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STANDARD LIFTING LUG DESIGN

20 TONS CAPACITY

Generals:
total weight (Empty Skid + lifted equipment) = 20000 kgs = 44,092 lbs
number of lifting points = 1
Safety Factor, FS = 2.0
Min. sling angle, q = 60 degrees
Max. load per lifting lug = 40,000 kgs = 88,184 lbs

Lug Dimensions:
Height of hole centreline, H = 120 mm = 4.72 inch
Width of Lug, W L = 300 mm = 11.81 inch
Radius of Lug, R = 150 mm = 5.91 inch
Diameter of Hole, DH = 60 mm = 2.36 inch
Thickness of Lug, tL = 28 mm = 1.10 inch

Allowable Stresses:
Lug Material A 36 Fy = 36,000 psi
Allowable Tension Stress, 0.6 x Fy = 1,519 Kg/cm2 = 21,600 psi
Allowable Shear Stress, 0.4 x Fy = 1,012 Kg/cm2 = 14,400 psi
DH/2R = 0.20
Stress-Concentration Factor (near hole), K = 2.5
(for flat plate with centrally located circular hole in tension based on DH/2R value)

Tension Stresses in the Lug:

Weight in each Lug, W = 40,000 kgs = 88,160 lbs
Cable Tension at Lug, F = 46,188 kgs = 101,798 lbs
Inertia Moment of Lug, IL = 6,300 cm4 = 151.36 in4

Stress at Lug to Beam Joint = 1,136 Kg/cm2 = 16,153 psi

ST = F.cos (q). H.(W L/2)/IL +
Safe Ratio = 74.78%
F.sin(q)/(W L.tL)

Stress at near the hole = 1,488 Kg/cm2 = 21,160 psi

ST = K .F. sin (q) / [(2.R -DH).tL] Safe Ratio = 97.96%

Shear Stresses in the Lug:

Stress at Lug to Beam Joint = 275 Kg/cm2 = 3,909 psi

SS = F.cos(q) / (tL.W L) Safe Ratio = 27.15%

Stress at near the hole = 344 Kg/cm2 = 4,887 psi

SS = F.cos(q) / [(2.R - DH).tL] Safe Ratio = 33.93%
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Stresses in Weld:
The calculation used is conservative as it only includes top fillet welds (actual stresses are lower)

Leg size of fillet weld, LW = 25.0 mm = 0.98 in

use 45 degree fillet weld
Throat size of fillet feld, tW = 17.68 mm = 0.70 in
Length of weld, Ww1 = 2.W L + 2.tL 656.0 mm = 25.83 in
Length of weld including welding in web of beam, W 1,743.4 mm = 68.64 in
W w2 = W w1 + W L + 2.Hbeam
Section Modulus of weld lines, SW = 530,330 mm3 = 32.36 in3
SW= tw.W L2/3
Efficiency of weld, n = 100%
Allowable Load on weld 675 Kg/cm2 = 9,600 psi

Tension Stress at the weld = 652 Kg/cm2 = 9,276 psi

ST=[F.cos(q).H/SW+ F.sin(q)/
Safe Ratio = 96.62%
(W w2.tw)] / n

Shear Stress at the Weld = 30.86 Kg/cm2 = 2,832 psi

ST=[ F.cos(q)/ (W w1.tw)]/ n Safe Ratio = 29.50%