CONSTRUCTION OF STEEL GIRDERS- PRACTICAL CONSIDERATIONS IN

DESIGN OF WEB-FLANGE CONNECTION

By Ravindra Kumar Goel

IRSE-88
Director/B&S, RDSO, Lucknow

ABSTRACT

Indian Railways is in the process of adopting welded connections for the

design of Railway Bridges. The design of connection is to be done with respect
of the fatigue strength for a specified number of cycles of maximum and
minimum stress, to which the bridge component is subjected. The economy of
the design depends not only upon the type of weld and welding methodology
adopted but also the ease with which the fabrication can be done. The practical
difficulties associated with the fabrication of girders with welded connections are
to be visualized by the designer so as give an economical design. The paper
briefly describes the considerations involved in the design of web & flange
connection for a railway plate girder bridge.

1.0 INTRODUCTION

Double sided filet welds have been conventionally used in web to flange
connection of standard plate girders designed by RDSO. The fillet weld is
designed to carry the design horizontal shear at the top edge of the web plate.
Various design considerations and the codal provisions are to be kept into
consideration for the design of this connection. This is the most important
connection to be made using advanced welding technology such as submerged
arc welding. The design parameters and constraints involved in the design of
12.2m span welded plate girder to MBG loading for 10 million cycles of fatigue
are described in the following paragraphs.

2.0 DESIGN PROVISIONS

IRS Welded Bridge Code lays down the stipulations regarding maximum
permissible stresses to be taken in different type of welds for design of
dynamically loaded structures from fatigue considerations. Since fatigue strength
of welded structures depends upon the constructional details, the type of weld is
to be decided before the permissible stresses and consequently the size of
members and the welds are determined. Stresses due to dead load, live load
and impact, stresses resulting from curvature and eccentricity of track, and
secondary stresses as defined in clause 3.3.2 (a) of IRS Steel Bridge code, only
are to be considered for effects due to fatigue. All other items mentioned in
clause 3.1 of IRS Steel Bridge code and secondary stresses as defined in clause
3.3.2 (b) there of are to be ignored when considering fatigue.
3.0 PERMISSIBLE STRESSES IN WELDS

(a) Fillet welds

i) The basic permissible stress in fillet welds based on thickness

equal to the throat thickness shall be 100 N/mm2 (10.2
kg/mm2) where a fillet weld is subjected to shear stress in two
directions, the actual stress shall be taken as the vector sum
of the separate shear stresses and shall not exceed 100
N/mm2 (10.2 kg/mm2).

ii) Load carrying fillet welds in dynamically loaded structures

shall be designed such that the stress on the total effective
area of fillet welds does not exceed the relevant values
specified in Table for class ‘G’ Constructional details of
Appendix ‘G’ to IRS Steel Bridge code, subject to a maximum
of 100 N/mm2 (10.2 kg/mm2).

iii) Load carrying fillet welds in dynamically loaded structures

shall be designed so that secondary bending stresses are not
developed (e.g. single lap joints shall not be used).

(b) Butt Welds

Stresses in butt welds shall not exceed the permissible stresses of

the parent metal as specified in IRS Steel Bridge Code. However,
such welds are to be tested for their strength using non-destructive
testing techniques such as radiography, ultrasonic testing or any
other equally effective technique.

4.0 DESIGN OF WELD BETWEEN FLANGE PLATE & WEB

Based on the existing design stipulation attempt was made to design a load
carrying double sided fillet weld for the above connection with following
parameters:

i) Clear span = 12.2m

ii) Type of loading = MBG
iii) No. of fatigue cycles = 10 million
iv) Dead load = 10.24t
v) Super Imposed Dead Load = 5.32t
vi) Dead load + Super imposed dead Load + = 283.86t
Impact load + Wind load
4.1 Calculation of Permissible Stress in Fatigue

f  10.24 + 5.32
Stress ratio  min  = = 0.05482
 fmax  283.86

Accordingly, for class ‘G’ for 1 x 107 cycles permissible stress in

fatigue (tensile) has been worked out from Appendix ‘A’ of SBC as under:

3.8 - 3.3
Permissible Stress = 3.3 + x 0.05482
0.1

= 3.574 kg/mm 2

= 0.3574 t/cm 2

4.2 Calculation of Minimum Size of Fillet Weld

From maximum bending moment consideration, minimum cross section required

is as shown in figure 1. For this cross-section the critical design parameters are
as under:

i) Horizontal shear = 0.48 t/cm

ii) Vertical shear = 0.706 t/cm

Therefore, resultant shear (R) = 0.854 t/cm

Hence, minimum size “S” of double sided

fillet weld is computed as below:

2 x 0.7 S x0.3574 = 0.854

or S = 1.706 cm = 17.06mm, Say 18mm.

