6659x

2017-11-21

Design of Web Fillet Welds of Crane Girders According to EN 1993-6

At the end of the topic on the design of welds on runway beams - after the technical articles about the rail weld seam in the ultimate limit state and the limit state of fatigue - a technical article about web fillet welds now follows. Both the ultimate limit state and the fatigue limit state are considered.

Ultimate limit state

The applied loads cause both horizontal and vertical wheel loads that must be considered in the design. An eccentric wheel load application of the vertical wheel loads is not considered in the ultimate limit state design, and therefore no additional torsional moment occurs.

Web Welds as Double Fillet Welds

In the following text is a set of formulas for the stress and design calculation.

Stresses Due to Wheel Load

\begin{array}{l} \max σ_{⊥} = \frac{F_{z, Ed} H_{Ed}}{2 \cdot \sqrt{2} \cdot a_{w} \cdot l_{eff}} \max τ_{⊥} = \frac{F_{z, Ed} H_{Ed}}{2 \cdot \sqrt{2} \cdot a_{w} \cdot l_{eff}} \\ τ_{⊥} = \frac{F_{z, Ed} - H_{Ed}}{2 \cdot \sqrt{2} \cdot a_{w} \cdot l_{eff}} σ_{⊥} = \frac{F_{z, Ed} - H_{Ed}}{2 \cdot \sqrt{2} \cdot a_{w} \cdot l_{eff}} \\ τ_{∥} = \frac{V_{Ed} \cdot S_{y}}{l_{y} \cdot 2 \cdot a_{w}} τ_{∥} = \frac{V_{Ed} \cdot S_{y}}{l_{y} \cdot 2 \cdot a_{w}} \\ σ_{v, w, Ed} = \sqrt{σ_{⊥} ² 3 \cdot τ_{⊥} ² 3 \cdot τ_{∥} ²} σ_{v, w, Ed} = \sqrt{σ_{⊥} ² 3 \cdot τ_{⊥} ² 3 \cdot τ_{∥} ²} \end{array}

Formula 1

Weld Design

\begin{array}{l} σ_{v, w, Rd} = \frac{f_{u}}{β_{w} \cdot γ_{M 2}} \frac{σ_{v, w, Ed}}{σ_{v, w, Rd}} \leq 1.00 \\ σ_{⊥, w, Rd} = \frac{0.9 \cdot f_{u}}{γ_{M 2}} \frac{σ_{⊥, w, Ed}}{σ_{⊥, w, Rd}} \leq 1.00 \end{array}

Formula 2

Fatigue limit state

In contrast to the ULS, the stresses resulting from horizontal loads are neglected; thus, only the vertical wheel loads are taken into account. However, depending on the existing damage class and the National Annex used, the eccentric wheel load of 1/4 of the rail head width must be considered. Thus, an additional torsional moment occurs, which must be transferred by the rail welds first, and then by the top flange, the web and finally by the web welds.

Eccentric Wheel Load Application in GZE

The rail welds must transfer this torsional moment almost entirely. On the other hand, the effect of the torsional stiffness of the top flange should be considered for the welds on the web as this has a crucial influence on the web bending and thus on the stress in the weld.

When determining the torsional constant of the top flange, [2] only assumes the top flange as long as the rail is not rigidly fixed. Only in that case is the torsional moment determined from the rail and the flange. Another approach is described in [5], where the individual torsional stiffness components of the rail and the flange are added together so it is possible to achieve higher stiffness of the top flange. However, this approach is not provided in [2].

It is necessary to combine two stress components for the design of the web fillet welds. There are the stresses due to the centric wheel load and the stresses due to the torsional moment. The full torsional moment M_T is partially absorbed by the top flange; thus, the component M_web due to the web bending remains for the weld design.

Finally, it should be noted that this calculation procedure and description only applies to the double fillet welds between the top flange and the web. If the welds on the bottom flange and the web should also be designed as fillet welds, the wheel load effects are negligibly small due to the existing length of the applied wheel loads. In this case, the stress components due to bending or shear stress as well as the minimum thicknesses are governing.

In the following text is a set of formulas for the stress and design calculation.

