STANDARD LIFTING LUG DESIGN

71 TON CAPACITY

Generals Data:
Max vertical load = 71.00 Ton = 156527 lbs
Total weight, W = 71.00 Ton = 156527 lbs
Number of lug, NL = 1.0
Safety Factor, SF = 1.50
Weight, W SWL = 106.5 Ton
Angle, α = 90.0 deg = 1.57 rad
Max vertical force, Fz = W SWL = 106.50 Ton = 234790 lbs
Max horizontal force (in-plane), Fy = W SWL / tan (α) = 0.00 Ton = 0 lbs
(1)
Max lateral force (out-of-plane), Fx = 0.05 Fz = 5.33 Ton = 11739 lbs
Max tension force in sling, Fsl = (Fz2 + Fy2 + Fx2)0.5 = 106.63 Ton = 235083 lbs

Shackles Data: (Shackle Crosby G-2130 85"T WLL)

Shackle working load limit, WLLs = 85.00 Ton = 187391 lbs
Safety factor of shackle, SFs = 2.0
Shackle max. proof load, MPLs = 170.00 Ton = 374782 lbs
Pin diameter, DP = 83 mm = 3.25 in
Jaws width, W J = 127 mm = 5.00 in
Jaws height, HJ = 330 mm = 12.99 in

Sling Data: (77 T WLL) = 77

Diameter of sling, Ds = 76 mm = 3.00 in
Working Load Limit, WLLsl = 75% x 1.5P / (5 x 9.81) = 100.0 Ton = 220460 lbs
Safety factor of sling, SFsl = 2.0
Sling ultimate load, Usl = 200 Ton = 440920 lbs

FZ Fsl

R
α
FY

HT DH
Z
HH

X Y

WL
Lug Dimensions:
Total Height of lift lug, HT = 330 mm = 12.99 in
Height of hole centreline, HH = 150 mm = 5.91 in
Width of lug, W L = 360 mm = 14.17 in
Radius of lug, R = 180 mm = 7.09 in

Page 1
Diameter of hole, DH = 88 mm = 3.44 in
Thickness of lug, tL = 50 mm = 1.97 in
Radius of cheek, r = 150 mm = 5.91 in
Thickness of cheek, tC = 12 mm = 0.47 in
Check shackle strength, Fsl / MPLs = Safe Ratio = 62.73%
Check sling strength, Fsl / Usl = Safe Ratio = 53.32%
Check space of hole and pin, Dp / DH = Clear Ratio = 94.29%
Dp - DH = 5.00 mm = 0.20 in
Check space of jaws and lug thickness, tL+2tC / W J = Clear Ratio = 58.27%
(W J - tL - 2 tC)/2 = 26.50 mm = 1.04 in
Check space of jaws, lug height and dia. of sling = Clear Ratio = 75.92%
HJ - R - 1.5Ds + DH/2 = 79.45 mm = 3.13 in

Material, Stress and Properties Data:

Lug material = AH-36
Yield stress, Sy = 344.74 MPa = 50000 psi
Allowable stress based on AISC Code 9th Ed. :
Allow. Tensile Stress, Sta = 0.6 Sy = 206.84 MPa = 30000 psi
Allow. Bending Stress, Sba = 0.66 Sy = 227.53 MPa = 33000 psi
Allow. Shear Stress, Ssa = 0.4 Sy = 137.90 MPa = 20000 psi
Allow. Bearing Stress, Sbra = 0.9 Sy = 310.26 MPa = 45000 psi
DH/2R = 0.24
(2)
Stress-Concentration factor (near hole), K = 2.25
(for flat plate with centrally located circular hole in tension based on DH/2R value)
Section modulus of lugs, SLy = tL2 W L / 6 = 150.00 cm3 = 9.15 in3
Section modulus of lugs, SLx = tL W L2 / 6 = 1080.00 cm3 = 65.91 in3

Stresses at Lug:
Tension stress z-axis, Stz = Fz /(W L tL) = 58.02 MPa = 8415 psi
Bending stress z-axis, Sbz = HH(Fy/SLx+Fx/SLy) = 52.22 MPa = 7574 psi
Shear stress y-axis, Ssy = Fy / (W L tL) = 0.00 MPa = 0 psi
Shear stress x-axis, Ssx = Fx / (W L tL) = 2.90 MPa = 421 psi
Total stress, ST = Sqrt( (Stz+Sbz)2+ Ssy2+ Ssx2) = 110.28 MPa = 15995 psi
Check tension stress z-axis, Stz/Sta = Safe Ratio = 28.05%
Check bending stress z-axis, Sbz/Sba = Safe Ratio = 22.95%
Check shear stress y-axis, Ssy/Ssa = Safe Ratio = 0.00%
Check shear stress x-axis, Ssx/Ssa = Safe Ratio = 2.10%
Check total stress, ST/Sy = Safe Ratio = 31.99%
Unity Check, Stz/Sy + Sbz/Sy + Ssy/Sy + Ssx/Sy = Safe Ratio = 32.82%

