REPORT

visited site on 24th may 2013 and inspected crane runway girder in sms division.
Findings
4 no 20 ton crane + 2no 100 ton crane + 4no 20 ton
Details of crane runway girder of span 6mts is as follows
V

Section element
S Shapes ISMC300
Sheet 230 x 16
Sheet 840 x 16
Sheet 230 x 16
Equal Angles ISA100X100X8
Equal Angles ISA100X100X8
Equal Angles ISA100X100X8
Equal Angles ISA100X100X8

Rotation angle
-90.0
0
90.0
0
90.0
180.0
270.0
0

Material
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel

E (kN/mm^2)
205.0
205.0
205.0
205.0
205.0
205.0
205.0
205.0

The overall dimensions of the section are 300 x 880 mm

Basic geometry of the composite section is as below
Parameter
A
cross sectional area
angle between y-z and u-v axes

Iy
moment of inertia about axis parallel to y passing through centroid
Iz
moment of inertia about axis parallel to z passing through centroid
It
torsional moment of inertia (st. venant)
iy
radius of gyration about axis parallel to y passing through centroid
iz
radius of gyration about axis parallel to z passing through centroid
Wu+
max elastic modulus about u-axis
Wumin elastic modulus about u-axis
Wv+
max elastic modulus about v-axis
Wvmin elastic modulus about v-axis
Wpl,u plastic modulus about u-axis
Wpl,v plastic modulus about v-axis
Iu
moment of inertia about u-axis
Iv
moment of inertia about v-axis
iu
radius of gyration about u-axis
iv
radius of gyration about v-axis
au+
centroid to edge of compression zone along +ve u-axis
aucentroid to edge of compression zone along -ve u-axis
av+
centroid to edge of compression zone along +ve v-axis
avcentroid to edge of compression zone along -ve v-axis
yM
distance to centroid along y-axis
zM
distance to centroid along z-axis
yP
distance to equal area axis along y-axis
zP
distance to equal area axis along z-axis

1.
2.
3.
4.
5.
6.

Value
31520.0
-0.0
3778983128.11
109575553.01
2009064.81
346.25
58.96
7611443.48
9863887.76
730503.66
730503.66
9951968.72
1183658.17
3778983128.11
109575553.01
346.25
58.96
23.18
23.18
241.48
312.94
-150.0
-383.11
-150.1
-305.3

Welding in crane runway girders are cracked at many places

Joints in rail, cap channel, and built-up girder are not staggered
Fish plate in rail and girders are missing at many places
Lateral bracing is missing (horizontal thrust protection)
Bolts clamping rail and cap channel are loose
Wheels are eating rails on both sides

Recommendations

1. Lateral bracing to be provided

2. Fish plates to be provided IN RAILS AND IN GANTRY GIRDER

mm2
deg
mm4
mm4

mm4
mm
mm
mm3
mm3
mm3
mm3
mm3
mm3
mm4
mm4

mm
mm
mm
mm
mm
mm
mm
mm
mm
mm

3. Alignment of rails to be done

4. Diagonal check of crane wheels to be done
5. Welding to be re done using appropriate welding rods (7018
AFTER HEATING)
6. Crane load test to be done
Crane runway furnace side at ends was calculated for loads as
suggested by mahalaxmi management ie: 20 ton lifting load and found
to be safe in vertical direction
0.837 utilization ratio
Assuming crane dead wt as
Crab weight
End carriage weight
Lifting weight
Rail height from ground
Rail c/c
End carriage wheel to wheel
Min hook approach

5
17.5

15
ton
3
23
mts
25.03
5.5
1.2

ton
ton each
ton
mts
mts
mts

Calculations attached in pdf format

But still runway girder requires lateral support (HORIZONTAL SUPPORT) due to
weak base plate arrangement
TENTATIVE LATERAL BRACING DETAILS ATTACHED