APPENDIX B

Design Example

Lifting Lug
Design a lifting lug for design load of 50 ton.
Select Crosby G209 / G2130 or Green Pin G4163 shackle, which has a working load limit of 110 kip.
Design condition
Working Load Limit WLL := 55.0 ⋅ ton WLL = 110.0 ⋅ kip
Service class Class := 0
Design Category Catg := "B"
Nominal design factor Nd := 3 for Category B lugs - Cl. 3-1.3 of ASME BTH-1 2008 (N d = 2 for Category A)

Angle from vertical in plane of lug plate θin_plane := 30 ⋅ deg

Angle from vertical out of plane of lug plate θout_plane := 10 ⋅ deg (Side load condition)

The WLL for side load condition is modified per following table
(See Cl. 26-1.9.4 (g) & Fig. 4 of ASME BTH-1 2008)
WLLm := WLL if 0 ⋅ deg ≤ θout_plane ≤ 5 ⋅ deg Load angle % WLL reduction
0 - 5 deg None
 θout_plane − 5 ⋅ deg 
WLL ⋅  1 − 30% ⋅  if 5 ⋅ deg < θout_plane ≤ 45 ⋅ deg 6 - 45 deg 30%
 40 ⋅ deg 
46 - 90 deg 50%
 θout_plane − 45 ⋅ deg 
WLL ⋅  1 − 50% ⋅  if 45 ⋅ deg < θout_plane ≤ 90⋅ deg
 45 ⋅ deg 
"error" otherwise

WLLm = 105.88 ⋅ kip

Shackle Data
For Crosby G209 / G2130 or Green Pin G4163 shackle
Diameter of Pin Dp := 2.750 ⋅ in Shackle Grip Grip := 4.125 ⋅ in

Dia of shackle eye
Minimum grip clearance
(between shackle & lugplate)
Deye := 5.750 ⋅ in Clear length in-side shackle ClearV := 10.250 ⋅ in
(Pin to bow clearance)
1 Minimum sling rope to lug 1
Gripclr := in Ropeclr := ⋅ in
4 plate clearance 2

 1 WLL 1  5
Sling Rope dia (Approx) Ropedia := Round  ⋅ ⋅ in , ⋅ in = 2 ⋅ in
 8 ton 8  8

Pin Material used Fy_pin := 36 ⋅ ksi Fu_pin := 58 ⋅ ksi Epin := 29000 ⋅ ksi

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3DG-C15-00014-000, Appendix B Page 1 of 6
Appendix B (contd..)

Lug Data
Plate Material used ASTM A36 Fy_pl := 36 ⋅ ksi Fu_pl := 58 ⋅ ksi Epl := 29000 ⋅ ksi

Lug Plate thickness t pl := 2.0 ⋅ in Doubler plate (donuts) thickness t pl_dbl := 0.5 ⋅ in

6
Doubler plate to lug plate weld welddbl := ⋅ in
16
Pin hole diameter Dh := 3.0 ⋅ in

Dimension "a", pin-hole to lug a := 5.25 ⋅ in Dimension "b_e", pin-hole to lug plate be := 5.25 ⋅ in
plate edge in direction of load edge transverse to direction of load

 1 
Dia of doubler plate Dpl_dbl := Round  3.0 ⋅ Dh , ⋅ in = 9 ⋅ in
 4 
Base Plate Data
3
Base Plate thickness t pl_base := 2.25 ⋅ in Base plate to lug plate weld weldbase := ⋅ in ( assumed)
4

Geometry checks
Plate width W lug := Dh + 2 ⋅ be = 13.500 ⋅ in Plate width at base W lug.base := 18.00 ⋅ in

Ratio of pin-hole dia. Dh OK. This ratio should be less than 1.10 preferably.
= 1.091
in lug pate to pin dia Dp See Cl. 3-3.3.5 ASME BTH-1 (commentary on pin to hole clearance).

Dimension "a"

if  a >
2
⋅ Dh , "OK" , "Increase dimension a"  = "OK"

 3 

Dimension "be"

if  be >
1
⋅ Dh , "OK" , "Increase dimension b_e"  = "OK"

 2 
Grip "Increase plate thickness" if (tpl + 2 ⋅ tpl_dbl) < 0.75 ⋅ Grip = "Increase plate thickness"
"Reduce plate thickness" if t pl + 2 ⋅ t pl_dbl > ( Grip − Gripclr )

"Grip is OK" otherwise

Vertical Clearance
in bow
(
"OK" if a ≤ ClearV − Ropedia + Ropeclr ) = "OK"

"not enough clearance for rope" otherwise

Horizontal Clearance
in bow
(
"OK" if be ≤ ClearV − Ropedia + Ropeclr ) = "OK"

"not enough clearance for rope" otherwise

Height of lug plate to Pin-hole centre from plate attachment hhole := 5.00 ⋅ in

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3DG-C15-00014-000, Appendix B Page 2 of 6

Appendix B (contd..)

