+1 905.946.0864 GUIDE FOR THE DESIGN OF CRANE-SUPPORTING STEEL STRUCTURES SECOND EDITION R.A. MACCRIMMON NIAGARA FALLS, ONTARIO Canadian Institute of Steel Construction Institut canadien de la construction en acier 3760 14th Avenue, Suite 200 Markham, Ontario L3R 3T7 Copyright © 2009 by Canadian Institute of Steel Construction All rights reserved. This book or any part thereof must not be reproduced in any form without the written permission of the publisher. Second Edition First Printing, December 2007 Second Revised Printing, January 2009 Third Printing, August 2009 ISBN 978-0-88811-132-6 PRINTED IN CANADA TABLE OF CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi PREFACE TO THE SECOND EDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii CHAPTER 1 - INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHAPTER 2 - LOADS 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.2 Symbols and Notation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.3 Loads Specifi c to Crane-Supporting Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.3.2 Vertical Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2.3.3 Side Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3.4 Traction Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3.5 Bumper Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.3.6 Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.4 Load Combinations Specifi c to Crane-Supporting Structures . . . . . . . . . . . . . . . . . . . . . 6 2.4.1 Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.4.2 Ultimate Limit States of Strength and Stability . . . . . . . . . . . . . . . . . . . . . . . . . 7 CHAPTER 3 - DESIGN FOR REPEATED LOADS 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.2 Exclusion for Limited Number of Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 3.3 Detailed Load-Induced Fatigue Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3.3.2 Palmgren-Miner Rule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3.3 Equivalent Stress Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.3.4 Equivalent Number of Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.3.5 Fatigue Design Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3.4 Classifi cation of Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.4.2 Crane Service Classifi cation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.4.3 Number of Full Load Cycles Based on Class of Crane . . . . . . . . . . . . . . . . . . . . . 14 3.4.4 Fatigue Loading Criteria Based on Duty Cycle Analysis . . . . . . . . . . . . . . . . . . . . 16 3.4.5 Preparation of Design Criteria Documentation . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.4.5.1 Fatigue Criteria Documentation Based on Duty Cycle Analysis . . . . . . . . . . . . . 17 iii 3.4.5.2 Criteria Documentation Based on Class of Crane Service (Abbreviated Procedure) . . . 18 3.5 Examples of Duty Cycle Analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 3.5.1 Crane-Carrying Steel Structures Structural Class of Service SA, SB, SC . . . . . . . . . . . . 18 3.5.2 Crane-Carrying Steel Structures Structural Class of Service SD, SE, SF . . . . . . . . . . . . 19 CHAPTER 4 - DESIGN AND CONSTRUCTION MEASURES CHECKLIST 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.2 Comments on the Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CHAPTER 5 - OTHER TOPICS 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.2 Crane-Structure Interaction in Mill or Similar Buildings . . . . . . . . . . . . . . . . . . . . . . . 32 5.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.4 Methods of Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.5 Notional Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.6 Segmented Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.7 Building Longitudinal Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.8 Building Expansion Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 5.9 Mono-symmetric Crane Runway Beams, Lateral-Torsional Buckling . . . . . . . . . . . . . . . . 34 5.9.1 Design Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.10 Biaxial Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5.11 Heavy Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.12 Intermediate Web Stiffeners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.13 Links to Crane Runway Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.14 Bottom Flange Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5.15 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5.16 End Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5.17 Unequal Depth Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5.18 Underslung Cranes and Monorails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5.19 Jib Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5.20 Truss Type Crane Runway Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 5.21 Column Bases and Anchor Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 5.22 Dissimilar Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 5.23 Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 5.24 Rail Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 5.25 Outdoor Crane Runways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 iv 5.26 Seismic Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 5.27 Standards for Welding for Structures Subjected to Fatigue . . . . . . . . . . . . . . . . . . . . . . 