Stresses near the Hole:

Tension stress, Stz = K Fz / [(W L - DH) tL] = 172.47 MPa = 25015 psi
Tension stress, Sty = K Fy / [(HH + R - DH) tL] = 0.00 MPa = 0 psi
Shear stress, Ssx = K Fx / [(W L - DH) tL] = 8.62 MPa = 1251 psi
2 2 2
Total stress, ST = Sqrt( Stz + Sty + Ssx ) = 172.68 MPa = 25046 psi
Bearing stress, Sbr = Fsl / [Dp (tL + 2tc)] = 171.29 MPa = 24843 psi
Pull-out shear, Ssp = Fsl / [tL(R - ½DH) + 2tc(r - ½DH)] = 111.69 MPa = 16199 psi
Check tension stress z-axis, Stz/Sta = Safe Ratio = 83.38%
Check tension stress y-axis, Sty/Sta = Safe Ratio = 0.00%
Check shear stress x-axis, Ssx/Ssa = Safe Ratio = 6.25%

Page 2
Check total stress, ST/Sy = Safe Ratio = 50.09%
Check bearing stress, Sbr/Sba = Safe Ratio = 55.21%
Check pull-out shear stress, Ssp/Ssa = Safe Ratio = 81.00%
Unity Check, Stz/Sy + Sty/Sy + Ssx/Sy = Safe Ratio = 52.53%

Note:
1. Lateral force is calculated based on 5% vertical force
2. Taken from Roy Craig Jr., "Mechanic of Materials", page : 619, Figure: 12.3

Page 3
 WELD CALCULATION OF LIFTING LUG
71 TON CAPACITY

General Data:
Max vertical load = 71.00 Ton = 156527 lbs
Total weight, W = 71.00 Ton = 156527 lbs
Number of lug, NL = 1.00
Safety Factor, SF = 1.50
Calculated Total Weight, W C = 106.50
Angle, α = 60 deg = 1.05 rad
Vertical force z-axis, Fz = 106.50 Ton = 234792 lbs
Horizontal force y-axis, Fy = 0.00 Ton = 0 lbs
Lateral force x-axis, Fx = 5.33 Ton = 11740 lbs
Sling force, Fsl = 106.63 Ton = 235085 lbs

FZ Fsl

R
α
FY

DH
HT
Z
HH

X Y

WL

Lug Dimensions:
Width of lug, W L = 360 mm = 14.17 in
Thickness of lug, tL = 50 mm = 1.97 in

Weld length (assume only top and bottom side welded -conservative method)
Weld length around on lug, Aw = 2W L + 2tL = 820 mm = 32.28 in
Length of weld around on each cheek, Ac = 2πr = 942 mm = 37.11 in
Fillet weld dimension on lug, w = 30 mm = 1.18 in
Fillet weld dimension on cheek, wc = 10 mm = 0.39 in
Allowable weld stress, Sw = 66.19 MPa = 9600 psi

Load on fillet weld per linear inch of weld:

Tension stress of weld, St = Fz / Aw = 1273.67 N/mm = 7273 lbs/in
Shear stress of weld, Ss = Fy / Aw = 0.00 N/mm = 0 lbs/in
Lateral stress of weld, Sl = Fx / Aw = 63.68 N/mm = 364 lbs/in
Cheek plate stress of weld, Scp = Fsl tc / [Ac (tL + 2tc)] = 179.92 N/mm = 1027 lbs/in

Load on weld:
Tension stress of weld, ft = St / (0.707w) = 60.05 MPa = 8710 psi
Shear stress of weld, fs = Ss / (0.707w) = 0.00 MPa = 0 psi
Lateral stress of weld, fl = Sl / (0.707w) = 3.00 MPa = 435 psi
Total stress of weld, fT = Sqrt( ft2 + fs2 + fl2 ) = 60.13 MPa = 8720 psi
Each cheek pl. stress of weld, fc = Scp / (0.707wc) = 25.45 MPa = 3691 psi

Page 4
Check tension stress, ft/Sw = OK Ratio = 90.72%
Check shear stress, fs/Sw = OK Ratio = 0.00%
Check lateral stress, fl/Sw = OK Ratio = 4.54%
Check total stress, fT/Sw = OK Ratio = 90.84%
Unity Check, ft/Sw + fs/Sw +fl/Sw = OK Ratio = 95.26%
Check cheek plate stress = OK Ratio = 38.45%

Book Reference : Eugene F.Megyesy, "Pressure Vessel Handbook-Eleventh Edition", page : 459.

Page 5