PROJECT REPORT

on

Course No. 10109

ByT.VIJAYAKUMAR AXEN/FBW/AJJ, S. RLY S.ARUMUGAM ARULAPPAN AXEN/CN/TBM, S.RLY

H.S.SAXENA, AXEN(CON)/CCG, W. RLY

Acknowledgement
We are grateful to

Sri V.B.SOOD, Professor Bridges

Who has guided us right through the study of this project. We are also thankful to-

Sri N.K.KHARE, Course Director.

For having helped us in training programme.

INTRODUCTION

Open web girders are used for track bridges over valleys and large rivers. Standard length of open web girders in railways are 30.5, 45.7, 61.0 and 76.2 metres. Engineering workshops, Arakkonam is fabricating welded type girder since 1981. Present production capacity is 80 MT per month. With the past experience in welded girder fabrication, this workshop taken up the work of fabrication open web girder 30.5m span for SC Railways in Purna - Akola section. Subsequently EWS/AJJ has manufactured 4 spans of open web girder 45.7m span for Nethravathi Bridge. Presently, fabrication of 61.0m riveted type girder of 10 3 spans for North Eastern Railway is under progress.

SALIENT FEATURES OF OPEN WEB GIRDER

RDSO Drg No. BA 11461 to BA 11479 (M.B.G. Standard) Weight of girder 65 MT Overall length of girder 32.460m Effective length of girder 31.926m (Center to center of Bearings) Height of girder 7.637m Width of girder 5.760m Type of loading MBG Loading
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Flow Process Chart for Fabricating Open Web Girder

INSPECTION OF WELDED TYPE GIRDERS

INSPECTION BEFORE WELDING INSPECTION DURING WELDING

INSPECTION AFTER WELDING

INSPECTION BEFORE WELDING

Inspection of raw steel and its conformation to IS : 2062 Gr. B killed and normalised variety for plates over 12 mm thick. For plates of 10 mm and 12 mm thick, the condition of normalisation is not necessary. In the absence of SAIL or Mill certificate, samples of plates with code no. are being tested at ACMT/LAB/EWS/AJJ. Preparation of welding procedures specification sheets for various welds involved in the fabrication of a particular span. Welding procedure qualification records and approval of welders are to be taken up after the approval of WPSS is received. (Ref. IS - 7307 part I and IS 7310 part I). Whether welding consumables are of the brands as per the latest instructions received from RDSO, as supplemented to IRS-M.28 and IRS-M.39. Transferring of cast number to cut pieces from parent metal.

INSPECTION DURING WELDING

Checking whether approved welding consumables are used by the welders. Checking whether the approved welders do the weld. Checking the approved parameters for welding is being employed and are being recorded in the register. Checking for any distortions and suggesting methods to minimize them. Marking defects etc observed during the inspection for rectification. Attempts to make I-section or any other member is permitted only after passing Radiographic Test on the Butt welded joint.

INSPECTION AFTER WELDING

The fillet welds are checked by visual and Dye-penetrant test. Defects noticed are to be rectified and details are recorded. Etching tests. Radiographic film test.

VISUAL INSPECTION
The finished welds shall be visually inspected and shall conform to the size and contour specified in the drawing. The following types of defects can be detected during visual inspection. Weld defects at the surface such as blow holes, pipes, exposed porosity, exposed inclusions, etc. Surface cracks in the weld metal or in the parent metal adjacent to it. Damage to the parent metal such as undercut, burning, overheating, etc. Profile defects such as excessive convexity, concavity or unequal leg lengths etc. Incorrect finish, uneven welds, spatter, etc.

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DYE PENETRANT TEST

In the dye or liquid penetrant testing, a suitable liquid penetrant is applied to the surface of the portion under examination and remains there for a sufficient time to allow the liquid in to any defect open at the surface. After the penetration time, the excess penetrant which remains on the surface is removed. Then, a light color absorbent called developer is applied on the surface. This developer acting as a blotter draws out a portion of penetrant which had earlier seeped in to the surface opening. As the penetrant is drawn out, it diffuses in to the coating of the developer forming the indication of the surface discontinuities as a flaws.
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Defects noticed in D.P. Test

Blow hole ( Enlarged view )

After rectification of defects

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ETCHING TESTS

Etching tests on run-off coupons and at the edges of girders for checking the root fusion and throat length. Etching tests are conducted on smooth, clean surface by

applying 2 % nitric acid. cleaning it with water. cleaning it with alcohol

Then check the leg length, throat and penetration and recording the details in Etching Test Register.

RADIOGRAPHIC FILM TEST

Butt joints, if any, have to be done by submerged arc welding and radiography (Gamma Ray) testing has to be done to ensure the quality of weld. In radiography, the ability of short wave length radiations such as X-ray and Gamma rays to penetrate the object opaque to ordinary light is utilized to produce a shadow of any internal defect or image. To check the Internal defects of weld in Butt Weld Joints on Flange and Web plate Joints. For radiographic examination, Iridium 192 isotope is used. Radiographic tests are conducted as per IS : 1182 / 1983.
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NUMBERING OF PANEL POINTS

30.5 m Span OWG

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CAMBER IN STEEL GIRDER

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CAMBER IN STEEL GIRDER Contd..

