Singly Symmetric Combination Section Crane Girder Design Aids

by

Patrick C. Johnson
The Pennsylvania State University
University Park, PA 16802
and
Jeffrey A. Laman, Ph.D., P.E.
Associate Professor of Civil Engineering
The Pennsylvania State University
University Park, PA 16802

Abstract

Crane runway girders are distinguished by long unbraced lengths and biaxial bending.

Combination sections consisting of a W shape with a channel cap are typically efficient for these

conditions, but time consuming to design due to the iterative process required due to biaxial

bending and the complex stability equations provided in AISC (2005) specifications. This paper

presents developed Zx tables, flexural strength graphs, and introduces a trial section selection

method. Included herein are updated design charts to allow for fast and efficient analysis of the

typical combination sections provided in Table 1-19 of the AISC Steel Construction Manual.

Also presented is an overview of crane girder design procedures and an abbreviated design

example.

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Introduction

The design or evaluation procedure for combination sections – a wide flange with a channel

cap – is specified in Section F4 of the AISC Specification for Structural Steel Buildings (AISC,

2005), which covers singly symmetric I-shaped members bent about their major axis. Reversal

of the specified AISC evaluation process for direct design is not feasible; therefore design

becomes a matter of trial and error. The situation is compounded for a combination section that

supports x- and y-axis moments as in the case of a crane girder where Chapter H of the AISC

Specification must be applied. As a result, design aids are needed to streamline the design

process that facilitates rapid selection of the most economical combination section. This paper

updates a previously published paper by Laman (1996), presenting new design aids, formatted in

the style of familiar AISC tables and figures, including the basis by which the aids are developed

and a supporting example. Also presented is a method to determine the equivalent x-axis moment

required for beams subjected to biaxial moments.

There are available many texts and design aids that address the design of industrial buildings

with cranes, such as the design guide by Fisher (2004). While these sources explain the loading

and evaluation required for crane runway girders, they do not offer any systematic approach to

the selection of trial sections. The problems of a trial and error approach are further compounded

by the lack of design aids for quickly determining the capacity of the combination sections.

Crane Girder Design Basis

Crane girders are distinguished by long unbraced lengths and combined bending about the x-

and y-axis as well as torsion. For typical loading and spans, a wide flange section with a channel

cap normally provides an efficient cross section for the design. Historically, the assumption has

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been made that the channel and the wide flange top flange resist the horizontal loads and the

combination section resists the vertical load. This simplifies the analysis of the actual condition

and eliminates the need for an analysis of torsional effects on the combination section (Laman,

1996). Given the complexity of AISC (2005) design equations due to lateral torsional buckling

strength determination, design tables and graphs are needed to speed the process. Currently the

AISC Specification contains design tables and graphs to assist with wide flange and channel

design under lateral torsional buckling and serve as a model for the aids presented herein. Based

on AISC 2005 Ch F.4 and the flow chart of Figure 1, design aids presented in Table 2 and 3 and

Figures 2 and 3 have been developed. With the availability of these new design aids, a trial

section selection methodology is now possible and is presented here.

Mueq Method

Defining the ratio of Mnx to Mny as a plastic section modulus ratio, ZR:

M nx Z x Fy Z x
ZR    (1)
M ny Z y Fy Z y

and observing that a nearly linear relationship between ZR and Mnx exists for each channel

section used as a cap, equation H1-1b can be rearranged into an explicit function for Mnx:

M ux M
 uy  1 (2)
M nx M ny

Now substituting ZR for the moment ratio into Equation (2)

M ux M uy
 1 (3)
M nx M nx
ZR

Rearranging Equation (3):

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 M ux ZRM uy 
 1 (4)
M nx M nx

Rearranging Equation (4):

M ux  ZRM uy   M nx (5)

Equation (5) is an approximation based on an assumed linear relationship between ZR and Mnx.

