A REPORT

ON
“ELECTRICAL OVERHEAD TRAVELLING CRANE”
Submitted to
Dr. Balaji P.S.
FOR
MECHANICAL SYSTEM DESIGN PROJECT
ME481
NATIONAL INSTITUTE OF TECHNOLOGY
ROURKELA

Submitted By:
Name:
Roll no:

1
 CONTENTS
1. WORK DISTRIBUTION
2. INTRODUCTION
3. PROBLEM STATEMENT
4. DESIGN
a. TROLLEY STRUCTURE
b. MAIN GIRDER
c. SIDE TRUSSES
d. HORIZONTAL TRUSSES
e. END GIRDER
f. GANTRY GIRDER
g. COLUMN
h. PULLEY
i. ROPE
j. ROPE DRUM
k. HOOK

2
 WORK DISTRIBUTION
S.no Roll no Name Job

1. 116ME0504 G. VAMSHI KRISHNA Design of End girders and

gantry girders

2. 116ME0505 E. KASHISH VEDA Design and solid works of

trolley structure, pulley,
columns, Analysis of
trolley structure

3. 116ME0506 K. VENKATESH Design of main girder,

rope drum, solid works of
main girder, gantry girder
and rope drum

4. 116ME0507 B. VIKAS Design of trolley structure,

main girder, hook, solid
works and analysis of
hook

5. 116ME0508 V. NEHIL Design of rope, stiffeners,

report and ppt

6. 116ME0509 G. KAMAL Design and solid works of

horizontal truss

7. 116ME0593 VIKRAM KUMAR Design and solid works of

side truss, report

8. 116ME0595 RANJAN KUMAR Design and solid works of

side truss

3
 DESIGN OF E.O.T. CRANE
INTRODUCTION
A crane is a machine that is capable of raising and lowering heavy objects and moving the
objects from one place to other. An overhead crane usually consists of three separate motions:
1. The first motion is the hoist, which raises and lowers the material.

2. The second is the trolley (cross travel), which allows the hoist to be positioned directly above
the material for placement.

3. The third is the gantry or bridge motion (long travel), which allows the entire crane to be
moved along the working area.

Cranes are distinguished from hoists, which can lift objects but cannot move them sideways. The
design of overhead cranes vary widely according to their major operational specifications such
as: type of motion of the crane structure, weight and type of the load, location of the crane,
geometric features, operating regimes and environmental conditions.

TYPES OF ELECTRIC OVERHEAD CRANES

There are various types of overhead cranes with many being highly specialized, but the great
majority of installations fall into one of four categories:

1. Single Girder Cranes - The crane consists of a single bridge girder supported on two end
trucks. It has a trolley hoist mechanism that runs on the bottom flange of the bridge girder.

2. Double Girder Bridge Cranes - The crane consists of two bridge girders supported on two end
trucks. The trolley runs on rails on the top of the bridge girders.

3. Gantry Cranes - These cranes are essentially the same as the regular overhead cranes except
that the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs
running on fixed rails or other runways. These “legs” eliminate the supporting runway and
column system and run on a rail either embedded in, or laid on top of the floor.

4. Monorail - For some applications such as production assembly line or service line, only a
trolley hoist is required. This type of crane is designed using I-beams like those found in ceiling
structures of many factories. The trolleys run along the flat surface on the bottom horizontal bars
of the beam. The hoisting mechanism is similar to a single girder crane with the difference that
the crane doesn’t have a movable bridge and the hoisting trolley runs on a fixed girder.

Single Girder or Double Girder- Both single and double girder cranes are equally rigid, strong,
and durable. The principle difference between single and double girder cranes is hook height
(how far above the floor your hoist will lift). Double girder cranes typically allow 18-36 inches
higher lift, because the hoist is placed between the cross girders rather than under them.
Therefore, the depth of the cross girder is gained in switching to double girders.

4
 PROBLEM STATEMENT
An extra heavy-duty electrical overhead travelling (EOT) crane of the following specification is
required for the central repair shop of an integrated steel plant. Design the structural component
such as
1. Trolley Structure
2. Girders
3. Horizontal trusses
4. Side trusses
5. End girders
6. Wire ropes
7. Pulleys
8. Hoisting drum
9. Crane hook
And also, the column supporting the crane. Design the assembly layout and all the design
components in any design software and validate the design using analysis software.
Span length= 22 m
Width = span length / 10 = 2.2m
Main hoist Crane capacity = 68 tonnes
Auxiliary hoist Crane capacity = 14 tonnes

5
 DESIGN OF TROLLEY STRUCTURE
 Mounting details on Trolley Structure:
1. Gear Box with shaft and coupling for trolley travel mechanism: 939.30667 kg
2. Brake for trolley travel mechanism: 121.4933 kg
3. Motor for trolley travel mechanism: 462.4 kg
4. Motor for main hoisting mechanism: 1589.38667 kg
5. Floating shaft with coupling for main hoisting mechanism: 145.06667 kg
6. Brake for main hoisting mechanism: 433.386667 kg
7. Gear Box for main hoisting mechanism: 3880.5333 kg
8. Rope drum for main hoisting mechanism: 2196.8533 kg
9. Equaliser Block for main hoisting mechanism: 404.3733 kg
10. Plumber block for main hoisting mechanism: 260.21333 kg
11. Gear Box for auxiliary hoisting mechanism: 1237.6 kg
12. Rope drum for auxiliary hoisting mechanism: 761.6 kg
13. Plumber block for auxiliary hoisting mechanism: 59.5 kg
14. Motor for auxiliary hoisting mechanism: 821.1 kg
15. Floating shaft with coupling for auxiliary hoisting mechanism: 119 kg
16. Brake for auxiliary hoisting mechanism: 214.9 kg
17. Equaliser Block for auxiliary hoisting mechanism: 71.4 kg
18. Tension in the rope around the rope drum of the main hoist = (1.05) * (capacity of main hoist
* 2/n)

n is the number of rope falls provided in main hoist. Here the number of rope falls are chosen to
be 8.
Tension in the rope around the rope drum of the main hoist = (1.05*68000* 2/8) =17850 kg

19. Tension in the rope around the equaliser block of the main hoist = 1.05*(capacity of main
hoist*(n-2)/n) = 53550 kg

20. Tension in the rope around the equaliser block of the auxiliary hoist = 1.05 * (capacity of
auxiliary hoist * (n’-2)/n’) here n’ is the number of rope falls provided in auxiliary hoist which is
chosen to be 6 here.
6
Tension in the rope around the equaliser block of the auxiliary hoist = 11.25 kg

21. Tension in the rope around the rope drum of the auxiliary hoist = 1.05 * (capacity of
auxiliary hoist * 2/n’) = 1.05*14000*2/8 = 3675 kg
It is calculated that total load from all the mountings placed on the trolley structure is 13726 kg.

1. For Beam 1, Referring to loading diagram, support reactions are evaluated and they are
R(1) = R(1)’ = w(9,19)/2= (404.3733 + 53550)/2 = 26977.18665 kg (264646.201 N) and
maximum bending is found out to be which occurs at the mid-section of the beam
87303.423 Nm (890247.1595 kg-cm).

