Design criteria of the codes that govern construction of
offshore drilling platforms are analyzed and evaluated BYP. W. MARSHALL AND A. A. TOPRAC I nt r oduct i on Recently publ i shed codes (Refs. 1,2) include cri teri a for t he desi gn and constructi on of wel ded connec- ti ons for ci rcul ar tubes, whi ch have been in use for a number of years i n offshore dri l l i ng pl at f or ms. The purpose of t hi s paper is to document t he background data underl yi ng these cri teri a, in t er ms of static and fati gue st rengt h. :z^x. 40( ^0. 50 CHORD ~ Fig. 1 Simple joint 20^. 0. 50 BRANCH MEMBERS P. W. MARSHALL is Staff Civil Engineer, Offshore Construction, Shell Oil Com- pany, New Orleans, La. A. A. TOPRAC is Professor of Civil Engineering, The Univer- sity of Texas at A ustin. Paper is based on a survey sponsored by the WRC Subcommittee on Welded Tubu- lar Structures. St at i c St r engt h Simple and Punching Shear Joints Currentl y t he most popular style of wel ded connect i on for i ntersecti ng circular tubes as used i n fi xed off- shore structures is t he " si mpl e" j oi nt i l l ustrated i n Fig. 1. The tubular mem- bers are si mpl y wel ded together, and all load is t ransf erred f rom one branch t o t he other via t he chord, wi t hout any help f r om st i f f eni ng ri ngs or gusset plates. To prevent exces- sively hi gh localized stresses i n t he chord, a short l ength of heavi er section (joint can) is often used in t he connecti on area. In such cases, t he probl em of j oi nt desi gn reduces t o that of sizing t he j oi nt can, parti c- ularly wher e compl ete j oi nt penet ra- t i on groove wel ds (as def i ned for tubular structures (Ref. 2) are used at the ends of the branch members. Al t hough the compl ete stress pi cture is much more compl ex, t he concept of punchi ng sffear, Fig. 2, has been qui te useful i n correl at i ng test data and f ormul at i ng desi gn cri teri a. The average (or nomi nal ) punchi ng shear stress, v p , acti ng on t he pot en- ti al fai l ure surface is cal cul ated as: v B = r U rV-r(V*y V *g TOR 0 0 0.5 I.O I . I . I . I . I . I . I (D 60* 30' 0* BRACE INTERSECTION ANGLE S Fig. 2 Punching shear Fig. 3 Intersection line effects 192- s I M A Y 19 7 4 LINE LOAD Q K/ i n CLOSED RING Jo Ltt UNIT WIDTH STRIP BEAM KELLOGG <t < . i . : V TEST DATA FOR TUBULAR JOINTS A T V p . ^ M ( ^ ) - ' YIELD p " t 0.5 y "0 0.5 1.0 /3=C/R Fig. 4 Simplified punching shear criteria Table 1 Closed Ring and Kellogg Solutions for Punching Shear and Line Load Capacities Case Punching shear capacity Total joint capacity proportional to Closed ring t 2 x length xf(/?) Kellogg Fv 2.34xY-5 t 1 5 x perimeter wher e T = t b / t = rati o of branch thi ckness t o chord thi ckness, 6 = angl e bet ween member axes (see Fig. 2), f a and fb = nomi nal axial and bendi ng stresses i n branch, respectively. It is to be noted t hat onl y t he compo- nent of t he branch member load whi ch is perpendi cul ar to t he mai n member (chord) wal l is consi dered be- cause t hi s component is responsi bl e for most of t he localized stresses. The t erms K a and k b relate to t he l ength and secti on modul us, respecti vel y, of t he tube-to-tube i ntersecti on, whi ch is ki nd of a saddl e-shaped oval (Ref. 3). Speci fi cal l y t he t erms represent t he ratio of t he true peri meter (or sec- t i on modulus) t o t hat of t he ci rcul ar brace; t hey are pl otted in Fig. 3, as a f unct i on off? (defi ned above) and/ 3, wher e P FU ' R brace to chord di ameter (or radius) ratio To specify desi gn al l owabl e val ues for t he punchi ng shear stress t heoret i cal and experi mental consi derati ons are discussed bel ow. Theoretical Approach Sol uti ons for elastic stresses in cyl i ndri cal shel l s subjected to localized l i ne loads are available for t he very si mpl e load cases shown in Fig. 4. The closed ri ng sol uti on and Kellogg f ormul a (Ref. 4) i ndi cate punchi ng shear and line load capacities as shown i n Table 1. Note t hat punchi ng shear capaci ty is defi ned in rel ati on to t he very i mpor- t ant nondi mensi onal parameter J wher e 7 =R/ t = chord t hi nness ratio, radi us/ t hi ckness Thi s is anal ogous to t he span to depth ratio of a stri p beam, for whi ch si mi l ar rel ati onshi ps may be deri ved (see Fig. 4). These t wo rel ati vel y crude physi cal models mi ght be expected to bracket t he behavior of si mpl e tubul ar j oi nt s, since t he branch member loads t he chord al ong a combi nat i on of l ongi - t udi nal and ci rcumf erent i al l i nes. Unfortunatel y they yi el d di vergent results and tend to i ndi cate di sturb- ingly hi gh stresses i n practi cal desi gn si tuati ons. However, t hey both do reflect t he strong dependence of total j oi nt capacity on chord t hi ckness and branch member peri meter. The addi - ti onal effect of di ameter rati o, f(/3), as i ndi cated by Roark, was consi dered paradoxi cal i n t hat test data wi t h tubul ar connect i ons did not show t he same monot oni c i ncrease in j oi nt ef f i - ci ency as depi cted i n Fig. 4. In fact, T- j oi nt tests ci ted by Toprac (Ref. 4) showed j oi nt effi ci ency (in t erms of t he rati o of hot spot stress to punch- ing shear) passi ng t hrough a mi n- i mum i n t he mi drange of di ameter ratios. A sophi sti cated anal yti cal sol uti on (Ref. 5) yi el ds t he more real i