**5022.1TA**

**[BELOW-THE-HOOK LIFTING DEVICE]{.underline}**

## Engineering Note Cover Page for MD-ENG-112

Lifting Device Numbers:

  ----------- ------------ ------------- ------------ -------- ------------
  FNAL Site                Div. Specific **160**      Asset    
  No/                      No.                        No.      

              If                         If                    If
              applicable                 applicable            applicable
  ----------- ------------ ------------- ------------ -------- ------------

ASME B30.20 Group: \[X \] Group I Structural and Mechanical Lifting
Devices

(check one) \[ \] Group II Vacuum Lifting Devices\
\[ \] Group III Magnets, Close Proximity Operated\
\[ \] Group IV Magnets, Remote Operated

+--------------------------+-------------------------------------------+
| Device Name or           | **38 Ton Lifting Fixture For the SciBooNE |
| Description              | Scibar & EC**                             |
|                          |                                           |
|                          | **Detector**                              |
+--------------------------+-------------------------------------------+

+---------+-----------------------------+------------------------------+
| Device  | \[ \] Purchased from a      |                              |
| was     | Commercial Lifting          |                              |
|         |                             |                              |
|         | Device Manufacturer. Mfg    |                              |
|         | Name                        |                              |
+---------+-----------------------------+------------------------------+
| (check  | \[ **X**\] Designed and     | **Eng. Drawing: ME -         |
| all     | Built at Fermilab           | 444427**                     |
| appl    |                             |                              |
| icable) |                             |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Designed by Fermilab  |                              |
|         | and Built by a              |                              |
|         |                             |                              |
|         | Vendor. Assy drawing number |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Provided by a User or |                              |
|         | other Laboratory            |                              |
+---------+-----------------------------+------------------------------+
|         | \[ \] Other: Describe       |                              |
+---------+-----------------------------+------------------------------+

  ------------------------ --------------------- ------ -------------------
  Engineering Note         **Edward Chi**        Date   **January 22,
  Prepared by                                           2007**

  Engineering Note         **Dave Pushka**       Date   **February 8,
  Reviewed by                                           2007**
  ------------------------ --------------------- ------ -------------------

Lifting Device Data:

  -------------------- --------------------------------------------------
  Capacity             **76,000 lbs**

  Fixture Weight       **2,740 lbs.**
  -------------------- --------------------------------------------------

Service: \[ X\] normal \[ \] heavy \[ \] severe (refer to B30.20 for
definitions)

  ------------------ ---------------- ---- ------ --------- -- ------ --- -------- -- -- --
  Duty Cycle         \_\_\_\_\_\_\_                                                      
                     8, 16 or 24 hour                                                    
                     rating                                                              
                     (applicable to                                                      
                     groups III, and                                                     
                     IV)                                                                 

  Inspections                                                                            
  Frequency                                                                              

  Rated Load Test by                       Date                Load                      
  FNAL (if                                                                               
  applicable)                                                                            

  \[ \] Check if                                                                         
  Load Test was by                                                                       
  Vendor and attach                                                                      
  the certificate                                                                        

  Satisfactory Load                                                                      
  Test Witnessed by:                                                                     

  Signature (of Load                                                                     
  Test Witness)                                                                          
  ------------------ ---------------- ---- ------ --------- -- ------ --- -------- -- -- --

Notes or Special Information:

The load test procedures and the load test also should make as part of
the note.

  --------------------------------------- ------------------------------------------------------
  ![](media/image1.png){width="0.875in"   **Fermilab**
  height="0.8194444444444444in"}          

  --------------------------------------- ------------------------------------------------------

**Particle Physics Division**

**Mechanical Department Engineering Note**

# Number: MD-ENG- 112 Date: January 22, 2007

Project Internal Reference:

Project: SciBooNE

Title: The 38 Ton Lifting Fixture for the SciBooNE Scibar & EC Detector

Author(s): Edward Chi

Reviewer(s): Dave Pushka 02/08/2007

Key Words: Beam, lifting fixture, bolt, allowable stress, weld, tensile,
shear

Abstract Summary: The 38 ton lifting fixture is specially designed for

lifting and moving the Scibar and Electron Catcher

detector of the SciBooNE experiment. The calculated

working stresses of some critical locations, the welding

sizes, the lifting pin and the connecting bolts subject to

the applying loads have been extensively studied and

discussed per the related applicable specifications and

codes.