2. For Beam 2, Referring to loading diagram, support reactions are evaluated and they are
R(2) + R(2)’ w(1,2,3,R(1)’,5/2,6)= (939.30667 + 121.4933 + 462.4 + 26977.18665 +
145.06667 /2+ 433.386667) = 29006.3 kg (284551.868 N) so R(2) = 14257.4 kg
(139865.094 N) & R(2)’ = 14748.96 kg (144687.2976 N) and maximum bending is
found out to be which occurs at the mid-section of the beam 151522.602 Nm
(1546149.07 kg-cm).

3. For Beam 3, Referring to loading diagram, support reactions are evaluated and they are
R(3) = R(3)’ = w(8,18,R(1))/2= (2196.8533+17850+26977.18665)/2 = 23512.02 kg
(230652.916 N) and maximum bending is found out to be which occurs at the mid-
section of the beam 25863.221978 Nm (263731.4677 kg-cm).

4. For Beam 4, Referring to loading diagram, support reactions are evaluated and they are
R(4) + R(4)’ w(14,15/2,17,12,21,15/2)= (821.1,119/2,71.4,761.6,3675,119/2) = 880.6 kg
(8638.686 N) so R(4) = 3037.671668 kg (29799.559 N) & R(4)’ = 2843.815003 kg
(2897.82518 N) and maximum bending is found out to be which occurs at the mid-
section of the beam 287.108835Nm (29134.40201 kg-cm).

5. For Beam 5, Referring to loading diagram, support reactions are evaluated and they are
R(5) + R(5)’ w(R(2)’,7,R(3)’,13,R(4)’,7)=
(14748.95064+23512.01998+3880.5333+59.5+3037.671668) = 45238.675588 kg
(443791.4075 N) so R(5) = 26114.87149 kg (256186.8893 N) & R(5)’ = 19123.8041 kg
(187604.5182 N) and maximum bending is found out to be which occurs at the mid-
section of the beam 18992.05122 Nm (193665.0254 kg-cm).

6. For Beam 6, Referring to loading diagram, support reactions are evaluated and they are
R(6) + R(6)’ w(4,5/2,R(2),10,R(3),11,R(4))=
(14257.35598+1589.38667+145.06667/2+23512.01998+260.21333+1237.6+2843.81500
3) = 43772.9243 kg (43772.9243 N) so R(6) = 25437.82095 kg (249545.0235 N) & R(6)’
= 18335.10385 kg (179867.3688 N) and maximum bending is found out to be which
occurs at the mid-section of the beam 17474.88034 Nm (178194.188 kg-cm).

7
8
9
 For all design bending moments minimum section modulus are to be calculated. Allowable
bending stress for structural steel from I.S. Code/Design Data Book is taken here as 1650 kg/cm2
(16500000 kg/m2)

Sl. No. Of Max B.M. Design B.M. (kg- Min. Section Selected Section &
cm) Modulus, Z its Section Modulus
Trolley (kg-cm)
(cm3) from Steel
Beam = 1.30*Max B.M. ( cm3)
Table

1 8902.471595 11573.21307 701.4 ISLB550, 2228.16

2 15460.48678 20098.63281 1218.098 ISLB550, 2228.16

3 25863.221978 33622.18857 2037.708 ISLB550, 2228.16

4 2857.108835 3714.241486 225.105 ISLB550, 2228.16

5 18992.05122 24689.66659 1496.343 ISLB550, 2228.16

6 17474.88034 22717.34444 1376.81 ISLB550, 2228.16

10
 Sl. No. Of Specification of Max induced stress Specific Actual Actual
section selected (kg/cm2) = Design weight of Beam weight of
Trolley
B.M./Zact the Length beams
Beam
section, w (cm)
(kg)
(kg/cm)
from Steel
Table

1 ISLB550 519.4067 846.6 0.66 558.75

2 ISLB550 902.028 846.6 2.2 1862.52

3 ISLB550 1508.966 846.6 2.2 1862.53

4 ISLB550 166.695 846.6 2.2 1862.52

5 ISLB550 1108.074 846.6 2.64 2235.02

6 ISLB550 1019.5562 846.6 2.64 2235.02

Total dead loads of all the trolley beams = 10616.35 kg

Weight of ISLB 550 = 86.3 kg/m
So, specific weight = 86.3*9.81= 846.6N
Actual weight of beam = 846.6*0.66 = 558.75N

Trolley structure load = 1.15 * Dead loads of all trolley beams = 1.15 * 10616.35 = 12208.8117
kg

Trolley structure load with all its mountings = 1.05 * (Trolley structure load + weight of all its
mountings)
Therefore, Trolley structure load with all its mountings = 1.05*(1244.5271 + 13726) =
15719.053 kg

11
So, wheel load of the trolley i.e., maximum load per wheel of the trolley = P = (Trolley structure
load with all its mountings + Capacity of the crane)/number of wheels used = (15719.053 +
68000)/4 = 20,929.76 tonnes
So maximum wheel load of the trolley is 21,000 kg.

DESIGN OF MAIN GIRDER

Dead load analysis:
1. Self -weight of girder for 68 T capacity and 22 m span crane may be determined from the
following empirical formulae: Gmain= 10Qton*(22-5) kg

where, Gmain is the self-weight of the main girder Qton is the main capacity of the crane in tonne
and L is the span of the crane in metres. Self-weight of girder for 68 tonne capacity and 22 m
span, Wmain = Gmain=11,560 kg

2. Half of the self-weight of the horizontal truss as well as platform truss on one side of the
crane, which are assumed to be 1/6th of the main girder weight. In this case it is found to be
0.5*(1/6*11560*2) = 1926.67 kg.
3. Half of the self -weight of the cross bracings on one side of the crane, which is assumed to be
1/30th of the main girder weight. In this case it is found to be 0.5 * 1/30 * 11560 = 192.67 kg

4. Total weight of the rail mounted on the main girder for running the trolley is assumed to be
0.1 kg/cm. In this case it is estimated to be 0.1*100*22 = 220 kg

5. Half of the self -weight of the flooring provided on platform truss i.e. 0.5* (Length * breadth
(i.e. centre distance between main girder and side truss)) * thickness of plate used for flooring in
meter * factor of perforations made on plate usually 0.5 * specific weight of the steel plate
generally used as flooring material in kg/m3 = 0.5*[22*0.8*0.0127*0.5*7.8*10^-3] = 436 kg
Specific weight of steel= 7.8*10^-3 kg/m^3
Total uniformly distributed load= 14335.34 kg
u.d.l = 14335.34/22 = 651.606 kg/m

Concentrated Load:
1) Half of the weight of the operator’s cabin which is assumed to be in between 1000 to 1500
kg. In this case it is assumed to be 0.5*1400 kg i.e. 700 kg, acting 1/10th of the span from left
hand end of the main girder.

