Advantages of steel bridge girders

• Low dead weight to live load ratio

• Less seismic forces due to above
• Shallow construction depth, slender
appearances and low embankment height
• Speed of construction once jigs are made
• Least disturbance in urban areas (ROBs too)
• Longer life and scrap value low Life Cycle Cost
 Fixing of formation Levels
Rail Level (RL)
Open Web
RL
3.50 m
PSC Box 1.25

PSC Girder RL to Bottom Open Web RL to Bottom

of girder Girder of girder

24.4 M PSC box 2800 mm 30.5 m Welded 1250 mm

25 T (B-10270) 25 T (B-11678)
 Some important Instructions
• As per Railway Board’s letter No. 2005/CE-
I/BR-II/8 dated 28-05-2009 - All new bridges
of span > 24.4 m would be of steel only
(composite also)
• STR - Standard Technical Requirement for
being eligible for approval by RDSO/tendering
for Railway bridges
 TYPES OF GIRDERS ON I.R.
BY TYPE OF CONNECTIONS
• Welded Girders
• Riveted Girders
• Bolted Girders
BY TYPE OF CONSTRUCTION
• Open web girders
• Plate girders
• Foot over bridges
• Turn tables
PLATE GIRDER COMPONENTS
 ISOMETRIC VIEW OF PLATE GIRDER
Span GAD Drawing No.
25 T Loading DFC 32.5 T
Loading
12.2 m RDSO B-16014 RDSO B-16017
18.3 m RDSO B-16015 RDSO B-16018
24.4 m RDSO B-16016 RDSO B-16019
 Lighter than
plate girder
but entails
higher care
in
fabrication
and thus
higher per
ton costs
OPEN WEB GIRDER
 Numbering of Nodes and members of
OWG

(Right Side Truss of OWG)

Left Side Truss of OWG L0’ L1’, L2’ …& U0’, U1’, U3’…
ASSUMPTIONS IN DESIGN OF OWG
• All members are straight and free to rotate at joints
• All joints lie at the intersection of centroidal axis of
the member
• All loads including weight of members are acting at
joints
Span GAD Drawing No.
25 T Loading DFC 32.5 T Loading
30.5 m RDSO B-11678 RDSO B-17061
45.7 m RDSO B-17001 RDSO B-17081
61.0 m RDSO B-17021
76.2 m RDSO B-17041
RDSO STANDARD OWG SPANS
Open Web Girder
Deck type Bridge/Under slung Girder
 COMPOSITE GIRDERS
• Drawings available for
– Plate girders
– ROB girders

• Shear Connectors
 STITCHING OF GIRDERS
• Riveted girders
• Welded girders
• Welded v/s Riveted Girders
– Riveted requires holes and overlaps so extra steel
– Require rolled sections – only in discreet sizes
– Making rivets is cheap
– Riveted easier – only matching of holes important
– Less stress concentration in welded – better fatigue
performance
– More inventory of steel sections in riveted
– Welded requires stricter quality control
 CONNECTIONS IN ASSEMBLY AT SITE
• Riveted – The only method
as per RDSO drawings even
for welded girders
• Bolted – HSFG bolts – Use
started as per ROB drawings
• Welded – Field welding not
permitted as per WBC. To
be used in Bogibeel Bridge
for first time for Railway
Bridges
HOW TO DOWLOAD BRIDGE DRAWING
FROM RDSO WEBSITE
(Please note that the drawings are accessible only if
you are on RAILNET and not on general INTERNET)
•1ST METHOD – Go to IRICEN web site - http://
www.iricen.indianrailways.gov.in
•Click on “Contact us” on extreme RHS
•Click on “Link to Websites” menu option
•Click on “Indian Railway Sites” option
•Click on “Railnet Sites” option
•Click on link to “RDSO”
HOW TO DOWLOAD BRIDGE DRAWING
FROM RDSO WEBSITE
• Click on “Directorates” tab
• Click on “Bridges & Structures” link
• Click on “B&S Drawings” link
• Select Topic
• Select the span and type (the set of drawings is
visible)
• Click on the individual drawing (drawing opens)
• To save the drawing – Right click the mouse and
select option “Save Image as” and save the
drawing on your hard disk/pen drive
HOW TO DOWLOAD BRIDGE DRAWING
FROM RDSO WEBSITE
• 2ND METHOD – Go to INTERNET
• Type 10.100.2.19 (RDSO railnet site opens)
• Click on “Directorates” tab
• Click on “Bridges & Structures” link
• Click on “B&S Drawings” link
• Select Topic
• Select the span and type (the set of drawings is visible)
• Click on the individual drawing (drawing opens)
• To save the drawing – Right click the mouse and select
option “Save Image as” and save the drawing on your
hard disk/pen drive
 FABRICATION