Applicable Codes:

"Allowable Stress Design", AISC, 9^th^ edition

"Below-the-Hook Lifting Devices", ASME B30.20

#5022, ES&H Manual, FermiLab.

"Structural Welding Code-Steel", AWS D1.1-90

"Aluminum Design manual" by The Aluminum

Association, Inc. 6^th^ edition.

**[Design the lifting fixture (38 tons) for moving the SciBooNE Scibar
and EC detectors]{.underline}**

*[General]{.underline}*:

The assembled Scibar and EC detector weights about 35 tons, and it will
move from the CDF assembly hall to the SciBooNE enclosure as one piece.
All the materials used for the lifting fixture are recycled from the
existing materials for the cost savings. Though some configurations of
the fixture are awkward due to the availability of the materials,
however, we never compromise the safety and applications of the fixture.
The following calculations and analysis will approve our ultimate
principles.

*1. [Design Criteria, Assumptions]{.underline}* [*and
References*:]{.underline}

[Total design load]{.underline} P~y~ [and the loading capacity of the
fixture P~yc~:]{.underline}

The fixture is designed to lift the SciBooNE Scibar and Electron Catcher
detectors from the CDF assembly hall and move it to the SciBooNE
experimental enclosure.

Figure 1.1 is showing the data of the total weight of the detector with
the lifting fixture, it also indicates the coordinated location of the
center of the gravity.

![](media/image2.png){width="6.253472222222222in"
height="3.3895833333333334in"}

Figure 1.1, [The data of the load and the location of the center of the
gravity]{.underline}.

It found out that the total weight of the detector and fixture is
\~70,279 lbs, where the fixture weight is about 2, 733 lbs, and the
detector weight is about 67,546 lbs. We assume there is about 12% of the
additional accessorial and miscellaneous item weight, that leads to the
total applying capacity load of the lifting fixture P~yc~ = 1.12 x
67,546 lbs = 75,651 lbs → 76,000 lbs, so:

P~yc~ = 76,000 lbs = 38 tons (lifting capacity)

P~y~ = 76,000 lbs + 2,740 lbs = 78,740 lbs.

Where P~y~ = 78,740 lbs is the total load applying under the crane hook
from

the lifting pin.

[Allowable stresses]{.underline}:

All materials for the lifting fixture are: ASTM A36 ( or better, or
unless it specified):

F~u~ = 58 ksi, F~y~ = 36 ksi

F~b~ = F~y~ /3.0 = 12 ksi = F~v~ = F~p~ = F~t~

(per section 20-1.2.2.2, ASME B30.20)

All bolt materials: ASTM A325, F~u~ = 105 ksi

F~t~ = 44 ksi, P~at~ = 34.6 kips (for 1" nominal dia.)

F~v~ = 21 ksi, P~av~ = 16.5 kips (for 1" nominal dia.)

(per page 4-3, part 4, ASD 9^th^ edition)

All welding metals are E70, where F~u~ = 70 ksi

F~wv~ = 0.30 x 70 ksi = 21ksi

[References]{.underline}:

Figure 1.2 of page 4 is an isometric view of the 38 tons lifting
fixture.

From page 13, there is a listing for the reference drawings which
related to this engineering note.

![](media/image3.png){width="4.436111111111111in"
height="2.7472222222222222in"}

Figure 1.2, [The isometric view of the 38 tons lifting
fixture]{.underline}

2\. *[Find out the working stresses when the lifting force P~v~ applying
vertically]{.underline}.*

Figure 2.1 is simulating the force distribution of the bracket when
force applying

vertically through the middle lifting pin.