2) Half of the weight of the mountings for the crane travel mechanism which is usually to be in
between 700 to 1300 kg for 20 tonne crane. In this case it is found to be 0.5*1000*68/20 i.e.
1700 kg acting at the midspan of the main girder.

12
Calculation for dead loads:

• Total uniformly distributed load on main girder = Sum total of all loads from (1) to (5) as
estimated in previous section i.e. 11560 + 1926.67 +192.67 +220 +436 = 14335.34 kg.
Therefore, uniformly distributed load on the girder is equal to 14335/22 = 651.606 kg/m.
In addition to above uniformly distributed load, one concentrated load of 1700 kg is at the
midspan and another at the 1/10th from the left of 700 kg.

• Therefore, the maximum bending moment on the girder due to dead load is 49542.207kg-
m and the maximum shear force on the girder due to dead load is-8087.67 kg.

MOVING LOAD ANALYSIS:

• In order to evaluate maximum bending moment due to the above loading system, one of
the moving loads i.e. 21000 kg should be located at (3.5/4) =0.875 m away from the mid
span of the girder.
• Wheel load is (11-0.875) =10.125m

• Now, the maximum bending moment which occurs under the heaviest load of moving
load system is 195711.6938 kg-m

• and the maximum shear force which occurs at left support is 38659.09 kg.

Evaluation of shear force and bending moment of the design: To allow for an unaccounted
load such as impact load or braking load, multiplying factors are multiplied for dead load and
moving load which are taken to be 1.1 and 1.2 respectively.

13
Thus, Design maximum bending moment=1.1* Mx(dead Load)+1.2* Mx(moving load)
=1.1*49542.207 +1.2*195711.6938
=28935046.03 kg.m
Design maximum Shear Force=1.1* Qy(dead Load)+1.2* Qy(moving load)
=1.1*8647.67+1.2*38659.09
=55903.345 kg

DESIGN OF BUILT UP PLATE GIRDER

• Maximum allowable stress in both compression and tension is 𝜎allow =1575 kg/cm2 (from
data book)

• Overall minimum depth of the girder=5*(Mx,max/𝜎allow )1/3cm

=5*(28935046.03/1575)1/3 cm =131.93 cm

• Usually maximum depth of the girder is taken as 1/10th to 1/12th of the span of the girder,
which is equal to in this case 220cm to 183cm. Taking the depth of the web of the girder
(d) be 180 cm which is between 1381.93cm to 183cm. Therefore, taking allowable shear
stress for the structural steel 945 kg/cm2.

• Thickness of Web(t)= Max Design Shear force of the girder/ (d * allowable shear stress)
= 55903.345 / (180*945) = 0.33 cm
• For Vertically stiffened webs, minimum allowable ratio between its depth and thickness
i.e.(d/t) in practise is 200.

So, t =180/200=0.9cm= tw, it can be taken as 1cm. Assuming 5 cm on top and bottom of
web tf , Distance between flanges is found out to be D’=185cm.

• But from empirical relation 𝜎allow *D’*(A+ Aw/6) =M

• Where M=maximum design bending moment

• Aw=cross section area of the web in cm2
14
 • 1575*185(A+(180*1)/6) =28935046.03
• A=69.30 cm2

• For Flange with unstiffened edges = 16t+16t+t=33t=33*1 cm=33 cm.

• However, Flange Plate of 30 cm width(d) is adopted.
• Thickness of the Flange plate(t’) =A/b =69.30/30=2.31 cm.

• But for design purpose thickness of t’=2.5cm is to be adopted.

CHECK FOR STRENGTH OF THE GIRDER:

For strength calculation:

• Area moment of Inertia for the cross section of built up girder,

• Ix-x=30[((185)3-(180)3)/12] + (1*(180)3)/12 = 1735062.5 cm4

• Therefore,section modulus of the cross-section Zx-x= Ix-x/Ymax= 1735062.5/(185/2)=

18757.43 cm3

• So, the maximum bending stress induced on the girder=28935046.03/18757.43 =1542.6

kg/cm2

• Since, 1542.6 kg/cm2 < 1575 kg/cm2.

Therefore, the design is safe.

DESIGN OF STIFFENERS
Vertical stiffeners are of two types i.e. End bearing Stiffener and Intermediate stiffener. Here
only vertical stiffeners are used and horizontal stiffeners are not required as the depth of the web
is not much.

End or Bearing Stiffeners: (safe from bearing stress)

• As per Data Book, thickness of the stiffener is 2 times the thickness of the web. So,
tstiffness=2*1=2cm=20mm

• Width of the stiffener on one side of the girder is 12 times the thickness of the web. So,
ws=12*1=12cm=120mm

• Effective length of the stiffener is 0.7 times depth of the web. So, ls=0.7*180=1260mm

• Checking the bearing stress on Stiffeners, the end

• Area of the cross section of the stiffener, As=20* ts * ws +2.0* ws * ts
=20*10*10+2*20*120=6800mm2.

15
• Area moment of inertia of the section, (Ix-x)s=1/12*[ts*(2ws+t)3 +t3*(20*t-ts)] = (1/12)
*[20(2*120+10)3+103*(20*10-20)] =260.567*105 mm4

• Minimum radius of gyration for the section, rs= √((𝐼𝑥 − 𝑥)𝑠/𝐴𝑠) =61.9021 mm

• Now, Slenderness ratio, ls/rs=1260/61.9021= 20.355

• For this ratio, allowable crushing stress,= σc= 1348.1575 kg/cm2.

• So, the permissible buckling load on the stiffener=σc*As = 91674.71 Kg

• Maximum shear force = 55903.345

• Checking the bearing stress on Stiffeners, the end

• Area of the cross section of the stiffener, As=20* ts * ws +2.0* ws * ts
=20*10*10+2*20*120=6800mm2.
• Area moment of inertia of the section, (Ix-x)s=1/12*[ts*(2ws+t)3 +t3*(20*t-ts)] = (1/12)
*[20(2*120+10)3+103*(20*10-20)] =260.567*105 mm4

• Minimum radius of gyration for the section, rs= √((𝐼𝑥 − 𝑥)𝑠/𝐴𝑠) =61.9021 mm

• Now, Slenderness ratio, ls/rs=1260/61.9021= 20.355

• For this ratio, allowable crushing stress,= σc= 1348.1575 kg/cm2.
• So, the permissible buckling load on the stiffener=σc*As = 91674.71 Kg

• Maximum shear force = 55903.345

• Checking the bearing stress on Stiffeners, the end

• Area of the cross section of the stiffener, As=20* ts * ws +2.0* ws * ts
=20*10*10+2*20*120=6800mm2.

• Area moment of inertia of the section, (Ix-x)s=1/12*[ts*(2ws+t)3 +t3*(20*t-ts)] = (1/12)

*[20(2*120+10)3+103*(20*10-20)] =260.567*105 mm4

• Minimum radius of gyration for the section, rs= √((𝐼𝑥 − 𝑥)𝑠/𝐴𝑠) =61.9021 mm

• Now, Slenderness ratio, ls/rs=1260/61.9021= 20.355

• For this ratio, allowable crushing stress,= σc= 1348.1575 kg/cm2.

