Avoiding Common Crane Runway Problems by JOHN E, MUELLER, PE, Structural Consultant, Broad Crane & Engineering Service Co., Detroit, MI F ALL STRUCTURAL ELEMENTS in a plant building, crane runways are among the most susceptible to failure. ‘These rigid structures are subjected to pounding from rigid moving structures, without the benefit of @ ‘cushioning intermediary, such as tres provide between car and high- way. Runways are subject to the vertical stresses of the crane weight, the horizontal stresses pro- duced by erane movement, an ict Toads resulting from chain slippage, a sudden pulling action, or lifting at an angle. Because of their length, crane runways are al- 20 susceptible to thermal expan- sion. Yet, they are required to ‘maintain Tateral and vertical align- ‘ment within very narrow tolerances. Despite their apparent rigi crane runways are dynamic struc~ tures that must incorporate a great deal of movement and flexibility. Runway rails can slip, girders can deflect under load and their ends ‘may rotate, and columns can be deformed by moving loads. The most effective method of hhandling the complex toads that are applied to a runway is to trans- fer them to the outside of the sys- tem—from the girder (0 the run- way column, and then through bracing down to the foundation. Because this dynamic struc- ture—the runway—has not always been well understood, engineers Ihave sought to produce rigidity, or to restrict movement within the runway system, often doing more hharm than good. "A. number of errors that are commonly made during either con- struction of erane runways or their subsequent repair are discussed in this article, Recommended alterna- tives also are suggested. Error No. 1: Excess Rigidity—In many plants the ral is mounted to the runway girder by fixed rail clamps that bind the ail firmly against movement, Fig. 1. Five #s20 is connection causes two problems: First, the horizontal ‘thrust created by crane movement is teansmitted directly to the girder. ‘However, the girder is not designed to accept such horizontal stresses. Second, although the rail is a continuous member, the girder ‘undemeasth normally consists of individual spans that run from column to column. (A continuous ‘welded girder would be extremely expensive.) The ends of the indi- vidual girders rotate under the ‘moving crane load, applying a ten sile force to the continuous rail time, the rail becomes misaligned and causes shearing of bolts. The rail or girder may also crack. ‘The solution to this problem is a floating rail, Fig. 1, that simply rests on the girder. It is by clips that provide space for movement above the rail and to each side of it. In this arrangement, the rail slips under the crane loud aud acts as a shock absorber. Any remain- ing impact is transmitted by the ‘girder to the column and, through the column, down into the build- ing’s foundation. "When the ends of the girders ro- tate, they do not place tension ‘upon the rail. And, there is less strain from thermal expansion be- ‘cause the ral is froc to slide along the girder. i a - FIXED corm Fig. 1, Fixed rail clamp firmly binds Because of the reduced stain the rail tends to remain in its or pal alignment, and virtually no f38- tener maintenance is required ‘A ct Yen, rail tolerance for rail movement to the left or right (an industry standard) can be met, while allowing room for thermal ‘expansion, by positioning the clips Ya in. to each side ofthe rail Error No, 2: Unnecessary Use of knee Bracing—Eager to help sup- port runway loads, many engineers dd knee bracing at the junction of the runway girder and the building column, This practice is useless and may actually be harmful. Heavy bracing, in particular, can cause problems. "The knee brace draws loads 10 itself that would otherwise be ap- plied to the column and the foun- Gation, When the girder bends un- der load it compresses the knee brace. Making the Knee brace heavier simply draws more load to it, Fig, 2. ‘The Knee brace is never utilized it there is vertical bracing between columns. In any case, there i a high probability that fasteners will ‘become loote or sheared, oF fa Aigue failure wil occur overtime, i kee bracing is used, Furthermore, ifthe knee brace is compressed be- yond its yield point, it may deform the girder or cause cracks in the sirder