Because Mnx is not initially known, an equivalent moment, Mueq, is substituted for Mn in

Equation (5). Then ZR is replaced with the linear function of Mueq and solved for Mueq:

M ueq  M ux  ZRM ueq M uy (6)

Making the linear substitution for ZR into Equation (6):

M ueq  M ux  mMueq  bM uy (7)

where the coefficients m and b represent the straight-line slope and intercept for the relationship.

Distributing terms:

M ueq  M ux  mM ueq M uy  bM uy (8)

Collecting terms of Equation (8):

1  mM Muy ueq  M ux  bM uy (9)

And solving for Mueq results in Equation (10):

M ux  bM uy
M ueq  (10)
1  mM uy

The derivation for ASD is similar and results in the following equation:

M ax  bM ay
M aeq  (11)
1 1.5mM ay

The coefficients m and b have been determined based on a regression analysis of all values

for applicable channel caps for spans in 10 ft. increments up to 100 ft and are provided in Table

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1. The resulting equivalent moment determined from Equation (10) (LRFD) or Equation (11)

(ASD) is then used to select a trial section from Zx tables presented in Table 2 (Fy = 36 ksi) or

Table 3 (Fy = 50 ksi) or from design graphs presented in Figures 1 and 2 to select a trial section.

For unbraced lengths greater than the limiting length for yielding (Lb > Lp), the strong axis

moment, Mux or Max, should be divided by the buckling moment modification factor, Cb, for a

more accurate selection.

M ax
 bM ay
Cb
M aeq  (12)
1 1.5mM ay
M ux
 bM uy
Cb
M ueq  (13)
1  mM uy

Table 1. b and m Values for Typical Combination Sections.

Channel
Lb = 10' 20' 30' 40' 50' 60' 70' 80' 90' 100'
Cap
b 1.5 1.4 1.3 1.1 1.1 0.75 0.6 0.5 0.4 0.4
MC18x42.7
3
m*10 1.9 1.9 1.9 1.9 1.6 1.7 1.7 1.7 1.7 1.6
Fy = 50 ksi

b 1.1 1.0 0.9 0.9 0.8 0.6 0.5 0.4 0.4

C15x33.9
m*103 3.0 3.0 3.0 2.8 2.6 2.5 2.5 2.5 2.3
b 0.7 0.7 0.6 0.7 0.5 0.4 0.4 0.4
C12x20.7
m*10³ 6.3 6.0 6.0 5.1 5.0 5.0 4.6 4.2
b 0.2 0.2 0.2 0.1 0.2 0.1
C10x15.3
m*103 13 12 12 11 11 11
Channel
Lb = 10' 20' 30' 40' 50' 60' 70' 80' 90' 100'
Cap
b 1.4 1.5 1.4 1.3 1.3 1.1 0.85 0.7 0.6 0.5
MC18x42.7 3
m*10 2.7 2.6 2.6 2.6 2.5 2.3 2.3 2.3 2.3 2.4
Fy = 36 ksi

b 1.1 1.0 1.0 0.9 0.9 0.9 0.7 0.6 0.6 0.6
C15x33.9 3
m*10 4.1 4.1 4.1 4.1 3.9 3.5 3.4 3.4 3.1 3.0
b 0.7 0.7 0.7 0.7 0.7 0.5 0.5 0.5
C12x20.7
m*10³ 8.4 8.4 8.0 8.0 7.3 7.3 6.7 6.2
b 0.2 0.2 0.2 0.2 0.2 0.2
C10x15.3 3
m*10 17 17 17 17 16 16

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Mueq is then used in the design graphs presented in Figure 2 (Fy = 36 ksi) or Figure 3 (Fy = 50 ksi)

to select a trial section. The use of these graphs is identical to the widely used and familiar Beam

Design Moment graphs already provided in Part 3 of the AISC Steel Manual (AISC, 2005).

Singly Symmetric Crane Girder Design Procedure

1. Determine deflection limits and stiffness requirements. Vertical deflection is typically

L L
limited to for light and medium cranes and for heavy cranes. Horizontal
600 1000
L
deflection is typically limited to for all cranes. Ix is based on the full combination
400
section, while Iy is based only on the channel and the top flange of the W shape.

