Analysing The Possibility of an 8m Guide Rail

Until material properties have been researched, mild steel will be used as a basis for simple design calculations.

Density of Mild Steel: 7800 kg/m3

If the maximum weight is to be 30kg per section, then the volume available for the beam is:
V = m / ρ = 30 / 7800 = 3.85e-3 m3

If the length of the beam is 8m, that gives an available cross sectional area of:
3.85e-3 / 8 = 4.8e-4 m2 ( = 480mm2)

This is equivalent to 22 x 22mm square. Clearly this is inadequate to support a 1000kg load.

If the guide rail is constructed of 2 sections each 4m long, then the available cross-sectional area will be:
(30 / 7800) / 4 = 961.5mm2

Which would give us a 31 x 31mm solid square cross section of mild steel. Again, this suggests that it may not be possible to construct such a beam that will support a 1000kg load. However, until further calculations have taken place, the possibility of joining separate sections will be considered an issue that is to be addressed.

If two separate sections are used to construct the guide rail, we have to ensure that the join will be able to withstand the stresses and bending moments.

A possible solution to joining the sections could be to use two smaller I-beams that have smaller cross-sectional area. These would slot between the flanges of the guide rail.


In order to decrease the weight without sacrificing the properties of the I-beam, we can remove diamond cut-outs from the vertical face.


This also provides us with a mechanism for attaching the smaller joining I-beams to the guide rail via the use of a couple of pins.


As yet, the dimensions for the I-beam are yet to be decided until stress analysis takes place. However, from the properties from the second moment of area of an I-beam, we know that if the forces are assumed to be vertical then we can design the I-beam to be as narrow as possible, focusing the length in the vertical plane.