CONTRACT TR383 - ANALYSIS AND DESIGN OF LIFELINE SYSTEM FOR REPLACEMENT OF ROOFS OF COVERED

LINKWAYS.

1. Design statement

These design calculations are for the life line system for replacement of roofs of covered linkways.

2. Design information

2.1 Relevant Design Codes and Reference

a) SS EN 1990:2008 - Basic of Structural Design

b) SS EN 1991-1-1:2002 - Actions on Structures

c) SS EN 1993-1-1:2005 - Design of Steel Structures

d) SS EN 1993-1-8:2005 - Design of joints

e) SS EN 74-1:2005 - Couplers for tubes - Requirements and testprocedures

f) SS EN 12811-1 - Scaffolds - Performancerequirements and general design

g) SS EN 10255:2013 - Non-alloy steel tubes suitable for welding and threading - Technical delivery conditions

h) BS 5950-1:2000-Structural use of steelwork in building - Code of practice for design - Rolled and welded sections

i) BC1-2012 - Design Guide of Steel Structures

j) LTA M&W - LTA’s Material and Workmanship Specification (Version A1 Dated on Jun 2010)

2.2 Material Properties

A) Structural steel conforming to BS EN 10025:2013

Structural strength class S355

2
Characteristic yield strength of structural steel fy = 355 N/mm
2
Modulus of elasticity of structural steel Es = 210000 N/mm

B) Scaffolding coupler conforming to BS EN 74-1

Structural strength class Class B

Characteristic value of resistances for Swivel coupler (SW) FS,K = 15.0 kN BS EN 74-1 Table C.1

3. Analysis and design of lifeline system

3.1 Data

a) c/c span of of the lifeline "F" frame l = 3000 mm (max.)

3.2 Load calculation

Self weight of Ø48.3x4.0mm thk. CHS W1 = 4.37 kg/m (or) 0.04 kN/m __(1)

Self weight of 60x60x4.0mm thk. SHS (F-frame) W2 = 6.97 kg/m (or) 0.07 kN/m __(2)

Worker's weight (2 Nos., Consider moving load) P = 160.0 kg (or) 1.57 kN

Services (Moving load) W L = 1.57 kN __(3)

3.3 Analysis and design of Ø48.3x4.0mm thk. CHS

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 Properties of the section
2 2
Area of the section A = 5.57x10 mm
3 3
Plastic modulus W pl, y = 7.87x10 mm

Dead load of Ø48.3x4.0mm thk. CHS/ m = 1.0x0.04

= 0.04 kN/m

Design dead load of Ø48.3x4.0mm thk. CHS/ m = 1.35x0.04

0.05 kN/m

Live load (Moving load) on Ø48.3x4.0mm thk. CHS/ m = 1.57 kN __Ref.(3)

Design live load (Moving load) on Ø48.3x4.0mm thk. CHS = 1.5x1.57

= 2.36 kN __(4)

2
Design moment (Consider moving load at the center) MEd = (0.05x3.0 )/8+(2.36x3.0)/4

= 1.83 kNm __(5)

Design Shear effect VEd = 0.05x(3.0/2+3.0/2)+2.36

(Consider moving load at the support) = 2.51 kN __(6)

Checking of ultimate limit state

a) Bending Moment Resistance

In Eurocode 3

Clause 6.2 covers the cross sectional resistance

Clause 6.2.5 deals with the cross sectional resistance for bending.

MEd
≤ 1.0
Mc,Rd

EN 1993-1-1 Clause 6.2.5 Equation 6.12

MEd = 1.83 kNm __Ref.(5)

Mc,Rd = W pl fy / γ M0

γ M0 = 1.0
3
W pl fy / γ M0 = 7.87x10 x355/1.0
6
= 2.79x10 Nmm (or) 2.79 kNm

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 MEd
= 1.83/2.79
Mc,Rd

= 0.66 <1 Ok

b) Shear Resistance

In Eurocode 3

Clause 6.2 covers the cross-sectional resistance

Clause 6.2.6 deals with the crosssectional resistance for shear.