Fig. 1
4.2 Limitations on the Fillet Size

As calculated above a minimum size of fillet weld of 18 mm is required.

However, the same is considered un-acceptable as making of 18 mm fillet weld
in workshop would require at least two passages of welding using submerged arc
welding technique. This will involve additional work of welding at the fabrication
stage and will adversely affect the productivity besides being uneconomical.
Further from metallurgical point of view it is found not desirable to provide a fillet
weld of size greater than the minimum thickness of the connecting plates.
Therefore the option available was either to increase the thickness of web plate
or to go for better type of welding. The first option was considered uneconomical
and impracticable from fabrication point of view. On the other hand it was noted
that IRS Welding Code vide Clause 13.3 permits higher fatigue strength of butt
welds i.e. equal to that of the parent metal. Therefore, it was found practicable to
design the connection using double bevel butt weld.

5.0 Considerations in Double Bevel Butt weld

5.1 Special Consideration

For butt welding, special considerations are to be made before welding for the
preparation of fusion faces, angle of bevel, root radius and root face so that the
limits of accuracy required in welding can be achieved. The detailed provisions in
this regarding are specified in IS-9595 and other related application standard.
However, when no appropriate application standard exists it is recommended
that, for manual welding, the tolerance on limits of gap and root face should be
+0.5 mm on the specified dimensions for material upto and including 12mm thick.
The tolerance on the included angle between the fusion faces of a V preparation
is recommended to be + 5o. However, practically such tolerances are for
guidance only. Closer tolerances are necessary for automatic process and
particular requirements depend on the characteristics of the process. It should
be noted that the quality of root face preparation and the appropriate gap has a
direct bearing on the strength of the weld. In order to get a good quality weld
following checks should be exercised:

(i) It shall be ensured, if necessary, by suitable non-destructive tests that the

fusion faces and adjacent surfaces shall be free from cracks, notches or
other irregularities which might be the cause of defects or would interfere
with the deposition of the weld material.

(ii) Fusion faces and the surrounding surface shall be free from heavy scale,
moisture, oil, paint or any other substance which might affect the quality of
the weld or impede the progress of welding. Certain proprietary protective
coatings are specially formulated with the intention that they should not
interfere with welding. The effectiveness of such coatings is is however
need to be demonstrated and established by means of specimen welding.

5.2 Assembly for Welding

(i) Parts to be welded shall be assembled such that the joints to be

welded are easily accessible and visible to the operator.

(ii) Jigs and manipulators should be used, where practicable, so that

the welding can be carried out in the most suitable position. Jigs
shall maintain the alignment with the minimum restraints so as to
reduce the possibility of locked in-stress.
5.3 Alignment of Butt Joints

The root edges or root face of butt joints shall not be out of alignment by more
than 25 percent of the thickness of the thinner material for material upto and
including 12mm thick, or by more than 3mm for thicker material. For certain
applications and welding processes, closer tolerances may be necessary.

CONNECTION BETWEEN WEB & FLANGE PLATE

5.4 QUALITY CONTROL

To ensure proper quality control on butt weld a proper quality assurance

programme is to be decided before starting the fabrication in accordance with
instructions laid down in IRS:B1-2001. The butt weld so prepared is examined
for its integrity and soundness by ultrasonic or other equally effective non-
destructive testing technique.

6.0 SAMPLE PREPARATION AND TESTING

In order to ascertain the further practical difficulties in making a good quality

Double Bevel butt joint a simple joint was got prepared and tested. The welding
procedure specification sheet outlining the welding procedure and the welding
parameters is appended as Annexure-I. The sample joint was tested in the
Metallurgical & Chemical Directorate of RDSO. The dye penetration & micro
etching tests performed on the test piece yielded satisfactory results. The test
report is appended on Annexure-II. On the basis of above, the design of flange
butt connection using double bevel butt weld for use in 12.2m span welded plate
girder was approved and provisional drawings No RDSO/B-16003, B-16003/1, B-
16003/2, B-16003/3 were issued. Feedback from railways on the use of this
connection is awaited.

7.0 CONCLUSION

An economical Welded connection has been designed by taking adequate

considerations of the fabrication difficulties, welding technology available and the
existing codal provisions. The double bevel butt weld has been suggested
instead of conventional fillet weld. The design is expected to meet the aspirations
of field engineers and result in economy of cost, material & fabrication time.