• The process of building up / putting together,

properly shaped individual components (rolled
section & plates) to form the desired
structure
– Tested steel of required quality
– Appropriate design and drawings
– Well equipped workshop
– Experienced and skilled staff
– Inspection at every stage
 WELDED GIRDERS
• The girders where jointing of members is
done by welding are called welded girders.

• For smaller jobs not very suitable because

of practical difficulty of non-availability of
required infrastructure, trained manpower,
special quality steel and other machines
etc.
 RIVETED GIRDERS
• The girders where jointing of members is
done by riveting are called riveted girders

• Earlier used as welding techniques were not

very well developed

• Fatigue characteristics not very good and

ensuring the quality is difficult

• Used mostly by railways only in India.

 BOLTED GIRDERS
• The girders where jointing of members is
done by bolting are called bolted girders

• Not used due to the possibility of loose

bolts in service

• Friction grip bolts can be used, but not very

popular at the moment in India.
 AUTHORITY FOR INSPECTION
Welded Open Web RDSO
Girders
Riveted Open Web Railway Workshops by
Girder RDSO
Trade by
RDSO/Railway
Welded Plate Girders First 1000 MT by RDSO
Further by Railways
Welded Composite First 1000 MT by RDSO
Girders Further by Railways
Inspection by RITES/IRCON to be discontinued
 WELDED GIRDERS

• MATERIALS
– Parent metal as per IS:2062
– Filler wire & flux for submerged arc
welding as per IRS specification M-39
– Wire for CO2 welding as per
RDSO/M&C specification
 WELDED GIRDERS
• ADVANTAGES
– Lightweight, particularly for BG (up to 25%)
– Cheaper
– Less inventory, different sections are not required
– Easier splicing
– Require less maintenance
– Better appearance
• NOTE:
– Even for welded girders, connections are made by
rivets only as field welds are not allowed

– Stiffeners in plate girders are riveted as the welded

stiffeners lead to distortion and stress concentration
 QUALITY CONTROL: STAGES
• Suitability of the workshop
• Quality Assurance Plan
• Actual Quality Control
 WPSS/WPQR
Pre-fabrication Stage
 During Fabrication
Post fabrication
 WELDED GIRDERS
• PRE-REQUISITES
– Highly skilled and trained manpower for
welding
– More stringent quality control during
execution
– More sophisticated machines for execution
– Special quality steel is required
– better infrastructure for execution i.e.
covered shed for welding and other
activities
 FABRICATION STANDARDS
• IS:2062, IS:1852, IS:808 For Structural Steel
• IRS B1-2001 (Fabrication Specification)
• Indian Railway Bridge Manual
• IS:1148, IS:1929 For Rivets
• IRS Welded Bridge Code
• IS: 814, IS:816, IS:822, IRS M-28, IRS M-39 For
Welding
• IRS Steel Bridge Code
• Schedule of Technical Requirements (STR) issued
by RDSO
• Special conditions of Contract
(For foot over bridges, RDSO has issued letter No FOB/CBS in
March 2008 – Basically covers the provisions of IRS:B1)
 WELDED GIRDERS
• Detailed quality assurance plan (QAP) to
be prepared before starting the work:
– Raw material inspection
– Manufacturing process
– Welding parameters prior to
commencement of fabrication
– Fabrication of members
– Riveting work
– Final inspection & clearance
– Metallising and painting
 TESTED STEEL OF REQUIRED
QUALITY
• IS:2062 GR.A SEMI KILLED OR KILLED - For
fob and other structures subjected to non –
critical loading, including foot over bridges

