"MONORAIL.

xls" Program
Version 1.6

"MONORAIL" --- MONORAIL BEAM ANALYSIS

Program Description:

"MONORAIL" is a spreadsheet program written in MS-Excel for the purpose of analysis of either S-shape or
W-shape underhung monorail beams analyzed as simple-spans with or without overhangs (cantilevers).
Specifically, the x-axis and y-axis bending moments as well as any torsion effects are calculated. The actual and
allowable stresses are determined, and the effect of lower flange bending is also addressed by two different
approaches.

This program is a workbook consisting of three (3) worksheets, described as follows:

Worksheet Name Description

Doc This documentation sheet
S-shaped Monorail Beam Monorail beam analysis for S-shaped beams
W-shaped Monorail Beam Monorail beam analysis for W-shaped beams

Program Assumptions and Limitations:

1. The following references were used in the development of this program:

a. Fluor Enterprises, Inc. - Guideline 000.215.1257 - "Hoisting Facilities" (August 22, 2005)
b. Dupont Engineering Design Standard: DB1X - "Design and Installation of Monorail Beams" (May 2000)
c. American National Standards Institute (ANSI): MH27.1 - "Underhung Cranes and Monorail Syatems"
d. American Institute of Steel Construction (AISC) 9th Edition Allowable Stress Design (ASD) Manual (1989)
e. "Allowable Bending Stresses for Overhanging Monorails" - by N. Stephen Tanner -
AISC Engineering Journal (3rd Quarter, 1985)
f. Crane Manufacturers Association of America, Inc. (CMAA) - Publication No. 74 -
"Specifications for Top Running & Under Running Single Girder Electric Traveling Cranes
Utilizing Under Running Trolley Hoist" (2004)
g. "Design of Monorail Systems" - by Thomas H. Orihuela Jr., PE (www.pdhengineer.com)
h. British Steel Code B.S. 449, pages 42-44 (1959)
i. USS Steel Design Manual - Chapter 7 "Torsion" - by R. L. Brockenbrough and B.G. Johnston (1981)
j. AISC Steel Design Guide Series No. 9 - "Torsional Analysis of Structural Steel Members" -
by Paul A. Seaburg, PhD, PE and Charlie J. Carter, PE (1997)
k. "Technical Note: Torsion Analysis of Steel Sections" - by William E. Moore II and Keith M. Mueller -
AISC Engineering Journal (4th Quarter, 2002)
2. The unbraced length for the overhang (cantilever) portion, 'Lbo', of an underhung monorail beam is often debated.
The following are some recommendations from the references cited above:
a. Fluor Guideline 000.215.1257: Lbo = Lo+L/2
b. Dupont Standard DB1X: Lbo = 3*Lo
c. ANSI Standard MH27.1: Lbo = 2*Lo
d. British Steel Code B.S. 449: Lbo = 2*Lo (for top flange of monorail beam restrained at support)
British Steel Code B.S. 449: Lbo = 3*Lo (for top flange of monorail beam unrestrained at support)
e. AISC Eng. Journal Article by Tanner: Lbo = Lo+L (used with a computed value of 'Cbo' from article)
3. This program also determines the calculated value of the bending coefficient, 'Cbo', for the overhang (cantilever)
portion of the monorail beam from reference "e" in note #1 above. This is located off of the main calculation page.
Note: if this computed value of 'Cbo' is used and input, then per this reference the total value of Lo+L should be
used for the unbraced length, 'Lbo', for the overhang portion of the monorail beam.
4. This program ignores effects of axial compressive stress produced by any longitudinal (traction) force which is
usually considered minimal for underhung, hand-operated monorail systems.
5. This program contains “comment boxes” which contain a wide variety of information including explanations of
input or output items, equations used, data tables, etc. (Note: presence of a “comment box” is denoted by a
“red triangle” in the upper right-hand corner of a cell. Merely move the mouse pointer to the desired cell to view
the contents of that particular "comment box".)