8.0 REFERENCES

[1] Indian Railway Standard:1962. Code of Practice for the Design of

Steel/Wrought Iron Bridges (Steel Bridge Code), Research Designs &
Standards Organisation, Ministry of Railways, Lucknow, India.

[2] Indian Railway Standard:1986. Bridge Rules, Research Designs &

Standards Organisation, Ministry of Railways, Lucknow, India.

[3] IRS:B1:2001. Indian Railway Standard Specification for Fabrication and

Erection of Steel Girder Bridges and Locomotive Turn Table, Research
Designs & Standards Organisation, Ministry of Railways, Lucknow, India.
 ANNEXURE-II
M&C DIRECTORATE
Test Report N0. 157/04

In reference to above, two samples of bevel weld were received from B&S
Directorate to carry out metallurgical testing.

1. Marking and M&C Lab Identification No.

S.No. Description of Paint marking Lab Identification

component No.
1 Fillet weld 18mm size FILLET WELD 157/04/1
done by SAW
technique in two passes 1

2 Bevel butt weld with FILLET BUTT 157/04/2

edge preparation as per WELD
WPSS
2

2. Sample particulars (as furnished)

Particulars Sample No. 157/04/01 Sample No.157/04/2

Description of Test piece I-sec. Fillet I-section Fillet but weld
component weld
Welding process SAW SAW
Welding position Vertical Vertical
Date of welding 22-9-04 22-9-04

3. Dye penetrating test

Dye penetrating test was conducted on both sample nos. 157/04/1 and
157/04/2. No appreciable defects were observed.

4. Macro etching test

One transverse slice of each sample was cut polished & etched.
Following observations are observed:
 Sample No. 157/04/1

Description of Size of weld I1-1 I1-2

component H V H V
Weld size 18 17.0 18.8 20.4 19.0
Throat - 12.0 14.0
Root penetration - 7.8 7.4

Sample No. 157/04/2

Description Size of weld I1-1 I1-2

of component H V H V
Weld size 18 15.7 19.2 17.5 15.0
Throat - 12.0 12.0
Root penetration - 8.2 7.0

5. Remark

i) Dye penetrating test found satisfactory in both the samples.

ii) Weld joints found satisfactory in both the samples.
 ANNEXURE-I

WELDING PROCEDURE DATA SHEET FOR DOUBLE BEVEL BUTT WELD

NAME AND ADDRESS OF : Bridge Workshop/JRC

FABRICATOR

WORK ORDER NO. : A-2210

AUTHORITY : -

CONSIGNEE : -

DESCRIPTION OF JOB AND : Fabrication of I-Sec. Welded girder Test

piece as per RDSO Drg. No. for HM loading.

MATERIAL SPECIFICATION : IS : 2062-99 Gr. B. Fully killed fully

normalized

DESCRIPTION OF : I-section fillet butt weld

COMPONENT

WELDING PROCESS : SAW

WELDING POSITION : Vertical

WPSS NUMBER FOLLOWED : -

JOINT DESIGN DETAILS :

AND SKETCH
DATE OF WELDING : 22-9-04

S.N. DESCRIPTION SIZE TYPE CLASS BRAND DRYING

METHOD
1 Electrode for 4mm Coated IRSM-28 TROARO Heated in
(track weld) A-3 electric oven
for 2 hrs. at
250oc
2 Electrode Wire 4mm Un- IRSM-39 ESSAB -
coated
WELDING CURRENT TYPE : DC
POLARITY : Reverse
WELDER QUALIFICATION : B17, 18 : 7310 Pt. 1

NAME OF WELDER : -

TICKET NO. : 1262

WELDING PARAMETERS

WELD ELECTRODE CURRENT ARC/ WIRE TROLLY GAS

PASS OR/WIRE VOLTAGE FEED SPEED FLOW
NO. DIA SPEED RATE
MM Amp. Volt M/min M/min Ltr./min
1 4 575+10 32 2.90 0.3 -
2 4 600+10 36 3.10 0.25

PROVISION OF RUN IN AND RUN OFF : Yes

CLEARING OF WELD BEAD BEFORE :

LAYING NEXT WELD BEAD : Yes

RECTIFICATION OF WELD DEFECTS : Yes

(IF ANY)

INSPECTION OF WELD

PREPARED BY NAME DESIGNATION SIGNATURE

JE/WELDING

SSE/W

ABE/W

MICRO ETCHING TEST : FILLET-BUTT JOINT All dimensions in mm

Description Weld I1-1 I2-2 I1-10 I2-20

size H V H H V H V
Weld size 18 17 17 18 1 17 18 18 17
Throat 12 13 12
Root 5 6 5 5
Penetration
2 4

3 1