• IS:2062 GR.B0 FULLY KILLED AND

NORMALIZED – For welded/riveted girders
subjected to railway loading (if service temp.
Does not fall below 0 oc ).Plates less than 12
mm. Thick need not be normalized

More than 12 mm thick plates should be

ultrasonically tested
TESTED STEEL OF REQUIRED
QUALITY
• IS:2062 GR.C fully killed and normalized – For
welded/riveted girders subjected to railway
loading (if service temp. Falls below 0oC).
Plates less than 12 mm. Thick need not be
normalized

(Rolled sections like angles, channels, I –

sections etc. Conforming to IS:2062 Gr. A may
be used in the structures till such time rolled
sections conforming to IS:2062 Gr.B/C are not
available)
TESTED STEEL OF REQUIRED
QUALITY
• KILLED
– Process of reducing the dissolved oxygen to
a minimum
– Achieved by addition of silicon , aluminium
to prevent reaction between carbon and
oxygen
– Silicon percentage between 0.1 to 0.4
– in MTC (manufacturer’s test certificate),
remarks are given such as al killed, Al-Si
killed
TESTED STEEL OF REQUIRED
QUALITY
• NORMALISATION
– The process of heat treatment for
improving the mechanical properties
– Resulting into grain refinement and
uniformity in structure of steel
– MTC should clearly specify whether steel is
normalised or not
TESTED STEEL OF REQUIRED
QUALITY
• All the steel should be supplied with
manufacturer test certificate (MTC)
• MTC should specify
– The specification to which steel conforms
– Whether killed/normalised
• Statement Of Material Test Certificates
Should Be Maintained As Per Sr. No. 7 Of
Appendix I of B1-2001
 STATEMENT OF MATERIAL
TEST CERTIFICATES

One Page should be allotted for each span

 TESTED STEEL OF REQUIRED
QUALITY
• Steel for rivets shall be as per IS:1148

• For field riveting, rivets to IS:1149 are used

(higher strength)

• When the steel is received without any test

certificate , the sample should be sent for
testing
 CAST/ HEAT MARK NUMBER
AND TEST CERTIFICATES
• The cast mark No. Should be transferred to
each and every piece to be cut before actual
cutting of plates

• One sample from every cast mark should be

sent for testing in the lab

• Sampling should be done in the presence of

inspecting agency and should be sent to the
laboratory after stamping by him
HEAT MARK
Transferring of heat mark
 APPROPRIATE DESIGN AND
DRAWINGS
• Work should be executed as per approved
drawings

• All the drawings should be checked thoroughly

before starting execution

• If any particular section is not available , the

possibility of using alternative section may be
explored
WELL EQUIPPED WORKSHOP

• WORKSHOP MAINLY CONSISTS OF—

1. TEMPLATE/JIG SECTION
2. CUTTING SECTION
3. TACK ASSEMBLY FIT-UP SECTION
4. WELDING SECTION
5. DRILLING SECTION
6. INITIAL ASSEMBLY SECTION
7. RIVETING SECTION
8. FINAL ASSEMBLY SECTION
9. INSPECTION
10. PAINTING SECTION
11. DISPATCH SECTION
 WORKSHOP FLOW CHART
FOR FABRICATION
Raw Material Cutting Straightening
from Workshop Section Section

Tack assembly
Welding
section
(If required)
(Jig Fixing)

Initial Light Member

Drilling
Assembly sections

Riveting Inspection
Final Assembly
(If required) (including RDSO)

Dispatch Painting
1. TEMPLATE/JIG SECTION
– Templating is nothing but drawing the complete structure on full
scale (1:1)
– Normally half span is drawn on a leveled smooth concrete/steel
floor(other half - mirror image)
– Start with lower point of middle vertical as it deflects at right
angles to the bottom chord & mark bottom camber point as given
in drawing
– Mark nodal camber points by compass method from two
individual points.
– Nominal as well as camber layout will be drawn on the floor.
Length of members as per camber layout
– Complete the drawing & ensure that L0 point coincides on both
nominal & camber drawing.
– The jigs/masters jigs for main gussets will be fabricated using
nominal layout