• So, the permissible buckling load on the stiffener=σc*As = 91674.71 Kg

• Maximum shear force = 55903.345

16
 DESIGN OF SIDE TRUSSES
Side Struss:
Side Truss is an integral part of the EOT crane that contributes strength as well as
rigidity. It shares the total load on the whole system at the same time provides space to hold
some parts like travelling mechanism. There are two members of side truss each on one side of
the crane and side at the main girder.
Side truss has 10 panels at equal length. The top members are called top chords and the bottom
members are called bottom chords. It has 6 vertical members and 10 inclined members.
The Side Truss carries different loads.
1. Dead Load:
(i) Self Weight (880kg)
(ii) Weight of Horizontal Truss (Wh)
(iii) Weight of Platform (Wpl)
(iv) Weight of Cross bracing (Wcb)
(v) Weight of Flooring (Wfl)
(vi) Operator’s cabin and components for long travelling mechanism.
Hence, we assume that uniformly distributed load and concentrated loads are acting on the joints
only.

2. Moving Load:
This load is due to movement of operators with his equipment’s. We assume a load of 700
kg as moving load.
All the stationary forces except the weight of side truss are shared equally by the main girder and
side truss. So, half of the effective force is considered in design process.

Design of Side Truss:

1. Dead Load Analysis:
Self-weight = 40×22
= 880 kg
Total Load = Self weight + ½ [Wh + Wfl + Wpl + Wcs]
= 880 + ½ [2×1926.66 + 2×192.66 + 2×436]

17
 = 3435.26 kg
(i) Half of self weight of horizontal truss + platform =1926.66 kg
(ii) Half of self weight of cross bracing = 192.66 kg
(iii) Half of self weight of flooring = 436 kg
K=total load/ No of points = 3435.6/10 = 343.526 kg
K1=weight of operations cabin/4 = 1200/4 = 300 kg
K2= weight of components of travelling mechanism/4 = 3400/4 = 850 kg

Loads at different nodes:

At node 2 = K1+K/2 = 3217.63 N
At node 7 = K2+K = 6435.26 N
At node 8 = K + K1/2 = 4938.26 N
At node 9 = K = 3435.26 N
At node 10 = K + K2/2 = 7685.26 N
At node 11 = K2+K = 11935.26 N
At node 12 = K + K2/2 = 7685.26 N
At node 13 = K = 3435.26 N
At node 14 = K = 3435.26 N
At node 15 = K = 3435.26 N
At node 3 = K2 = 8500 N
At node 1 = R1 = 31076.3 N
At node 4 = R2 = 26276.3 N
Calculations:
1. Forces are obtained using Staadpro software.
2. Shear force, axial force are obtained from Staadpro by giving suitable coordinates
Top Nodes FORCE(N) NATURE(C=Compressive
Members T=Tensile)
1 2 0
7 0
7 7 49280 C
8 -49280
8 8 49280 C
9 -49280
9 9 78820 C
10 -78820
10 10 78820 C
11 -78820
11 11 77620 C

18
 12 -77620
12 12 77620 C
13 -77620
13 13 45680 C
14 -45680
14 14 45680 C
15 -45680
15 15 0 -
3 0

Bottom Nodes FORCE(N) NATURE

Members
3 1 -38290 T
5 38290
4 5 -65770 T
16 65770
5 6 -33750 T
4 33750
16 16 -84190 T
17 84190
17 17 -63370 T
6 63370

Vertical Nodes FORCE(N) NATURE

Members
2 2 3220 T
1 -3220
6 4 8500 C
3 -8500
20 5 4940 C
8 -4940
23 16 7690 C
10 -7690
26 17 7690 C
12 -7690
29 6 3440 C
14 -3440

19
 Inclined Nodes FORCE(N) NATURE
Members
18 1 41530 C
7 -41530
19 7 -17160 T
5 17160
21 5 23320 C
9 -23320
22 9 -18460 T
16 18460
24 16 7590 C
11 -7590

25 11 9290 C
17 -9290
27 17 -20160 T
13 20160
28 13 25010 C
6 -25010
30 6 -18300 T
15 18300
31 15 36610 C
4 -36610

MEMBERS DESIGN:
1) Top Chords
Maximum Force, Fmax= 78.82 kN
σc= 1000 kg/cm2
Area= Fmax/ σc =7.82 cm2
From steel table; Rolled steel ISA 7070 (Equal Angle Section)
Selected area =8.06 cm2, t= 6mm, A=B=90 mm, W/m=61.8 N/m
rg=2.14 cm
Z=7.3
Effective length, l= 0.85 L =0.85 × 220 =187 cm
Slenderness ratio, l/ rg=187/2.14 =87.38
for l/ rg=87.38, the value of σc=979.41 kg/cm2
Fallowable= σc × a =979.41 8.06 = 7894.0446 kg = 78940.446N > Fmax

20
 Design is safe (ISA 70×70)
2) Bottom Chords
Maximum Force, Fmax = 84.19 kN (Tensile)
σt =1650 kg/cm2 =16500 N/cm2
Area = Fmax/ σt =5.10 cm2
From steel table; Rolled steel ISA 5050 (Equal Angle Section)
Selected area =5.68 cm2, t= 6mm, A=B=50 mm
3) Diagonal Chords
Considering Compressive force:
Maximum Force, Fmax= 41.53 kN
σc= 10000 N/cm2
Area= Fmax/ σc = 4.153 cm2
From steel table, (Equal Angled Rolled Steel)
ISA 45×745, t= 5 cm, A=4.28 cm2, A=B= 45 mm, W/m= 39.2 N/m & rg= 1.36 cm
l =0.85 × 311.1 = 264.435 cm
l/rg = 194.44
By Interpolation, σc = 264.576 kg/cm2
Fallowable= σc × a = 264.576 × 4.75 =1097.99 kg < 4153 kg
Design is unsafe
Selecting another steel type from Steel Table:- ISA 6565
a = 7.44 cm2, t= 6 mm, A=B= 65 mm, rg =1.98 cm, W/m = 5.8 kg/m
So, l/rg = 264.435/1.9 =133.55
By Interpolation, σc =570.73 kg/cm2
Fallowable = σc × a =570.73 × 7.44 =4246.234 kg > 4153 kg
So, Design is safe
Considering Tensile force:
Fmax=54591 N
σt= 16500 N/cm2

21
Area = 3.31 cm2
From steel table, (Equal Angled Rolled Steel)
ISA 50×50: t= 4 mm , A= 3.88 cm2 , A=B= 50mm , W/m = 30 N/m , rg= 15.314 mm
4) Vertical Chords
Fmax= 8.50 kN
σc= 10000 N/cm2
Area= Fmax/ σc = 0.85 cm2
From steel table, (Equal Angled Rolled Steel)
ISA 20×20: Selected area = 1.12 cm2
t= 3 mm, A=B=20 mm & rg=0.58 cm, W/m =0.9 kg/m
l=0.85×L =0.85 × 220 =187 cm
l/ rg=322.41
So, Design is unsafe
Taking ISA 4040
a =2.34 cm2, t=3 mm, W/m =1.8 kg/m, rg =1.21 cm
l/rg =187/1.21 =154.54
For l/r =154.54, By Interpolation, we get σc =415.50 kg/ cm2
So, Fallowable =415.40 × 2.34 =972.036 N> 8.5 Kn
Hence, Design is safe (ISA 4040)
Checking the weight of side truss
Weight= (4 × 2.2 + 2 × 1.1) ×1.8 + 10× 3.11 × 5.8 + 5× 2.2 × 4.5 + 10 × 2.2 × 6.3
= 388.28 kg < 880 kg
Design is safe as the calculated weight is less than the allowable weight.

