STANDARD LIFTING LUG DESIGN

5 TONS CAPACITY

Generals Data:
Number of lug, NL = 1.0
Safety Factor, SF = 2.00
Pad Eye Load / Weight, WSWL = 5 Ton
Angle, α of Load with Vertical = 60.0 deg = 1.05 rad Table 1. API RP 2A WSD Sec.2.4.2.c
Out of Plane Angle Ø = 5.0 deg = 0.09 rad LIFT TYPE DLF
Dynamic Load Factor DLF (Table 1) = 2.0 Lift as Open Sea 2.0

Design Load Lift at Sheltered Locations 1.5

Load in vertical force, Pz = WSWL COS α = 2.50 Ton = 5512 lbs
Load in horizontal force (in-plane), Py = WSWL sinα.cosØ = 4.31 Ton = 9510 lbs
Load in lateral force (out-of-plane), Px = WSWL sinα.sinØ = 0.38 Ton = 832 lbs
Max tension force in sling, Fsl = (Fz2 + Fy2 + Fx2)0.5 = 5.00 Ton = 11023 lbs
Pad Eye Design Load Pd = P x DLF = 10 Ton = 22046 lbs
Design Load in Vertical Direction, PzD = Pz x DLF = 5 Ton = 11023 lbs
Design Load in horizontal force (in-plane), PyD = Pz x DLF = 9 Ton = 19020 lbs
Design Load in lateral force (out-of-plane), P xD = Pz x DLF+ 5% Pd = 1 Ton = 2766 lbs

Shackles Data: (Shackle Crosby G-2130 7/8"" 6 1/2 T WLL)

Check R > 1.25 DH = OK
Shackle working load limit, WLLs = 6.50 Ton = 14330 lbs
Safety factor of shackle, SFs = 2.0
Shackle max. proof load, MPLs = 13.00 Ton = 28660 lbs
Pin diameter, DP = 25 mm = 1.00 in
Jaws width, WJ = 37 mm = 1.44 in
Jaws height, HJ = 84 mm = 3.31 in

Sling Data: (5T WLL)

Diameter of sling, Ds = 16 mm = 0.63 in
Minimum Breaking Force, P = 1490 N = lbs
Working Load Limit, WLLsl = 75% x 1.5P / (5 x 9.81) = 34.2 Ton = 75341 lbs
P
Safety factor of sling, SFsl = 4.0
Sling ultimate load, Usl = 137 Ton = 301363 lbs

PZ

α R
PY
Ø

HT DH
Z
HH PX

Y
X

WL
Lug Dimensions:
Total Height of lift lug, HT = 155 mm = 6.10 in
Height of hole centreline, HH = 80 mm = 3.15 in
Width of lug, WL = 150 mm = 5.91 in
Radius of lug, R = 75 mm = 2.95 in
Diameter of hole, DH = 35 mm = 1.38 in
Thickness of lug, tL = 15 mm = 0.59 in
Radius of cheek, r = 0 mm = 0.00 in
Thickness of cheek, tC = 0 mm = 0.00 in
Check shackle strength, Fsl / MPLs = Safe Ratio = 38.46%
Check sling strength, Fsl / Usl = Safe Ratio = 3.66%
Check space of hole and pin, Dp / DH = Clear Ratio = 72.57%
Dp - DH = 9.60 mm = 0.38 in
Check space of jaws and lug thickness, tL+2tC / WJ = Clear Ratio = 40.98%
(WJ - tL - 2 tC)/2 = 10.80 mm = 0.43 in
Check space of jaws, lug height and dia. of sling = Clear Ratio = 97.02%
HJ - R - 1.5Ds + DH/2 = 2.50 mm = 0.10 in

Material, Stress and Properties Data:

Lug material = A-36
Yield stress, Sy = 248.21 MPa = 36000 psi
Allowable stress based on AISC Code 9th Ed. :
Allow. Tensile Stress, Sta = 0.6 Sy = 148.93 MPa = 21600 psi
Allow. Tensile Stress at pin hole, Stp = 0.45 Sy = 111.70 MPa = 16200 psi
Allow. Bending Stress, Sba = 0.66 Sy (In-Plane) = 163.82 MPa = 23760 psi
Allow. Bending Stress, Sbao = 0.66 Sy (out of-plane) = 163.82 MPa = 23760 psi
Allow. Shear Stress, Ssa = 0.4 Sy = 99.28 MPa = 14400 psi
Allow. Bearing Stress, Sbra = 0.9 Sy = 223.39 MPa = 32400 psi
Allow. Von Misses Stress, Sx = 0.75 Sy = 186.16 MPa = 27000 psi
Allow. Hertz Stress,(at Pin Hole) SH = 2.5 Sy = 620.53 MPa = 90000 psi

DH/2R = 0.23

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Stress-Concentration factor (near hole), K (2) = 2.50
(for flat plate with centrally located circular hole in tension based on DH/2R value)
Section modulus of lugs, SLy = tL2 WL / 6 = 5.63 cm3 = 0.34 in3
Section modulus of lugs, SLx = tL WL2 / 6 = 56.25 cm3 = 3.43 in3