Steel triangulated (open web) girders are provided with camber to compensate the deflection under load. Out of the total design camber, the part corresponding to dead load is called dead load camber. The balance is called live load camber which should be available as visible and measurable camber in the girder when not carrying the live load

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MAIN COMPONENTS OF OPEN WEB GIRDER

PRIMARY MEMBERS

SECONDARY MEMBERS

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19

PRIMARY MEMBERS
Bottom chord Top chord End Rakers Diagonals Vertical members Floor system

Cross girders Rail bearers or stringers

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SECONDARY MEMBERS
Bottom lateral bracings Top lateral bracings Sway bracings and knee sway Portal bracings and knee portal Corner brackets End stools and end bracket Main gussets Bearings

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BOTTOM CHORD

22

TOP CHORD

23

END RAKERS

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DIAGONALS

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VERTICAL MEMBERS

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FLOOR SYSTEM CROSS GIRDERS

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RAIL BEARERS OR STRINGERS

FLOOR SYSTEM

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TRIAL ASSEMBLY AT THE WORKSHOPS

Selection of assembly site

Erection facilities
Assembly Camber measurement
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SELECTION OF ASSEMBLY SITE

The assembly of Girder has to be done on a firm and leveled platform. Hence, the concrete platform available nearby the Structural Shop was selected.

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ERECTION FACILITIES

Road mobile crane was utilized for erection. Gantries and Hoist were arranged since the height of the crane was only 9m and the requirement was about 10m for handling the top chord and diagonal.

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ASSEMBLY

The bed for assembly was made with ISMB 400 mm and packing plates about 200mm to facilitate assembly. The bed was checked and leveled with water level.

32

Contd..
Bottom chords 2 nos. were laid from one end with bottom gussets and the cross girders assembled in between bottom chords, also stringers in between cross girders.

Contd..

Black bolts 50 % and drifts 50 % are used for connecting the joints. (In fields 40 % holes filled with drifts and remaining with black bolts as per manuals.)

Contd..

Similarly the successive bottom chords were laid with cross girders and stringers. Bottom laterals were assembled in position. The cross measurement and diagonal measurements checked and tightened all the black bolts. Insert the camber jacks over platform below every bottom panel joints in such away that all the joints are in run out condition except central jack.

Levels were taken at top of bottom chord at every nodal joint

Contd..

Erect all the vertical members at nodal point and diagonals were fixed subsequently with temporary gussets. (Gussets holes are drilled for the camber profile) Check to ensure that chords is in one level. bottom

36

Contd..

Provide camber to all panel joints of bottom chords as per camber diagram by lowering the jacks at the ends, keeping central jacks with out disturbing.

Check the correctness.

camber

readings

and

adjust

for

37

contd

Top chord members are to be elastically strained, so that erected from centre to outwards. Temporary gussets were replaced with permanent gussets before drifting. Drifts are driven with hammer, check for trueness of holes in the adjacent group holes. Care should be taken so that holes are not damaged.( elongated or teared).

Contd..

5 Ton Pulley block was used for assembling the members to keep the joint in position. End Rakers were erected in the last, the upper end was first connected and drifted, then connection was made at lower end. Sway bracings, top laterals bracings and portal bracing were erected subsequently. All joints were tightened and drifted.

39

Contd..

Lowered the jacks duly keeping the end supports in position. Dead load camber was checked by leveling instrument, also with water level. The measurements recorded as L1-11 mm (13.1 mm) , L2- 22 mm (21.0 mm) , L3- 26 mm (26.3 mm) ,L422 mm (21.0 mm) and L5- 10 mm (13.1 mm).

COST OF THE GIRDER (Per MT)

Revenue Rate Descriptio Cost n (in Rs.) Stores Labour Labour Oncost Stores Oncost Total 41459.0 4 26791.9 8 31346.6 2 1607.52 Home Rly. Rate Description Revenue Rate Proforma Oncost @ 41% Cost (in Rs.) 101205.00 Foreign Rly. Rate Description Revenue Rate Proforma Oncost @ 91% Freight Freight Total 3014.66 128057 Cost (in Rs.) 101205.0 0 52906.13

23836.83

3014.66

Supervision Profit

4608.12 10882.79
172617
41

101205

Total

PROBLEM ENCOUNTERED & REMEDIAL MEASURES.

The Bottom chords after fastening with bolts and drifting, the jacks were lowered for the camber but due to the shorter length of bottom chord member, the camber not formed. Solution: The bottom chord joints were loosened and replaced with under size bolts and also removed drifts , then achieved the required camber after erecting the top chord and end rakers.

Care was taken to drive the drifts and close supervision was made to avoid elongation and tearing of drilled holes in gussets and members.

PROBLEM ENCOUNTERED & REMEDIAL MEASURES.

Leveling instruments were tried to measure the camber. It was a failure due to the poor accuracy in reading on a length of 30M.

Measuring of camber with Piano wire 0.5mm DIA, 10 kg weight at both end as per bridge code was a failure due to sag in 30M length. Solution: Water level with a diameter of 6 mm and length of 40M was used to check the level of the girder.

PROBLEM ENCOUNTERED & REMEDIAL MEASURES.

Slight deformation of the chord members fabricated by welding has been observed and some gap was formed between top chord end and junction U1. Solution: Jacks were used to close the gap by lifting the floor system. Further, 5 Ton pulley block was used to erect the member in position.