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Lifting beams — SWL 800 kg & 1,300 kg

Complete mechanical substantiation of two welded lifting beams: shell models, materials, mesh, connections, load cases, stresses, displacements and analytical verification of assemblies.

DisciplineHandling · Industrial lifting · FEA substantiation

Documented scope6 project stages

Lifting beams — SWL 800 kg & 1,300 kg — FORGIA industrial project

01 — Project journey

From requirement to industrial reality.

A documented view of the decisive engineering, manufacturing and validation steps.

01Calculation geometries & shell models
02Mesh & refinement areas
03Contacts, connections & boundary conditions
04Load cases & self-weight
05Lifting-beam stresses & displacements
06Lifting plates & assemblies

Stage 01

Calculation geometries & shell models

Both lifting beams are simplified at their neutral surfaces and actual thicknesses are assigned to the shell elements to preserve the stiffness of plates, stiffeners and arms.

Model data101.57 kgModel mass — 800 kg lifting beam

Complete structure modelled

Model data111.23 kgModel mass — 1,300 kg lifting beam

Complete structure modelled

Model data2 configurationsCapacities analysed

SWL 800 kg and SWL 1,300 kg

Technical review points

Load cases
Boundary conditions
Mechanical response
Reviewable results

Lifting beams — SWL 800 kg & 1,300 kg — Calculation geometries & shell models — view 1

Lifting beams — SWL 800 kg & 1,300 kg — Calculation geometries & shell models — view 2

Lifting beams — SWL 800 kg & 1,300 kg — Calculation geometries & shell models — view 3

Lifting beams — SWL 800 kg & 1,300 kg — Calculation geometries & shell models — view 4

Stage 02

Mesh & refinement areas

Triangular and quadrilateral surface mesh with detailed control around end plates, central stiffeners and load-transfer areas.

Model data2.5 mmNominal mesh size

Value applied to the complete model

Model dataTri + quadElement families

Surface elements for shell models

Model dataS235 / S355Main material grades

Properties assigned part by part

Technical review points

Technical objective
Interfaces
Acceptance criteria

Lifting beams — SWL 800 kg & 1,300 kg — Mesh & refinement areas — view 1

Lifting beams — SWL 800 kg & 1,300 kg — Mesh & refinement areas — view 2

Lifting beams — SWL 800 kg & 1,300 kg — Mesh & refinement areas — view 3

Lifting beams — SWL 800 kg & 1,300 kg — Mesh & refinement areas — view 4

Stage 03

Contacts, connections & boundary conditions

Modelling of welded and bolted assemblies, rigid connections and supports to transfer loads while retaining the degrees of freedom representative of actual operation.

Model dataA · B · CReaction points

Translations and rotations defined locally

Model dataWelded + boltedInterfaces represented

Load transfer between subassemblies

Technical review points

Load cases
Boundary conditions
Mechanical response
Reviewable results

Lifting beams — SWL 800 kg & 1,300 kg — Contacts, connections & boundary conditions — view 1

Lifting beams — SWL 800 kg & 1,300 kg — Contacts, connections & boundary conditions — view 2

Stage 04

Load cases & self-weight

Each SWL is applied to the lifting-eye bearing surface together with structural self-weight to reproduce the vertical load transmitted to the lifting beam.

Model data7,848 NApplied load — SWL 800 kg

Remote vertical force

Model data12,753 NApplied load — SWL 1,300 kg

Remote vertical force

Model data9.8066 m/s²Gravitational acceleration

Self-weight included

Technical review points

Technical objective
Interfaces
Acceptance criteria

Lifting beams — SWL 800 kg & 1,300 kg — Load cases & self-weight — view 1

Lifting beams — SWL 800 kg & 1,300 kg — Load cases & self-weight — view 2

Stage 05

Lifting-beam stresses & displacements

Separate review of Von Mises fields by material grade, control of areas around the lifting interfaces and comparison of global displacements for both capacities.

Validated95.32 / 117.5 MPaS355 — 800 kg lifting beam

Calculated / allowable stress

Validated84.95 / 90 MPaS235 — 1,300 kg lifting beam

Calculated / allowable stress

Validated0.16 / 0.22 mmMaximum displacements

Lifting beams 800 / 1,300

Technical review points

Technical objective
Interfaces
Acceptance criteria

Lifting beams — SWL 800 kg & 1,300 kg — Lifting-beam stresses & displacements — view 1

Lifting beams — SWL 800 kg & 1,300 kg — Lifting-beam stresses & displacements — view 2

Lifting beams — SWL 800 kg & 1,300 kg — Lifting-beam stresses & displacements — view 3

Lifting beams — SWL 800 kg & 1,300 kg — Lifting-beam stresses & displacements — view 4

Lifting beams — SWL 800 kg & 1,300 kg — Lifting-beam stresses & displacements — view 5

Lifting beams — SWL 800 kg & 1,300 kg — Lifting-beam stresses & displacements — view 6

Stage 06

Lifting plates & assemblies

Solid submodel of the lifting plates followed by analytical verification of bolts, threads, pins and commercial components using forces extracted from the global calculation.

Validated42.38 / 90 MPaLifting plates — S235

Calculated / allowable stress

Validated192.15 / 200 MPaM12 bolts — equivalent stress

Governing case for the 1,300 kg lifting beam

Validated22.18 / 108.25 MPaØ15 pins — shear

Calculated / allowable stress

Technical review points