sti c pi c- ture presented in Fig. 5. These resul ts are consi st ent wi t h those obtai ned experi ment al l y and wi t h f i ni t e ele- ment anal yses (Ref. 6), i nsofar as stress levels in t he chord and load transfer across t he wel d (Q) are con- cerned. For t hi s j oi nt , t he stress con- cent rat i on factor is 7.3, and t he calr culated average punchi ng shear stress, v Pi at whi ch f i rst yi el d at t he hot spot occurs (Fy = 36 ksi) is onl y 2.5 ksi. Comparabl e punchi ng shears for Roark and Kellogg woul d be 2.2 ksi and 3.4 ksi , respectively. Figure 6 summari zes t he results of a parameter study made wi t h com- puter programs based on Ref. 5. The punchi ng shear stress, v p , at whi ch yi el d stress is predi cted for axially loaded T-connecti ons, is presented as a f unct i on of chord t hi nness ratio, y , and br ace/ chor d di amet er rati o, /? . As was previ ousl y not ed ex- peri mental l y, j oi nt effi ci ency (i n t erms of punchi ng shear at yield) passes t hrough a mi mi num for a di ameter ratio in t he range of 0. 4 to 0.7. Throughout t hi s range, punchi ng shear effi ci ency is more or less i nde- pendent of di ameter rati o, but vari es inversely wi t h t he 0.7 power of chord t hi nness ratio Y Correspondi ngl y, the overall capa- city of t he connect i on woul d be pro- porti onal to the product of brace peri meter (or i ntersecti on length) and t 1 - 7 , wher e t is chord thi ckness a result whi ch is surpri si ngl y consi s- tent wi t h the oversi mpl i fi ed ap- proaches consi dered earlier. However, the use of f i rst yi el d as a fai l ure cri t eri on shows t hat el asti c theori es seriously underpredi ct t he available static st rengt h of practi cal tubular connecti ons. For exampl e, a mi l d steel scale model of t he connec- ti on in Fig. 5 actual l y carri ed t he load shown (appropri atel y scaled down). Natural l y, a hot spot stress of 1 60 ksi for mi l d steel is unreal i sti c and t he materi al is beyond yi el d, and sub- j ected to strai ns in excess of 5300 P i n. / i n. Under these ci rcumstances, it appears t hat theoreti cal elastic anal - yses wi l l be of l i mi ted use in f ormul at - ing practi cal desi gn cri teri a for static or quasi -stati c l oadi ng condi ti ons. Empirical Approach. Tubular j oi nt s have a t remendous reserve capacity beyond the point of fi rst yi el d (Ref. 7), W E L D I N G R E S E A R C H S U P P L E M E N T ! 193- s PUNCHING SHEAR AT FIRST YIELD f lY.fi) AXIALLY LOADED TEE JOINT T =l . 0 Fig. 5 Theoretical elastic stresses axially loaded T-joint as i l l ustrated in Fig. 7. If a secti on through t he chord at its i ntersecti on wi t h the brace is consi dered for smal l loads in the elastic range, t he di st ri bu- t i on of ci rcumf erent i al stresses on the outside surface are shown as Stage 1 i n t he fi gure. Beyond yi el d, t he connecti on deforms (Stage 2) whi l e t he appl i ed load conti nues to i ncrease. Finally, at loads 2.5 t o 8 t i mes t hat at f i rst yi el d, t he j oi nt fai l s by pullout fai l ure as shown for t ensi on loads or by localized col l apse of t he chord for compressi on loads (Stage 3). The average punchi ng shear stress at f ai l ure*, v p , has been pl otted in Fig. 8 relative to speci fi ed mi ni mum yi el d st rengt h, F y , and as a f unct i on of chord t hi nness ratio.Y; 38 static tests whi ch fai l ed in the punchi ng shear mode are represented, al ong wi t h t wo speci mens whi ch fai l ed after onl y a f ew cycles of fati gue l oadi ng. The solid circles represent K-j oi nts; t he rest are T and cross j oi nt s. Data are from Toprac (Refs. 4, 7) and other sources (Refs. 8, 9). For rel ati vel y stocky chord mem- bers t hi ckness greater t han 7% of di ameter or 7 less t han 7 t he j oi nts may be said to have a 100% punchi ng shear effi ci ency, in the sense that t he shear st rengt h of the materi al is ful l y mobilized on the potenti al fai l ure sur- face. This cri teri on is met by ASTM A- 53 standard wei ght pipe under 2 i n. CHORD ,_ THINNESS ' t o RATIO Fig. 6 Parameter study di am, by extra strong pipe under 5 i n. di am, and by double extra strong pipe t hrough 1 2 i n. di am. Larger and/ or t hi nner chords shoul d be treated on the basis of a reduced punchi ng shear capaci ty as gi ven by the curve in Fig. 8 and F ( 2 ) " Ul ti mate v n Allowable v 0.5 xy c 0.9 x y (2a) Here, t he desi gn al l owabl e punchi ng shear stress i ncorporates a safety factor of 1.8 wi t h respect to the empi ri cal curve for ul ti mate punchi ng shear. Its i ntended range of appl i ca- t i on is for t he mi d-range of di ameter ratios for whi ch v P is more or less i ndependent of / 3. Si nce t he proposed empi r i cal desi gn curve makes use of t he post- yi el d reserve st rengt h of si mpl e tubular connect i ons, it wi l l be i nstruc- ti ve to revi ew t he sources of thi s extra capacity. These are: I . The di fference bet ween elastic and plastic bendi ng st rengt h (l ocal - ized) of t he cyl i ndri cal shel l , a factor of 1.5. * Failure was defined as first crack for tension loads. This would functionally impair the joint for subsequent fatigue service. *'*The ultimate strength criteria developed by Reber (Ref. 9) reduces to: Ultimate v p = f (f$)- 0.55x y c All simple T, Y and K connections are tested on a common basis. Although K connections have lower elastic stresses than the corresponding T and Y connections, they also have less reserve strength, so that the ultimate capacities come out similar. The chief difference between Reber's results and equation (2) is in the degree of conservatism with respect to the scatter band shown by the test results. Reber provides a good average fit whereas the curve for equation (2) falls on the safe side of most of the data. Reber's f(/S) shows relative- ly little influence of diameter ratio: i. e., f (R ) - R 1 2. Restraint to plastic f l ow caused by tri axi al stresses at t he hot spot, a factor of 1.6 for t he si t uat i on of Fig. 5. 