22
 DESIGN OF HORIZONTAL TRUSS

Two horizontal truss are used on each side of trolley i.e.., total 4 horizontal trusses are used. One
connecting main girder and side truss on top and one at bottom. Another horizontal truss on
other side.
As the crane moves there will be frictional force on the wheels. When it accelerates Inertia force
come into picture. Equating the inertia force and frictional force we get the acceleration of the
crane and force on each joint. Then, from force polygon or by analytical method i.e.., joint
method, we find forces on each member due to inertia force.

Q = Capacity of crane = 68 x 103 kg (given)

Gm = Main load = 11,560 kg
Gs = Side truss load = 880 kg
Gh = Horizontal truss load = 970 kg
Gpl = Platform load = 970 kg
Gcb = Cross bracing load = 390 kg
Gfl = Floor load = 872 kg
Grail = Weight of rail = 220 kg
Goc = Weight of operator’s cabin = 1400 kg
Glt = Weight of long travel mechanism = 1700 kg

Weight of crane, G = 2(Gm+ Gs + Gh + Gpl + Gcb + Gfl + Grail) + Glt +Goc

G = 34824 kg
Weight of trolley, Go = P x 4 – 1.15Q = 21000 x 4 – 1.15 x 68000
= 5800 kg
Equating Inertia force with braking force,
𝑄+𝐺+𝐺𝑜 𝑄+𝐺+𝐺𝑜
𝑋𝑎= 𝑋𝑀 [Assume, M = 0.2]
g 2

=> a = Mg/2
=> a =g/10

23
Total distributed horizontal force (i.e.., inertia force)
𝑄+𝐺+𝐺𝑜
= 𝑋𝑎
g
68000+34824+5800 9.81
= 𝑋
9.81 10

= 10862.4 kg
𝑄+𝐺+𝐺𝑜 68000+34824+5800
Load/Joint = K = 40(11−1) = = 271.56kg
400
𝑄+𝐺𝑜 68000+5800
Pin = = = 1845 kg
40 40

Load on each joint will be as shown in below Fig:

Horizontal Truss
At node I = K/2 (down) = 1333 N
At node III = K (down) = 2666 N
At node IV = K (down) = 2666 N
At node VI = K (down) = 2666 N
At node VII = K + (Pin/4) (down) = 7189.8625 N
At node IX = K + Pin (down) = 20766 N
At node X = K + (3Pin/4) (down) = 16240.5875 N
At node XII = K (down) = 2666 N
At node XIII = K (down) = 2666 N
At node XV = K (down) = 2666 N
At node XVI = K/2 (down) = 2666 N
At node II = R1 (up) = 30524 N
At node XVII = R2 (up) = 32335 N

24
1) Top Chords:
Sl. No. Beams Forces (N) Nature of the force
1 I-III 0 Compressive
2 III-IV 55716 Compressive
3 IV-VI 55716 Compressive
4 VI-VII 100768 Compressive
5 VII-IX 100768 Compressive
6 IX-X 108009 Compressive
7 X-XII 108009 Compressive
8 XII-XIII 59337 Compressive
9 XIII-XV 59337 Compressive
10 XV-XVI 0 Compressive

2) Vertical Chords:
Sl. No. Beams Forces (N) Nature of the force
1 XVI-XVII 1333 Compressive
2 XIII-XIV 2666 Compressive
3 X-XI 16241 Compressive
4 VII-VIII 7190 Compressive
5 IV-V 2666 Compressive
6 I-II 1333 Compressive

3) Diagonal Chords:
Sl. No. Beams Forces (N) Nature of the force
1 II-III 41283 Compressive
2 III-V 37512 Tensile
3 V-VI 33742 Compressive
4 VI-VIII 29972 Tensile

25
 5 VIII-IX 19804 Compressive
6 IX-XI 9564 Compressive
7 XI-XII 32532 Tensile
8 XII-XIV 36302 Compressive
9 XIV-XV 40072 Tensile
10 XV-XVII 43843 Compressive

4) Bottom Chords:
Sl. No. Beams Forces (N) Nature of the force
1 II-V 38718 Compressive
2 V-VIII 11667 Tensile
3 VIII-XI 46863 Tensile
4 XIV-XVII 36908 Compressive
5 XI-XIV 17097 Tensile

Horizontal Truss Members design

1. Diagonal Member:
Maximum Compressive Force = 43843 N
Maximum Tensile Force = 40072 N
Ϭt = 1650 kg/cm2
Considering maximum tensile force,
Area, a = 40072/16500 = 2.429 cm2
Taking section, From Steel Table ISA 60 x 60
a = 5.75 cm2, r = 1.27 cm
l = 0.85 x L = 0.85 x 297 = 252.45 cm
l/r = 198, Ϭc = 900 kg/cm2
Fallowable = Ϭc x a = 900 x 5.75 kg
= 50776 N > 43843 N
Hence, the design is safe.

26
Considering maximum compressive force,
a = 40072/10000 = 4.0072 cm2
Taking section ISA55 x 55,
a = 5.27 cm2, r = 1.670 cm
l = 0.85 x L = 187 cm
l/r = 187/1.67 = 111.97, Ϭc = 800 kg/cm2
Fallowable = Ϭc x a = 4216 kg
= 41316 N < 43843 N
Hence, the design is unsafe

Now consider, ISA65 x 65

a = 6.25 cm2, r = 1.988 cm
l = 0.85 x L = 187 cm
l/r = 187/1.988 = 94.06, Ϭc = 970 kg/cm2
Fallowable = Ϭc x a = 970 x 6.25 kg
= 60620 N > 43843 N
Hence, the design is safe.

2. Vertical Member:
Fmax = 16241 N
a = 16241/10000 = 1.6241 cm2
Now consider, ISA50 x 50,
a = 2.95 cm2, r = 1.53 cm
l/r = 116.66, Ϭc = 698.06 kg/cm2
Fallowable = Ϭc x a = 698.06 x 2.95 kg
20180 N > 16241 N
Hence, the design is safe.
Check for Weight:
There are 10 inclined members and 6 vertical members.

