTION (IS-800):

Parameter HOT Crane EOT Crane

Upto 50 T Over 50 T
Limiting vertical L/500 L/750 L/1000
Deflection under
imposed (crane)
loads (without impact
factor)

9.0 CRANE BUFFER STOPS:

Crane stops are necessary as a safety measure and are provided on the crane girders
at a safe distance from the end of the building gables and act as buffer barriers to
protect the gable structures against possible collision and/or falling of the gantry.

The basic horizontal force Py(tonnes); acting along the crane track that can be
produced by the impact of the gantry crane on the crane buffer stops is calculated by
the formula given as Py = m V2 /F, ( where V is in m/s), refer IS-875 Part 5 Cl.6.1.4
for notations and explanation.

10.0 CLASSIFICATION OF CRANES (Ref. Appendix A of IS-807):

• Electrically operated travelling EOT cranes - carried on civil structures.
• Hand operated travelling HOT cranes - carried on civil structures.
Other cranes are:
• Electrically driven jib cranes mounted - on high pedestal or portal carriage for use in
cargo etc.
• Mobile Power driven cranes – used in building construction works
• Travelling jib cranes – used in building construction works
• Derrick cranes – used at Docks
• Transporters – used on big vehicles such as trucks etc.
• Misc. cranes – such as Noval cranes, winches, locomotive cranes.

11.0 CO-ORDINATION:
PI will provide approved vendor list. Requirement of Insert plates / or frames on floor or
walls for installation of isolator panel shall be provided by EL.
END