`

Failure Investigation Analysis of Steel Gantry beam at

Sheela Foam Pvt Ltd, Vapi, Gujarat

Page | 1

Table of Contents
1

Introduction ............................................................................................................................. 5

Investigation Methodology ..................................................................................................... 7

2.1.1

Estimation of worst case temperature deviations in a day: ....................................... 7

2.1.2

Analysis of the gantry beam for static load: ............................................................. 7

2.1.3

Quantifying the dynamic axial thrust in the gantry beam: ........................................ 7

Instrumentation ....................................................................................................................... 8
3.1

Accelerometers: ................................................................................................................ 8

3.2

Strain Gauges: .................................................................................................................. 8

3.3

Temperature Sensors: ....................................................................................................... 8

3.4

Data recorded from the instrumentation: ....................................................................... 11

Post processing of Instrumentation data ............................................................................... 22

4.1

Crane Forces Calculations .............................................................................................. 22

4.2

Grabber Force Calculation ............................................................................................. 30

1. Grabber Acceleration profile ..............................................Error! Bookmark not defined.

2. Acceleration profile pattern determination for both grabbers ............................................ 32
4.2.1
4.3

Procedure to decide the acceleration pattern ...................Error! Bookmark not defined.

4.3.1
5

Accelerometer data for various arrangements ........................................................ 32

Results obtained due to axial thrust ........................................................................ 44

Static Analysis of Gantry girder ........................................................................................... 45

5.1

Computer model: ............................................................................................................ 45

Stress analysis for gantry beam............................................................................................. 49

Conclusions ........................................................................................................................... 50

Page | 2

List of Tables
Table 1 Terminology used in the report ........................................................................................ 10
Table 2 Data recorded from the instrumentation for case1 ........................................................... 11
Table 3 Data recorded from the instrumentation for case 2.......................................................... 12
Table 4 Data recorded from the instrumentation for case 3.......................................................... 13
Table 5 Data recorded from the instrumentation for case 4.......................................................... 14
Table 6 Data recorded from the instrumentation for case 5.......................................................... 15
Table 7 Data recorded from the instrumentation for case 6.......................................................... 16
Table 8 Data recorded from the instrumentation for case 7.......................................................... 17
Table 9 Data recorded from the instrumentation for case 8.......................................................... 18
Table 10 Data recorded from the instrumentation for case 9........................................................ 19
Table 11 Data recorded from the instrumentation for case 10...................................................... 20
Table 12 Data recorded when strain gauge is placed on bottom flange of beam 2 ...................... 21
Table 13 Temperature Data .......................................................................................................... 21
Table 14 Different ratios considered during the operation of the crane. ...................................... 24
Table 15 Start and End phase acceleration values for arrangement 1 at particular time instant .. 30
Table 16 Acceleration values for accelerometer locations at LGE and LGC ............................... 31
Table 17 Acceleration data for arrangement 1 .............................................................................. 33
Table 18 Acceleration data for arrangement 2 .............................................................................. 33
Table 19 Acceleration data for arrangement 3 .............................................................................. 33
Table 20 Acceleration data for arrangement 4 .............................................................................. 34
Table 21 Acceleration data for arrangement 5 .............................................................................. 34
Table 22 Maximum and Minimum moments for frame element under consideration ................. 49

Page | 3

List of Figures
Fig. 1 View of the crane supported by steel structure..................................................................... 5
Fig. 2 Crane movement with mass (foam) ..................................................................................... 6
Fig. 3 Image illustrating the connection between the crane rollers and the I-beam ....................... 6
Fig. 4 Elevation or Front view of crane and grabbers supported on four beams ............................ 9
Fig. 5 Horizontal acceleration profile along the tower crane........................................................ 26
Fig. 6 Horizontal acceleration profile along beam B1B2............................................................... 26
Fig. 7 Force equilibrium along B1B2............................................................................................. 27
Fig. 8 Horizontal acceleration profile along beam B2B3............................................................... 27
Fig. 9 Force equilibrium along B2B3............................................................................................. 28
Fig. 10 Horizontal acceleration profile along beam B3B4............................................................. 28
Fig. 11 Force equilibrium along B3B4.......................................................................................... 29
Fig. 12 Resultant horizontal dynamic axial thrust on gantry beams ............................................. 29
Fig. 13 Acceleration profile for experimental trial 1 (1a and 1b of table 2) ................................. 31
Fig. 14 Acceleration profile for experimental trial 1 (2a and 2b of table 2) ................................. 32
Fig. 15 Anti-symmetric pattern ..................................................................................................... 35
Fig. 16 Symmetric pattern............................................................................................................. 35
Fig. 17 Gantry and Tower crane- Grabber system ....................................................................... 45
Fig. 18 Plan view of steel shed ..................................................................................................... 46
Fig. 19 Schematic diagram of Gantry-beam ................................................................................ 47
Fig. 20 3-D view of macro-model in SAP-2000 ........................................................................... 47
Fig. 21 Elevation of Transverse truss ........................................................................................... 48
Fig. 22 Critical section under consideration ................................................................................. 48

Page | 4

1 Introduction
This report presents the scientific investigation of possible causes of local warping and
deflection in the steel girder at Sheela foam Pvt Ltd. (Unit-12) located in Talwada, Gujarat.
The following section presents information collected by a team of IIT Gandhinagar. The crane
moves on four I-beam-girders by rollers, along the length of the girder and lifts the foams with
mechanical grabbers. Four gantry beams are suspended from the roof truss with rigid
connections. More details regarding gantry beams can be seen in further sections. The grabber
portion is attached to crane by suspension cables. These grabbers are used to lift the foams of
mass up to a capacity of 10 ton by anchoring the mass. The self-weight of the crane assembly
is 5 ton as per the information given by the sheela foam personnel. The grabber can move in
upward and downward direction during operation. The whole grabber and mass moves along
with the crane in the longitudinal direction of shed or along the length of I girder. More info
regarding the operation of tower crane grabber can be seen in Fig.(1-3)

Fig. 1 View of the crane supported by steel structure

Page | 5

Fig. 2 Crane movement with mass (foam)

Fig. 3 Image illustrating the connection between the crane rollers and the I-beam

Page | 6

2 Investigation Methodology
2.1.1 Estimation of worst case temperature deviations in a day:
Temperature sensors are placed on the top flange of the beam during morning 11:00 am, at
1:00 pm and at 5:30 pm to observe the maximum deviations in the value. However,
maximum temperature difference is considered as 25o C for calculation of stresses due to
change in temperature.
2.1.2 Analysis of the gantry beam for static load:
The entire gantry beam steel truss are modelled in SAP-2000 and analyzed for moving
loads with an addition 25% provision for impact.