27
Weight = 2.765 x 10 x 45 + 6 x 1.8 x 23 x 9.81
= 3681.054 N
= 375.2349 kg < 1000 kg
Hence, the design is safe.

HORIZONTAL TRUSSES
Members Section Dimension Section Selection
Vertical Chords a = 2.95 cm2, r = 1.53 cm, t = ISA5050
4mm & A = B = 50 mm
Diagonal Chords a = 6.25 cm2, r = 1.988 cm, t = ISA6565
8 mm & A = B =65 mm

28
 DESIGN OF END GIRDER

End girders often have I-beam cross section composed of two load-bearing
flanges separated by a stabilizing web. End girders is located at the end of the
main girder and perpendicular to it. Two end girders are located on each side and
also support the crane wheel.

From the previous calculations:

Q = Capacity of crane = 68 x 103 kg (given)

Gm = Main load = 11560 kg
Gs = Side truss load = 700 kg
Gh = Horizontal truss load = 963.335 kg
Gpl = Platform load = 963.335 kg= Gbht(Bottom Horizontal truss)
Gcb = Cross bracing load = 385.34kg
Gfl = Floor load = 872 kg
Grail = Weight of rail = 220 kg
Goc = Weight of operator’s cabin = 1400 kg
Glt = Weight of long travel mechanism = 3400 kg
Dead Load acting at 1, 2, 3 and 4
P1= ½ Gs + ½ [Gbht/2+ Gfl/2 + Gcb/2+ Gpl/2]
P1= 1145.995 Kg
P2= G main/2 + Grail/2 + ½ [ Gpl/2 + Gfl/2 +Gcb/2 + Gbht/2]
P2= 6685.995
P3= G main/2 + Grail/2 + ½ [Gpl/2 + Gfl/2 + Gcb/2 + Gbht/2] + ½ Goc(L-l)/L + ½ G tm *1/2
P3= 8165.995 Kg
P4= Gside/2+ ½ [ Gpl /2 + Gfl/2 + Gcb/2 + GBHT/2] + ½ Goc(L-l)/l +1/2Gtm *1/2
P4= 2625.995Kg
Ra = 7831.76 kg & Rb = 10792.22 kg

29
P1=11242.210 P2=65589.61 P3=80108.41 P4=26055.31

𝑅𝐴 =76829.565 𝑅𝐵 = 10792.22

SHEAR FORCE DIAGRAM

65587.35

25761.01

-2.2563
11242.21

80110.667

BENDING MOMENT DIAGRAM

12366.43 28337.11

59799.65 59799.65

Here Maximum bending moment is 59779.658 Nm or 6093.747 kgm.

30
For Moving Loads:

Minimum approach distance (f) = 0.1L, f= 2.2 m

No moving load will act at 1 and 4
Q= 68000 Kg
Go= Weight of trolley structure = 5800 Kg
P1’=P2’ = (Q+Go)/2 * (L-f)/L = 33210 Kg
Ra’ = Rb’ = 33210 Kg

P1=325790.1 P2=325790.1

Re Rf
SHEAR FORCE DIAGRAM

325790.1

325790.1
BENDING MOMENT DIAGRAM

358369.1 358369.1

31
Maximum Bending moment = (BM)max = 358369.1Nm = 36531 kgm (for moving load)
Mdesign = φ*M dead + ϕ* Mmoving
= 1.2*6093.747 + 1.25*36531 = 52976.2464 kgm = 519696.9772 Nm
σb = 1575Kg/cm^2
Z = Mdesign/σb = 3363.555 cm^3
Section Selected: ISWB600
Zx-x = 3540 cm^3
Zy-y = 376 cm^3
w/m = 133.70 Kg/m
Sectional area = 170.38 cm^2
Ix-x = 106198.50 cm^2
Rx-x = 24.97 cm
Depth of section (h) = 600 mm
Width of flange (w) = 250 mm
Thickness of Flange(tf) = 21.3 mm
Thickness of web(tw) = 11.2 mm
Now, crane wheel diameter (D) = 710 mm (given)
Width at wheel = D/4 = 177.5 mm
Taking clearance at 1cm on both sides,
Gap clearance at 1cm on both sides,
Gap between two I-section, = 177.5 +20 = 197.5 mm
Maximum space available with the section ISWB600
Is 2*(250-11.2) = 47.7 cm > 19.75 cm
So it is possible.
Checking strength of I section:
σ b = Md/Zz-z = 1496.50 Kg/cm^2 < 1575 Kg/cm^2
So, the design is safe.

32
Inertia Load-
Bending moment due to Inertia Force = 10% of Md
Mi = 5297.62 Kg-m
When trolley brake is applied inertia force will act on the girder at b and c in horizontal
direction and so BM will act in horizontal direction.
σhor = MI / Zy-y = 1408.941 Kg/cm^2
Total Stress = 0.5 * (1496.50+1408.941)
=1452.72 kg/cm^2 < 1575 kg/cm^2
So, the design is safe.
Weight of end girder = 6.6 m* 133.7 Kg/m = 882.42Kg

DESIGN OF GANTRY GIRDER

Gantry girders are laterally unsupported beams to carry. heavy loads from place to place at the
construction sites, mostly these are of steel material.

Design Calculations:

Span of Gantry Girder = 10 m

1. Dead load: self-load = 270kg/m

BFmax = wl2/8 = 270 x 100/8 = 3375 kg m
2. Moving load:
G = weight of crane with trolley
= 2 [Gm + Gside + Gh + Gpl + Grail + Gfl + Gcb] + Glt + Goc + 2(G end girder)
G = 22228.85 kg
GT = weight of the trolley = 5800 kg
Q = 68000 kg

f = 2.2

33
 22 m

Let the wheel of crane is at minimum approach distance, i.e. f = 2.2m.

Load per wheel of crane

R1 = 0.5*G + (Q + GT)*(L-f)/L

R1 = 77534.425

P = 0.5*R1 = 38767.2125 kg
b’ = b + b/2 + b/2 = 2b = 2 x 2.2 = 4.4 m

Maximum moving BM = Mmax = P (L-b’/2)2/2l

Mmax = 77463.2925 kg m

Design BM = Md = 1.15 x Mdead + 1.2 x Mmoving

=1.15 x 3375 + 1.2 x 84848.12 = 96837.201 kg-m

Allowable bending stress σb = 1000 kg/cm2

Section modulus (z) =Mdesign/σb = 9683.7 cm3

So selecting from Steel table data book,

Double joint with channel and pates on the flange,

Two I sections will be used,

Joint designation: ISWB600

Top flange: ISMC400

For the joint, w/m = 145.21 kg/m

34
For the flange, w/m = 49.40 kg/m

Maximum allowable shear = 66.9 x 104 kg

For the top flange: -

Plate width = 320 mm

Plate thickness = 16 mm

For the bottom flange:-

Plate width = 320 mm

Plate thickness = 32 mm

Radius of gyration = 91.4 mm

Zc = 11022.5 cm3

Zt = 10941.4 cm3

Actual bending stress = Md/Zc = 878.5411 kg/cm2

So design is safe.