web. suse. FLOATING inder and retards movement in any ‘itcction. ts use can lead to a misaligned rail, sheared bolts, and crack {ng in the rail or girder. A floating tioned by clips that provide air spat right of it ‘movement. Thould be used Inctead. It is post. ‘above the rail and to the left and SEPTEMBER 30,1976 + PLINT ENGINEERING © 63rig, 2. Keo bracing draws ads to i FF that would ottwevise be ranstred i2'tne column and down inte tne four, Sauter, hon the goer bende unde} it compresses the ke brace, Use oF 2 diphagm of ‘astuer pate-also Shuses problems. When the det end toutes, the dlphvogm atterpts to fe Srain the rotation. Fastonere mvarably Become sheared, and local tion eee, te Goma Bek: Fig, 3. Direct top flange connection per lunrestrited girder rotation. Dia. phragm and knee bracing are ‘CRANE RUNWAY PROBLEM CHECKLIST Problem 1 Cracks in runway rail 2, Misoligned rol 1. Fixad rail clamps 2, Supporting structures (euch 0: columns) Corrective Aion For ‘corresponding probable cause 1, Insel floating rel 2. Inspeet and eopair displaced or deformed 3. Shoored rail fasteners 1. Gracks in runway girder 1. Diephreghm connection. 1. Remove dlophroom-so- “web; deformed girder "7" between column and” "> web conection; connect sora vmorscons girder web ===" —-> giedar chap flange wih " Sheared or lose gindor 2. Testoners 8. Cracks in connecting rater! 1, Frectures in plates or conolee of verial Xbracing joints 3. Crane out of clignment Overled knoe bracing 2 3. Fixed rll elompe 1. Vetizal Xibracing foo close fo ends of building orto bullding expontion 3. Inspect end repair crane fing caMtaction sore orn 2. Remove ine bracin making sre vertical Xebracing is edequete for Toad 23. Install lostng rit 1. natal racing 0 clove tocenterofbullding ot posilo, oto conterof expansion field —— TD ori The best solution is to remove the knee bracing since it serves no useful purpose, Fig. 3. However, it may be wise to explain to em- ployees why this action has been taken. There have been cases in Which workers, accustomed to see ing the knee braces in place, have filed a safety grievance when they ‘were removed Error No. 3: Connecting Girder to Column at the Web—When the girder end rotates under load, and the girder web is connected to a column by a diaphragm or fastener plate, the connecting plate resists rotation. As a result, fasteners are subjected to large shear forces, and cracks may occur in the diaphragm orweb, Fig, 4, ‘These probiems can be eliminat- ed by connecting the girder to the column at the upper flange only, using sliding connections. This ar rangement allows the girder end to rotate without producing strain on the connection. If a stiffener is re- quired, it should be a simple weld- edstiffener, Fig. 5, Error No. 4: Wrong Placement of Column Bracing—Vertical cross bracing between columns ‘carries the longitudinal forces into the foundation. There is a. great temptation to locate the bracing at the ends of the building, because end bracing can take up the shock cf eran stops. Some engineers also feel that end bracing is best for resisting wind forces. And, when construction of the facility is be- gun, bracing at the two ends helps the erector plumb the building. However, the building end is al so the end of the runway’ thermal- expansion field. At this location, the bracing will be subject to max- imum expansion or contraction forces that occur in a long runway, Fig. 6. These forces will often overstress the bracing and cause fractures in plates or angles, and may loosen diagonal members and fasteners. If the bracing is. too strong to fail, it may overstress or deflect the entre wall framing, Tn general, cross bracing should be placed as close to the center of the building as possible, to permit free expansion or contraction in an ‘outward direction, Fig. 6. Some other ronway problems are the result of hard treatment rather than poor design, Thus, a crane that is out of alignment may cause cracks in runway members ‘or misalignment or shearing of fas- teners. In one recent case, steel slabs ‘were piled high near a column, The excessive Joad even- tually moved the column founda- tion out of position, causing run- way misalignment. ‘rele 262 on postcard SEPTEMBER 30,1975 © PLANT ENGINEERING = 05alt FLoaTs ON GIRDER TO. 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