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MONORAIL BEAM ANALYSIS

For S-shaped Underhung Monorails Analyzed as Simple-Spans with / without Overhang
Per AISC 9th Edition ASD Manual and CMAA Specification No. 74 (2004)
Job Name: Modificacion Tubos de carga 412-FC-01 Subject: Cerro Matoso
Job Number: 3448 Originator:Indisa S.A. Checker:

Input:
RL(min)=-1.34 RR(max)=15.67
Monorail Size: L=6.5 Lo=1
Select: S12x50 x=3.1
Design Parameters: S=0.6
Beam Fy = 36 ksi
Beam Simple-Span, L = 6.5000 ft. S12x50
Unbraced Length, Lb = 6.5000 ft.
Bending Coef., Cb = 1.00 Pv=13.95
Overhang Length, Lo = 1.0000 ft. Nomenclature
Unbraced Length, Lbo = 7.5000 ft.
Bending Coef., Cbo = 1.00 S12x50 Member Properties:
Lifted Load, P = 11.000 kips A = 14.60 in.^2 d/Af = 3.32
Trolley Weight, Wt = 0.100 kips d = 12.000 in. Ix = 303.00 in.^4
Hoist Weight, Wh = 0.100 kips tw = 0.687 in. Sx = 50.60 in.^3
Vert. Impact Factor, Vi = 25 % bf = 5.480 in. Iy = 15.60 in.^4
Horz. Load Factor, HLF = 10 % tf = 0.659 in. Sy = 5.69 in.^3
Total No. Wheels, Nw = 4 k= 1.438 in. J = 2.770 in.^4
Wheel Spacing, S = 0.6000 ft. rt = 1.250 in. Cw = 502.0 in.^6
Distance on Flange, a = 0.5000 in.
Support Reactions:(with overhang)
Results: RR(max) = 15.67 = Pv*(L+(Lo-S/2))/L+w/1000/(2*L)*(L+Lo)^2
RL(min) = -1.34 = -Pv*(Lo-S/2)/L+w/1000/(2*L)*(L^2-Lo^2)
Parameters and Coefficients:
Pv = 13.950 kips Pv = P*(1+Vi/100)+Wt+Wh (vertical load)
Pw = 3.488 kips/wheel Pw = Pv/Nw (load per trolley wheel)
Ph = 1.100 kips Ph = HLF*P (horizontal load)
ta = 0.514 in. ta = tf-bf/24+a/6 (for S-shape)
λ = 0.209 λ = 2*a/(bf-tw)
Cxo = -0.813 Cxo = -1.096+1.095*λ+0.192*e^(-6.0*λ)
Cx1 = 0.687 Cx1 = 3.965-4.835*λ-3.965*e^(-2.675*λ)
Czo = 0.186 Czo = -0.981-1.479*λ+1.120*e^(1.322*λ)
Cz1 = 1.783 Cz1 = 1.810-1.150*λ+1.060*e^(-7.70*λ)

Bending Moments for Simple-Span:

x = 3.100 ft. x = 1/2*(L-S/2) (location of max. moments from left end of simple-span)
Mx = 20.89 ft-kips Mx = (Pv/2)/(2*L)*(L-S/2)^2+w/1000*x/2*(L-x)
My = 1.63 ft-kips My = (Ph/2)/(2*L)*(L-S/2)^2

Lateral Flange Bending Moment from Torsion for Simple-Span:

(per USS Steel Design Manual, 1981)
e = 6.000 in. e = d/2 (assume horiz. load taken at bot. flange)
at = 21.662 at = SQRT(E*Cw/(J*G)) , E=29000 ksi and G=11200 ksi
Mt = 0.50 ft-kips Mt = Ph*e*at/(2*(d-tf))*TANH(L*12/(2*at))/12

X-axis Stresses for Simple-Span:

fbx = 4.95 ksi fbx = Mx/Sx
Lb/rt = 62.40 Lb/rt = Lb*12/rt
Fbx = 21.60 ksi Fbx = 12000*Cb/(Lb*12*(d/Af)) <= 0.60*Fy fbx <= Fbx; O.K.
(continued)

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Y-axis Stresses for Simple-Span:

fby = 3.43 ksi fby = My/Sy
fwns = 2.10 ksi fwns = Mt*12/(Sy/2) (warping normal stress)
fby(total) = 5.53 ksi fby(total) = fby+fwns
Fby = 27.00 ksi Fby = 0.75*Fy fby <= Fby; O.K.

