CRANE RUNWAYS

Crane runways calculation software

CRANE RUNWAYS CALCULATION

What are crane runways ?
Different types of cranes

top-mounted crane bridge underslung crane bridge monorail hoist block

The main difference between the configurations of these hoisting devices is the working load limit (WLL); see also «lifting point».
From commercially catalogues of overhead travelling crane suppliers, it is generally found that :

for heavy loads, the top-mounted crane bridges have a capacity up to 1200 kN (120T),
for middle range loads, the underslung crane bridges have a capacity up to 125 kN (12.5T).

The crane bridge can be manufactured in hot rolled section or in box section.

Some of the suppliers of overhead travelling crane products and accessories:

ABUS, FAYAT ADC, GH cranes & components, HADEF, KONECRANES, OMIS, SMAK, VERLINDE, ...
Your company is not is the list ? Contact us to add it.

Different types of ways

commercially available profiles reinforced with angles welded reconstructed sections

for top-mounted crane only !

The construction of crane runways can be achieved by attachment to the main frames of the buiding or by mounting on independent columns.
For top-mounted crane, they are made of two longitudinal beams (I-shape or box-shape) on which are fixed the rails where the wheels of
the crane circulate. In this case, the runways are controlled under torsion effect due to the eccentricity of the vertical and horizontal loads.
Some reinforcement can be added to the top flange to prevent excessive torsion or deflection.
For underslung crane, they are also made of two longitudinal beams but the wheels circulate directly on the bottom flange of the beams.
Here, additional checking like local bending are required for the bottom flange.
For monorail hoist block, the principle is the same as underslung crane but with only one longitudinal beam and no lateral load.

How to calculate crane runways ?

Step 1 - Loadings calculation from EN 1991-3
Extract of the standard §2.2.1 Classifications of actions - General
(l)P Actions induced by cranes shall be classified as variable and accidental actions which are represented by various models as described in 2.2.2
and 2.2.3.

Extract of the standard §2.2.2 Classifications of actions - Variable actions

(1) For normal service conditions, variable crane actions result from variation in time and location. They include gravity loads including hoist
loads, inertial forces caused by acceleration/deceleration and by skewing and other dynamic effects.

(2) The variable crane actions should be separated into:

variable vertical crane actions caused by the self-weight of the crane and the hoist load;
variable horizontal crane actions caused by acceleration or deceleration or by skewing or other dynamic effects.

(3) The various representative values of variable crane actions are characteristic values composed of a static and a dynamic component.
 (4) Dynamic components induced by vibration due to inertial and damping forces are in general accounted by dynamic factors φ to be applied to
the static action values. Fϕ,k = ϕi ⋅ Fk (2.1)
​ ​ ​

where:
Fφ,k is the characteristic value of a crane action;
φi is the dynamic factor, see Table 2.1;
Fk is the characteristic static component of a crane action.

(5) The various dynamic factors and their application are listed in Table 2.1.

(6) The simultaneity of the crane load components may be taken into account by considering groups of loads as identified in Table 2.2. Each of
these groups of loads should be considered as defining one characteristic crane action for the combination with non-crane loads.
NOTE: The grouping provides that only one horizontal crane action is considered at a time.

Table 2.1 Dynamic factors φi

Dynamic factors Effects to be considered To be applied to

φ1 Excitation of the crane structure due to lifting the hoist load off the ground self-weight of the crane
φ2 Dynamic effects of transferring the hoist load from the ground to the crane hoist load
φ3 Dynamic effects of sudden release of the payload if for example grabs or magnets are used hoist load
φ4 Dynamic effects induced when the crane is travelling on rail tracks or runways self-weight of the crane and hoist load
φ5 Dynamic effects caused by drive forces drive forces
φ6 Dynamic effects of a test load moved by the drives in the way the crane is used test load
φ7 Dynamic elastic effects of impact on buffers buffer loads

Table 2.2 - Groups of loads and dynamic factors to be considered as one characteristic crane action