2.1.3 Quantifying the dynamic axial thrust in the gantry beam:

Due to crane movement, particularly during stopping phase, an axial thrust in the beam is
generated which causes the elongation of the beam in axial direction. Since, the beam is
rigidly clamped at the end, the above mentioned strain will generate significant stresses in
the cross section of the beam. If the section design is insufficient, it may cause warping
of the beam.

Page | 7

3 Instrumentation
3.1 Accelerometers:
In order to calculate the dynamic axial thrust due to crane on gantry beam, piezoelectric
accelerometer sensitivity of around 3mV/g and full scale range of +/- 10g are placed at 11
different positions on crane and grabber. The positions of accelerometers are decided such
that the acceleration values along the length of crane and grabber can be captured. Due to
limited number of accelerometers available for the 42 m length of the crane, the
acceleration values are estimated on any other point of crane by extrapolations.

3.2 Strain Gauges:

Quarter bridge Type-1, self-temperature compensating strain gauges are placed on the top
flange of all the four beams to record the localized strain caused due to impact of crane
start and stop.

3.3 Temperature Sensors:

Temperature sensors are placed on the beam during different time of day to capture the
maximum possible fluctuations.

Page | 8

12 m

18 m

LC

MC

B1

LGE

12 m

RC
B3

B2

LGB1

LGB2

28 m

LGC

GJ

RGC

B4

RGB3

RGB4

RGC

28 m

Fig. 4 Elevation or Front view of crane and grabbers supported on four beams
Page | 9

LC
MC
RC
LGE
RGE
LGC
RGC
LGB1
LGB2
RGB3
RGB4
GJ
B1,B2,B3 and B4
S1,S2, S3 and S4
SBF2

Left Crane
Medium Crane
Right Crane
Left Grabber End
Right Grabber End
Left Grabber Center
Right Grabber Center
Left Grabber Below Beam 1
Left Grabber Below Beam 2
Right Grabber Below Beam 3
Right Grabber Below Beam 4
Grabber Joint
Beam 1,2,3 and 4 respectively
Strain values from strain gauge at beam 1,2,3 and 4 respectively
Strain gauge at lower flange of beam 2
Table 1 Terminology used in the report

Grabber:
Portion of machine which is used to lift the mass.
Crane:
Upper portion of the machine which is supported on four beams by wheels.
Start Phase:
When crane is started and moved along the length of the main girders.
End Phase:
When crane is stopped along the length of the main girders. It can be stopped suddenly or slowly
depending upon the need of crane operator.

Page | 10

3.4

Data recorded from the instrumentation:

CASE 1: Accelerometer on grabber and

strain gauges on beam 2 and beam 3
(LGB2, RGB3, S2 and S3)
PHASE LGB2 (g)
MR_Crane backward movement with 5 Start
tonne load
-0.1748
End
0.7375
Start
MR_Crane forward with 5 tonne load
0.1879
End
0.51
MR_Crane forward movement with 5 tonne Start
load(trial 2)
0.1865
End
0.6428
Start
MR_crane backward without load 3
-0.00778
End
0.2301
Start
MR_crane forward without load 2
0.028
End
0.1259
MR_crane backward with 5 tonne load trial Start
2
0.1457
End
0.6183

RGB3 (g)

S1
_

0.29658
-1.204
0.624
1.129

S2

S3

1.36E-04

1.59E-04

_
_

_
3.03E-04

3.60E-04

1.3177
-0.36
-1.165
0.318
-0.4962

3.58E-04

_
2.97E-04

3.19E-04

_
_

_
_

2.70E-04

3.38E-04

-0.765
0.9667

_
3.16E-04

_
_

_
1.027

S4
_

3.13E-04
_

3.55E-04
_

Table 2 Data recorded from the instrumentation for case1

Page | 11

CASE 2 : Accelerometer on grabber and

strain gauges on beam 1 and beam 4
( LGB1, RGB4, S1 and S4)
MR_Crane forward without load

MR_Crane backward without load

MR_Crane forward with 5 tonne load

MR_Crane backward with 5 tonne load

MR_Crane backward with 5 tonne load(trial 2)

MR_Crane forward with 5 tonne load(trial 2)

PHASE LGB1 (g)

Start
0.1
End
-1.5427
Start
-0.3053
End
-1.81
Start
-0.1414
End
0.5965
Start
-0.089
End
-0.205
Start
0.098
End
0.8172
Start
0.1248
End
-0.0027

RGB4 (g)

S1

0.1577

1.54E-04

S2
_

S3
_

S4
1.52E-04

-0.5372
0.112

1.09E-04

1.10E-04

0.4945
0.743

1.37E-04

1.37E-04

0.885
-1.12

2.50E-05

2.50E-05

-0.7156
0.8307

4.30E-04

4.24E-04

1.2812
-0.1954

2.27E-04

2.30E-04

1.262

Table 3 Data recorded from the instrumentation for case 2

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`
CASE 3: Accelerometer on grabber and crane
(LC, LGE and RGE)

PHASE

LC (g)

MC (g)

MR_crane backward with load

Start
End

-0.47
0.8951

_
_

MR_crane backward without load

Start
End

-0.78
1.3376

MR_crane forward with load trial 2

Start
End

MR_crane forward with load

RC (g)

LGE (g)

RGE (g)