3. St rai n hardeni ng for t he mi l d steels represented i n t he test data, t he ul ti mate tensi l e st r engt h (whi ch is at least locally utilized when a j oi nt fai l s by separati on of t he materi al ) is greater t han t he specified mi ni mum yi el d st rengt h, F y , (whi ch is used for t he empi ri cal correl ati on and desi gn formul a) by factors f rom 1.6 to 2.4. Corres- pondi ngl y, it is suggested t hat F y used in cal cul ati ng t he al l owabl e v p shoul d not exceed t wo- t hi r ds ( 2/ 3) the tensi l e st rengt h. 4. Further i ncreases i n capaci ty re- sult f rom the redi st ri but i on of load, whi ch occurs as t he connect i on yields and approaches its l i mi t load. If t he cyl i ndri cal shel l is vi s- ualized as a net work of ri ngs and stri ngers, t he sequence of events may occur as i l l ustrated in Fig. 9. Plastic behavi or, tri axi al stresses, strai n hardeni ng, load redi st ri but i on and large def ormat i on behavi or place extraordi nary demands on t he duct i l - ity of t he chord mat eri al . Some l ocal - ized yi el di ng wi l l occur at desi gn load levels. These consi derati ons shoul d be kept i n mi nd when sel ect i ng steel s for tubular structures (Ref. 8). Further Refinements By and large, desi gn codes repre- sent a consensus of engi neeri ng prac- tices i n a parti cul ar f i el d. There was a general f eel i ng that, whi l e t he data of Fig. 8 (as repl otted in t erms of/? in Fig. 10) di d not j ust i f y t aki ng di ameter ratio /? i nto account, experi ence i ndi - cated a benefi ci al effect as t he di am- eter ratio approaches uni ty, as i ndi - cated by the heavy dashed l i ne in Fig. 10. Square Tubes. Consi derabl e i nsi ght i nto t he effect of /? on t he ul t i mat e 194- s I M A Y 19 7 4 FAILURE STAGE 1 STAGE 2 DEFLECTION Fig. 7 Reserve strength of a tubular connection I.Or MATERIAL LIMIT V P F y / y j ULTIMATE PUNCHI NG SHEAR 20 30 40 50 60 R/ t *y CHORD THINNESS RATIO Fig. 8 Empirical design curve static strength ^ Fig. 9 Load redistribution. First yielding occurs at hot spot A. Cross hatched yield line is analogous to plastic hinge in a continuous frame. Full strength of ring AB is reached when yielding also occurs at B, after considerable angle change at hot spot. Ring AB continues to deform at constant load while rest of joint catches up, resulting in more uniform load dis- tribution. Limit load of joint is reached when ring CD and stringer CE also yield. Deformed shape is indicated by dashed lines punc hi ng shear capaci t y of t ubul ar connecti ons was gai ned f rom consi d- erati on of a l i mi t anal ysi s of square tubes. Usi ng t he yi el d l i ne pattern of Fig. 11 and t he upper bound t heorem of plastic desi gn, the ul t i mat e punch- ing shear stress v p is obt ai ned as: 0.25 /?(!-/?) o.5*y 0.2 0.4 0.6 0.6 DIAMETER RATI0-/3 Fig. 10 Static strength /3 effects wher e /? and Y are def i ned i n a manner anal ogous to t he usage for ci rcul ar tubes. The second t erm on t he ri ght of equati on (3) is qui te si mi l ar to t he empi ri cal punchi ng shear, equati on (2); onl y t he exponent of Y is di ffer- ent. The leading t erm corresponds to t he /? effect and has t he f ol l owi ng properties: 1. Mi ni mum value of 1.0, whi ch occurs at /? = 0.5. 2. Increasi ng punchi ng shear effi - ciency at larger and smal l er /? - ratios; t hi s is comparabl e t o t he theoreti cal results for ci rcul ar T- j oi nt s, Fig. 6. 3. Where/ ?approaches its l i mi ts (0 and 1.0), punchi ng shear is l i mi ted by t he shear st rengt h of t he mate- rial (or by other consi derati ons such as web crippling). Test data (Ref. 10) for t he specific case of 5 x 5 x 0.187 chord are also plotted in Fig. 11. Failure was defi ned as when j oi nt def ormat i on reached 3% of chord wi dt h. The st rengt h i n- crease for /? -rati os over 0.5 appears to be conf i rmed, wi t h t he test data showi ng st rengt hs rangi ng f rom 1.5 to 1.8 t i mes t he computed "upper bound" l i mi t load. Thi s reserve st rengt h undoubtedl y comes f rom some of t he same sources di scussed above for ci rcul ar tube connect i ons. For/? -rati os under 0.5, however, t he test data show equati on (3) to be i ncreasi ngl y less conservati ve as /? decreases. The dotted l i ne (Fig. 11) represents a punchi ng shear cri teri a whi ch is i ndependent of t he j3 -rati o, gi ven by: v = f o r / ? < 0.5 0.5 Y (3a) i o (3) Note t hat t hi s strai ght sl opi ng l i ne goes t hrough t he ori gi n; total j oi nt capacity goes to zero as t he brace peri meter and/ 3 -rati o also approach zero. The combi nat i on of equati ons (3) and (3a) results in cri t eri a wi t h more or less consi stent safety factors throughout t he range of/?. W E L D I N G R E S E A R C H S U P P L E M E N T ! 