Groups of loads
Symbol Section Ultimate Limit State Test load Accidental
1 2 3 4 5 6 7 8 9 10
1 Self-weight of crane Qc 2.6 φ1 φ1 1 φ4 φ4 φ4 1 φ1 1 1
2 Hoist load Qh 2.6 φ2 φ3 - φ4 φ4 φ4 η(1) - 1 1
3 Acceleration of crane bridge HL, HT 2.7 φ5 φ5 φ5 φ5 - - - φ5 - -
4 Skewing of crane bridge HS 2.7 - - - - 1 - - - - -
5 Acceleration or braking of crab or hoist block HT3 2.7 - - - - - 1 - - - -
6 In-service wind Fw Annex A 1 1 1 1 1 - - 1 - -
7 Test load QT 2.10 - - - - - - - φ6 - -
8 Buffer force HB 2.11 - - - - - - - - φ7 -
9 Tilting force HTA 2.11 - - - - - - - - - 1
1
η is the proportion of the hoist load that remains when the payload is removed, but is not included in the self-weight of the crane.

Step 2 - Iterative mechanical analysis

Each of the crane bridge longitudinal positions (along the runway) and transversal positions (staggered or skewed wheels with respect to the rail
axis) must be analyzed to detect maximum forces and deformations.

We have developed a specific mechanical solver to do exactly this job.

Step 3 - Serviceability Limit States checkings from EN 1993-6

Four main criteria should be checked, the limiting values of :
vertical deflection of the runway beam : generally L/600
horizontal deflection of the flange supporting the crane : generally L/600
web breathing : generally b/tw < 120
vibration of the bottom flange : generally Lf / if,z ⩽ 250

Some other criteria may have to be checked.

Step 4 - Ultimate Limit States checkings from EN 1993-6
For a top-mounted crane bridge :
Torsion caused by loads eccentricity
Stresses - Von Mises criteria
Transverse buckling of the flanges
Local buckling :
Local buckling of the flanges
Local buckling of the web under shear
Local buckling of the web under point load
Interactions between local buckling type

EXTRACTS OF RESULTS GIVEN BY THE SOFTWARE

See the features of Crane Runways
Available in English/French, otherwise «Google Translate»!
B2 - Way geometry and section parameters
B21 - Runway element
stiffener on support continuous on support = no split
stiffener on support stiffener on support

6.0m 4.0m

B22 - Cross section

Minimum steel grade of the elements : S275 (fy = 275 MPa, E = 210000 MPa)
Runway section : IPE360
Rail section : 50x30 (the rail is welded on the runway and the wear of the rail of 25% is taken into account in the calculations of the characteristics.)

Mechanical characteristics :
L40x40x5 Area : A=91.6 cm2
Shear areas :
on z-z : : Asz=42.7 cm2
top flange on y-y : Asy,top=25.6 cm2
bottom flange on y-y : Asy,bot=21.6 cm2
Second moments of area :
Z
about y-y : Iy=21261.3 cm4 (with : : zG = 21.7cm)
Y top flange about z-z : Iz=1529.4 cm4
bottom flange about z-z : Iz=521.1 cm4

Travee 1

Mechanical characteristics :
Area : A=84.0 cm2
Shear areas :
on z-z : : Asz=35.1 cm2
top flange on y-y : Asy,top=21.6 cm2
bottom flange on y-y : Asy,bot=21.6 cm2
Second moments of area :
Z
about y-y : Iy=19834.0 cm4 (with : : zG = 20.6cm)
Y top flange about z-z : Iz=544.5 cm4
bottom flange about z-z : Iz=521.1 cm4

Travee 2

F1 - Ultimate Limit States F11 - Stresses and Von Mises criteria §6.2
2 2 2
( ) +( ) −( )⋅( )+3⋅( ) ≤1
σx,Ed σz,Ed σx,Ed σz,Ed τEd
EN1993-1-1 (6.1)
​ ​ ​ ​ ​

fy /γ M 0 fy /γ M 0 fy /γ M 0 fy /γ M 0 fy /γ M 0
​ ​ ​ ​ ​

​ ​ ​ ​ ​ ​ ​ ​ ​ ​

top flange web top bottom flange flanges middle

Span right above left above right below left below right left right above left above right below left below above below

