10-01-2023
Welding of Welded Steel
Bridge Girders With Ir
Welded Bridge Code
Session - 5
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Preparation of Joint Faces
• Preparation of joint faces shall be done as per IS: 9595.
• Fusion Faces
– The preparation of fusion faces, angle of preparation root radius and root
face shall be as specified in IS: 9595 and IS:4353. Where the gap
between the root faces of a butt joint is excessive, the gap shall not be
bridged since this procedure often leads to cracking. The fusion faces of
the joint shall be built-up with weld metal to give the appropriate gap
before the weld proper is commenced.
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Preparation of Joint Faces
• The preparation of fusion faces, angle of bevel, root radius and root face
shall be such that the limits of accuracy required by the appropriate
application standard can be achieved. When however, no appropriate
application standard exists and this standard is itself to be used, it is
recommended that, for manual welding, the tolerances on limits of gap and
root face should be ±1 mm on the specified dimensions for material up to and
including 12 mm thick and ±2 mm for material over 12 mm thick. The
tolerance on the included angle between the fusion faces of a V preparation
is recommended to be ±5 degree and for U and J preparations + 10 degree.
For an automatic process, closer limits are necessary and particular
requirements depend on the characteristics of the process.
Preparation of Joint Faces
❖ 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.
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Preparation of Joint Faces
❖ Fusion faces and the surrounding surfaces 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 use of such coatings is not excluded by the
requirements of this clause but shall be demonstrated by means of specimen
welds that the coating complies with the above requirements.
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Permissible Stresses in Welds
• Since fatigue strength of welded structures depends upon the constructional
details, this shall be decided before the permissible stresses and
consequently the size of members and weld sizes 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
clause3.3.2 (a) of IRS Steel Bridge Code, shall only 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 should
be ignored when considering fatigue.
Permissible Stresses in Welds
➢ Butt welds - Stresses in butt welds shall not exceed the permissible stresses
of the parent metal as specified in IRS Steel Bridge Code.
➢ Fillet welds
• The basic permissible stress in fillet welds based on a 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).
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Permissible Stresses in Welds
• 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,
Appendix ‘G’ to IRS Steel Bridge Code, subject to a maximum of 100 N/mm2
(10.2 kg/mm2).
• 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).
Reduction in Permissible Stresses
• The permissible stresses for field welds of structural members shall be
reduced to 80% of those specified in clauses 13.3 and 13.4. (of WBC)
Field welds shall not be adopted for bridges carrying road/railway loading
without the specific approval of the Board.
• If over-head welds are unavoidable, the stresses permitted shall be 80%
of those specified in clauses 13.3 and 13.4 and modified by clause 14.1
(of WBC) if field welding is involved.
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Reduction in Permissible Stresses
• In structures subjected to dynamic loading, tensile or shear stresses in
butt welds shall not exceed 66% of the permissible stresses as specified
in clause 13.3 and as modified by clauses 14.1 and 14.2 (of WBC) as
applicable, unless the welds are examined radiographically, ultrasonically
or other non-destructive testing methods which are equally effective and
present satisfactory evidence to the Engineer that welds are meeting the
quality requirement.
Structural Details
• Changes in section shall be gradual and re-entrant notch-like corners shall
be avoided.
• Attachment of fittings and making openings at locations of severe fatigue
stress shall preferably be avoided.
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Structural Details
• Packings - Where a packing is used between two parts, the packing and
the welds connecting it to each part shall be capable of transmitting the
load between the parts, except where the packing is too thin to carry the
load or permit the provision of adequate welds, when it shall be trimmed
flush with the edges of the narrower part and the load shall be transmitted
through the welds alone, the welds being increased in size by an amount
equal to the thickness of the packing.
Arrangement of Welds
• Fillet welds at right angles to the lines of principal stresses in a plate
subjected to tension shall be avoided in dynamically loaded structures.