195- s 60 50- 40 in D_ -*. I D_ 3 0 2 0 SPECIFIC RESULTS FOR 5X5X.I87 CHORD MATERI AL LI MI T v p = 0 . 4 Fy^ / LI MI T ANALYSI S 0. 25 Fy /3(l-/3) 0.5 y-^ P " 0 . 5 y FOR /3 < 0 . 5 YIELD LINES 0 0. 2 Fig. 11 Ultimate strength analysis square tubes 0.4 0.6 0.8 /9 - RATIO I.O HINGE LINES SIMPLIFIED LIMIT ANALYSIS . 0.5 II. /3<l-/9) 0.5 y 2 TTR 4 0 30 < O UJ CM -i 20 & < CE o z 10 EMPI R, CAL V " - f>S?833fi) 3 8 7 -CONSTANT VP FOR 0.25 < f3< 0.75 0 0.2 0.4 0.6 DIAMETER RATIO /3 Z 7 /*?. 12 Japanese results cross joints 0.8 I.O Japanese Research A si mpl i fi ed l i mi t anal ysi s of cross j oi nt s wi t h circular tubes has been re- ported (Ref. 11), whi ch empl oys t he physi cal model of Fig. 1 2 t o deri ve an expressi on for theoreti cal ul t i mat e strength whi ch can be reduced to t he f ol l owi ng: 0- 5 0(1-0) B, 2 TR (4) When the effecti ve l ength B P is taken as equal to t he chord ci rcumf erence, t he last t er m becomes unity, and equati on (4) becomes i denti cal wi t h equati on (3), wi t h a t erm for t he basic vari ati on of v p wi t h F y and 7 , mod- ified by a t erm expressi ng t he /? - effect. Test data were used to j usti fy an empi ri cal modi fi cati on of t he expres- sion for ul ti mate punchi ng shear, leading to t he results pl otted i n Fig. 12, and 0.3 0( 1- 0. 833 0 ) 0. 304 y (4a) In t hi s expressi on t he t erm for /? - effect has t he f ol l owi ng properti es and i mpl i cati ons: 1. A value of 1.0 for 0 = 0.6 2. Increasi ng j oi nt effi ci ency for larger 0 -rati os, up to a l i mi t i ng i n- crease of 1.8-fold f or 0= 1.0. Note t hat for t he mi d-range of di am- eter ratios (/3from 0.25 to 0.75) t he assumpti on of const ant punchi ng shear also provi des a reasonabl e fi t to t he data of Fig. 12, i n l i ne wi t h earl i er results. For very smal l /3-rati os, t here is l i ttl e experi ment al j ust i f i cat i on for the large i ncreases in j oi nt effi ci ency predi cted by t he/ ? -modi fi er in equa- t i on (4a). Accordi ngl y, it has been rec- ommended that a modi fi er of uni ty be used for val ues of 0 less t han 0.6. Thi s is consi stent wi t h t he resul ts for square tubes, and appears to be con- servative wi t h respect to t heoret i cal resul ts (Fig. 6). Proposed 0-Effect Appl yi ng t he modi fi er, Q , j , for t he effects of di amet er ratio, to t he punch- ing shear cri teri a of equati ons pro- posed earl i er (equati ons (2) and (2a) one obtai ns: Ul ti mate v = Q, Al l owabl e Vy - Q wher e Q 0.3 /? (1-0. 833/ ?) 0.5 x y 7 Fy B 0.9 xY 07 for /?> 0.6 (5) 196-s I MAY 1 97 4 _ 0.4 cr 0.3 0. 2- 0.1 - t CHORD AREA Ac Pmax -1.0 -0.8 -0.6 COMPRESSION -0.4 -0.2 0.2 0.4 0.6 CHORD UTILIZATION RATIO U = FyTc" 0.8 1.0 TENSION and Q=1. 0 f or / ?<0. 6 These cri teri a, i ncl udi ng Qff, are pl ot- ted as the heavy dashed l i ne in Fig. 10. Interaction Effects Japanese data (Ref. 11), showi ng t he extent t o whi ch axial load i n t he chord member reduces its capaci ty t o carry punchi ng shear, are pl otted i n Fig. 13. The proposed modi fi er Q f for i nteracti on effects woul d be used in desi gn as f ol l ows: Al l owabl e v = (6) Of - Qs 0. 9xY? where Q f = 1.22 - 0.5 | U| for | U| >0. 44 Q f =1 . 0 f or | U| <0. 44 and | U| = chord uti l i zati on rati o at t he connect i on. Fig. 13 Interaction effects of stress in chord NEGATIVE ECCENTRICITY ZERO ECCENTRICITY POSITIVE ECCENTRICITY ^ H E A R ON 6' OVERLAP WELD SHEAR ON 2.5 OVERLAP WELD SHEAR ON 9" VERT. WELD BEARING ON LEG COMFARISON OF JOINT EFFICIENCIES TYPE OF JOINT POSITIVE ECCENTRICITY ZERO ECCENTRICITY NEGATIVE ECCENTRICITY CALCULATED BASED ON NOM. YIELD I 37* IN 6^8< 4 1 % 6 2 % 86% TEST RESULTS BASED ON ULTIMATE 255 K IN 6%oj> 5 4 % 82% 108% Fig. 14 Joints of various eccentricities W E L D I N G R E S E A R C H S U P P L E M E N T ! 197- s * , ) Fig. 15 Components of resistance for overlapping joints In desi gn | Uj woul d be taken as t he AISC ratio for t he chord at t he tubular connect i on ( wi t h respect to cri teri a based on yield). Equation (6) i ncl udes safety factors and corresponds t o a symmet ri cal fai l ure envel ope, as shown by t he solid l i ne (Fig. 13). Wher e heavy wal l j oi nt cans are used at tubular connect i ons, t he uti l i zati on ratio wi l l of t en be less t han 0. 44 for t he j oi nt can, correspondi ng t o no reducti ons due to i nteracti on. For hi ghl y stressed K and X-j oi nt s wi t hout j oi nt cans, but wi t h equal di - ameters, the increase in j oi nt effic- iency over equati on (2a) wi l l be l i mi ted to about 30%, when both Qj and Q f are consi dered. Overlapping Joints In overl appi ng j oi nt s, t he braces i ntersect each other as wel l as t he chord, and part of t he load is t rans- ferred di rectl y f r om one brace t o an- other t hrough thei r common wel d. One advantage of such j oi nt s is t hat , since t he chord no longer must t rans- fer t he ent i re load, its t hi ckness can be reduced and "j oi nt cans" el i m- i nated. The amount of overl ap can be control l ed by adj usti ng t he eccentri c- ity of brace centerl i nes, as i ndi cated in Fig. 14. Negative eccentri ci ty (Ref. 12) can be used to i ncrease t he amount of overl ap and t he static load transfer capaci ty of t he connect i on. A crude ul ti mate st rengt h anal ysi s is proposed (see Fig. 1 5), in whi