1 163.4 MPa 110.3 MPa 151.9 MPa 101.2 MPa 50.4 MPa 91.9 MPa 101.9 MPa 87.4 MPa 105.7 MPa 91.4 MPa 48.0 MPa 73.0 MPa
2 169.8 MPa 120.6 MPa 167.8 MPa 122.6 MPa 39.3 MPa 81.6 MPa 76.7 MPa 58.6 MPa 79.8 MPa 61.1 MPa 41.1 MPa 54.8 MPa
Table F11.a - Maximal Von Mises criteria by span for each of the twelve checking points.

top flange web top bottom flange flanges middle

Span right above left above right below left below right left right above left above right below left below above below

1 0.594 0.401 0.552 0.368 0.183 0.334 0.371 0.318 0.385 0.332 0.174 0.265
2 0.618 0.439 0.61 0.446 0.143 0.297 0.279 0.213 0.29 0.222 0.15 0.199
Table F11.b - Maximal Von Mises ratio by span for each of the twelve checking points.

top flange web top bottom flange flanges middle

right above left above right below left below right left right above left above right below left below above below

Stress 8.4 m 8.4 m 8.4 m 8.4 m 6.0 m 6.0 m 2.1 m 2.7 m 2.1 m 2.7 m 2.1 m 2.1 m
ULS-STR 11 4 11 4 8 8 12 8 12 8 8 8
Crane 8.4 m 8.4 m 8.4 m 8.4 m 4.2 m 4.2 m 2.1 m 0.9 m 2.1 m 0.9 m 2.1 m 2.1 m
Table F11.c - Position of stress, ULS combination and position of crane for the maximal rate of each of the twelve control points.
F12 - Transverse buckling of the flanges §6.3
NEd Mz,Ed
+ kzz ⋅ ≤1 EN1993-1-1 (6.60 + 6.61)
​ ​

min{kf l ⋅ χz ; 1} ⋅ NRk /γM 1 Mz,Rk /γM 1

​ ​ ​

​ ​
​ ​ ​ ​

F121 - Top flange

Combination for the maximal work rate: ULS-STR 11

Span NEd Mz,Ed kc Lcr,z λf Ncr,z kfl χz Cm,z kzz Ratio Section position Crane position

1 174.5 kN 15.0 m.kN 0.82 4.92 m 0.995 1309.6 kN 1.1 0.543 0.964 1.048 0.691 2.7 m 2.7 m
2 89.7 kN 9.3 m.kN 0.82 3.28 m 1.018 1049.0 kN 1.102 0.529 0.971 1.022 0.681 8.4 m 8.4 m
Table F121 - Maximal buckling ratio by span for top flange.

F122 - Bottom flange

Combination for the maximal work rate: ULS-STR 12

Span NEd Mz,Ed kc Lcr,z λf Ncr,z kfl χz Cm,z kzz Ratio Section position Crane position

1 135.2 kN 1.9 m.kN 0.91 5.46 m 1.466 362.3 kN 1.147 0.326 0.935 1.086 0.585 6.0 m 2.4 m
2 134.4 kN 1.9 m.kN 0.752 3.008 m 0.808 1194.0 kN 1.081 0.657 0.959 1.042 0.358 6.0 m 2.4 m
Table F122 - Maximal buckling rate by span for bottom flange.

F13 - Local buckling §6.6

F131 - Local buckling of the flanges EN1993-1-5 §4

NEd My,Ed
η1 = + ≤1 EN1993-1-5 (4.14)
​ ​

A ⋅ fy /γ M 0 Wel,y ⋅ fy /γM 0
​ ​ ​

​ ​ ​ ​ ​

Combinations for the maximal work rates: ULS-STR 8 (top flange), ULS-STR 8 (bottom flange)

top flange bottom flange

Span My Wel,y Ratio Section position Crane position My Wel,y Ratio Section position Crane position

1 71.1 m.kN 1288.1 cm3 0.202 2.1 m 2.1 m -36.3 m.kN 977.8 cm3 0.136 5.7 m 2.1 m
2 40.0 m.kN 1121.3 cm3 0.131 8.6 m 6.8 m -49.9 m.kN 964.6 cm3 0.188 6.2 m 2.4 m
Table F131 - Maximal local buckling ratio by span for each flange.