VEd
≤ 1.0
Vpl,Rd

EN 1993-1-1 Clause 6.2.6 Equation 6.17

VEd = 2.51 kN __Ref.(6)
Vpl,Rd = (AV (fy/√3))/(γM0)
2 2
AV = 5.57x10 mm
2
Vpl,Rd = (5.57x10 x(355/√3))/1.0
3
= 114.16x10 N (or) 114.16 kN

VEd
= (2.51/114.16)
Vpl,Rd

= 0.022 <1 Ok
Since, VED / Vpl,Rd is less than 0.5, no effect on the moment resistance EN 1993-1-1 Clause 6.2.8 (2)

Section is adequate in bending and shear.

3.4 Analysis and design of scaffolding coupler clamp connection

a) Force resistance

In Eurocode EN 12811-1:2003

Clause 10.3.3.5 (11) covers the force resistanve of the Sleeve coupler

(FS/2 FS,d)+(MB/MBd) ≤ 1.0

EN 12811-1:2003 Clause 10.3.3.5 Equation 11

Design forces acting on the coupler FS,1 = 2.51 kN __Ref.(6)

Design bending moment action on the coupler MB,1 = 0.0 kNm

Design resisting force FS,d = FS,k / gm

FS,k = 15.0 kN BS EN 74-1 Table C.1

gm = 1.0

EN 12811-1:2003 Clause 10.3.2.2

FS,d = 15.0/1.0

= 15.0 kN
(FS/2 FS,d)+(MB/MBd) = 2.51/(2x15.0)+(0.0/0.0)
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 = 0.08 <1 Ok

b) Checking of weld between coupler and F-frame

Checking of welds

Fw,Ed
≤ 1.0
Fw,Rd

Design weld resistance per unit length Fw,Rd = fvw,d x α

Throat thickness of the fillet weld α = 2.84 mm

(for a fillet weld with an 4mm leg length)

fvw,d = (fu/√3)/(βw gM2)
2
Nominal ultimate tensile strength of the weaker part jointed fu = fu,bp = 470 N/mm

For S355 steel, Correlation factor βw = 0.90

gM2 = 1.25
fvw,d = (470/√3)/(0.90x1.25)
2
= 241.20 N/mm
Fw,Rd = 241.20x2.84

= 685.01 N/mm

Weld length Lw = px48.3

= 151.66 mm

Design shear effect = 2.51 kN __Ref.(6)

3
Fw,Ed = 2.51x10 /151.66

= 16.55 N/mm
Fw,Ed
= 16.55/685.01
Fw,Rd

= 0.024 <1 Ok

3.5 Analysis and design of F-frame

Use 60x60x4.0mm thk. SHS @ maximum 3000mm c/c spacing

Properties of the section

2 2
Area of the section A = 8.79x10 mm

Weight of the section W1 = 6.97 kg/m (or) 0.068 kN/m

3 3
Plastic Modulus W pl = 18.30x10 mm

Design dead load of the Ø48.3x4.0mm thk. CHS at point A = 0.05x(3.0/2+3.0/2)

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 = 0.15 kN

Design live load (Moving load) on Ø48.3x4.0mm thk. CHS at point A = 2.36 kN __Ref.(4)

Consider case 1 for evaluating the maximum bending moment, shear effect, tension force and compressive force.
Bending moment at point C MC = 2.36x1.65+0.15x1.0+0.09x1.0x(1.0/2)+

0.09x1.65x0.0
MC = 4.09 kNm

To find the horizontal forces at point C & E

Take bending moment at point E ME =0

0 = 2.36x2.15+0.15x1.0+0.09x1.0x(1.0/2)+
0.09x2.15x0.0-HCx0.50

0.50HC = 5.27

HC = 5.27/0.50

= 10.54 kN
Hc-HE = 2.36 kN

HE = -2.36+HC

= -2.36+10.54
HE = 8.18 kN

Consider case 2 for evaluating the maximum vertical force and shear force at connection plate.
To find the vertical force at point D VD = 2.36+0.15+1.0x0.09+(1.65+0.50)x0.09+

2x0.50x0.09
VD = 2.88 kN

Design tension force (Max.) = 8.18 kN __(7)

Design compressive force (Max.) = 10.54 kN __(8)

Design bending moment (Max.) = 4.09 kNm __(9)

Design shear effect (Max.) = 10.54 kN __(10)