41 5.28 Erection Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.29 Standards for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 5.30 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 CHAPTER 6 - REHABILITATION AND UPGRADING OF EXISTING CRANE-CARRYING STEEL STRUCTURES 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.2 Inspections, Condition Surveys, Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.3 Loads, Load Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 6.4 Structural Modelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 6.5 Reinforcing, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.5.1 Reinforcing an Existing Runway Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.5.2 Reinforcing an Existing Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.5.3 Welding to Existing Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 CHAPTER 7 - SUGGESTED PROCEDURE FOR DESIGN OF CRANE RUNWAY BEAMS 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.2 Design Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.3 Design Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 APPENDIX A - DESIGN EXAMPLES Design Example 1 Illustration of Design of a Mono-symmetric Section Crane Runway Beam . . . . . . . . . . . . . . . . 80 Design Example 2 Illustration of Design of a Heavy-Duty Plate Girder Type Crane Runway Beam . . . . . . . . . . . . . 95 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 v FOREWORD The Canadian Institute of Steel Construction is a national industry organization representing the structural steel, open-web steel joist and steel plate fabricating industries in Canada. Formed in 1930 and granted a Federal charter in 1942, the CISC functions as a nonprofi t organization promoting the effi cient and economic use of fabricated steel in construction. As a member of the Canadian Steel Construction Council, the Institute has a general interest in all uses of steel in construction. CISC works in close co-operation with the Steel Structures Education Foundation (SSEF) to develop educational courses and programmes related to the design and construction of steel structures. The CISC supports and actively participates in the work of the Standards Council of Canada, the Canadian Standards Association, the Canadian Commission on Building and Fire Codes and numerous other organizations, in Canada and other countries, involved in research work and the preparation of codes and standards. Preparation of engineering plans is not a function of the CISC. The Institute does provide technical information through its professional engineering staff, through the preparation and dissemination of publications, and through the medium of seminars, courses, meetings, video tapes, and computer programs. Architects, engineers and others interested in steel construction are encouraged to make use of CISC information services. This publication has been prepared and published by the Canadian Institute of Steel Construction. It is an important part of a continuing effort to provide current, practical, information to assist educators, designers, fabricators, and others interested in the use of steel in construction. Although no effort has been spared in an attempt to ensure that all data in this book is factual and that the numerical values are accurate to a degree consistent with current structural design practice, the Canadian Institute of Steel Construction, the author and his employer, Hatch, do not assume responsibility for errors or oversights resulting from the use of the information contained herein. Anyone making use of the contents of this book assumes all liability arising from such use. All suggestions for improvement of this publication will receive full consideration for future printings. CISC is located at 3760 14th Avenue, Suite 200 Markham, Ontario, L3R 3T7 and may also be contacted via one or more of the following: Telephone: 905-946-0864 Fax: 905-946-8574 Email: [email protected] Website: www.cisc-icca.ca Revisions This Edition of the Design Guide supersedes all previous versions posted on the CISC website: www.cisc-icca. ca. Future revisions to this Design Guide will be posted on this website. Users are encouraged to visit this website periodically for updates. vi PREFACE TO THE SECOND EDITION Since the fi rst printing of this design guide in January 2005, the author has received many useful and constructive comments along with questions, answers to which could generate more information for the designer of these structures. Additionally, changes to the National Building Code of Canada (NBCC) and refi nements to the companion load concept upon which load combinations are based have occurred. CSA Standard S16, Limit States Design of Steel Structures is being updated and new provisions that affect the design of these structures are being introduced. The second edition refl ects the signifi cant changes that are warranted due to the above information and now includes an index. The fi rst two chapters contain an introduction that explains the intent of the publication (unchanged) and information on loads and load combinations. Important changes in this area are included, most notably in the refi nement of the load combinations, section 2.4.2. Chapter 3, Design for Repeated Loads, remains essentially unchanged, with a few clarifi cations added. Chapters 4, 5 and 6, Design and Construction Measures Checklist, Other Topics, and Rehabilitation and Upgrades have been updated to refl ect comments and additional information. References have been added and updated. Several comments and questions related to the fi gures and design examples have prompted revisions to some of the fi gures and the two design examples. The intent of this publication remains to provide a reference for the practicing designer that refl ects Canadian and North American practice. The author wishes to thank all those who took the time to comment and provide suggestions. Special thanks to the late David Ricker (reference 27) who took the time to constructively comment in depth, providing a number of suggestions which have been incorporated into this edition. vii viii