2. Determine the applied loads including crane manufacturer specified maximum wheel loads,

rail weight, and runway girder weight. Maximum wheel loads are increased by 25% for cab

or remotely operated bridge cranes and 10% for pendant operated bridge cranes.

3. Calculate the x- and y-axis bending moments and shear forces, applying suitable load

combinations and determine the equivalent moment from Equation (10) or (11).

4. Using the equivalent moment, select a trial section from either or Figure 2 or 3 Table 2 or 3.

Long spans supporting light cranes are normally controlled by deflection, therefore trial

selection may be based on moment of inertia.

5. Evaluate the trial section for flexural and shear capacity based on AISC Specification
Chapter F.4 following the flowchart in Figure 1, Chapter G, and Chapter H. Flexural capacity
can also be determined quickly with the assistance of Table 2 or 3. Mny is calculated as the y-axis
plastic bending strength of the wide flange top flange and the channel for combination sections:
 t f b 2f 
M ny  ZW top flange  Z x channelFy    Z x channel  Fy (14)
 4 

7. Check concentrated load criteria in Section J10 of the AISC Specification.

8. Evaluate fatigue provisions of AISC (2005) Appendix 3

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Example by LRFD Methods

Crane Capacity = 20 tons

Bridge Span = 70′- 0″
Cab operated
Bridge weight = 57.2 kips
Trolley weight = 10.6 kips
Max wheel load = 38.1 kips (no impact included)
Wheel spacing = 12′- 0″
Runway girder span = Lb = 30′- 0″, Fy = 50 ksi

1. Calculate the maximum factored moments and shears:

Pu vert per wheel = 55.2 kips (assuming  = 1.6 for lifted and trolley weight)
Pu horz per wheel = 4.05 kips
wu (self weight of girder and rail) = 0.19 klf
Mux = 683 ft-kips, Cb = 1.19
Muy = 39 ft-kips
Vuy = 119 kips
Vux = 6.5 kips

2. Determine Mueq

Expect a C15×33.9 channel cap. From Table 1, with Lb = 30′- 0″ and Fy = 50 ksi get values
for b and m:
b = 0.9
m = 3.0×10-3

 bM uy 683 ft - kips
M ux
Cb  0.939 ft - kips
M ueq   1.19  690 ft - kips
1  mM uy  
1 - 3  10-3 39 ft - kips

3. Select first trial section:

From Figure 3, with Mueq = 690 ft-kips and Lb = 30′- 0″, select a W24×68 + C15×33.9

Mpx = 967 kip-ft Ix = 2710 in4

Lp = 10.2 ft Iy = 385 in4
Lr = 43.2 ft

4. Evaluate Mcx and Mcy
All of the sections listed in Table 1-19 of the Manual meet the compact web criteria in
Table B4.1, so the web plastification factors, Rpc and Rpt, are the ratio between the plastic
moment capacity and the compression and tension flange yield moments. Thus RpcMyc = Mp
and RptMyt = Mp, which can be substituted into the equations in §F4 of the Specification.

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 Lp = 10.2 ft < Lb = 30 ft < Lr = 43.2 ft
S 173 in. 3
FL  xt Fy  50 ksi  26.9 ksi
S xc 321 in. 3
  Lb  L p 
M nx  C b  M p  M p  FL S xc   Mp
  L  L 
 r p 
  1 ft  30 ft  10.2 ft 
M nx  1.19967 kip - ft  967 kip - ft  (26.9 ksi321 in. 2     967 kip - ft
  12 in.  43.2 ft  10.2 ft 
M nx  974 kip - ft  967 kip - ft
M ny  Fy Z y  Fy Z y top flange  Z x channel  
 t f b 2f 
M ny  Fy   Z x channel 
 4 
 
 0.585 in.8.97 in.2  1 ft 
M ny  50 ksi   50.8 in. 3  
 4  12 in. 
M ny  261 kip - ft

5. Evaluate Chapter H interaction (Equation H1-1b)

Pr M M ry
 rx   1.0
2 Pc M cx M cy
M ux M uy
0   1.0
M nx M ny
683 kip - ft 39 kip - ft
  1.0
0.9967 kip - ft  0.9261 kip - ft 
0.785  0.166  1.0
.951  1.0 o.k.