Shear force:-

1. Dead load:-
SFmax = wl/2 = 1350 kg (due to self
weight)
2. Moving load
ΣMB = 0
R1” *10 = P*10 + P*5.8
R1” = 60476.8515 Kg
SFmoving = 1.56 P-P = 0.56 P
=21709.639 Kg
SFmax = 1.15 SFdead + 1.2 SFmoving
= 27604.0668 kg < 66.9 x 104 kg

Hence the design is safe.

35
Lateral force:-

Lateral BM = 10% of moving BM

(BM)t = 7746.32kgm

Stress σt = (BM)t / Zt =

=70.79 kg/cm2

σc + σb = 949.3394 kg/cm2 < 1000 kg/cm2

Hence design is safe

FINAL DIMENSION:

Gantry girder section is double joint with channel and plates on the flanges

Joint designation: ISWB600

Top flange: ISMC400

36
 DESIGN OF COLUMN
Column
Height of the column = lifting height =10m
Total compressive load = max shear force on the gantry girder+ weight of the gantry girder
=29000kg
Let compressive stress=1000kg/m2
Bulking area = 9.128 cm2
Selecting section: ISHB 200
(Two joints of same size with flanges butting and welded columns)
Area = 95.08cm2
H=200mm, b=400mm
Wt/m=74.6kg/m
rxx=10.9cm
ryy=8.71cm
l/r =91.16
for l/r =91.16, σC=891. 63Kg/cm2
Maximum bulking load = σC*a = 84775.8kg > Total compressive load
Hence design is safe.
Final dimension:
Section: ISHB 200
H=200mm, b=400mm.

37
 DESIGN OF PULLEY
Pulley
Pulley material: cast iron
Pulley dia = 18 d to 27 d

Taking 25d = 25x54 = 1350mm

Pulley diameter= 1350mm

Symbol Value in terms of d Value(mm)

d 54
t 0.4d 21.6
h 1.6d 86.4
B1 2.7d 145.8
B2 2.1d 113.4
l 0.75d 40.5
R0 1.1d 59.4

Fig: Cross section of Pulley.

38
 DESIGN OF ROPES
Wire rope is a complex mechanical device that has many moving parts all working in tandem to
help support and move an object or load. In the lifting and rigging industries, wire rope is
attached to a crane or hoist and fitted with swivels, shackles or hooks to attach to a load and
move it in a controlled matter. It can also be used to lift and lower elevators, or as a means of
support for suspension bridges or towers.
Wire rope is a preferred lifting device for many reasons. Its unique design consists of multiple
steel wires that form individual strands laid in a helical pattern around a core. This structure
provides strength, flexibility, and the ability to handle bending stresses.
There are four basic components that
make up the design of a finished wire
rope:

1. Wires made from metal that form

a singular strand
2. Multi-wire strands laid around a
core in a helical pattern
3. A fiber or steel core
4. Lubrication

Selecting wire rope:

Lifting capacity : 68 tons = 68000 KgF

Step a) selecting type of wire rope and its

designation
Option of type of rope

1. Cross lay
2. Parallel lay
Selecting cross-lay.
Wire ropes are manufactured from steel wire
Reason to select cross-lay:

 Does not have a tendency to rotate while load is being lifted.

 Easy to handle
 It does not kink.
Designation of rope:
16*9, 6*9, 6*37

39
Step b) Calculating tensile load per fall (F) KgF
𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑 𝑜𝑛 𝑟𝑜𝑝𝑒
F= 𝑁𝑜.𝑜𝑓 𝑓𝑎𝑙𝑙𝑠 𝑥 𝜂
𝑝𝑢𝑙𝑙𝑒𝑦

𝜂𝑝𝑢𝑙𝑙𝑒𝑦 – to account friction

Total load on rope = Load on hook + weight of snatch block(assume 5% of load hook)
68000+3400
F= 95 = 18789.473 KgF
4𝑥( )
100

Step c) Selection of rope diameter

 Consider tensile and bending failure of rope
P = Breaking Strength
𝐹⋅𝜎𝑢
P= 𝜎𝑢 𝑑 …… (1)
− ∗50000
𝑛 𝐷min

Where F = 18789.473 KgF

𝜎𝑢 = 18000 KgF/ 𝑐𝑚2 (From Rudenko text book )

𝜎𝑢
= n’ * duty factor …… (PSG 9.2 middle of page table class 2 crane based on strength , Duty
𝑛
factor = 1.2 and n’ = 4(PSG 9.1 bottom right general purpose, Class 2 factor of safety).
Rope Application:
𝐷min
Selecting 𝑑

 PSG 9.1 bottom left table = 23

 Based on no. of bends. PSG 9.1 middle table
No. of bends = 8
𝐷min
Therefore, = 31
𝑑

𝐷min
Since, = 31
𝑑

𝐷min
Put = 31 in equation 1, we get ,
𝑑

18789.473∗18000
Breaking strength = 18000 1 = 158256.9952 = 158.256 tonnes
− ∗50000
4∗1.2 31

Select standard rope from PSG 9.4

40
Rope diameter = d = 54 mm
Nominal breaking strength = 169.7 tonnes
Step d) Analysis of life of wire ropes
Type-1: Expected life given
0.4∗𝑍
N = 𝑎∗𝑍
2 ∗𝛽

Where N = rope life in months of 25 days= assuming no. of months =12

Since it is medium duty = 16 hrs/day
Z = no. of respected bends corresponding to
a = 3400

𝛽 = 0.4

𝑍2 = 3
12∗3400∗0.4∗3
Z= = 122400 = 122.4*103
0.4

By 9.8 top table:

By interpolation;
100−130 83−95
=
110−122.4 83−𝑚

(83−95)∗(110−122.4)
(83-m) = 110−1303

83-m = -7.44
m = 83+7.44 = 90.44
90.44
Therfore, m= = 0.9044
100

Note:
Z : actual value of Z is obtained by *1000
m : actual value of m is obtained by /1000
𝐷
= m.𝜎. 𝑐1 . 𝑐2 .c+8 …. PSG 9.7 bottom half table
𝑑

Where,

𝑐1=1.24

41
𝑐2 = 0.89
c= 0.95
10∗𝐹
𝜎 = 𝜋∗𝑑2 , where F=18789.473 and 𝑑2 = 54 mm
𝐷 𝐷
= 27.4 < 𝑑 selected
𝑑

𝐷
Therefore, our 𝑑 = 31 will give more life than expected.