F132 - Local buckling of the web under shear EN1993-1-5 §5

VEd
η3 = ≤1 EN1993-1-5 (5.10)
​

χw ⋅ fyw ⋅ hw ⋅ t
​ ​

​ ​ ​

3 ⋅ γM 1
​

​ ​

Combination for the maximal work rate: ULS-STR 1

Span kτ hw/tw limmax σE τcr λrel,w χw Ratio Section position Crane position

1 5.352 41.825 66.299 hw/tw < limmax : La vérification n'est pas nécessaire
2 5.368 41.825 66.395 hw/tw < limmax : La vérification n'est pas nécessaire
Table F132 - Maximal local buckling ratio by span for the web under shear.

F133 - Local buckling of the web under point load EN1993-1-5 §6

FEd
η2 = ≤1 EN1993-1-5 (6.14)
​

fyw ⋅ Lef f ⋅ tw
​ ​

​ ​ ​

γM 1 ​

Combination for the maximal work rate: ULS-STR 1

Span FEd; ss Fcr λrel,F χF Leff Ratio Section position Crane position

1 41.4 kN 0.075 m 1737.0 kN 0.563 0.888 0.222 m 0.085 5.7 m 3.9 m

2 41.4 kN 0.075 m 1739.3 kN 0.563 0.888 0.223 m 0.085 7.0 m 5.1 m
Table F133 - Maximal local buckling ratio by span for the top of the web under point load.

F134 - Interactions EN1993-1-5 §7

η2 + 0.8 ⋅ η1 ≤ 1.4
​ ​ EN1993-1-5 (7.2)
Combination for the maximal work rate: ULS-STR 8

Span η2 η1 Ratio Section position Crane position

1 0.085 0.202 0.246 2.1 m 2.1 m

2 0.085 0.131 0.189 8.6 m 6.8 m
Table F134.a - Maximal local buckling interaction ratio by span under point load.

η 1 + (1 − ) ⋅ (2 ⋅ η3 − 1)2 ≤ 1
Mf ,Rd
si 0.5 < η3 EN1993-1-5 (7.1)
​

​ ​ ​ ​

Mpl,Rd ​

Combinations for the maximal work rates: ULS-STR 1 (top flange), ULS-STR 1 (bottom flange)

top flange bottom flange

Span η3 Wf,Rd Wpl,Rd η1 Ratio Section position Crane position η1 Ratio Section position Crane position

1 0.0 η3 ≤ 0.5 : La vérification n'est pas nécessaire

2 0.0 η3 ≤ 0.5 : La vérification n'est pas nécessaire
 Table F134.b - Maximal local buckling interaction ratio by span under shear.

F2 - Serviceability Limit States

Limiting values of horizontal deflections (EN1993-6 7.1) : L/600
Limiting values of vertical deflections (EN1993-6 7.2) : L/600
Limiting values for web breathing (EN1993-6 §7.4(3)) : b/tw < 120
Limiting values for vibration of the bottom flange (EN1993-6 §7.6(2)) : Lf / if,z ⩽ 250

Combinations for the maximal deflection rates: SLS 6 (vertical), SLS 4 (horizontal)

SLS z SLS y Web breathing Vibration of the bottom flange

Span Abscissa Ratio Abscissa Ratio Ratio Ratio

1 2.7 m 0.378 3.0 m 0.843 0.349 0.56

2 8.2 m 0.16 8.2 m 0.89 0.349 0.373
Table F2 - Maximal SLS ratios and associate positions by span for each axis.

F3 - Conclusion
Maximum work rate: 89.0%, the section is correct.