• Accumulation of weld joints in a single location shall be avoided (See Fig.
Below).
• Sizes or lengths of fillet welds shall be sufficient to provide for better
distribution of stress. Excessive sizes or lengths shall not be specified.
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Structural Details
➢ Intermediate stiffeners
• Where intermediate stiffeners are connected to the web by intermittent
fillet welds placed in pairs, one weld on either side of the stiffeners, the
effective length of each weld shall be not less than four times the
thickness of the stiffeners, subject to the provisions of clause 6.7 ( of
WBC).
• Where staggered intermittent fillet welds are used, the effective length of
each weld shall be not less than 10 times the thickness of the stiffener,
subject to the provisions of clause 6.7 ( of WBC).
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Structural Details
➢ Intermediate stiffeners
• Fillet welds placed on one side only of the stiffener shall not be used.
• Intermediate stiffeners carrying cross bracings or diaphragms shall not be
connected to the web by intermittent fillet welds.
Structural Details
➢ Safety Precautions:
➢ Provisions of IS:818, IS:1179 and IS:3016 shall generally apply for safety
and health requirements during welding operations.
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Welding Procedures
• Welding work shall be given to a contractor who does produce satisfactory
evidence of his ability to handle the work in a competent manner. The
contractor shall also prove the ability of the operator/Welders employed by
him to produce welds of the required strength. The contractor shall employ
a competent welding supervisor to ensure that quality of materials and the
standard of workmanship comply with the requirements laid down in this
code.
➢ The sizes and length of welds shall not be less than those specified in the drawings nor shall they
be substantially in excess of the requirements without prior approval of the Engineer. The location
of welds shall not be changed without prior approval of the Engineer. Welds shall preferably be
made in flat position.
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Sequence of Welding
• In case of welds in structures subjected to dynamic loading, adequate
means of identification, either by identification stamp or other records shall
be provided to enable each weld to be traced to the welding operator by
whom it was made.
• During the entire welding of cooling cycle, the joints shall not be subjected
to any external forces or shocks.
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Sequence of Welding
• Freedom of movement of one member of a joint shall be allowed wherever
possible. No butt joint shall be welded without allowing one component,
freedom of movement of the order of 1.5 mm.
• In making welds under conditions of severe external shrinkage restraint,
the welding shall be carried out with electrodes having type 6 covering as
per IRS:M-28 Specification.
➢ In case of welding using direct current, earthing on the work piece to be welded shall be
connected carefully at more than one location with a view to avoid “Arc Blow” during
welding.
Sequence of Welding
• All welds should be done by submerged arc welding process either fully
automatic or semi-automatic. Carbon-di– oxide (CO2) welding or manual
metal arc welding may be done only for welds of very short runs or of
minor importance or where access of the locations of weld does not permit
automatic or semi-automatic welding.
• Neither the depth of fusion nor the maximum width in the cross section of
weld metal deposited in each weld pass shall exceed the width of the face
of the weld pass. (see Fig. 21 & 22 Below)
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Sequence of Welding
➢ Position of Welding
• For fabrication of steel bridge girders the following positions of welding
shall be adopted.
I. Flat and horizontal position for Submerged Arc Welding (SAW) and
II. Horizontal or horizontal-vertical position for welding done using manual
metal Arc welding (MMAW) or CO2 welding.
• Note – Different positions have been shown diagrammatically in Fig. Below
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Position of Welding/Tack Welding
• Where a tack weld is incorporated in a welded joint, the shape, size and
quality shall be suitable for incorporation in the finished weld and it shall
be free from all cracks and other welding defects. Tack welds, which are
prone to cracking, shall be cut out and rewelded.
• Tack welds shall not be made at extreme ends of joints.