Combined Stress Ratio for Simple-Span:

S.R. = 0.434 S.R. = fbx/Fbx+fby(total)/Fby S.R. <= 1.0; O.K.

Vertical Deflection for Simple-Span:

Pv = 11.200 kips Pv = P+Wh+Wt (without vertical impact)
∆(max) = 0.0127 in. ∆(max) = Pv/2*(L-S)/2/(24*E*I)*(3*L^2-4*((L-S)/2)^2)+5*w/12000*L^4/(384*E*I)
∆(ratio) = L/6154 ∆(ratio) = L*12/∆(max)
∆(allow) = 0.1733 in. ∆(allow) = L*12/450 Defl.(max) <= Defl.(allow); O.K.

Bending Moments for Overhang:

Mx = 9.79 ft-kips Mx = (Pv/2)*(Lo+(Lo-S))+w/1000*Lo^2/2
My = 0.77 ft-kips My = (Ph/2)*(Lo+(Lo-S))

Lateral Flange Bending Moment from Torsion for Overhang:(per USS Steel Design Manual, 1981)
e = 6.000 in. e = d/2 (assume horiz. load taken at bot. flange)
at = 21.662 at = SQRT(E*Cw/(J*G)) , E=29000 ksi and G=11200 ksi
Mt = 1.05 ft-kips Mt = Ph*e*at/(d-tf)*TANH(Lo*12/at)/12

X-axis Stresses for Overhang:

fbx = 2.32 ksi fbx = Mx/Sx
Lbo/rt = 72.00 Lbo/rt = Lbo*12/rt
Fbx = 21.60 ksi Fbx = 12000*Cbo/(Lbo*12*(d/Af)) <= 0.60*Fy fbx <= Fbx; O.K.

Y-axis Stresses for Overhang:

fby = 1.62 ksi fby = My/Sy
fwns = 4.42 ksi fwns = Mt*12/(Sy/2) (warping normal stress)
fby(total) = 6.05 ksi fby(total) = fby+fwns
Fby = 27.00 ksi Fby = 0.75*Fy fby <= Fby; O.K.

Combined Stress Ratio for Overhang:

S.R. = 0.332 S.R. = fbx/Fbx+fby(total)/Fby S.R. <= 1.0; O.K.

Vertical Deflection for Overhang:

(assuming full design load, Pv without impact, at end of overhang)
Pv = 11.200 kips Pv = P+Wh+Wt (without vertical impact)
∆(max) = 0.0054 in. ∆(max) = Pv*Lo^2*(L+Lo)/(3*E*I)+w/12000*Lo*(4*Lo^2*L-L^3+3*Lo^3)/(24*E*I)
∆(ratio) = L/2220 ∆(ratio) = Lo*12/∆(max)
∆(allow) = 0.0267 in. ∆(allow) = Lo*12/450 Defl.(max) <= Defl.(allow); O.K.

Bottom Flange Bending (simplified):

be = 7.200 in. Min. of: be = 12*tf or S*12 (effective flange bending length)
tf2 = 0.859 in. tf2 = tf+(bf/2-tw/2)/2*(1/6) (flange thk. at web based on 1:6 slope of flange)
am = 1.818 in. am = (bf/2-tw/2)-(k-tf2) (where: k-tf2 = radius of fillet)
Mf = 6.339 in.-kips Mf = Pw*am
Sf = 0.521 in.^3 Sf = be*tf^2/6
fb = 12.16 ksi fb = Mf/Sf
Fb = 27.00 ksi Fb = 0.75*Fy fb <= Fb; O.K.