ch t he punchi ng shear capaci ty for t hat por- t i on of t he brace reachi ng t he mai n member and t he membrane shear capacity of the common wel d be- t ween braces are assumed t o act si mul taneousl y. Thus, t he total capa- city of the connect i on for t ransf erri ng loads perpendi cul ar to the chord be- comes P si n 9 wher e (7) v = al l owabl e punchi ng shear stress equati on (6) for t he mai n member t = mai n member wal l thi ck- ness I = ci rcumferenti al l ength for that porti on of t he brace whi ch contacts the mai n member and v = al l owabl e shear stress for w the common wel d bet ween q 10,000 5,000 CYCLES OF LOAD Fig. 16 Family of fatigue design curves (see Table 1) 198- s I M A Y 1 9 7 4 t he braces* t w = t hroat t hi ckness for the common wel d bet ween braces* 1 2 = t he proj ected chord l ength (one side) of t he overl ap- ping wel d, measured i n t he pl ane of the braces and per- pendi cul ar to t he mai n member ** A compari son of computed capa- cities, in t erms of brace axial load, P, using ul ti mate v p and yi el d v w x t w , versus test results is gi ven in Fig. 14. Equation (6) appears t o be conserva- tive in predi cti ng static j oi nt capa- cities, provi ded t here is suffi ci ent duc- ti l i ty that the sti ffer el ement (the over- lap) does not fai l before t he rest of t he j oi nt catches up. At elastic load levels the overlap is so much sti ffer t hat it tri es to carry t he ent i re l oad; thus, wher e overl appi ng j oi nt s are i nt en- ti onal l y used, some desi gners like to proporti on the overlap to carry at least 50% of t he acti ng transverse load. Wher e extreme amount s of overlap are used, it may become necessary to check t he capacity of t he connecti on for t ransf erri ng loads parallel to the mai n member as wel l as transverse loads. Both may be accompl i shed wi t h vector combi nat i on of t he various st r engt h el ement s, as suggested in Figs. 14 and 15. Fati gue Few members or connecti ons in conventi onal bui l di ngs need to be de- signed for fati gue, since most load changes occur i nfrequentl y or pro- duce only mi nor cyclic stresses. The ful l desi gn wi nd or earthquake loads are suffi ci entl y rare t hat fati gue need not be consi dered. However, crane runways and sup- porti ng structures for machi nery are often subject to fati gue loading condi - ti ons. Offshore structures are subject to a conti nuous spectrum of cyclic wave loadings, whi ch requi re consi d- erati on of cumul ati ve fati gue damage (Ref. 13). Wel ded tubular connecti ons, in par- ticular, requi re special attenti on to f a- tigue, since stati cal l y acceptable de- signs may be subject to localized plastic strai ns, even at nomi nal l y al l owabl e stress levels. Fatigue may be defi ned as damage that results in fracture after a suffi - *Except that the line load capacity v w x r w should not exceed the shearing capacity of the thinner adjoining base metal. "Projected chord length is proportional to the resultant of membrane shear, acting at peak value along the full length of the overlapping weld. Table 2 Fatigue Categories , (b) -.(b) Stress category Si t uat i on A Plain unwel ded tube. A Butt spl i ces, no change in sect i on, f ul l penet rat i on groove wel ds, ground f l ush, and i nspected by x-ray or UT. B Tube wi t h l ongi t udi nal seam. B Butt spl i ces, f ul l penet rat i on groove wel ds, ground f l ush. B Member s wi t h cont i nuousl y wel ded l ongi t udi nal st i f f eners. C Butt spl i ces, f ul l penet rat i on groove wel ds, as wel ded. D Member s wi t h t ransverse (ring) st i f f eners, or mi scel l aneous at t achment s such as cl i ps, brackets, etc. D Tee and cruci f orm j oi nt s wi t h f ul l penet rat i on wel ds (except at tubul ar connect i ons). Si mpl e T, Y, or K connect i ons wi t h f ul l penet rat i on tubul ar groove wel ds. Bal anced T and cruci f orm j oi nt s wi t h parti al penet rat i on groove wel ds or f i l l et wel ds (except at tubul ar connecti ons). Member s wher e doubl er wr ap, cover pl ates, l ongi t udi nal st i f f eners, gusset pl ates, etc., t er mi nat e (except at tubul ar connect i ons). Si mpl e T, Y, and K type t ubul ar connect i ons wi t h parti al penet rat i on groove wel ds or f i l l et wel ds; al so compl ex t ubul ar connect i ons in whi ch load t ransf er is accompl i shed by overl ap (negati ve eccent ri ci t y, )gusset pl ates, ri ng st i f f eners, etc. F End wel d of cover pl ate or doubl er wr ap; wel ds on gusset pl ates, st i f f eners, etc. G T and cruci form j oi nt s, loaded in t ensi on or bendi ng, havi ng f i l l et or parti al penet rat i on groove wel ds. G' Si mpl e T, Y, or K connect i ons havi ng f i l l et or parti al penet rat i on groove wel ds. X Mai n member at si mpl e T, Y, and K connect i on. X Unrei nf orced cone-cyl i nder i nt ersect i on. X Connect i ons whose adequacy is det er mi ned by t est i ng an accuratel y scal ed steel model . K ( c| Si mpl e K type t ubul ar connect i ons in whi ch gamma rati o R/ T of mai n member does not exceed 24. Si mpl e T and Y t ubul ar connect i ons i n whi ch gamma rati o R/ T of mai n member does not exceed 24. (c) Ki nds of st r ess' 3 ' TCBR TCBR TCBR TCBR TCBR TCBR TCBR TCBR TCBR in branch member (main member must be checked separately per Category K or T). TCBR in member (weld must also be checked