Design vertical force/ shear effect at connection plate (Max.) = 2.88 kN __(11)
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Checking of ultimate limit state

a) Tension Resistance

In Eurocode 3

Clause 6.2 covers the cross-sectional resistance

Clause 6.2.3 deals with the tension resistance

NEd
≤ 1.0
Nt,Rd

EN 1993-1-1 Clause 6.2.3 Equation 6.5

Design tension force (Max.) NEd = 8.18 kN __Ref.(7)

Nt,Rd = A fy/(γM0)
2 2
Gross cross sectional area A = 8.79x10 mm
2
Nc,Rd1 = (8.79x10 x355)/1.0
3
= 312.05x10 kN (or) 312.05 kN

NEd
= 8.18/312.05
Nc,Rd

= 0.026 <1 OK

b) Compressive Resistance

In Eurocode 3

Clause 6.2 covers the cross-sectional resistance

Clause 6.2.4 deals with the compressive resistance

NEd
≤ 1.0
Nc,Rd

EN 1993-1-1 Clause 6.2.4 Equation 6.9

Design compressive force (max.) NEd = 10.54 kN __Ref.(8)

Nc,Rd = A fy/(γM0)
2 2
Gross cross sectional area A = 8.79x10 mm
2
Nc,Rd1 = (8.79x10 x355)/1.0
3
= 312.05x10 kN (or) 312.05 kN

NEd
= 10.54/312.05
Nc,Rd

= 0.034 <1 OK

c) Bending Moment Resistance

In Eurocode 3

Clause 6.2 covers the cross sectional resistance

Clause 6.2.5 deals with the cross sectional resistance for bending.

MEd
≤ 1.0
Mc,Rd

EN 1993-1-1 Clause 6.2.5 Equation 6.12

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 MEd = 4.09 kNm __Ref.(9)
Mc,Rd = W pl fy / γ M0

γ M0 = 1.0
3
Mc,Rd = 18.30x10 x355/1.0
6
= 6.50x10 Nmm (or) 6.50 kNm
MEd
= 4.09/6.50
Mc,Rd

= 0.63 <1 Ok

d) Shear Resistance

In Eurocode 3

Clause 6.2 covers the cross-sectional resistance

Clause 6.2.6 deals with the crosssectional resistance for shear.

VEd
≤ 1.0
Vpl,Rd

EN 1993-1-1 Clause 6.2.6 Equation 6.17

VEd = 10.54 kN __Ref.(10)
Vpl,Rd = (AV (fy/√3))/(γM0)
2 2
AV = 8.79x10 mm
2
Vpl,Rd = (8.79x10 x(355/√3))/1.0
3
= 180.16x10 N (or) 180.16 kN

VEd
= (10.54/180.16)
Vpl,Rd

= 0.059 <1 Ok
Since, VED / Vpl,Rd is less than 0.5, no effect on the moment resistance EN 1993-1-1 Clause 6.2.8 (2)

Section is adequate in tension, compression, bending and shear.

Checking of welds

Fw,Ed
≤ 1.0
Fw,Rd

Design weld resistance per unit length Fw,Rd = fvw,d x α

Throat thickness of the fillet weld α = 2.84 mm

(for a fillet weld with an 4mm leg length)

fvw,d = (fu/√3)/(βw gM2)
2
Nominal ultimate tensile strength of the weaker part jointed fu = fu,bp = 470 N/mm

For S355 steel, Correlation factor βw = 0.90

gM2 = 1.25

fvw,d = (470/√3)/(0.90x1.25)
2
= 241.20 N/mm
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 Fw,Rd = 241.20x2.84

= 685.01 N/mm

Checking of welds against tension force

Design tension force (Max.) NEd,1 = 8.18 kN __Ref.(7)

Weld length Lw,1 = 4x60.0+2(2x75.0+10.0)

= 560.0 mm
3
Fw,Ed,1 = 8.18x10 /560.0

= 14.61 N/mm

Fw,Ed
= 14.61/685.01
Fw,Rd

= 0.021 <1 Ok

Checking of welds against bending moment

Design bending moment (Max.) MEd = 4.09 kNm __Ref.(9)

Lever arm z = ZT,l+ZC,r

ZT,l = 60.0/2+75.0 (Triangular plate)

= 105.0 mm

ZC,r = 60.0/2+75.0 (Triangular plate)