Clearance of eye from attachment ( 1/2" clearance + weld size 1/2")

1 1 Deye  Dh − Dp 
"OK" if hhole >  ⋅ in + ⋅ in + +   = "OK"
2 2 2  2 
"not enough clearance for eye" otherwise

Clearance of 1/4 inch beyond weld (Lug plate to washer plate weld)

 3.0 ⋅ Dh 
 >  ⋅ in + welddbl
1
"OK" if a − = "OK"
 2  4 
"not enough clearance for lug plate to washer plate weld" otherwise

Static Strength of Lug plate in Pinned connection Cl. 3-3.3.1 of ASTM BTH-1 2008
Allowable tensile strength of lug plate through the pin-hole : tensile strength of the effective area on a plane through the
centre of pinhole perpendicular to the line of action of the applied load
Strength reduction factor for 2
 Dp 
Cr := 1 − 0.275 ⋅ 1 − 
dia of pin-hole larger than
= 0.89 Eqn. 3-46 of ASTM BTH-1 2008
required for snug tight conditon  Dh 

Effective width to each side of  Fu_pl Dh  Eqn. 3-47 & 3-48 of

pinhole "b_eff" (for local stress beff := min be , 4 ⋅ t pl , 0.6 ⋅ ⋅ ⋅ be = 3.84 ⋅ in
 Fy_pl be  ASME BTH-1 2008
check per ASME BTH-1)  
Fu_pl
Allowable tensile strength Pt := Cr ⋅ ⋅ 2 ⋅ t pl ⋅ beff = 220.06 ⋅ kip
1.20 ⋅ Nd Eqn. 3-45 of ASTM BTH-1 2008
through the pin-hole
Allowable single plane fracture strength of lug plate beyond the pin-hole : fracture strength beyond the pinhole on a
single plane parallel to the line of action of the applied load
Minimum distance from centre
of pin hole to the edge of plate
Redge := (0.5 ⋅ Dp + a) if θin_plane ≥ 45⋅ deg = 6.625 ⋅ in

in the direction of applied load (0.5 ⋅ Dp + be) otherwise

Note that for a lug used in upending operation, the line of applied load varies from 0 to 90 degrees.

Fu_pl   Dh  0.92 ⋅ be

Allowable single plane fracture Pb := Cr ⋅ ⋅ 1.13 ⋅  Redge − +  ⋅ t = 216.47 ⋅ kip
strength beyond the pin-hole 1.20 ⋅ Nd   2  be  pl
 1+
Dh 
Eqn. 3-49 of ASTM BTH-1 2008  
Allowable double plane shear strength of lug plate beyond the pin-hole : double plane shear strength beyond the
pinhole parallel to the line of action of the applied load
Radius of curved edge (circular) redge := Redge = 6.625 ⋅ in

Half of the angle of contact Dp

ϕ := 55 ⋅ ⋅ deg = 50.42 ⋅ deg Eqn. 3-52 of ASTM BTH-1 2008
between pin and lug plate ϕ Dh

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3DG-C15-00014-000, Appendix B Page 3 of 6

Appendix B (contd..)

2
Loss of length of shear plane  Dp 2 
Z := redge − redge −  ⋅ sin ( ϕ)  = 0.085 ⋅ in Eqn. C3-2 of ASTM BTH-1 2008
for curved edge (circular)  2 

Total area of two shear  Dp  2 Eqn. 3-51 of ASTM BTH-1 2008

Av := 2 ⋅ a + ⋅ ( 1 − cos ( ϕ) ) − Z ⋅ t pl = 22.65 ⋅ in
planes beyond the pin hole  2  modified for curved edge

Allowable double plane shear 0.70 ⋅ Fu_pl

Pv := ⋅ Av = 255.49 ⋅ kip Eqn. 3-50 of ASTM BTH-1 2008
strength beyond the pin-hole 1.20 ⋅ Nd

WLL
Allowable static strength ( )
Ppin := min Pt , Pb , Pv = 216.47 ⋅ kip Interaction ratio IRpin :=
P pin
= 0.508

Bearing Stress between lug plate and pin Cl. 3-3.3.4 of ASME BTH-1 2008

Since the service class is 0, the bearing stress limitation per eqn 3-54 of ASME BTH-1 is not applied,
eventhough the pin may rotate under load for a fairly large no. of cycles

(
1.25 ⋅ min Fy_pl , Fy_pin ) = 15.00⋅ ksi
Allowable bearing stress Fp := Eqn 3-53 of ASME BTH-1
Nd

(
Projected area of the pin Apin_proj := Dp ⋅ t pl + 2 ⋅ t pl_dbl = 8.25 ⋅ in ) 2

WLL fp
Bearing stress f p := = 13.33 ⋅ ksi Interaction ratio IRbrg := = 0.889
Apin_proj Fp

Combined Axial and Bending Stresses on lug plate due to in plane and out of plane forces
Allowable bending stress, minor axis bending Cl. 3-2.3.4 of ASME BTH-1 2008
1.25 ⋅ Fy_pl
Fby := = 15.00 ⋅ ksi Eqn. 3-25 of ASME BTH-1 2008
Nd

Allowable bending stress, major axis bending Cl. 3-2.3.3 of ASME BTH-1 2008
Effective bending length Lb := 2.2 ⋅ hhole = 11.000 ⋅ in Cantilever assumed

Cb := 1.0 Conservative Eqn. 3-12 of ASME BTH-1 2008

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3DG-C15-00014-000, Appendix B Page 4 of 6

Appendix B (contd..)