From figure 2.1 and the engineering drawing ME -- 444427, it is found
that:

L = 139.75"

Figure 2.1, [Force distribution diagram of the lifting fixture as it
applies vertically]{.underline}

P~y~ = 76,000 lbs.

R~1~ = R~2~ = 38,000 lbs.

\*. The distance between the lugs for the lifting pin.

So, M~max~ = (P~y~ L) / 4

= (78,740 lbs x 139.75 in) / 4

= 2,751,000 in-lbs. @ the center

Assuming R~1~ = R~2~ = P~y~/2 = 39,370 lbs.

2.1 **Calculate the working stress at several different locations**

2.1a. [The *working stress in the center of the lifting fixture (x = L/2
= 70")*]{.underline}*:*

Per figure 2.2, the sectional modulus S~xc~ and the other geometrical
properties in the center of the spreader bar of the strong axis x-x are
calculated as following:

I~xx1~ = (447 x 2) in^4^ = 894 in^4^ for two S15x42.9 I-beams

A~1~ = 12.6 in^2^ x 2 = 25.2 in^2^

y~1~ = 7.5 + 1 = 8.50 in

I~xx2~ =\[(14.50 -- 6.50) x ( 2.0^3^) /12\] in^4^ = 5.333 in^4^

A~2~ = (2.0 x (14.5 -- 6.5)) in^2^ = 16 in^2^

y~2~ = 17.0 in

I~xx3~ =\[(14.50 x 1.0^3^) /12\] in^4^ = 1.208 in^4^

A~3~ = 1.0 x 14.5 in^2^ = 14.5 in^2^

y~3~ = 0.50 in

I~xx4~ = (2 x 1.0 x 12^3^) ÷ 12) in^4^ = 288 in^4^

A~4~ = ((12.0 x 1.00 x 2) in^2^ = 24 in^2^

y~4~ = 8.50 in

I~xx5~ = (2 x 1.44 x 5.125^3^) ÷ 12) in^4^ = 32.3 in^4^

A~5~ = (5.125 x 1.44 x 2) in^2^ = 14.76 in^2^

y~5~ = 10.50 in

Since y = ∑A~i~y~i~ ÷ ∑A~i~

= ((25.2 x 8.5 + 16 x 17.0 + 14.50 x 0.5 + 24 x 8.50 --14.76 x 10.5) /
64.94) in

= (542.47 / 64.94) = 8.353 in

![](media/image4.png){width="5.0in" height="4.753472222222222in"}

Figure 2.2, [The cross section view of the lifting fixture in the center
locatio]{.underline}

∆d~1~ = 0.147 in, ∆d~1~^2^ = 0.0216 in^2^

∆d~1~^2^ A~1~= 0.544 in^4^

∆d~2~ = 8.647 in, ∆d~2~^2^ = 74.77 in^2^

∆d~2~^2^ A~2~= 1,196 in^4^

∆d~3~ = 7.853 in, ∆d~3~^2^ = 61.67 in^2^

∆d~3~^2^ A~3~= 894 in^4^

∆d~4~ = 0.147 in, ∆d~2~^2^ = 0.0216 in^2^

∆d~2~^2^ A~2~= 0.518 in^4^

∆d~5~ = 2.147 in, ∆d~2~^2^ = 4.6096 in^2^

∆d~2~^2^ A~2~= 68 in^4^

Also:

∑I~i~ = I~xx1~ + I~xx2~ + I~xx3~ + I~xx4~ - I~xx5~

= (894 + 5.33 + 1.208 + 288 -- 32.3) in^4^

= 1,156 in^4^

∑∆d~i~^2^ A~i~ = (0.544 + 1,196 + 894 + 0.518 - 68) in^4^

= 2,023 in^4^

I~total~ =∑I~i~ +∑∆d~i~^2^ A~i~

= 3,179 in^4^

S~xc1~ = I~total~ ÷ 8.353 in = 380 in^3^

S~xc2~ = I~total~ ÷ (18- 8.353) in = 329 in^3^

The max. calculated bending stress f~b~:

f~bc~ = M~max~ / S~xc1~ → compressive bending stress

= 2,751,000 lbs-in ÷ 380 in^3^

= **[7.239 ksi]{.underline}** \< F~b~ = 12 ksi,

f~bc~ = M~max~ / S~xc1~ → tensional bending stress

= 2,751,000 lbs-in ÷ 329 in^3^

= **[8.362 ksi]{.underline}** \< F~b~ = 12 ksi,

The calculated shear stress f~v~:

f~v~ = F~y~ / A~total~ = 78,740 lbs / 64.94 in^2^ = **[1.213
ksi]{.underline}** \< F~v~ = 12 ksi

2.2a. [The *working stress at the location where x=19.94" away from the
end of the lifting *]{.underline}

*[fixture (x =19.94")]{.underline}:*

Per figure 2.3, as it indicating, there is no top connecting plate.
However, an 8"x4"x1/4" rectangular tube locates in the middle. The
sectional modulus S~xc~ and the other geometrical properties at the
location of x = 19.94" of the lifting fixture with respect the strong
axis x-x are calculated as following:

![](media/image5.png){width="2.9034722222222222in"
height="3.2291666666666665in"}

Figure 2.3, [The cross section view of the lifting fixture at the x =
19.94" location]{.underline}

I~xx1~ = (447 x 2) in^4^ = 894 in^4^ for two S15 x 42.9 I-beams

A~1~ = 12.6 in^2^ x 2 = 25.2 in^2^

y~1~ = 7.5 + 1 = 8.50 in

I~xx2~ =(14.50 x 1^3^) / 12 in^4^ = 1.2083 in^4^

A~2~ = 1.0 x 14.50 in^2^ = 14.50 in^2^

y~2~ = 0.50 in

I~xx3~ = (10.56 x (8.0^3^- 7.50^3^) ÷ 12) in^4^ = 79.31 in^4^

A~3~ = 0.25 x 10.56 x 2 in^2^ = 5.28 in^2^

y~3~ = (4.50 + 4.00) in = 8.50 in

Since y = ∑A~i~y~i~ ÷ ∑A~i~

= ((25.2 x 8.5 + 14.5 x 0.5 + 5.28 x 8.5) / 44.98 ) in

= 5.921 in

∆d~1~ = 2.579 in, ∆d~1~^2^ = 6.651 in^2^

∆d~1~^2^ A~1~= 167.605 in^4^

∆d~2~ = 5.421 in, ∆d~2~^2^ = 29.387 in^2^

∆d~2~^2^ A~2~= 426.111 in^4^

∆d~3~ = 2.579 in, ∆d~3~^2^ = 6.651 in^2^

∆d~3~^2^ A~3~= 35.117 in^4^

I~total~ =∑I~i~ +∑∆d~i~^2^ A~i~ = ((894 + 1.208 + 79.31) + (167.605 +
426.111 +35.117)) in^4^

= (974 + 628) in^4^

= 1,602 in^4^

A~total~ = A~1~ + A~2~ + A~3~ = 44.98 in^2^

S~xc~ = I~total~ ÷(16 -- 5.921) in = 158.9 in^3^

The moment @ this location when the fixture is lifted:

M~@\ x=19.94"~ = 19.94 in x 39,370 lbs = 785,038 lbs- in

The calculated bending stress f~b~:

f~b~ = M~@\ x=19.94"~ / S~xc~

= 785,038 lbs-in ÷ 158.9 in^3^

= **[4.94 ksi]{.underline}** \< F~b~ = 12 ksi,

The calculated shear stress f~v~:

f~v~ = R~i~ / A~total~ = 39,370 lbs / 44.98 in^2^ = **[0.876
ksi]{.underline}** \< F~v~ = 12 ksi

**The working stresses of the lifting fixture are satisfactory when it
is subjected 38 tons lifting force vertically.**

I don't think the deflection is an issue for this application regarding
the values of the calculated working stresses. To this end, I omit the
calculations of the fixture deflection.