_
_

-0.25927
0.4195

0.24
0.31

_
_

_
_

-0.76
0.74911

-0.32
0.347

-0.39
-0.505

_
_

_
_

0.24
0.4588

-0.39
1.0583

Start
End

-0.69
1.08

_
_

_
_

-0.314
-0.477

-0.46
-0.43

MR_crane forward without load

Start
End

0.4893
-0.957

_
_

_
_

0.189
-1.0558

0.209
-0.498

MR_crane backward with load trial 2

Start
End

-1.63
1.6678

-0.3657
-0.353

0.0184
-0.4153

Table 4 Data recorded from the instrumentation for case 3

Page | 13

CASE 4: Sensors on crane (LC, MC and RC)

PHASE LC (g)

MC (g)

RC (g)

MR_Crane backward run with 5 tonne load trial 2

Start

0.56

0.42

-0.72

End

-2.57

-1.33

1.54

Start

-2.37

-0.73

1.19

End

-1.68

-2.27

1.76

Start

0.48

-0.52

0.75

End

-2.17

1.80

-2.72

Start

3.10

1.16

1.37

End

-1.98

-2.41

2.17

MR_Crane forward run with 5 tonne load trial 2

MR_Crane backward run with 5 tonne load

MR_Crane forward run with 5 tonne load

Table 5 Data recorded from the instrumentation for case 4

Page | 14

CASE 5:Sensors on crane (LC, RC and RGE)

MR_Crane forward run with 5 tonne load

PHASE
Start
End

MR_Crane backward run with 5 tonne load

Start
End

MR_Crane forward run with 5 tonne load. (trial 2)

Start
End

MR_Crane backward run with 5 tonne load. (trial 2)

Start
End

MR_Crane backward run without load

Start
End

MR_Crane forward run without load

Start
End

LC (g)

MC RC (g)

LGE

RGE (g)

1.0352

_
_

_
_

0.186

1.9478
1.2695
2.0236
0.754
2.661
0.632
2.621
0.4581
2.278
0.9624
1.7656

_
_
_
_
_
_
_
_
_
_

1.3736
1.3736
0.6511
1.4411
0.8558
2.472
0.7599
1.5626
0.7496
1.5875
1.176
2.3079

_
_
_
_
_
_
_
_
_
_

1.32316
0.9115
1.2518
0.1763
1.426
0.3053
1.0474
0.339
1.5151
0.299
1.0586

Table 6 Data recorded from the instrumentation for case 5

Page | 15

CASE 6: Sensors on crane ( LC, MC and LGE)

PHASE

LC (g)

MC (g)

LGE (g)

MR_Crane forward run with 5 tonne load

Start

1.906

-0.689

0.207

End

2.699

-1.83

-1.263

Start

-0.759

-0.497

0.132

End

-3.709

1.898

1.257

Start

1.388

0.458

-0.472

End

-4.601

1.881

1.485

Start

-1.796

-1.05

-0.3259

End

-3.2391

1.411

1.224

Start

1.398

0.334

0.358

End

-4.686

1.78

1.627

Start

0.65

0.457

0.277

End

-4.311

-1.264

2.08

MR_Crane forward run with 5 tonne load trial 2

MR_Crane backward run without load trial 2

MR_Crane forward run without load trail 2

MR_Crane backward run without load

MR_Crane forward run without load

Table 7 Data recorded from the instrumentation for case 6

Page | 16

CASE 7:
Sensors on crane (LC, MC and LGC)

LC(in g)

MC (in g)

MR_Crane forward run without load (trial 1)

0.9423

0.42209

3.5425

-3.013

1.9774

-0.7615

-4.488

1.1362

-1.7089

0.7095

4.7965

0.9134

-0.6931

0.6553

-2.2247

-2.9777

-0.7566

0.7023

MR_Crane backward run without load (trial 1)

MR_Crane backward run with 5 tonne load (trial 2)

MR_Crane forward run with 5 tonne load (trial 1)

Mr_Crane backward run with 5 tonne load (trial 1)

-3.3989

-0.7715

RC
_

LGE
_

LGC(in g)
0.3192
0.7048
-0.1673
-1.1211
-0.2689
1.295
-0.2253
-1.423
0.3071
-1.1297

Table 8 Data recorded from the instrumentation for case 7

Page | 17

CASE 8 : Sensors on crane (LC, RC and S3_A)

MR_crane without load forward

PHASE
Start
End

MR_crane with 5 tonne load forward trial 4

Start
End

MR_crane with 5 tonne load forward trial 3

Start
End

MR_crane with 5 tonne load forward trial 2

Start
End

MR_crane with 5 tonne load backward

Start
End

MR_crane with 5 tonne load backward trial 2

Start
End

LC (g)
-0.9965
-1.9107
-0.7789
1.8962
-0.7296
-0.611
0.75
-0.9687
0.8262
-1.193
-0.7232
-0.841

MC
_
_
_
_
_
_
_
_
_
_
_
_

RC (g)

S3_A

-0.535

5.00E-05

-2.081
0.8099

1.27E-04

-2.375
-0.813

2.58E-05

0.6165
0.51654

8.30E-05

-0.826
-0.496

6.17E-06

-3.7879
-1.26

5.82E-05

-0.9262

Table 9 Data recorded from the instrumentation for case 8

Page | 18

CASE 9: Accelerometers on grabber (LGE, LGC and RGC)

MR_Crane backward run without load trial 2

PHASE
Start
End

LGE (g)
-0.274
0.42247

LGC (g)
0.1
0.1208

RGC (g)
0.2345
0.3431

MR_Crane forward run without load

Start
End

0.235
-0.749

0.114
0.4076

-0.235
1.243

MR_Crane backward run without load

Start
End

0.1523
-0.756

-0.039
-0.644

0.219
0.492

Table 10 Data recorded from the instrumentation for case 9

Page | 19

CASE 10: Acceleration with strain (LGB2,

RGB3, S2 and S3)
LGB2 (g)
MR_Crane movement backward with load trial
2
0.209

MR_Crane movement backward with load

MR_Crane movement backward without load

S1
_

0.358

0.423

0.4375

0.259

0.57

0.527

0.42

0.176

0.2789

1.517

0.3036

MR_Crane movement forward with load trial 2 0.39217

MR_Crane movement forward without load

RGB3 (g)