(continued)

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Bottom Flange Bending per CMAA Specification No. 74 (2004):

(Note: torsion is neglected)

Local Flange Bending Stress @ Point 0: (Sign convention: + = tension, - = compression)

σxo = -10.73 ksi σxo = Cxo*Pw/ta^2
σzo = 2.46 ksi σzo = Czo*Pw/ta^2

Local Flange Bending Stress @ Point 1:

σx1 = 9.07 ksi σx1 = Cx1*Pw/ta^2
σz1 = 23.53 ksi σz1 = Cz1*Pw/ta^2

Local Flange Bending Stress @ Point 2:

σx2 = 10.73 ksi σx2 = -σxo
σz2 = -2.46 ksi σz2 = -σzo

Resultant Biaxial Stress @ Point 0:

σz = 10.23 ksi σz = fbx+fby+0.75*σzo
σx = -8.05 ksi σx = 0.75*σxo
τxz = 0.00 ksi τxz = 0 (assumed negligible)
σto = 15.86 ksi σto = SQRT(σx^2+σz^2-σx*σz+3*τxz^2)
<= Fb = 0.66*Fy = 23.76 ksi; O.K.

Resultant Biaxial Stress @ Point 1:

σz = 26.03 ksi σz = fbx+fby+0.75*σz1
σx = 6.80 ksi σx = 0.75*σx1
τxz = 0.00 ksi τxz = 0 (assumed negligible)
σt1 = 23.39 ksi σt1 = SQRT(σx^2+σz^2-σx*σz+3*τxz^2)
<= Fb = 0.66*Fy = 23.76 ksi; O.K.

Resultant Biaxial Stress @ Point 2:

σz = 6.54 ksi σz = fbx+fby+0.75*σz2
σx = 8.05 ksi σx = 0.75*σx2
τxz = 0.00 ksi τxz = 0 (assumed negligible)
σt2 = 7.41 ksi σt2 = SQRT(σx^2+σz^2-σx*σz+3*τxz^2)
<= Fb = 0.66*Fy = 23.76 ksi; O.K.

Point
1

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MONORAIL BEAM ANALYSIS

For W-shaped Underhung Monorails Analyzed as Simple-Spans with / without Overhang
Per AISC 9th Edition ASD Manual and CMAA Specification No. 74 (2004)
Job Name: Subject:
Job Number: Originator: Checker:

Input:
RL(min)=-4.31 RR(max)=21.71
Monorail Size: L=7 Lo=3
Select: W44x335 x=3.313
Design Parameters: S=0.75
Beam Fy = 36 ksi
Beam Simple-Span, L = 7.0000 ft. W44x335
Unbraced Length, Lb = 7.0000 ft.
Bending Coef., Cb = 1.00 Pv=14.05
Overhang Length, Lo = 3.0000 ft. Nomenclature
Unbraced Length, Lbo = 10.0000 ft.
Bending Coef., Cbo = 1.00 W44x335 Member Properties:
Lifted Load, P = 11.000 kips A = 98.30 in.^2 d/Af = 1.56
Trolley Weight, Wt = 0.200 kips d = 44.000 in. Ix = 31100.00 in.^4
Hoist Weight, Wh = 0.100 kips tw = 1.020 in. Sx = 1410.00 in.^3
Vert. Impact Factor, Vi = 25 % bf = 16.000 in. Iy = 1200.00 in.^4
Horz. Load Factor, HLF = 10 % tf = 1.770 in. Sy = 151.00 in.^3
Total No. Wheels, Nw = 4 k= 2.560 in. J = 74.400 in.^4
Wheel Spacing, S = 0.7500 ft. rt = 4.120 in. Cw = 536000.0 in.^6
Distance on Flange, a = 0.3750 in.
Support Reactions:(with overhang)
Results: RR(max) = 21.71 = Pv*(L+(Lo-S/2))/L+w/1000/(2*L)*(L+Lo)^2
RL(min) = -4.31 = -Pv*(Lo-S/2)/L+w/1000/(2*L)*(L^2-Lo^2)
Parameters and Coefficients:
Pv = 14.050 kips Pv = P*(1+Vi/100)+Wt+Wh (vertical load)
Pw = 3.513 kips/wheel Pw = Pv/Nw (load per trolley wheel)
Ph = 1.100 kips Ph = HLF*P (horizontal load)
ta = 1.770 in. ta = tf (for W-shape)
λ = 0.050 λ = 2*a/(bf-tw)
Cxo = -2.000 Cxo = -2.110+1.977*λ+0.0076*e^(6.53*λ)
Cx1 = 0.296 Cx1 = 10.108-7.408*λ-10.108*e^(-1.364*λ)
Czo = 0.193 Czo = 0.050-0.580*λ+0.148*e^(3.015*λ)
Cz1 = 2.711 Cz1 = 2.230-1.490*λ+1.390*e^(-18.33*λ)