3, *[The discussions of the lifting pin and the others:]{.underline}*

3.1, The size of the pin and the material:

As showing from figure 1.2, there is on lifting pin locates in the
center (axial dir. of the fixture) of the fixture. Per figures 2.1 and
2.2, it can assume the following force distribution data:

Load case: simple beam with concentrated load at the center

L = 10.0" (See figure 2.2)

P~y~ = 78,740 lbs.

R~1~ = R~2~ = 39,370 lbs.

M~max~ = (P~y~ L) / 4 (@ the center of the span L)

= (78,740 lbs x 10 in) / 4

= 196,8500 in-lbs.

Assuming use a cold finished round steel (C1018, ASTM 108) with dia. 5.0
in,

where:

F~u~ = 64 ksi, F~y~ = 54 ksi

The allowable stresses:

F~b~ = F~y~ /3.0 = 18 ksi = F~v~ = F~t~

(per section 20-1.2.2.2, ASME B30.20)

then:

I~xx~ = I~yy~ = (π d^4^) / 64 = 30.68 in^4^

S~xx~= I ÷ r = 12.272 in^3^

A~pin~ = (π d^2^) / 4 = 19.63 in^2^

f~b~ = M~max~ / S~xx~ = 196,850 in-lbs / 12.272 in^3^

= **[16.041 ksi]{.underline}** \< F~b~ = 18 ksi

f~v~ = R~i~ / A~pin~= 39,370 lbs / 19.63 in^2^

= **[2.006 ksi]{.underline}** \< F~v~ = 18 ksi

3.2, Bearing stresses of the pin hole area:

A~bearing~ = (1.4375 x 5.00) in^2^

= 7.1875 in^2^ → the bearing area of the hole, see fig. 2.2 for more
details

f~p~ = R~i~ / A~bearing~ = 39,370 lbs / 7.1875 in^2^

= **[5.478 ksi]{.underline}** \< F~p~ = 12 ksi

The design of the pin and the pin hole area are satisfactory.

4\. *[The connecting bolt and the welds of the lifting
fixture:]{.underline}*

4.1, The connecting bolts:

The lifting fixture is designed to use 8 bolts (4 bolts at each end of
the fixture) to connect with the Scibar & EC detector or other
connecting partner (see figures 1.1 & 1.2)

The spec. of the bolt: ASTM A325, 1"- 8 UNC, 31/2" length

F~t~ = 44 ksi (allowable tensile stress)

P~t~ = 34.6 kip (allowable tensional load for nominal 1" dia. bolt)

(per page 4-3, part 4, ASD 9^th^ edition)

Total allowable tensional load for eight 1" dia. A325 bolts:

8 x 34.6 kip = 276.8 kip \> 78.74 kip.

The computed pull out force P~out~ from the base metal:

Per eq. 5.3.2.1-1, section 5.3.2.1, part I-A of "Aluminum Design Manual"
6^th^ edition,

P~out~ = 0.85 t~b~ D F~tb~

= 0.85 x 1.25 in x 1.00 in x 58 ksi

= 61.62 kip (per bolt bearing area) \> 78.74 kip/8 = 9.85 kip

Where: t~b~ the thread bearing length on base metal (see drawing ME -
435903)

D.the nominal dia. of the bolt

F~tb~. The tensile strength of the base metal (see drawing ME - 435903)

So the bolt selection is satisfactory subject to the applying loads.