0.4143

1.6434

0.5803

0.1294

0.16489

0.777

0.269

S2

S3

4.00E-04

3.50E-04

_
_

_
3.94E-04

3.52E-04

_
_

2.52E-04

2.07E-04

_
_

3.90E-04

3.49E-04

_
_

_
_

_
_

S4
_

_
_

3.43E-04

2.98E-04

_
_

Table 11 Data recorded from the instrumentation for case 10

Page | 20

CASE 12:
Strain at end (bottom flange of beam 2)
crane forward with 5 tonne load
foam run forward
crane forward with 5 tonne load trial 2
crane backward with 4.5 tonne load

SBF2
1.72E-05
4.40E-05
9.17E-06
6.43E-05

Table 12 Data recorded when strain gauge is placed on bottom flange of beam 2

Temperature readings
Morning Temperature
Noon Temperature
Evening Temperature

Temperature( oC)
30.72
40.8
33.4

Table 13 Temperature Data

Page | 21

4 Post processing of Instrumentation data

4.1 Crane Forces Calculations
From the case 4 experimental data in starting phase of crane run, acceleration profile of
crane along its length (42 meter) can be distinguished by forward and backward run
respectively. The set of 4 data are grouped to the aforementioned criteria and the average
acceleration ratio for the forward and backward run of crane has been found out. Since, the
crane operation (i.e., speed and acceleration) at starting phase cannot be controlled by the
crane operator, so the assumption is made that these two category ratios remain unchanged
for the respective operations. End phase acceleration profile along the length of crane at
any instant depends on the stopping criteria. The stopping criteria is determined by
assuming the backward and forward run ratio at end phase are same as that of the starting
phase. The final ratios are calculated at end phase and is divided by backward or forward
run ratio as shown below to obtain different stopping criteria.

a) Case 4 : Start Phase : Sensors on crane ( L 310 M 309 and R 312) (1-LC,2-MC,3-RC)

CASE 4: START PHASE

3.5

ACCELERATION( IN G)

Crane backward with 5

tonne load trial 2

2.5
2

Crane forward run with 5

tonne load trial 2

1.5

Crane backward with 5

tonne load

1
0.5

Crane forward with 5

tonne load

0
0

(1-LC,2-MC,3-RC)

Page | 22

`
b) Case 4 : End Phase : Sensors on crane ( L 310 M 309 and R 312) (1-LC,2-MC,3-RC)

CASE 4: END PHASE

3

ACCELERATION( IN G)

2.5
Crane backward with 5
tonne load trial 2

Crane forward run with 5

tonne load trial 2

1.5
1

Crane backward with 5

tonne load

0.5

Crane forward with 5

tonne load

(1-LC,2-MC,3-RC)

Considering a particular trial consisting of start and end phase:

Crane Backward Run

with 5 tonne load
PHASE
Start Phase
End Phase

LC

MC
2.17
0.484

RC
1.79
0.524

2.72
0.74

Starting Phase ratio,

1: (

MC RC
) : ( ) = 1: 0.827:1.252 = 1: :
LC
LC

End/Ratio Phase ratio,

1: (

MC RC
) : ( ) = 1: 1.082:1.543 = 1: :
LC
LC

Stopping criteria ratio,

1: (

MC RC
) : ( ) = 1: 1.308:1.23 = 1: (/ ): (/)
LC
LC

Page | 23

STARTING
LC

E1

MC

RC

MR_Crane
backward run
with 5 tonne
load

2.171

1.7961

2.72

End

0.484

0.524

0.747

FINAL
ALPHA

BETA

Yama

delta

S1

0.827315

1.252879

1.082645

1.543388

1.308625

STARTING

E2

MR_Crane
forward run
with 5 tonne
load
End

3.1

1.16

1.37

1.976

2.412

2.17

FINAL

E3

End

2.367

0.73

1.19227

1.68

2.267

1.7629

ALPHA

BETA

Yama

delta

S1

0.374194

0.441935

1.220648

1.098178

3.262076

FINAL

E4

End

0.559

0.4201

0.723

2.5729

1.3268

1.536

1.231874

S2

2.484929

STOPPING

ALPHA

BETA

Yama

delta

S1

0.308407

0.503705

0.741067

1.049345

2.402886

ALPHA

BETA

Yama

delta

S1

S2

0.751521

1.293381

0.515683

0.596992

0.686186

0.461575

STARTING
MR_Crane
backward run
with 5 tonne
load trial 2

S2

STOPPING

STARTING
MR_Crane
forward run
with 5 tonne
load trial 2

STOPPING

FINAL

S2

2.083253

STOPPING

Table 14 Different ratios considered during the operation of the crane.

Page | 24

`
Average forward run ratio

= 1 : 0.34 : 0.47 (from E2 and E5)

Average backward run ratio = 1 : 0.79 :1.27 (from E1 and E4)

Stopping Criteria 1= 1: 2.32 : 1.93 (Average of stopping criteria of experiment E1, E2 and E3).
Stopping Criteria 2= 1: 0.686 : 0.46 (Stopping criteria of E4).

For any particular single accelerometer data of crane (i.e., at LC, MC or RC),from acceleration
ratios and stopping criteria, acceleration profile can be known.
For example, let acceleration at point LC (a1) for forward run is known. To compute MC and RC
for starting phase, forward run ratio for starting phase is multiplied with the value of a1 to get the
values of MC and RC, say a2 and a3.
Now, to obtain the values of end phase, each stopping criteria is to be multiplied individually to
have to possible end phase (which are categorized based on the stopping criteria):
Let ST1 and ST2 be two stopping criteria ratios. Assuming forward (F/W) and backward (B/W)
run ratios at end phase are same as that of in start phase.