per Category G). TCBR in member. TCBR in branch member (main member in simple T, Y, or K connections must be checked separately per Category K or T; weld must also be checked per Category G'). Shear in weld. Shear in weld (regardless of direction of loading). Nominal shear in weld (P/A + M/S) Hot spot, stress or strain on the outside surface of the main member, at the toe of weld joining branch member measured in model of prototype connection, or calculated with best available theory. Hot spot stress at angle change. Worst measured hot spot strain, after shake down. Punching shear on shear area (d > of main member. Punching shear on shear area < d| of main member. (a) T = tension, C= compression, B = bending, R = reversal. (b, c) Empirical curves based on "typical" connection geometries; if actual stress concentration factors or hot spot strains are known, use of curve X is to be preferred. (d) Equation 1 ci ent number of fl uctuati ons of stress. Wher e t he fati gue envi ronment i n- volves stress cycles of varyi ng magni - tude and varyi ng numbers of appl i ca- t i ons, f ai l ure is usually assumed to occur (or reach a gi ven probabi l i ty level) when t he cumul ati ve damage rati o, D, reaches unity, wher e D = 2 n / N (8) and n = number of cycles appl i ed at a gi ven stress range N = number of cycles at that stress range correspondi ng to fai l ure (or a gi ven probabi l - ity of fai l ure) Some desi gners l i mi t t he damage ratio to 0.33 when using medi an or best fit fati gue curves, correspondi ng to a safety factor of 3 on computed fati gue l i fe. An al ternati ve approach, whi ch wi l l be presented here, is to use fati gue curves whi ch fal l on t he safe side of most of t he data. It mi ght be noted t hat a linear cumul ati ve damage rule is consi stent wi t h t he fracture mechani cs approach to fati gue crack propagati on (Ref. 14). Stress fl uctuati ons wi l l be defi ned in terms of stress range, t he peak-to- trough magni t ude of t hese fl uctua- ti ons. Mean stress is i gnored. In wel d- ed structures we usually do not know t he zero poi nt, as t here are residual stresses as hi gh as yi el d whi ch resul t f rom t he heat of wel di ng. Wher e t here is localized plastic def ormat i on duri ng shakedown, a new set of resi d- ual stresses develop. What is usually measured on t he actual structure (or a scale model) is t he strai n range, wi t h t he zero poi nt undefi ned. The con- stant strai n range approxi mat i on is in fair agreement wi t h t he resul ts of f a- tigue tests on practi cal as-wel ded j oi nts, parti cul arl y in t he l ow cycle range. Fatigue cri teri a are presented as a set of S-N desi gn curves (Fig. 16) for t he various si tuati ons categorized in Table 2. Curves A, B, C, D, E, F, and G are consi stent wi t h AISC fati gue cri teri a (Ref. 15), whi ch appear i n t urn to re- flect the data published earl i er by WRC (Ref. 16). Curves rather t han tabul ated (step functi on) al l owabl es W E L D I N G R E S E A R C H S U P P L E M E N T ! 199- s c 2 \o 3 a* c 5 o 6 io 7 i o 8 CYCLES Fig. 17 Fatigue curve C nominal stress adjacent to weld 102 103 IO 4 105 106 107 |08 CYCLES Fig. 18 Fatigue curves C and X hot spot strain adjacent to weld o 7 w* CYCLES, N Fig. 19 Punching shear fatigue strength of 7 -connections ate used because t hey ar e mor e ap- pr opr i at e t o t ubul ar st r uct ur es ex- posed t o a c ont i nuous s pec t r um of cycl i c l oads. I n t hes e s i mpl e si t ua- t i ons t he n o mi n a l me mb e r st r ess (f a + f b) f ai r l y we l l r epr es ent s t he act ual st r ess as wo u l d be me a s u r e d adj a- cent t o t he we l d . See Fi g. 17. Cur ve X i s based o n c ur r ent des i gn pr act i ces f or of f shor e st r uct ur es (Ref . 8). The r el ev ant st r ess f or f at i gue f a i l - ur e of t ubul ar c onnec t i ons i s t he hot spot st r ess meas ur ed adj ac ent t o t h e we l d , as s h o wn i n Fi g. 18. Thi s i s usual l y c ons i der abl y hi gher t h a n t he n o mi n a l me mb e r st r ess, and wo u l d nor mal l y be d e t e r mi n e d f r o m a de- t ai l ed t heor et i c al ( Ref s. 5, 6), or ex- 10* IO 3 K) 4 io 5 io 6 o 7 o 8 CYCLES, N Fig. 20 Punching shear fatigue strength of K-connections Fig. 21 Fatigue curves D and D' nominal member stress at full penetration T welds and simple joints 100 E' .
T TEE LAP ' | 0 2 C 3 IO 4 IO 5 IO 6 O 7 IO 8 CYCLES GUSSET Fig. 22 Fatigue curves E and E' let welds and complex joints OVERLAP nominal member stress at fil- per i ment al ( Ref s. 4, 7), anal ysi s of t he c onnec t i on. Cat egor y X i s c ons i s t ent wi t h cat egor y C s i nc e t he l ocal t r ans v er s e st r ess adj acent t o t he we l d is c ons i der ed i n bot h cases. I n t he r ange of i nel ast i c st r esses and l ow cycl e f at i gue (Ref . 