4.2, The welding calculations:

*The welds at the end bottom bearing plate area with subject to the
lifting force*:

Per figure 1.1, figure 1.2 and drawing of ME -- 444427, it is found that
all the welds do not subject any significant moments along the major
axis. However, we still present some welding calculations to make sure
that all welding sizes are satisfactory.

![](media/image6.png){width="2.323611111111111in"
height="2.4583333333333335in"}![](media/image7.png){width="2.134027777777778in"
height="2.5in"}

Figure 4.1, [The welds at the bottom bearing plate of the lifting
fixture]{.underline}

Figure 4.1 is the welding configuration for the bottom bearing plate
(omitting the gussets conservatively). Treating the welds as a line,
then:

L = (5.5 x 4 + 8.5 x 2 + (8.5 -1.5) x 2) = 53 in \*

R~1~ = R~2~ = 39,370 lbs.

f~v~ = R~1~ / L = 39,370 lbs / 53 in

= 743 lbs/in

\*: Where 1.50" is the free of weld zone for the bolt washer access.

C = working load per unit length ÷ (effective factor × allowable stress)

= (743 lbs/in) ÷ (0.707 x 21 ksi) (See page 4 for F~v~ value)

= 0.05 in \< 0.375 in (designated weld size in the area)

Where: C is the size of the weld.

*The welds subject to the minor axis (assuming the z axis of the lifting
fixture) moment:*

When the lifting fixture is lifting through the bottom bearing plate, we
have discussed the primary and secondary stresses subject the major axis
moment in section 2 of page 5 to page 9. Here are the discussions of the
welds subject to the minor axis moment:

Per drawing of ME -- 444427, there is an 8"x4"x1/4" tube to connect two
beams together at each end of the fixture. Let's conservatively assume
that the tube will take all the loads and moment at this location as
showing from figure 4.2. By referring to figure 2.1, it is found that:

L = 21.25 in,

R~1~ = R~2~ = 39,370 lbs/2 = 19,685 lbs.

The moment @ x = 5.34" (where the tube welds to the beam)

M~x=5.34~ = 19,685 lbs x 5.34 in

= 105,118 lbs-in

![](media/image8.png){width="4.183333333333334in"
height="3.1368055555555556in"}

Figure 4.2, [The end connecting tube and the welds of the lifting
fixture]{.underline}.

Per figure 4.2, treating the welds as a line, it is found that:

( per page 276, table 5.16.1, part 5, "Steel Structures" by C. Salmon &
J.

Johnson, 3^rd^ edition)

d = 8.0 inch, b = 4.0 inch

L~w~ = 2 ( 6+3) = 18 in length of the welds

I~xx~ = d^2^ (3b + d)/ 6

= 213.33 in^3^

S~xx~ = d (3b+d) / 3

= 53.33 in^2^

f~v~ = R~1~ / L~w~ = 19,685 lbs / 18 in

= 1,094 lbs/in

f~b~ = M~x=5.34~ / I~xx~ = 105,118 lbs-in / 53.33 in^2^

= 1,971 lbs/in

f~r~ = ( f~b~^2^ + f~v~^2^ )^½^ = (1,094^2^ + 1,971^2^ )^½^

= 2,255 lbs/in

C = combined working load per unit length÷ (effective factor × allowable

stress)

= (2,255 lbs/in) ÷ (0.707 x 21 ksi)

= 0.152 in \< 0.187 in (designated weld size in the area)

Where: C is the size of the weld

**The designated weld sizes are satisfactory**.

***[Conclusions]{.underline}:***

The lifting fixture has been designed per the related engineering codes
after the calculations and discussions from several the most critical
areas, such discussions were

approached by computing the working structural stresses, bolt stresses
and weld sizes in

terms of the different applications.

***[Reference drawings related to this engineering note]{.underline}***:

3954.330- ME -- 444427

MC -- 444423

MC -- 444425

MC -- 444426

MC -- 444449

MC -- 444439

ME -- 444071 -1

ME -- 435903 -1