Values from stopping criteria 1:

F/W run
B/W run

(a1 of end phase ) x (Start phase F/W ratio) x (ST1)

(a1 of end phase ) x (Start phase B/W ratio) x (ST1)

Values from stopping criteria 2:

F/W run
B/W run

(a1 of end phase ) x (Start phase F/W ratio) x (ST2)

(a1 of end phase ) x (Start phase B/W ratio) x (ST2)

Following is an example illustrated to calculate the dynamic axial thrust on the beams for a case
when accelerometers are connected at point LC, MC and RC simultaneously. Present section
illustrates the dynamic axial thrust computation on each gantry beam (Fig.5) for a particular
accelerometer data. Accelerometers are kept at B1,C and B4 and accelerations at other intermediate
locations are interpolated by assuming linear variation as shown in Fig.5. Considering the mass of
crane as 5 tons (uniformly distributed along the length of the crane).

Page | 25

Fig. 5 Horizontal acceleration profile along the tower crane

Force distribution along beam B1B2:

Along the beam B1B2, trapezoidal acceleration profile is decomposed into linear combination of
acceleration profiles as shown in Fig.6 and forces F1 and F2 are evaluated as

F1 0.5 3.112 9.8 1428.4

261kN
F2 0.5 1.99 12 9.8 1428.4
167.3kN

Fig. 6 Horizontal acceleration profile along beam B1B2

Page | 26

`
Subsequently, horizontal reactions along beam B1B2 is computed as RB1=229.5 kN and
RB2=198.4 kN as shown in Fig.7

Fig. 7 Force equilibrium along B1B2

Along the beam B1B2, trapezoidal acceleration profile is decomposed into linear combination of
acceleration profiles as shown in Fig.8 and forces F1 , F2 ,F3 and F4 are evaluated as F1=94Kn,
F2=54.1kN,F3=54.8Kn and F4=59.1 Kn (Fig.9)

Fig. 8 Horizontal acceleration profile along beam B2B3

Page | 27

`
Subsequently, horizontal reactions along beam B2B3 is computed as RB1=143.5 kN and
RB2=119.4 kN as shown in Fig.3

Fig. 9 Force equilibrium along B2B3

Along the beam B1B2, trapezoidal acceleration profile is decomposed into linear combination of
acceleration profiles as shown in Fig.6 and forces F1 and F2 are evaluated as,

F1 0.5 1.25 12 9.8 1428.4

105kN
F2 0.5 1.39 12 9.8 1428.4
115.3kN

Fig. 10 Horizontal acceleration profile along beam B3B4

Page | 28

`
Subsequently, horizontal reactions along beam B3B4 is computed as RB1=108.45 kN and
RB2=115.4 kN as shown in Fig.11.

Fig. 11 Force equilibrium along B3B4

Furthermore, total horizontal dynamic axial thrusts along each beam is calculated by linear
superposition of horizontal reactions obtained in all above discussed cases as shown in Fig.8

Fig. 12 Resultant horizontal dynamic axial thrust on gantry beams

Maximum forces obtained from the observed data in beam 2= 369.45 KN (max value from all
the measured data)

Page | 29

4.2 Grabber Force Calculation

The grabber force calculation has been done for various arrangements of accelerometers in both
left and right grabbers. The recorded data are separated for both start and end phase of any
particular experimental trial. Table 15 shows the maximum acceleration values for start and end
phase for each experimental trial of arrangement 1. The accelerometers are placed at LGB2 and
RGB3 in arrangement 1.
ARRANGEMENT 1
EXPERIMENTAL TRIALS
Trial No.
MR_Crane backward

START PHASE
LGB2
RGB3

END PHASE
LGB2
RGB3

movement with 5 tonne

1

load

-0.17481

-0.03351

0.7375

0.0335

-0.00605

0.29658

-0.04699

-1.204

0.1457

0.10406

0.6183

0.016622

-0.00018

-0.765

0.061213

0.9667

0.1879

-0.01747

0.51

-0.00167

-0.01824

0.624

0.019155

1.129

0.1865 0.003942

0.6428

-0.0839

MR_crane backward with

2

5 tonne load trial 2

MR_Crane forward with

3

5 tonne load

MR_Crane forward
movement with 5 tonne
4

load trial 2

-0.00957

1.027

-0.03107

1.3177

0.028517

0.0217

0.1259

-0.18932

-0.01508

0.31874

-0.00857

-0.4962

-0.00778 0.031478

0.2301

0.014453

-0.01097

-1.165

MR_Crane forward
5

without load

MR_Crane backward
6

without load

-0.0041

-0.36

Table 15 Start and End phase acceleration values for arrangement 1 at particular time instant

Page | 30

`
From Table 15, it is observed that, at any time instant the maximum values of acceleration at
end phase is greater than the corresponding start phase acceleration values. The above trend is
also observed in all the arrangements considered. Hence, for calculation of forces in beam due
to grabber, only end phase acceleration values are considered.
4.2.1 Shape of acceleration profile
The accelerometers were placed at both the ends of the left grabber i.e., LGE and LGC and
various experimental trials were carried out. The maximum acceleration values have been
selected for end phase only (refer Table 15 of Grabber Force calculation).The recorded data
has been processed and the maximum end phase acceleration values in both the accelerometers
were selected which would be at different time instants. Table 16 shows the maximum end
phase acceleration values in both the accelerometers for each trials. The tabulated data is
plotted to scale for trial 1. (Appendix A show the scaled plots for all trials).