Stresses Due to Centric Wheel Load

σ_{z, Ed, cen, weld} = \frac{F_{z, Ed}}{2 \cdot a_{w} \cdot l_{eff}}

Formula 3

Stresses Due to Eccentric Wheel Load

\begin{array}{l} M_{T} = F_{z, Ed} \cdot \frac{b_{rail}}{4} \\ β = \frac{π \cdot h_{w}}{a} \\ I_{T, chord} = \frac{b_{cs} \cdot t_{f} ³}{3} \\ λ = \sqrt{\frac{2.98 \cdot t_{w} ³}{a \cdot I_{T}} \cdot \frac{\sin h ² (β)}{\sin h (2 \cdot β) - 2 \cdot β}} \\ σ_{z, Ed, ecc} = \frac{6}{t_{w} ²} \cdot M_{T} \cdot \frac{λ}{2} \cdot \tan h (\frac{λ \cdot a}{2}) \\ M_{web} = σ_{z, Ed, ecc} \cdot \frac{t_{w} ² \cdot l_{eff}}{6} \\ σ_{z, Ed, ecc, weld} = \frac{M_{web}}{(t_{w} a_{w}) \cdot a_{w} \cdot l_{eff}} \end{array}

Formula 4

Resulting Stress in Weld

σ_{z, Ed} = σ_{z, Ed, cen, weld} σ_{z, Ed, ecc, weld}

Formula 5

Designs

\begin{array}{l} \frac{γ_{Ff} \cdot ∆ σ_{E, 2}}{\frac{∆ σ_{c}}{γ_{Mf}}} < 1.00 \\ \frac{γ_{Ff} \cdot ∆ τ_{E, 2}}{\frac{∆ τ_{c}}{γ_{Mf}}} < 1.00 \end{array}

Formula 6

Summary

The three technical articles about various welds of crane girders explain this topic in detail. In the practical implementation in individual cases, it should be decided in particular whether to apply the torsional stiffness of the top flange as an addition of the individual components of the rail and the flange, or the flange only.

Links

Structural Analysis and Design Software for Cranes and Craneways

References

Seeßelberg, C.: Kranbahnen: Bemessung und konstruktive Gestaltung nach Eurocode, 5. Auflage. Berlin: Bauwerk, 2016
Eurocode 3: Bemessung und Konstruktion von Stahlbauten - Teil 6: Kranbahnen; EN 1993-6:2007 + AC:2009
Eurocode 1: Einwirkungen auf Tragwerke - Teil 3: Einwirkungen infolge von Kranen und Maschinen; DIN EN 1991-3:2010-12
Eurocode 3: Bemessung und Konstruktion von Stahlbauten - Teil 1-9: Ermüdung; EN 1993-1-9:2005 + AC:2009
Petersen, C.: Stahlbau, 4. Auflage. Wiesbaden: Springer Vieweg, 2013

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FAQ 005169 | Where is the fatigue design activated in the CRANEWAY program?

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[EN] FAQ 004874 | Is it possible to design intermittent welds in the CRANEWAY add-on module?

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[EN] FAQ 004693 | Is it necessary to enter the loads of a crane for each axle or wheel in the table of ...

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[EN] FAQ 004652 | Is it possible to design a crane runway girder without stiffeners on supports in CRANEWAY?

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KB 001612 | Method of Determining Allowable Deformation of Crane Runway Girders

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Craneway

Knowledge Base Articles

In CRANEWAY, the action of a rail as "statically effective" or "statically ineffective" is defined under "Rail‑Flange Connection" in the Details dialog box. This setting controls the calculation of the load introduction length according to EN 1993-6, Tab. 5.1.

When using interrupted welds between the rail and flange, make sure that the applied weld length does not exceed the length of the rigid load application of the wheel load according to Equation 6.1 in [1].

Design of Suspension Cranes with CRANEWAY

In CRANEWAY 8, you can design suspension cranes according to EN 1993-6. For the design, it is necessary to determine the local bending stresses in the lower flange due to wheel loads according to EN 1993‑6, Clause 5.8.

Maximum Vertical Deformation of Crane Runway Girder with Rigid Supports

This article describes the different options for determining the allowable deformation of crane runway girders. Since multi-span beams and flexible lateral supports (sway bracing) are used in practice, this article will show how to select the correct method.

Product Features

Craneway and weld stress analysis
Craneways and weld fatigue design
Deformation,
Plate buckling analysis for wheel load introduction
Stability analysis for lateral torsional buckling according to the second-order analysis of torsional buckling (1D FEA element)

For the design according to Eurocode 3, the following National Annexes are available:

DIN EN 1993-6/NA:2010-12 (Germany)
NBN EN 1993-6/ANB:2011-03 (Belgium)
SFS EN 1993-6/NA:2010-03 (Finland)
NF EN 1993-6/NA:2011-12 (France)
UNI EN 1993-6/NA:2011-02 (Italy)
LST EN 1993-6/NA:2010-12 (Lithuania)
NEN EN 1993-6/NB:2012-05 (Netherlands)
NS EN 1993-6/NA:2010-01 (Norway)
SS EN 1993-6/NA:2011-04 (Sweden)
CSN EN 1993-6/NA:2010-03 (Czech Republic)
BS EN 1993-6/NA:2009-11 (United Kingdom)
CYS EN 1993-6/NA:2009-03 (Cyprus)

In addition to the National Annexes listed above, you can also define a specific NA, applying user-defined limit values and parameters.