105.0 mm

Design tensile force (Max) NEd,2 = 4.09/0.105

= 38.95 kN

Consider half of the weld length only at the tension zone

Weld length Lw,2 = 0.5x560.0

= 280.0 mm
3
Fw,Ed,2 = 38.95x10 /280.0

= 139.11 N/mm

Fw,Ed
= 139.11/685.01
Fw,Rd

= 0.20 <1 Ok

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3.6 Analysis and design of coupler bracket

Use 10.0mm thk. plate (bend to shape) & 4 Nos. M12 bolts

Design of 10.0mm thk. plate (bend to shape)

Sectional area of the bend to shape plate A = 120.0x10.0

3 2
= 1.20x10 mm

Design tension force (Max.) = 8.18 kN __Ref.(7)

Design vertical force/ shear effect at connection plate (Max.) = 2.88 kN __Ref.(11)

Design bending moment (Max.) = (8.18x0.248)/4

= 0.51 kNm __(12)

Design shear effect (Max.) due to tensile force - Case 1 = 8.18/2

= 4.09 kN __(13)

Design shear effect (Max.) due to vertical force - Case 2 = 2.88 kN __Ref.(11)

a) Bending Moment Resistance

In Eurocode 3

Clause 6.2 covers the cross sectional resistance

Clause 6.2.5 deals with the cross sectional resistance for bending.

MEd
≤ 1.0
Mc,Rd

EN 1993-1-1 Clause 6.2.5 Equation 6.12

MEd.1 = 0.51 kNm __Ref.(12)

Mc,Rd = W pl fy / γ M0

γ M0 = 1.0
2
Section modulus of the end plate Z = (120x10.0 )/6
3 3
= 2.0x10 mm

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 3
Mc,Rd = 2.0x10 x355/1.0
6
= 0.71x10 Nmm (or) 0.71 kNm
MEd
= 0.51/0.71
Mc,Rd

= 0.72 <1 Ok

b) Shear Resistance (Case - 1)

In Eurocode 3

Clause 6.2 covers the cross-sectional resistance

Clause 6.2.6 deals with the crosssectional resistance for shear.

VEd
≤ 1.0
Vpl,Rd

EN 1993-1-1 Clause 6.2.6 Equation 6.17

VEd,1 = 4.09 kN __Ref.(13)
Vpl,Rd = (AV (fy/√3))/(γM0)

Cross sectional area of the end plate AV,1 = 120.0x10.0

2 2
= 12.0x10 mm
2
Vpl,Rd = (12.0x10 x(355/√3))/1.0
3
= 245.95x10 N (or) 245.95 kN

VEd
= (4.09/245.95)
Vpl,Rd

= 0.017 <1 Ok
Since, VED / Vpl,Rd is less than 0.5, no effect on the moment resistance EN 1993-1-1 Clause 6.2.8 (2)

c) Shear Resistance (Case - 2)

In Eurocode 3

Clause 6.2 covers the cross-sectional resistance

Clause 6.2.6 deals with the crosssectional resistance for shear.

VEd
≤ 1.0
Vpl,Rd

EN 1993-1-1 Clause 6.2.6 Equation 6.17

VEd,2 = 2.88 kN __Ref.(11)
Vpl,Rd = (AV (fy/√3))/(γM0)

Cross sectional area of the end plate AV,1 = (50.0+290.0+50.0)x10.0

2 2
= 39.0x10 mm
2
Vpl,Rd = (39.0x10 x(355/√3))/1.0
3
= 799.34x10 N (or) 842.18 kN

VEd
= (2.88/799.34)
Vpl,Rd
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 = 0.003 <1 Ok
Since, VED / Vpl,Rd is less than 0.5, no effect on the moment resistance EN 1993-1-1 Clause 6.2.8 (2)

End plate is adequate in bending and shear.

Design of 4 Nos. M12 bolts

Design tension force (Max.) = 8.18 kN __Ref.(7)

Design vertical force/ shear effect at connection plate (Max.) = 2.88 kN __Ref.(11)

Tensile resistance of M12 bolts (Gr. 8.8) Ft,Rd = 48.60 kN

Shear resistance per shear plane of M12 bolts (Gr. 8.8) FV,Rd = 32.40 kN

Tensile force on each bolt Ft,Ed = 8.18/4

= 2.05 kN < 48.60 kN Ok

Shear force on each bolt FV,Ed = 2.88/4

= 0.72 kN < 32.40 kN Ok

M12 bolts are adequate in tension and shear.

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