Accelerometers placed at LGE and LGC

Time
Experimental trial
Possibility instant LGE (g)
MR_Crane backward run without load
trial 2
1a
t1
0.422
1b
t2
0.012
MR_Crane forward run without load

2a
2b

t3
t4

-0.749
0.047

MR_Crane backward run without load

3a
t5
-0.756
3b
t6
-0.846
3b
t6
0
Table 16 Acceleration values for accelerometer locations at LGE and LGC

LGC (g)
-0.011
0.1208
-0.069
0.407
0.014
0
-0.644

Fig. 13 Acceleration profile for experimental trial 1 (1a and 1b of Table 16)

Page | 31

Fig. 14 Acceleration profile for experimental trial 1 (2a and 2b of Table 16)
From the tabulated data of maximum acceleration values (Table 16) and their corresponding scaled
plots shows that at a particular time instant when the acceleration value at LGE is maximum, the
corresponding value at LGC is close to zero and vice versa. This trend can be observed in all the
trials when grabber is moving without any mass. Thus for a particular time instant the acceleration
profile in the grabber can be taken as triangular. Since, grabber has its own self weight, so the
aforementioned conclusion will also be valid when grabber will move with mass.
4.2.2 Acceleration profile pattern determination for both grabbers
4.2.2.1 Accelerometer data for various arrangements
Following are the different arrangements considered for accelerometer profile pattern
determination
Arrangement 1: Accelerometers at LGB2 and RGB3
Arrangement 2: Accelerometers at LGE and RGE
Arrangement 3: Accelerometers at LGB2 and RGB3
Arrangement 4: Accelerometers at LGB1 and RGB4
Arrangement 5: Accelerometers at LGE, LGC and RGC

ARRANGEMENT 1 (LGB2 and

RGB3)
Case
MR_Crane backward movement with 5
tonne load
1a
1b
MR_crane backward with 5 tonne load
trial 2
2a
2b
MR_Crane forward with 5 tonne load
3a
3b
MR_Crane forward movement with 5
tonne load(trial 2)
4a
4b
5a
MR_crane forward without load 2
(Discarded)

Time
instant

LGB2 (g)

RGB3 (g)

t1
t2

0.7375
-0.04699

0.0335
-1.204

t3
t4
t5
t6

0.6183
0.061213
0.51
0.019155

0.016622
0.9667
-0.00167
1.129

t7
t8

0.6428
-0.03107

-0.0839
1.3177

t9

0.1259

-0.18932
Page | 32

`
5b
t10
-0.00857
MR_crane backward without load 3
6a
t11
0.2301
6b
t12
-0.01097
Table 17 Acceleration data for arrangement 1

ARRANGEMENT 2 (LGE and RGE)

MR_crane backward with load
MR_crane backward with load trial 2
MR_crane forward with load

Case
1a
1b
2a
2b
3a

Time
instant
t1
t2
t3
t4
t5

3b
t6
MR_crane forward with load trial 2
4a
t7
4b
t8
MR_crane forward without load
5a
t9
5b
t10
MR_crane backward without load
6a
t11
6b
t12
Table 18 Acceleration data for arrangement 2

LGE (g)
0.4195
-0.02384
-0.35306
-0.00383
-0.477445
0.003889
9
0.4588
-0.03028
-1.05584
-0.02169
0.74911
0.124286

ARRANGEMENT 3 (LGB2 and

Time
LGB2
RGB3)
Case
instant (g)
MR_Crane backward movement with
5 tonne load
1a
t1
0.423
1b
t2
-0.00991
MR_crane backward with 5 tonne
load trial 2
2a
t3
0.5245
2b
t4
0.00823
MR_Crane forward with 5 tonne load 3a
t5
0.9422
3b
t6
-0.0217
MR_Crane forward movement with 5 4a
tonnes load(trial 2)
(Discarded)
t7
1.643
4b
t8
0.0255
MR_crane forward without load 2
5a
t9
-0.77
5b
t10
-0.18488
6a
MR_crane backward without load 3 (Discarded)
t11
-0.184
6b
t12
0.005367
Table 19 Acceleration data for arrangement 3

-0.4962
0.014453
-1.165

RGE (g)
0.0044
0.3105
0.01516
-0.41525
0.03433
-0.43168
-0.02642
-0.50561
0.00688
-0.49869
-0.00183
0.34774

RGB3 (g)
0.0253
-0.4489
0.0258
-0.4194
0.028
0.56
-0.04174
-0.58
-0.101
-0.27705
-0.11656
-0.2789

Page | 33

`
ARRANGEMENT 4 (LGB1 and
Time
RGB4)
Case
instant
LGB1
MR_Crane backward with 5 tonne
load
1a
t1
-0.205
1b
t2
-0.06427
MR_Crane backward with 5 tonne
load(trial 2)
2a(Discarded) t3
0.8172
2b
t4
-0.01454
MR_Crane forward with 5 tonne load 3a
t5
0.5965
3b
t6
-0.01279
MR_Crane forward with 5 tonne
load(trial 2)
4a
t7
-0.5567
4b
t8
-0.0027
MR_Crane forward without load
5a
t9
-1.5427
5b
t10
-0.02142
MR_Crane backward without load
6a
t11
-1.81
6b
t12
0.018504
Table 20 Acceleration data for arrangement 4

ARRANGEMENT 5 :
(LGE, LGC and RGC )
MR_Crane backward run without
load trial 2

MR_Crane forward run without

load

MR_Crane backward run without

load

RGB4
-0.0165
-0.7156
-0.26577
1.2812
0.0709
0.885
-0.01598
1.262
0.09659
-0.5372
-0.02772
0.434

Time
instant

LGE (g)

LGC (g)

RGC (g)

1a
1b

t4

0.422

-0.011

0.058

t5

0.012

0.120

0.024

2a
2b

t6

-0.749

-0.069

0.157

t7

0.047

0.407

0.014

Case

3a
t1
-0.756
0.013
3b
t2
-0.846
0
3b
t3
0
-0.644
Table 21 Acceleration data for arrangement 5

-0.215
-0.129
- 0.129

The observations from the data leads to classification of acceleration profile in grabbers in two
patterns which are as follows:

Page | 34

`
Grabber Acceleration Pattern 1: Anti-symmetric pattern

Fig. 15 Anti-symmetric pattern

Grabber Acceleration Pattern 2: Symmetric pattern

Fig. 16 Symmetric pattern

Page | 35

`
The acceleration profile along the length of the grabber is triangular ( from 4.2.1). So, in order to
draw an acceleration profile from the data of various arrangements, following assumptions have
been made:
Assumptions:
1. For acceleration at LGE, LGC, RGE and RGC, values at any of these ends less than 0.035
g is assumed to be zero at that corresponding end.
2. The acceleration profile with different sign (+/-) in the two grabbers at any particular time
instant are discarded.
The tabulated data has been plotted for each experimental trial to determine the governing
acceleration profile pattern from above two observed patterns.
Case 1a of arrangement 1:
ARRANGEMENT 1 (LGB2 and
RGB3)
Case
MR_Crane backward movement with 5
tonne load
1a