Fy_pl  Lb ⋅ W lug.base  0.08 ⋅ Epl

Fbx := 1.25 ⋅ if  ≤
Nd  t pl
2  Fy_pl
 
Epl ⋅ Cb  Lb ⋅ W lug.base  1.9 ⋅ Epl
1.9 ⋅ if  >
 Lb ⋅ W lug.base   2  Fy_pl
Nd ⋅   t pl
 
 t pl
2 
 
   Lb ⋅ W lug.base  Fy_pl Fy_pl Fy_pl
min Cb ⋅ 1.52 − 0.274 ⋅  ⋅ ⋅ , 1.25 ⋅  otherwise
   t pl
2  E pl  Nd Nd 
     
Fbx = 15.00 ⋅ ksi Eqn. 3-19 thru 3-24 of ASME BTH-1 2008

 Fy_pl Fu_pl 
Allowable tensile stress Ft := min  , = 12.00 ⋅ ksi Eqn. 3-1 & 3-2 of ASME BTH-1 2008
 Nd 1.20 ⋅ Nd 
Computed stresses at base of lug

(
WLLm ⋅ cos θin_plane ) = 2.55⋅ ksi
Tensile stress f t := Shear stress
W lug.base ⋅ t pl

Bending stress f bx :=
(
WLLm ⋅ sin θin_plane ⋅ hhole ) = 2.45 ⋅ ksi f v1 :=
(
WLLm ⋅ sin θin_plane ) = 1.47 ⋅ ksi
 1 ⋅t ⋅W 2 W lug.base ⋅ t pl
 pl lug.base 
6 

f by :=
(
WLLm ⋅ sin θout_plane ⋅ hhole ) = 7.66 ⋅ ksi f v2 :=
(
WLLm ⋅ sin θout_plane ) = 0.51 ⋅ ksi
 1 ⋅W 2 W lug.base ⋅ t pl
 lug.base ⋅ t pl 
6 
ft f bx f by
Interaction ratio IRcomb := + + = 0.89 Eqn. 3-35 of ASME BTH-1 2008
Ft Fbx Fby

Weld check Cl. 3-3.4 of ASME BTH-1 2008

Nominal tensile strength Exx := 70 ⋅ ksi
of weld metal,
Allowable shear stress 0.60 ⋅ Exx
Fv_weld := = 11.67 ⋅ ksi Eqn. 3-55 of ASME BTH-1 2008
in weld 1.20 ⋅ Nd

Allowable tensile stress

Ft_weld := Ft = 12.00 ⋅ ksi Cl. 3-3.4.1 (a) of ASME BTH-1 2008
in weld

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3DG-C15-00014-000, Appendix B Page 5 of 6

Appendix B (contd..)

Lug plate to Doubler plate weld (weld strength is in proportion of plate thicknesses, See commentary after
cl. 3-3.3.1 in ASME BTH-1 2008)

Weld strength required
Weld length available
 tpl_dbl 
Weld1str := ⋅ WLLm = 17.65 ⋅ kip
 tpl + 2 ⋅ tpl_dbl 
 
Weld1len := π ⋅ Dpl_dbl = 28.27 ⋅ in

Weld strength available ( )

Weld1str_act := Fv_weld ⋅ 0.707 ⋅ welddbl ⋅ Weld1len = 87.46 ⋅ kip OK

Lug plate to Base plate weld

Length of weld along lug width lw := W lug.base Length of welds along lug thickness t w := t pl

Lever arm hhole = 5.00 ⋅ in

Tensile stress in weld

(
 cos θin_plane ) ( )
sin θin_plane ⋅ hhole sin θout_plane ⋅ hhole ( 1 )
f t_weld := WLLm ⋅  + + ⋅
(
 2 ⋅ lw + t w )  lw 
2  t w 
2  0.707 ⋅ weldbase ( )
  lw ⋅ t w + 3   lw ⋅ t w + 3  
     
f t_weld = 12.43 ⋅ ksi is > Ft_weld = 12.00 ⋅ ksi Not OK. Use full penetration butt weld.

Shear stress in weld

Along lug plate length Along lug plate width

f v_long :=
(
WLLm ⋅ sin θin_plane ) f v_trans :=
(
WLLm ⋅ sin θout_plane )
( )(
2 ⋅ lw + t w ⋅ 0.707 ⋅ weldbase ) ( )(
2 ⋅ lw + t w ⋅ 0.707 ⋅ weldbase )
2 2
f v_weld := f v_long + f v_trans = 2.64 ⋅ ksi is < Fv_weld = 11.67 ⋅ ksi OK.

Hence, Use full penetration butt weld.

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3DG-C15-00014-000, Appendix B Page 6 of 6