Bending Moments for Simple-Span:

x = 3.313 ft. x = 1/2*(L-S/2) (location of max. moments from left end of simple-span)
Mx = 24.07 ft-kips Mx = (Pv/2)/(2*L)*(L-S/2)^2+w/1000*x/2*(L-x)
My = 1.72 ft-kips My = (Ph/2)/(2*L)*(L-S/2)^2

Lateral Flange Bending Moment from Torsion for Simple-Span:

(per USS Steel Design Manual, 1981)
e = 22.000 in. e = d/2 (assume horiz. load taken at bot. flange)
at = 136.580 at = SQRT(E*Cw/(J*G)) , E=29000 ksi and G=11200 ksi
Mt = 0.97 ft-kips Mt = Ph*e*at/(2*(d-tf))*TANH(L*12/(2*at))/12

X-axis Stresses for Simple-Span:

fbx = 0.20 ksi fbx = Mx/Sx
Lb/rt = 20.39 Lb/rt = Lb*12/rt
Fbx = 23.76 ksi Fbx = 0.66*Fy fbx <= Fbx; O.K.
(continued)

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Y-axis Stresses for Simple-Span:

fby = 0.14 ksi fby = My/Sy
fwns = 0.15 ksi fwns = Mt*12/(Sy/2) (warping normal stress)
fby(total) = 0.29 ksi fby(total) = fby+fwns
Fby = 27.00 ksi Fby = 0.75*Fy fby <= Fby; O.K.

Combined Stress Ratio for Simple-Span:

S.R. = 0.019 S.R. = fbx/Fbx+fby(total)/Fby S.R. <= 1.0; O.K.

Vertical Deflection for Simple-Span:

Pv = 11.300 kips Pv = P+Wh+Wt (without vertical impact)
∆(max) = 0.0002 in. ∆(max) = Pv/2*(L-S)/2/(24*E*I)*(3*L^2-4*((L-S)/2)^2)+5*w/12000*L^4/(384*E*I)
∆(ratio) = L/487786 ∆(ratio) = L*12/∆(max)
∆(allow) = 0.1867 in. ∆(allow) = L*12/450 Defl.(max) <= Defl.(allow); O.K.

Bending Moments for Overhang:

Mx = 38.39 ft-kips Mx = (Pv/2)*(Lo+(Lo-S))+w/1000*Lo^2/2
My = 2.89 ft-kips My = (Ph/2)*(Lo+(Lo-S))

Lateral Flange Bending Moment from Torsion for Overhang:(per USS Steel Design Manual, 1981)
e = 22.000 in. e = d/2 (assume horiz. load taken at bot. flange)
at = 136.580 at = SQRT(E*Cw/(J*G)) , E=29000 ksi and G=11200 ksi
Mt = 3.57 ft-kips Mt = Ph*e*at/(d-tf)*TANH(Lo*12/at)/12

X-axis Stresses for Overhang:

fbx = 0.33 ksi fbx = Mx/Sx
Lbo/rt = 29.13 Lbo/rt = Lbo*12/rt
Fbx = 23.76 ksi Fbx = 0.66*Fy fbx <= Fbx; O.K.