Time
instant

LGB2 (g)

RGB3 (g)

t1

0.7375

0.0335

The measured value at LGB2 (0.7375 g) at time t1 is extrapolated linearly to the end point LGC
(1.073 g) as shown in Diagram 1. Similarly, measured value at RGB3 (0.0335 g) at time t1is
extrapolated to RGE (0.117 g) as shown in Diagram 3.
The measured value at LGB2 (0.7375 g) at time t1 is extrapolated linearly to the end point LGE
(2.581 g) as shown in Diagram 2. Similarly, measured value at RGB3 (0.0335 g) at time t1is
extrapolated to RGC (0.0469 g) as shown in Diagram 4.

Page | 36

Step 1:

Possibility 1:

The difference between maximum values of acceleration in Diagram 1 and Diagram 3

(LGC and RGE respectively) =1.03g -0.117g
=0.913 g

Possibility 2:

The difference between maximum values of acceleration in Diagram 1 and Diagram 4

(LGC and RGC respectively) =1.073g -0.0469g
=1.0261 g

Page | 37

Outcome 1:
From possibility 1 and possibility 2, the difference in the maximum acceleration values of
left and right grabber is minimum in possibility 1 (0.913 g) as compared to possibility 2
(1.0261 g). Hence, the possibility 2 is eliminated.

Step 2:

Possibility 3:

The difference between maximum values of acceleration in Diagram 2 and Diagram 3

(LGE and RGE respectively) =2.581g -0.117g
=2.464g

Possibility 4:

The difference between maximum values of acceleration in Diagram 2 and Diagram 4

(LGE and RGC respectively) =2.581g-0.0469g
=2.534
Page | 38

Outcome 2:
From possibility 3 and possibility 4, the difference in the maximum acceleration values of
left and right grabber is minimum in possibility 3 (2.464g) as compared to possibility 4
(2.534 g). Hence, the possibility 4 is eliminated.

Conclusion:
Considering the maximum values of acceleration in possibility 1 (1.03g and 0.117g at LGC and
RGE respectively) and possibility 3 (2.581g and 0.117g at LGE and RGE respectively). As the
variation in maximum acceleration values in both grabber should be minimum, so possibility 1
(anti-symmetric) is selected as the governing trend.

Case 5b of arrangement 3 :
ARRANGEMENT 3 (LGB2 and
RGB3)
Case
MR_crane forward without load 2
5b

Time
instant
t1

LGB2
(g)
-0.184

RGB3 (g)
-0.277

The measured value at LGB2 (-0.184g) at time t1 is extrapolated linearly to the end point LGC
(-0.257g) as shown in Diagram 1. Similarly, measured value at RGB3 (-0.277g) at time t1is
extrapolated to RGC (-0.388 g) as shown in Diagram 3.
The measured value at LGB2 (-0.184g) at time t1 is extrapolated linearly to the end point LGE
(-0.644g) as shown in Diagram 2. Similarly, measured value at RGB3 (-0.277g) at time t1is
extrapolated to RGC (-0.9695g) as shown in Diagram 4.

Page | 39

Step 1:

Possibility 1:

The difference between maximum values of acceleration in Diagram 3 and Diagram1

(RGC and LGC respectively) =0.388g-0.257g
=0.13g

Possibility 2:

The difference between maximum values of acceleration in Diagram 4 and Diagram 1

(RGE and LGC respectively) =0.9695g-0.257g
=0.7125g

Page | 40

Outcome 1:
From possibility 1 and possibility 2, the difference in the maximum acceleration values of
left and right grabber is minimum in possibility 1 (0.13g) as compared to possibility 2
(0.7125g). Hence, the possibility 2 is eliminated.

Step 2:

Possibility 3:

The difference between maximum values of acceleration in Diagram 2 and Diagram 3

(LGE and RGC respectively) =0.644g-0.388g
=0.256g

Possibility 4:

The difference between maximum values of acceleration in Diagram 4 and Diagram 2

(RGE and LGE respectively) =0.9695g-0.644g
=0.3255g

Page | 41

Outcome 2:
From possibility 3 and possibility 4, the difference in the maximum acceleration values of
left and right grabber is minimum in possibility 3 (0.256g) as compared to possibility 4
(0.3225g). Hence, the possibility 4 is eliminated

Conclusion:
Considering the maximum values of acceleration in possibility 1 (0.257g and 0.388g at LGC and
RGC respectively) and possibility 3 (0.644g and 0.388g at LGE and RGC respectively). As the
variation in maximum acceleration values in both grabber should be minimum, so possibility 1
(symmetric) is selected as the governing trend.
For all recorded cases, it has been observed that the majority of cases are following the antisymmetric pattern i.e., at same instant LGC and RGE will achieve maximum acceleration value
simultaneously OR LGE and RGC will achieve maximum acceleration value simultaneously (refer
Appendix A for plots of all the cases).
4.2.3 Grabber force calculation procedure
Following is an example illustrated to calculate the dynamic axial thrust on the beams due to
grabber for a case when accelerometers are placed at LGB2 and RGB3 simultaneously. Present
section illustrates the dynamic axial thrust computation on each gantry beam for a particular
experimental trial 1a which is at time instant t1 and for 1b which is at time instant t2. The mass of
grabber is taken as 10% of the total lifted mass (5000 kg) i.e., 500 kg. The mass (500 kg) is taken
to be equally distributed in the left and right grabber i.e., m= 250 kg for both left and right grabber.
Mass is assumed to be uniformly distributed along the length of both the grabbers.

