Design of Monorail Beam (4m span)

flange width b = 150 mm

flange thick t = 10 mm
overall web depth d = 300 mm 280
web thick tw = 6 mm
Span of the beam L = 4000 mm 4
Monorail beam Capacity W = 25 kN (including hoist weight of 5 kN)
Self weight of beam = 2 kN/m
BM due to crane load (WL/4) M3 = 25 kN-m
BM due to self wt (WL /8)2
M1 = 4 kN-m
Design Bending Moment (M1 + M3) M*m = 29 kN-m
Yield Strenth of Steel fy = 245 N/mm2

Nominal section Moment capacity Ms = fy x Z e

= 156702000 N-mm
= 156.702 kN-m
λef = ((b-tw/2xt) x sqrt(fy/250) = 7.128 < λep as per Table 5.2 of AS 4100
flange is compact
λew = (d-2*t)/tw x sqrt(fy/250) = 46.198 < λep as per Table 5.2 of AS 4100
web is compact
Section Modulus Ze = 639600 mm3

Nominal member moment capacity Mb = αm x αs x Ms

Moment modification factor αm = 1.7M*m

refer clause 5.6.1.1 a(iii) of AS 4100 sqrt((M2)2 + (M3)2 + (M4)2)
= 1.61 less or equal to 2.5
M2 = 12.5
M3 = 25
M4 = 12.5
slenderness reduction factor αs = 0.6 x (sqrt((Ms / Mo)^2+3)-(Ms/Mo))
refer eqn 5.6.1.1 (2) = 0.542

Buckling moment Mo = sqrt((π^2 x E x Iy)/Le^2) x (G x J + (π^2 x E x Iw)/Le^2))

Mo 129.692 KN-m 694578.3 24216309694

Elastic Modulus E = 200000 N/mm2

G = 80000 N/mm2
M.I. about YY axis Iy = 5630040 mm4
M.I. about xx axis Ix = 74076000 mm4
warping constant Iw = 1.18372E+11 mm6 refer appendix H
Torsion constant J = 120160 mm 4
refer appendix H

Effective length le = kt x kl x kr x L refer clause 5.6.3

1 x 1 x 1 x 4000 = 4000 mm

refer clause 5.6.1.1 Mb = 136.791 KN-m

capacity factor φ = 0.9 refer table 3.4
φMs 141.032 KN-m
φMb 123.112 KN-m
Lesser of above values is the section moment capacity
= 123.112 KN-m
Design bending Moment 29 KN-m
Hence Safe

for over hanging (case-2)

overhanging length = 2m 2000
Moment due to crane = 50 KN-m
Moment due to self weight of the beam = 4 KN-m
Design Bending Moment (M1 + M3) M*m = 54 KN-m
 hence safe

Check for deflection

allowable deflection d lim, v = Span / 600

= 6.67 mm

Deflection for case - 1 = 2.36 mm 0.112497075 2.249941502

Deflection for case - 2 = 4.77 mm 0.26999298 4.499883003

less than allowable deflection hence safe

Design of Monorail Beam (5.5m span)

flange width b = 200 mm

flange thick t = 12 mm
overall web depth d = 400 mm 376
web thick tw = 8 mm
Span of the beam L = 3000 mm 3
Monorail beam Capacity W = 15 kN (including hoist weight of 5 kN)
Self weight of beam = 3 kN/m
BM due to crane load (WL/4) M3 = 11.25 kN-m
BM due to self wt (WL /8)2
M1 = 3.375 kN-m
Design Bending Moment (M1 + M3) M*m = 14.625 kN-m
Yield Strenth of Steel fy = 245 N/mm2

Nominal section Moment capacity Ms = fy x Z e

= 240382240 N-mm
= 240.382 kN-m
λef = ((b-tw/2xt) x sqrt(fy/250) = 7.920 < λep as per Table 5.2 of AS 4100
flange is compact
λew = (d-2*t)/tw x sqrt(fy/250) = 46.528 < λep as per Table 5.2 of AS 4100
web is compact
Section Modulus Ze = 981152 mm3 (doubt)

Nominal member moment capacity Mb = αm x αs x Ms

Moment modification factor αm = 1.7M*m

refer clause 5.6.1.1 a(iii) of AS 4100 sqrt((M2)2 + (M3)2 + (M4)2)
= 1.80 less or equal to 2.5
M2 = 5.625
M3 = 11.25
M4 = 5.625
slenderness reduction factor αs = 0.6 x (sqrt((Ms / Mo)^2+3)-(Ms/Mo))
refer eqn 5.6.1.1 (2) = 0.862

Buckling moment Mo = sqrt((π^2 x E x Iy)/Le^2) x (G x J + (π^2 x E x Iw)/Le^2))

Mo 739.713 KN-m 3512711 1.5577E+11

Elastic Modulus E = 200000 N/mm2

G = 80000 N/mm2
M.I. about YY axis Iy = 16016042.6666667 mm4
M.I. about xx axis Ix = 216148650.666667 mm4
warping constant Iw = 602779781802.667 mm6 refer appendix H
Torsion constant J = 294570.666666667 mm 4
refer appendix H

Effective length le = kt x kl x kr x L refer clause 5.6.3

1 x 1 x 1 x 4000 = 3000 mm

refer clause 5.6.1.1 Mb = 374.067 KN-m

capacity factor φ = 0.9 refer table 3.4
φMs 216.344 KN-m
φMb 336.660 KN-m
Lesser of above values is the section moment capacity
= 216.344 KN-m
Design bending Moment 14.625 KN-m
Hence Safe

for over hanging (case-2)

overhanging length = 3m 3000
Moment due to crane = 45 KN-m
Moment due to self weight of the beam = 13.5 KN-m
Design Bending Moment (M1 + M3) M*m = 58.5 KN-m
 hence safe

Check for deflection

allowable deflection d lim, v = Span / 600

= 5.00 mm

Deflection for case - 1 = 0.22 mm 0.024397272 0.195178179

Deflection for case - 2 = 3.83 mm 0.702641444 3.122850862

less than allowable deflection hence safe