Stresses at Lug:
Tension stress z-axis, Stz = Fz /(WL tL) = 10.90 MPa = 1580 psi
Bending stress z-axis, Sbz = HH(Fy/SLx+Fx/SLy) = 112.80 MPa = 16360 psi
Shear stress y-axis, Ssy = Fy / (WL tL) = 18.80 MPa = 2727 psi
Shear stress x-axis, Ssx = Fx / (WL tL) = 1.64 MPa = 239 psi
Total stress, ST = Sqrt( (Stz+Sbz)2+ Ssy2+ Ssx2) = 125.13 MPa = 18148 psi
Check tension stress z-axis, Stz/Sta = Safe Ratio = 7.32%
Check bending stress z-axis, Sbz/Sba = Safe Ratio = 68.86%
Check shear stress y-axis, Ssy/Ssa = Safe Ratio = 18.94%
Check shear stress x-axis, Ssx/Ssa = Safe Ratio = 1.66%
Check total stress, ST/Sy = Safe Ratio = 50.41%
Unity Check, Stz/Sy + Sbz/Sy + Ssy/Sy + Ssx/Sy = Safe Ratio = 58.07%

Stresses near the Hole:

Tension stress, Stz = K Fz / [(WL - DH) tL] = 35.53 MPa = 5153 psi
Tension stress, Sty = K Fy / [(HH + R - DH) tL] = 58.75 MPa = 8521 psi
Shear stress, Ssx = K Fx / [(WL - DH) tL] = 5.36 MPa = 778 psi
Total stress, ST = Sqrt( Stz2+ Sty2+ Ssx2) = 68.87 MPa = 9989 psi
Bearing stress, Sbr = Fsl / [Dp (tL + 2tc)] = 128.69 MPa = 18666 psi
Pull-out shear, Ssp = Fsl / [tL(R - ½DH) + 2tc(r - ½DH)] = 56.85 MPa = 8245 psi
Check tension stress z-axis, Stz/Sta = Safe Ratio = 23.86%
Check tension stress y-axis, Sty/Sta = Safe Ratio = 39.45%
Check shear stress x-axis, Ssx/Ssa = Safe Ratio = 5.40%
Check total stress, ST/Sy = Safe Ratio = 27.75%
Check bearing stress, Sbr/Sba = Safe Ratio = 57.61%
Check pull-out shear stress, Ssp/Ssa = Safe Ratio = 57.26%
Unity Check, Stz/Sy + Sty/Sy + Ssx/Sy = Safe Ratio = 40.15%

Hertz/Contact Stress Check at Pin Hole

Pad Eye Design Load Pd = 10 Ton
Design Load per Unit Length P = 0.6666667 Ton/ mm
Modulus of Elasticity E = 200000 Mpa
Poisson Ratio v = 0.3
Diameter of Pin Hole DH = 35 mm
Diameter of Pin Dp = 25 mm
Hertz Stress at Pin Hole SH act=[P x E x ( DH - Dp)/(¶ x (1- v2) x DH-Dp)^0.5 = 22.45 Mpa
Allowable Hertz Stress SH = 620.53 Mpa
Hertz Stress SH check = Safe Ratio = 3.6%

Von Mises Stress Check as Lug

Von Mises Stress Check as Lug (Actual) ((Stz+Sbz+Ssy)^2+3(Ssx^2+Ssy^2))^0.5 = 146.20
Von Mises Stress Check as Lug (Allowed) = 186.16
Von Mises Stress Check as Lug Check = Safe Ratio = 78.5%

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

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 WELD CALCULATION OF LIFT LUG
5 TON CAPACITY

General Data:
Number of lug, NL = 1.00
Safety Factor, SF = 2.00
Calculated Total Weight, WC = 5.00
Angle, α = 60 deg = 1.05 rad
Vertical force z-axis, Fz = 2.50 Ton = 5512 lbs
Horizontal force y-axis, Fy = 4.31 Ton = 9510 lbs
Lateral force x-axis, Fx = 0.38 Ton = 832 lbs
Sling force, Fsl = 5.00 Ton = 11023 lbs

FZ Fsl

R
α
FY

DH
HT
Z HH

X Y

WL

Weld length (assume only top and bottom side welded -conservative method)
Weld length around on lug, Aw = 2WL + 2tL = 330 mm = 12.99 in
Length of weld around on each cheek, A c = 2πr = 0 mm = 0.00 in
Fillet weld dimension on lug, w = 10 mm = 0.39 in
Fillet weld dimension on cheek, wc = 0 mm = 0.00 in
Allowable weld stress, S w = 66.19 MPa = 9600 psi

Load on fillet weld per linear inch of weld:

Tension stress of weld, S t = Fz / Aw = 74.29 N/mm = 424 lbs/in
Shear stress of weld, Ss = Fy / Aw = 128.19 N/mm = 732 lbs/in
Lateral stress of weld, Sl = Fx / Aw = 11.22 N/mm = 64 lbs/in
Cheek plate stress of weld, Scp = Fsl tc / [Ac (tL + 2tc)] = 0.00 N/mm = 0 lbs/in

Load on weld:
Tension stress of weld, ft = St / (0.707w) = 10.51 MPa = 1524 psi
Shear stress of weld, fs = Ss / (0.707w) = 18.13 MPa = 2630 psi
Lateral stress of weld, fl = Sl / (0.707w) = 1.59 MPa = 230 psi
Total stress of weld, fT = Sqrt( ft2 + fs2 + fl2 ) = 21.02 MPa = 3048 psi
Each cheek pl. stress of weld, fc = Scp / (0.707wc) = 0.00 MPa = 0 psi

Check tension stress, ft/Sw = OK Ratio = 15.88%

Check shear stress, fs/Sw = OK Ratio = 27.39%
Check lateral stress, fl/Sw = OK Ratio = 2.40%
Check total stress, fT/Sw = OK Ratio = 31.75%
Unity Check, ft/Sw + fs/Sw +fl/Sw = OK Ratio = 45.67%
Check cheek plate stress = OK Ratio = 0.00%

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

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