Trial 1
MR_ Crane
backward
movement
with 5 tonne
load

Time
Instant

Arrangement 1 (Accelerometers at LGB2 and RGB3)

LGB
Case LGE
1
LGB2
LGC RGC RGB3

RGB4

RGE

t1

1a

0.7375

0.0335

t2

1b

-0.16

-1.2040

Case 1a of experimental trial 1 confirms to be Anti symmetric pattern with possibility 1 (refer
section 4.2.2.1) as the governing acceleration profile in both the grabbers. Fig. 17 shows the plots
for case 1a of experimental trial 1 at time instant t1 (with linear extrapolation).

Page | 42

(A)

(B)

Fig. 17 Acceleration profile in both left and right grabber for case 1a
The above acceleration profile (A) is loaded on left grabber and reactions R1 and R2 (i.e., at
locations LGB1 and LGB2) are calculated considering as simple supports at LGB1 and LGB2).
Similarly, acceleration profile (B) is loaded on right grabber and reactions R 3 and R4 (i.e., at
locations RGB3 and RGB4) are calculated.

Fig. 18 Horizontal force equilibrium along the length of the left grabber
Putting a1 = 1.03 g from (A) and m= 2500 kg, reactions R1 and R2 in left grabber are calculated to
be 39.5 kN and 315.51 kN respectively. Similarly, on putting a1 = 0.117 g from (B) and m = 2500
kg, reactions R3 and R4 in right grabber are calculated to be 4.49 kN and 35.83 kN respectively.
The force calculations are performed in similar manner for case 1b at time instant t2 for
experimental trial 1. Fig. 19 shows the plots (C and D) of acceleration profile at time instant t2 for
case 1b.

Page | 43

(C)

(D)

Fig. 19 Acceleration profile in both left and right grabber for case 1b
Putting a1 = 0.16 g from (C) and m= 2500 kg, reactions R1 and R2 in left grabber are calculated to
be 48.89 kN and 6.121 kN respectively. Similarly, on putting a1 = 1.68 g from (B) and m = 2500
kg, reactions R3 and R4 in right grabber are calculated to be 513.37 kN and 60.154 kN respectively.

4.3 Results obtained due to axial thrust

Maximum force obtained in beam 3 due to crane, from the extrapolated data = 1300 KN
Maximum force obtained in beam 3 due to grabber, from the extrapolated data due to 5 ton loading
= 563 KN
Total axial thrust acting on beam 3= 1300 KN +563 KN
= 1863 KN
Axial elongation due to above load,

PL
,
AE

where, P = axial thrust acting on the beam

L= length of the beam
A= area of cross section of beam
E= Modulus of elasticity
Axial displacement due to thrust = 126 mm
Corresponding strain value in 126m length =126 /126000 = 10 x E-4 (for the worst case
possible)
Maximum observed strain value in beam 3= 3.6 x E-4
Page | 44

5 Static Analysis of Gantry girder

Total weight of tower crane and grabber = 15 Ton.
Assuming grabber-crane system as rigid, static analysis is performed and reactions transferred to
individual girders is shown in Fig.14.

Fig. 20 Gantry and Tower crane- Grabber system

5.1 Computer model:

The gantry beam (Fig. 22) of length 126 m is suspended from transverse truss as shown in
Fig. 21 with rigid connections. A macro model of transverse truss and
gantry beams assembly is modelled in SAP-2000. Longitudinal trusses are not accounted for in
the macro-model, however roof loads transferred through longitudinal truss are explicitly taken
into account in the macro model. The transverse truss is modelled using truss elements whereas,
gantry beams are modelled using beam-column elements. Transverse truss is connected to the
supporting RC-column using a pinned connection, same is reflected in the macro model using
moment releases at the column ends. In case of transverse truss, along with its own self weight,
dead and live loads coming from roof and walk way are taken in into account. In case of gantry
beams, along with its own self weight, load due to tower crane and grabber are taken into account
as shown in Fig. 20. Due consideration is given to impact loading on gantry beam by additional
25% increase in vertical loading (IS: 875-Table 13-9). Complete Macro model of transverse truss
gantry assembly can be seen in Fig. 23- Fig. 24. Structural analysis is performed for
aforementioned macro model by considering moving vertical loads. (Influence line diagrams
methodology)
Page | 45

Fig. 21 Plan view of steel shed

Page | 46

Fig. 22 Schematic diagram of Gantry-beam

Fig. 23 3-D view of macro-model in SAP-2000

Page | 47

Fig. 24 Elevation of Transverse truss

Results
Static analysis is performed for aforementioned macro-model and maximum moment of
designated frame (Fig.19) is taken for cross-sectional stress analysis.

Fig. 25 Critical section under consideration

Page | 48

`
Element Forces - Frames
Frame

Station

OutputCase

CaseType

StepType

V2

V3

M2

M3

Text

mm

Text

Text

Text

kN

kN

kNm

kNm

kNm

2071

7500

Comb

Comb

Max

66

0.7

0.3

57.056

2071

7500

Comb

Comb

Min

-15

-0.9

-0.2

-127.57

Table 22 Maximum and Minimum moments for frame element under consideration

5.2 Stress analysis for gantry beam

Maximum Bending moment from static analysis (M) = 128 kNm
Area of the section (A) =9.3103 mm2
Sectional modulus (Z) =1.432106 mm3
Maximum tensile stress= M/Z= 90 MPa
Considering 25o increase in temperature during summer season, stress due to temperature is
=E..T
=60 MPa

Page | 49

6 Conclusions
This section illustrates the scientific study performed to investigate the failure analysis of the
gantry beam in Sheela foam steel shed. The stress on the gantry beam due to horizontal dynamic
axial thrust due to crane movement, due to vertical loading and temperature effects are quantified
independently and superimposed together. 90 MPa extreme fiber stress is obtained in static
analysis for vertical gravity loading with 25% provision for impact and is significantly less than
the yield stress. However processed results from on-site instrumentation infer significant
amplification of stress in the gantry beam beyond yield point due to horizontal dynamic axial thrust
and temperature effects. Furthermore, onsite observation by IIT-Gn team infers lack of expansion
joints for the gantry beam, which induce significant temperature stress to the order of 60 MPa. All
these aforementioned parameters infer that the gantry beam is under designed and all these critical
parameters needs to be given due consideration in their upcoming design.

Page | 50

Page | 51