17) it i s mo r e r eal i st i c t o deal i n t e r ms of hot spot st r ai n r at her t h a n st r ess. The dat a pl ot t ed i n Fi g. 18 r epr e- sent hot spot st r ess (or st r ai n) f r om act ual a s - we l d e d h a r d wa r e t ubul ar c onnec t i ons , pr essur e vessel s, l ab- or at or y model s and pr ot ot ype f ai l ur es f r o m a var i et y of sour ces ( Ref s. 13, 14, 16, 18, 19, 2 0, 21) . I n t he l o w cycl e r ange, t he des i gn cur ve c or r e- sponds t o r oughl y 9 5 % sur vi val ( 5 % f ai l ur e pr obabi l i t y) based on t est dat a wh i c h ar e spr ead out over a scat t er band mo r e t h a n one l og cycl e wi d e . Wi t h i n t hi s r ange, al l st r uct ur al q u a l - 2 0 0 - s I M A Y 1 9 7 4 ity steels show si mi l ar fati gue behavior, i ndependent of yi el d strength in t he range of 36 to 100 ksi: Di fferences whi ch show up for smoot h pol i shed laboratory spec- i mens in t he hi gh cycle range si mpl y do not apply to practi cal as-wel ded (notched) hardware subjected to l ocal - ized plastic strai ns in t he presence of a corrosi ve envi ronment (e.g., sea- water). Li ttl e data are available for t he high cycle range, over 2 x 10 6 cycles. In t he presence of i ni ti al f l ows and/ or corrosive envi ronment s, t here is no endurance l i mi t, and the fati gue strength conti nues to drop off. Unfortunatel y, use of curve X re- qui res knowl edge of stress concent ra- ti on factors and hot spot stresses wi t hi n t he tubular connect i ons i nf ormat i on whi ch woul d not be avai l - able to many desi gners. However, anyone shoul d be able to calculate punchi ng shear (equati on 1) and make use of the empi ri cal desi gn curves T and K (Figs. 19 and 20) for cyclic punchi ng shear i n, respec- ti vel y, T and K connecti ons. These are based on data assembl ed by Toprac (Ref. 21) f r om tests i n whi ch t he chord t hi nness rati o,"/ , was l i mi t ed to t he range of 1 8 to 24. Thus t he curves may err on the safe side for very heavy chord members ( 7 under 1 8), and they could be unconservati ve for chords wi t h 7 over 24. Si nce t he theoreti cal elastic punchi ng shear effi ci ency (Fig. 6) vari es i nversel y wi t h y - 7 , it is suggested t hat , for chords havi ng y greater t han 24, t he al l owabl e cyclic punchi ng shear be re- duced in proporti on to ( 24/ Y) 07 . Once f ai l ure of t he chord in t he punchi ng shear mode has been pre- vented, by t he use of heavy wal l "j oi nt cans" or by means of other j oi nt rei nf orcement , t he probl em of possible fati gue fai l ure i n t he braces remai ns. In si mpl e j oi nt s, localized stresses in the brace may reach 2.5 t i mes nomi nal f a + f b due to non- uni - f orm load transfer (a factor of about 2, Fig. 5), restrai nt to Poi sson' s-rati o breat hi ng (a factor of 1.6 for perfect axi symmetri c restrai nt), and cont i nu- ity wi t h t he severely def ormed chord. Accordi ngl y, curve D' (Fig. 21) when applied to nomi nal brace stress takes these factors i nto account. Data poi nts are for thick wal l ed si mpl e j oi nt s tested by Bouwkamp et al (Refs. 14, 19), for whi ch fai l ure occurred in the brace (branch member) rather t han in the chord (mai n member). Wher e some other f orm of j oi nt re- i nforcement is used (such as brace overlap, gussets, or rings) localized stresses i n the brace may become larger and more di ffi cul t to ascertai n and thus have to be desi gned accord- ing to curve E' (Fig. 22), whi ch i mpl i es stress concent rat i on factors as high as 6. However, it shoul d be stated also that for some connect i ons of t hi s type curve E is too conservati ve but unfortunatel y at thi s stage no di sti nc- ti on can be made. Curves D, E, F, and G are l i mi t ed t o si tuati ons in whi ch nomi nal member stresses represent act ual l oad transfer across t he wel d. Curve G' is shi fted down to a factor of 2.0 t o account for the uneven di stri buti on of load transfer across the wel d at t he tube-to-tube i ntersecti on (Ref. 5). The data supporti ng the empi ri cal desi gn curves, T, K, D', and E' general - ly show more scatter t han t he more basic data of Fig. 18, pri mari l y be- cause they neglect some of t he rel e- vant factors, and onl y represent " t ypi cal " connecti on geomet r i es. Wher e actual stress concent rat i on factors are known, t he use of curve X is to be preferred. Because of t he uncertai nty and scatter i nvol ved, cal cul ated fati gue lives shoul d be taken wi t h a heal thy amount of skepti ci sm, and shoul d be vi ewed more as a desi gn gui del i ne t han as an absolute requi rement of the code. Concl udi ng Remar ks The cri teri a presented have been developed pri mari l y on t he basis of re- search and experi ence wi t h fi xed off- shore pl at f orms. These structures are hi ghl y redundant, and localized t ubu- lar j oi nt f ai l ures can occur wi t hout leading to collapse of t he structure. One purpose in presenti ng thi s paper is to let potenti al desi gners of other classes of tubular structures see just how t he data fal l relative to the proposed cri teri a, and what t he scatter is, so that they may be in a posi ti on to evaluate t he sui tabi l i ty of the cri teri a for t hei r parti cul ar appl i ca- t i on. Al so, it is hoped t hat , as addi ti onal data become avai l abl e, t hey wi l l be compared agai nst t he cri teri a and data gi ven herei n. Such compari son, di scussi on, and r e- exami nat i on should eventual l y lead to a better desi gn. The authors are i ndebted to t hei r colleagues in t he various API , AWS, WRC, and ASCE task groups con- cerned wi t h wel ded tubular struc- tures, whose proddi ng and comment s helped shape t he gui del i nes present- ed here. References 1. API Recommended Practice for Plan- ning, Designing, and Constructing Fixed Offshore Platforms, API RP 2A, Fourth Edition (1973). 2. American Welding Society Structural Welding Code, AWS D1.1 -72 (1 972). 