6. Calculating Irequired based on the maximum deflection

L 360"
 vert max    0.6"
600 600 therefore I x  3372 in 4
L 360"
 vert max    0.9"
400 400 therefore I y  140 in 4

The trial section does not meet deflection requirements, so try a W27×84 + C15×33.9:

7. Flexural Capacity
Using Table 3:
Ix = 4050 in.4

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 Mpx =1190 kip-ft
Lp = 10.0 ft
Lr = 40.1 ft
BF = 9.85 k

M nx  Cb M p  BF Lb  L p   M p
M nx  1.191190 kip - ft  9.85 k 30.0 ft  10.0 ft   1190 kip - ft
M nx  1182 kip - ft  1190 kip - ft

8. Evaluate Interaction (Equation H1-1b)

Pr M M ry
 rx   1.0
2 Pc M cx M cy
M ux M uy
0   1.0
M nx M ny
683 kip - ft 39 kip - ft
  1.0
1182 kip - ft 251 kip - ft
0.578  0.155  1.0
0.733.  1.0 o.k.

9. Check shear, concentrated loads, and fatigue criteria.

The vertical shear is assumed to be resisted by the web of the W shape and horizontal shear
is assumed to be resisted only by the web of the channel, so Tables 3-6, 3-8, and 3-9 of the
Manual can be used to quickly determine shear capacity.

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 Select Trial
M n  R pc M yc  R pc Fy S xc (F4-1)
Combination Section
 = 0.9, W = 1.67

Lb, Cb, Mrx, Mry

  Lb  L p 
M n  Cb  R pc M yc  R pc M yc  FL S xc    R pc M yc
E
  L  L 
L p  1.1rt (F4-7)  r p 
Fy (F4-2)
 = 0.9, W = 1.67
rt : radius of gyration of flange
components and 1/3 web

Lb < Lp ? YES M n  Fcr S xc  R pc M yc (F4-3)

2
NO Cb 2 E J  Lb 
Fcr  1  0.078   (F4-5)
 Lb 
2
S xc ho  rt 
E J F S h 
2
 
Lr  1.95rt 1  1  6.76 L xc o  (F4-8)  rt 
FL S xcho  E J 
 = 0.9, W = 1.67
FL: (F4-6a or F4-6b)
Sxc: elastic section modulus w/r/t top flange
ho: distance between flange centriods
J = JWF + JC
M n  R pt M yt (F4-14)
 = 0.9, W = 1.67
Lb < Lr ? YES

NO

Figure 1. Flowchart of AISC Part 16, Chapter F.4 Evaluation Process

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Conclusion

A simplified design procedure is discussed for crane girders. An equivalent moment method

is presented for accurate selection of a combination section subjected to biaxial bending. Beam

design moment graphs are presented to allow rapid selection of trial sections and tables are

provided for efficient analysis of typical combination sections.

References

AISC, Steel Construction Manual, 13th Ed., American Institute of Steel Construction, Chicago,
IL, 2005.

Fisher, J.M., Design Guide No. 7 Industrial Buildings—Roofs to Anchor Rods, 2nd Ed., AISC,
Chicago, IL, 2004.

Laman, J.A., “LRFD Crane Girder Design and Aids,” Engineering Journal, AISC, Vol. 33, No.
4, 1996, pp. 153-158.

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Table 2. Zx Design Selection Table for Typical Combination Sections – Fy = 36 ksi.

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Table 3. Zx Design Selection Table for Typical Combination Sections – Fy = 50 ksi.

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 Figure 2. Combination Section Design Moment Diagram – Fy = 36 ksi.

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 Figure 3. Combination Section Design Moment Diagram – Fy = 36 ksi.

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