Y-axis Stresses for Overhang:

fby = 0.23 ksi fby = My/Sy
fwns = 0.57 ksi fwns = Mt*12/(Sy/2) (warping normal stress)
fby(total) = 0.80 ksi fby(total) = fby+fwns
Fby = 27.00 ksi Fby = 0.75*Fy fby <= Fby; O.K.

Combined Stress Ratio for Overhang:

S.R. = 0.043 S.R. = fbx/Fbx+fby(total)/Fby S.R. <= 1.0; O.K.

Vertical Deflection for Overhang:

(assuming full design load, Pv without impact, at end of overhang)
Pv = 11.300 kips Pv = P+Wh+Wt (without vertical impact)
∆(max) = 0.0006 in. ∆(max) = Pv*Lo^2*(L+Lo)/(3*E*I)+w/12000*Lo*(4*Lo^2*L-L^3+3*Lo^3)/(24*E*I)
∆(ratio) = L/55495 ∆(ratio) = Lo*12/∆(max)
∆(allow) = 0.0800 in. ∆(allow) = Lo*12/450 Defl.(max) <= Defl.(allow); O.K.

Bottom Flange Bending (simplified):

be = 9.000 in. Min. of: be = 12*tf or S*12 (effective flange bending length)
am = 6.700 in. am = (bf/2-tw/2)-(k-tf) (where: k-tf = radius of fillet)
Mf = 23.534 in.-kips Mf = Pw*am
Sf = 4.699 in.^3 Sf = be*tf^2/6
fb = 5.01 ksi fb = Mf/Sf
Fb = 27.00 ksi Fb = 0.75*Fy fb <= Fb; O.K.

(continued)

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Bottom Flange Bending per CMAA Specification No. 74 (2004):

(Note: torsion is neglected)

Local Flange Bending Stress @ Point 0: (Sign convention: + = tension, - = compression)

σxo = -2.24 ksi σxo = Cxo*Pw/ta^2
σzo = 0.22 ksi σzo = Czo*Pw/ta^2

Local Flange Bending Stress @ Point 1:

σx1 = 0.33 ksi σx1 = Cx1*Pw/ta^2
σz1 = 3.04 ksi σz1 = Cz1*Pw/ta^2

Local Flange Bending Stress @ Point 2:

σx2 = 2.24 ksi σx2 = -σxo
σz2 = -0.22 ksi σz2 = -σzo

Resultant Biaxial Stress @ Point 0:

σz = 0.50 ksi σz = fbx+fby+0.75*σzo
σx = -1.68 ksi σx = 0.75*σxo
τxz = 0.00 ksi τxz = 0 (assumed negligible)
σto = 1.98 ksi σto = SQRT(σx^2+σz^2-σx*σz+3*τxz^2)
<= Fb = 0.66*Fy = 23.76 ksi; O.K.

Resultant Biaxial Stress @ Point 1:

σz = 2.62 ksi σz = fbx+fby+0.75*σz1
σx = 0.25 ksi σx = 0.75*σx1
τxz = 0.00 ksi τxz = 0 (assumed negligible)
σt1 = 2.51 ksi σt1 = SQRT(σx^2+σz^2-σx*σz+3*τxz^2)
<= Fb = 0.66*Fy = 23.76 ksi; O.K.

Resultant Biaxial Stress @ Point 2:

σz = 0.18 ksi σz = fbx+fby+0.75*σz2
σx = 1.68 ksi σx = 0.75*σx2
τxz = 0.00 ksi τxz = 0 (assumed negligible)
σt2 = 1.60 ksi σt2 = SQRT(σx^2+σz^2-σx*σz+3*τxz^2)
<= Fb = 0.66*Fy = 23.76 ksi; O.K.

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