All results are arranged in result windows sorted by different topics. The design values are illustrated in the corresponding cross-section graphic. The design details cover all intermediate values.

General Stress Analysis

CRANEWAY performs the general stress analysis of a craneway girder by calculating the existing stresses and comparing them with the limit normal, limit shear, and limit equivalent stresses. Welds are also subjected to the general stress analysis with regard to parallel and vertical shear stresses and their superposition.

Fatigue Design

Fatigue design is performed for up to three cranes operating at the same time, based on the nominal stress concept according to EN 1993-1-9. In the case of fatigue design according to DIN 4132, a stress curve of crane passages is recorded for each stress point and evaluated according to the Rainflow method.

Buckling Analysis

Buckling analysis considers the local introduction of wheel loads according to the EN 1993-6 or DIN 18800-3 standards.

Deformation,

Deformation analysis is performed separately for the vertical and horizontal directions. The available related displacements are compared to the allowable values. You can specify the allowable deformation ratios individually in the calculation parameters.

Lateral-torsional buckling analysis

The lateral-torsional buckling analysis is performed in accordance with the second-order analysis for torsional buckling considering imperfections. The general stress analysis has to be fulfilled with the critical load factor greater than 1.00. As a result, CRANEWAY displays the corresponding critical load factor for all load combinations of the stress analysis.

Support forces

The program determines all support forces on the basis of the characteristic loads, including dynamic factors.

Detailed Settings for Crane Runway Calculation

During the calculation, crane loads are generated in predefined distances as load cases of the crane runway. The load increment for cranes moving across the crane runway can be set individually.

The program analyzes all combinations of the respective limit states (ULS, fatigue, deformation, and support forces) for each crane position. In addition, there are comprehensive setting options for specification of the FE calculation, such as length of finite elements or break-off criteria.

The internal forces of a crane runway girder are calculated on an imperfect structural model according to the second-order analysis for torsional buckling.

Geometry, material, cross-section, action, and imperfection data are entered in clearly arranged input windows:

Geometry

Quick and convenient data input
Definition of support conditions based on various support types (hinged, hinged movable, rigid, and user-defined, as well as lateral on upper or bottom flange)
Optional specification of warping restraint
Variable arrangement of rigid and deformable support stiffeners
Possibility to insert hinges

CRANEWAY Cross-Sections

I-shaped rolled cross-sections (I, IPE, IPEa, IPEo, IPEv, HE-B, HE-A, HE-AA, HL, HE-M, HE, HD, HP, IPB-S, IPB-SB, W, UB, UC, and other cross-sections according to AISC, ARBED, British Steel, Gost, TU, JIS, YB, GB, and others) combinable with section stiffener on the upper flange (angles or channels) as well as rail (SA, SF) or splice with user-defined dimensions
Unsymmetrical I-sections (type IU) also combinable with stiffeners on the upper flange as well as with rail or splice

Actions

It is possible to consider the actions of up to three simultaneously operated cranes. You can simply select a standard crane from the library. You can also enter data manually:

Number of cranes and crane axles (maximum of 20 axles per crane), center distances, position of crane buffers
Classification in damage classes with editable dynamic factors according to EN 1993-6, and in lifting classes and exposure categories according to DIN 4132
Vertical and horizontal wheel loads from self-weight, hoist load, mass forces from drive, as well as loads from skewing
Axial loading in driving direction as well as buffer forces with user-defined eccentricities
Permanent and variable secondary loads with user-defined eccentricities

Imperfections

The imperfection load applies in compliance with the first natural vibration mode - either identically for all load combinations to be designed, or individually for each load combination, as mode shapes may vary depending on the load.
Convenient tools available for scaling the mode shapes (rise determination of inclination and precamber).

Frequently Asked Questions (FAQ)

Is it possible in the CRANEWAY software to obtain the SLS rotational deformations of a continuous beam at the supports for an isostatic beam in the web plane?

Where is the fatigue design activated in the CRANEWAY program?

In CRANEWAY, there is a crane library with templates. Why is it grayed out?

How can I optimize the calculation time in CRANEWAY?

Where can I find the determined support forces for the crane runway girder? At the bottom flange of the crane runway girder or in the shear center of the cross-section?

Is it possible to manually adjust detail categories or a stress cycle of the detail categories?

Customer Projects

3D Model of Revolving Superstructure in RFEM (© IB Jürgen Ehlenz)

Revolving Superstructure for Shiploader, Germany

RSTAB Model of Crane Bridge (© IB Burgdorf GmbH)

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