Hence, it is safe.
𝐷
Note: If it fails here then use this calculated value of 𝑑 put in eq.1 and calculate new P and based
on new P modify the value of rope diameter from PSG 9.4.
Type-2: Expected life not given
𝐷
= m.𝜎. 𝑐1 . 𝑐2 .c+8
𝑑

Therefore, m = 1.06
Calculating Z from PSG 9.8
𝑁∗𝑎∗𝑍2 ∗𝛽
Z= 0.4

By interpolating we get
130−150 95−107
= 95−106
130−𝑍

Z = 148.33 * 103
0.4∗𝑍
N = 𝑎∗𝑍
2 ∗𝛽

Where Z= 148.33 * 103

a = 3400
𝛽 = 0.4
𝑍2 = 3
N= 15 months
Step e) Calculating wire diameter (𝑑𝑤 )

d = 1.5 * 𝑑𝑤 * √𝑁𝑜. 𝑜𝑓 𝑠𝑡𝑟𝑎𝑛𝑑𝑠 ∗ 𝑛𝑜. 𝑜𝑓 𝑤𝑖𝑟𝑒𝑠 𝑖𝑛 𝑒𝑎𝑐ℎ 𝑠𝑡𝑟𝑎𝑛𝑑

where d = 54

42
no. of strands = 6
no. of wires in each strand = 19

54 = 1.5 * 𝑑𝑤 * √6 ∗ 19
𝑑𝑤 = 3.371.

DESIGN OF ROPE DRUM

The rope drum should be made of seamless pipe machined & grooved accurately, to -ensure
proper seating of wire rope in a proper layer. The drum should be fitted with two heavy duty Ball
or Roller bearings of reputed make for smooth operation & longer life.

Fig(1).Cross-section of rope drum (circles indicating ropes)

From the figure,

d – diameter of the rope
R – groove radius of the drum
h1 – depth of the groove into the drum
p – pitch of the grooves in the drum

Calculations:
 Rope diameter = d = 54 mm
 From PSG table of “fatigue loading of ropes ; duty factor & life mechanism” designed by
P.S.G college of technology, Coimbatore, we obtained the parameters of standard groove
as tabulated below:-

43
 Drum groove radius, R 0.5d + 1.5 28.5mm

Pitch, p d+3 57 mm

Depth of the groove, h1 0.25d 13.5mm

 Rope drum dimensions:

1. Diameter of the drum = D = 23d to 36d = 23d = 23*54 = 1350mm = 1.35m

2. Length of the drum = (pitch × ground height × no. of rope falls)/Diameter of the drum
= 57 × 10000 × 4/1350
= 1688.9mm = 1.7 m.
3. Number of grooves or turns on drum for one rope = Z = 12
𝐻×i
𝑍 = (𝜋 × D) + 2

Where, H = hoisting height or ground height = 10m

i = transmission ratio = no. of rope falls/2 = 4/2 = 2

4. Wall thickness = w = (0.02D + 0.8)cm = 3.5cm = 35mm

5. Flange diameter = (D + 6d)cm = 167.4cm = 1.68m

Inside diameter = Din = D – 2w = 1.28m

44
 DESIGN OF HOOK
Design of a Standard Hook:
A lifting hook is a device for grabbing and lifting loads by means of a device such as a hoist or
crane. A lifting hook is usually equipped with a safety latch to prevent the disengagement of the
lifting wire rope sling, chain or rope to which the load is attached.
Introduction:
• Crane hooks are one of the important components which are used to transfer materials having
heavy loads, mainly in industries.

• Crane hooks are liable components subjected to failure due to stress in accumulation of heavy
loads. Failure of a crane hook mainly depends on three major factors i.e. dimension, material,
overload.

• The design parameters for crane hook are area of cross section, material and radius of crane hook.

• It is basically a hoisting fixture with pulley elongated by a rope or a chain designed to engage a
ring or link of a lifting chain or the pin of a shackle or cable socket and must follow the health and
safety guidelines.

• Crane hooks with trapezoidal, circular, rectangular and triangular cross section are commonly
used.

Selecting Standard Hook

Safe load or permissible load = Load to be lifted * Duty factor
Load to be lifted = 68 tonnes
Duty factor = 1.4 (PSG 9.2)
Here 1.4 is taken depending on the running hours/day i.e 3
Safe load = 68 * 1.4 = 95.25 tonnes
Selecting Mild steel as the material
σt = 400Mpa
τ = 240Mpa
Step 1: From standard table of IPSS: 1-08-004-18 based on IS:3815-1969
The standard working load of the hook is taken is 100 tonnes and medium duty

45
From the IS table,
D=320mm L=880mm
S=250mm R=40mm
b=200mm Ra=230mm
h=320mm Rb=165mm
d=200mm Rc=420mm
d1=180mm Rd=100mm
d0=Trap 170x16 Re=340mm
l=440mm Rf=300mm
L1=220mm Rg=40mm
L2=160mm Rh=7.5mm

46
Step -2: Cross section is considered as trapezium
C
R0=480
C N
c Co
c Ri=160
Co

bo=70
bi=200

C2
C1

Rn
e
c
Rc
A A
c c L

Fig 2: Trapezoidal cross section of hook

Inner dia. of hook, C = 320mm

bi = 200 mm
bo = 70 mm
Inner radius of curve beam, ri = C/2 =160 mm.
Outer radius of curve beam, ro = ri+C
= 160+320 = 480 mm.
Depth of the section, h = 320mm.
1
ℎ((bi+bo)
2
Radius of the neutral axis, rn = 𝑏𝑖𝑟𝑜−𝑏𝑜𝑟𝑖 𝑟𝑜
ln −(bi−bo)
ℎ 𝑟𝑖

47
 = 268.1027mm
Distance of centroidal axis from inner fiber,
ℎ 𝑏𝑖+2𝑏0 320 200+140
C1 = 3 [ 𝑏𝑖+𝑏𝑜 ] = [ 200+70 ]
3

= 134.321mm
Radius of centroidal axis, rc = ri+C1
= 160+134.321 = 294.321mm
Distance of neutral axis to centroidal axis,
e = rc−rn = 294.321 – 268.1027
= 26.2183 mm.
Distance of neutral axis to inner radius,
Ci =rn− ri
= 108.1027 mm.
Distance of neutral axis to outer radius,
Co = ro−rn = 480 – 268.1027
= 211.8973 mm.
Distance from centroidal axis to load, l = rc=294.321 mm.
Step-3:
1
Area of cross section, A= 2h(bi+bo) = 160*(270)

= 43200 mm2
Bending moment about centroidal axis,
Mb=F.l = 100* 9.81 * 294.321 * 103
= 2.887 * 108 Nmm
(1) Direct stress

𝐹
σd=𝐴 =22.7083 N/mm2
𝑀𝑏∗𝐶𝑖
(2) Bending stress at the inner fiber, σbi=𝐴∗𝑒∗𝑟𝑖

= 172.213 N/mm2 (Tensile)

𝑀𝑏∗𝐶0
Bending stress at the outer fiber, σbo=−
𝐴∗𝑒∗𝑟0

= - 112.5233 N/mm2 (Compressive)

(3) Combined stress at inner fiber,

48
 σri= σd+σbi = 22.7083 + 172.213
= 194.9243 N/mm2 (Tensile) < 400Mpa
Combined stress at outer fiber,
σro= σd+σbo = 22.7083 – 112.5233
= - 89.815 N/mm2 (Compressive) < 400Mpa
Hence it is safe
(4) Maximum shear stress,
τmax= 0.5×σmax
= 0.5×194.9243
= 97.46215 N/mm2 < 240Mpa

Hence the design of hook is safe

49