3. British Standard 449-1959 Appendix C, "Determination of the Length of the Curve of Intersection of a Tube with An- other Tube or with a Flat Plate", and British Standard 938-1 962, Spec, for Gen- eral Requirements for the Metal Arc Weld- ing of Structural Steel Tubes to B.S. 1775. 4. Toprac, A. A., et al., "Welded Tubular Connections: An Investigation of Stresses in T-Joints" Welding Journal, Vol. 45, No. 1, January 1966, Res. Suppl., pp. 1-s to 12-s. 5. Dundrova, V., Stresses at Intersec- tion of Tubes Cross and T-Joints, The University of Texas, S.F.R.L. Technical Report P-550-5( 1966). 6. Greste, Ojars, A Computer Program for the Analysis of Tubular K-Joints, University of California Structural Engi- neering Lab. Report No. 69-19(1969). 7. Beale, L. A., and Toprac, A. A., Analysis of In-Plane T, Y and K Welded Tubular Connections, Welding Research Council Bulletin 125, New York, N.Y., Oc- tober 1967. 8. Marshall, P. W., et at, "Materials Problems in Offshore Platforms," Offshore Technology Conference Preprint No. OTC 1043(1969). 9. Reber, J. B "Ultimate Strength De- sign of Tubular Joints," Offshore Technol- ogy Conference Preprint No. OTC 1664 (1972). 10. Graff, W. J., "Welded Tubular Con- nections of Rectangular and Circular Hol- low Sections," paper for presentation to the Texas Section, ASCE, El Paso, October 8-10,1970. 11. Toprac, A. A., et at, Studies on Tubular Joints in Japan Part I Review of Research Reports, report prepared for Welding Research Council, Tubular Struc- tures Committee, September, 1968. 12. Bouwkamp, J. G., Research on Tubular Connections in Structural Work, Welding Research Council Bulletin No. 71, 1961. 13. Bell, A. O., and Walker, R. C, "Stresses Experienced by an Offshore Mobile Drilling Unit," Offshore Tech- nology Conference Preprint No. OTC 1440 (1971). 14. Becker, J. F., et at, "Fatigue Failure of Welded Tubular Joints," Offshore Tech- nology Conference Preprint No. OTC 1 228 (1970). 15. American Institute of Steel Con- struction, Specifications for Design, Fab- rication and Erection of Structural Steel for Buildings, New York, N.Y., February 12, 1969. 16. Munse, W. H., and Grover, L., Fa- tigue of Welded Steel Structures, Welding Research Council, New York, N.Y. 1964. 17. Peterson, R. E., "Fatigue of Metals in Engineering and Design," ASTM Mar- burg Lecture, 1962. 18. Kooistra, L. F., Lange, E. A., and Pickett, A. G., "Full-Size Pressure Vessel Testing and its Application to Design," ASME Paper 63-Wa-293, 1 963. 19. Bouwkamp, J. G., Tubular Joints Under Static and Alternating Loads, Uni- versity of California, Structures and Mate- rials Research Report No. 66-15, Berk- eley, June 1966. 20. Toprac, A. A., and Natarajan, M.,An Investigation of Welded Tubular Joints: Progress Report, International Institute of Welding Comm. XV Doc. XV-265-69, June 1969. 21. Toprac, A. A., Design Consid- erations for Welded Tubular Connections, Report prepared for Welding Research Council, Tubular Structures Committee, December 1970. W E L D I N G R E S E A R C H S U P P L E M E N T ! 201- s 1974 Revisions to Structural Wel di ng Code The 1974 Revisions to Structural Welding Code (AWS Dl .l -R e v 2-74) contains the second set of authorized revisions to the Structural Welding Code, Dl.1-72. For convenience and overall economy in updating existing copies of the Code, 88 pages of the Code have been reprinted, 59 of which have been revised to incorporate changes. (The remaining pages are not changed but appear on the reverse side of revised pages.) To fulfill the needs of all Code purchasers, the 1974 revisions are avail- able as a bound book and as individual looseleaf sheets. The bound copies are intended primarily for libraries and others who wish to keep their original copies of the Code, as well as the subsequent revisions, intact. The looseleaf version will be ideal, however, for those Code users who plan to update their present Codes by inserting the revision pages into them. With the looseleaf pages, the time-consuming process of cutting, pasting, or tearing out will be avoided. To update the Code, old pages are simply removed and the new revised pages inserted in their place. All pages are 8V2 in. * 11 in. and are punched for three-hole looseleaf or post binders. All pages revised for 1974 are listed on the contents page, and all changes in figures and tables are enumerated and described immediately following the contents page. Changes in text material are denoted in bold italics; deleted material is crossed through with double lines. (The 1974 revisions can thus be distinguished from the 1973 revisions which are designated by regular italics and single cross-through lines.) The new pages are printed on blue stock, and pages containing 1974 (and/or 1973) revisions are clearly labeled. These are the principal changes in Code requirements: SMAW fillet welding of studs is now permitted. The prequalified status of joints welded by short-circuiting transfer GMAW has been removed. Camber tolerances of welded members have been revised. SNT qualification of all NDT operators is now required. Additions and deletions have been made to the lists of prequalified steels for buildings, bridges, and tubular structures. Bridge design criteria relating to fatigue stress have been eliminated. 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