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Position of Welding/Tack Welding
➢ Inter-Run Cleaning:
• Each run of weld bead shall be thoroughly cleaned to remove particles of
slag, spatters, etc. before the subsequent bead is super-imposed during
multi-pass welding. Similarly, each layer of weld should be thoroughly
cleaned of slag, spatters, etc, before depositing subsequent layers of weld
with particular reference to thorough cleaning of toes of the welds. Visible
defects, such as cracks, cavities and other deposition faults, if any, shall
be removed to sound metal before depositing subsequent run or layer of
weld.
Position of Welding/Tack Welding
➢ Stray Arcing on Work
• Stray arcing must be avoided as this can leave local hard spots or
cracking which are to be removed by mechanical means and be checked
by inspection depending upon the application.
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Inspection And Testing Of Welded Joint
➢ 27.1 Inspection and Testing of Welded Joints- Inspection of the welded
bridge girders carrying rail or rail-cum-road traffic weather of completely
welded type or partially welded type excect for foot over-bridges shall be
entrusted to RDSO. Accordingly, RDSO shall undertake inspection for the
first 1000 tonnes of welded plate girders after which the inspection shall
be taken over by the respective Zonal Railway/DFCCIL subject to setting
up of RDSO certified quality inspection unit (to be headed by officer not
below the rank of JA grade officer) by the respective Zonal
Railway/DFCCIL. However, RDSO is free to inspect the welding work if
considered necessary at any stage of work.
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Inspection And Testing Of Welded Joint
➢ The inspection of traingulated welded girders shall continue to be with
RDSO (CS 01 to WBC dtd 16.2.15).
➢ The Inspector designated by the purchaser shall ascertain that fabrication
by welding is performed in accordance with the requirements of WBC
code. Inspection of welds shall also be carried out in accordance with this
Code. For the provisions which are not incorporated in this Code, IS:822
“Code of procedure for inspection of welds” shall be followed.
Inspection And Testing Of Welded Joint
➢ He shall be furnished with complete detailed drawings showing the size,
length, type and location of all welds, which are required to be made.
• He shall be notified in advance of the start of any welding operations.
➢ He shall have free access to the work being done at all reasonable times
by the contractor and facilities shall be provided so that during the course
of welding he may be able to inspect any layer of weld metal. He shall be
at liberty to reject any material that does not conform to the provisions of
WBC code and to require any defective welds to be removed and re-
welded.
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Inspection Prior to Welding
➢ Parent Metal:
• All plates and sections shall be inspected in the contractor’s works before
fabrication. Verification of the quality of parent metal shall be carried out
by reference to the relevant test certificate. The Inspector may, at his
discretion, ask for spot checks to be made on the chemical composition
and physical properties of the material.
• Freedom from harmful defects such as cracks, surface flaws, laminations,
and rough, jagged or imperfect edges shall be verified by visual
examination of the material prior to welding. Dimensions of parts shall be
checked by measurement.
Inspection Prior to Welding
➢ Edge preparation and set-up of parts:
• Edge preparation shall conform to the relevant drawings and meet the
requirements of WBC code.
• After the parts are assembled in position for welding, the Inspector shall
check for incorrect root gap, improper edge preparation and other features
that might affect the quality of the welded joint.
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Verification of Operator’s Qualification
• Welding shall be permitted to be performed only by welders and welding
operators who are qualified in accordance with requirements of clause 20
of WBC.
• The Contractor shall, if so required, prescribe the welding procedure to be
followed. Before any welding on the actual job is allowed under the
contract, the Inspector shall verify, in accordance with the provisions of IS:
9595 and IS: 4353 as applicable, that the procedure prescribed is
satisfactory.
Inspection During Welding
• Filler material - Filler material shall be tested periodically to ensure that
the specified quality is being consistently maintained.
• While welding is in progress, visual examination shall be employed to
check details of work, such as proper arc, arc length, speed of weld
deposit, sequence of welding, cleaning of slag after each run in multi-run
welding, electrode spattering, manipulation of the electrode, employment
of proper current and voltage etc. Particular care shall be taken during the
early stages of the work.
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