–
TEMPLATE/JIG SECTION
TEMPLATE/JIG SECTION
• Layout is drawn to—
– To get unknown lengths
– To verify the camber diagram
– To fabricate the jigs/master jigs
– To verify the end profile of members at the joints

Size of the template shop dictates the max. Length of

the span which can be fabricated in shop.
Layout of Joints and Master
template
 NOMINAL LAYOUT

SYMMETRICAL/ MIRROR IMAGE

 TEMPLATE/JIG SECTION
• Jigs are the device used in the mass production of standard
jobs for drilling holes without marking for gusset/members
• Jig is the member with drilled holes of one component, so
that by placing this jig over the component ,holes can be
drilled in that component
• For Guiding The Drilling Tool And To Prevent Over Sizing Of
Holes Of Jig, Bushes Or Ferrules Are Provided Over The Jigs
• The internal dia. of bushes should be within tolerance – 0.0
mm to + 0.1 mm .When the bores exceed a tolerance of – 0.0
mm to +0.4 mm ,the bushes shall be rejected
TEMPLATE/JIG SECTION
For every working jig one master plate should
be fabricated. This master plate is used only
for checking the working jigs. Tolerance for
checking jigs from master plates shall be +0.0
mm to - 0.13 mm.

Details of all the jigs required for fabrication to

be maintained in a register as per item no.1 of
appendix I of B1 – 2001 . For every type of jig ,
one page should be allotted.
 FORMAT OF JIG REGISTER
DESCRIPTION OF JIG:
JIG NO. :
SHIPPING MARK OF THE COMPONENT FOR WHICH THE JIG IS
MADE :
DRAWING NO. FOR THE COMPONENT:
DATE OF OBSERVATIO COMPLIANCE INITIAL OF
INSPECTION N/ ACTION SUPERVISOR
INSPECTION IN CHARGE
NOTES
TEMPLATE/JIG SECTION
• All The Jigs Should Be Fabricated In Such A
Way That Identical Type Of Members &
Gusset Plates Should Be Interchangeable
• If the girder is made completely
interchangeable, then only the first span is
required to be erected completely in
contractor’s workshop
ELSE
• Each and every span is required to be
erected in the shop
TEMPLATE/JIG SECTION
• Requirement of precise jigs and
fixtures is very critical for open web
girders, for plate girders, the
requirement is not so stringent

• Foot over bridges are fabricated by

welding without use of jigs and
fixtures, even at site
2. CUTTING SECTION
• PLATES ARE CUT INTO DESIRED LENGTH USING
– Ordinary oxy acetylene cutting torch
– Pug cutting machine
– Profile cutting machine
– Guillotine shear machine( faster but for plates up to 10
mm thickness)

• ANGLES ARE CUT INTO DESIRED LENGTH USING

– Shaper Machine
– Shearing And Punching Machine
– Circular Saw Profile Cutting Machine
CUTTING SECTION

• Cutting allowance—
– 3mm up to 25 mm thickness
– 4mm up to 40 mm thickness
– 5 mm excess in width above 40 mm thickness
• After cutting it should be ensured that all the edges are
clean, reasonably square and true
• Cut material 200 mm Excess on both sides for Run In
&Run Out for members to be welded
• Use Double head cutting machine for long plates, single
head for gussets& hand cutter for angles/channels/flats
etc.
 Material straightening & dressing.

• Ensure quality of material before Cutting.

• Control distortion within permissible limit
during cutting
• Bent plates can be straighten on plate
straightening M/c& angles, channels on
hyd. Press after cutting.
• Pneumatic hand grinding is used to remove
mill scale
Plate Straightening Machine
Grinding for uniform Edges
Grinding of the
surface for
welding
3.TACK ASSEMBLY SECTION

• Steel sections after cutting to required size and

straightening will be brought to this section for
temporary assembly with tack welding/ bolting to
form a member so that it will be placed in fixture
for welding. jigs will be placed over tack assembled
member and clamped together for drilling holes.
 Marking & Tack welding
• Mark using line thread, chalk, tape, T-
square etc as per working drawing
• Place all mating parts in tacking fixtures
• Tack weld with MMAW @ 300 to 500 mm
apart
• Length of tack be@ 25 to 50 mm
• Tack alternatively on both sides to avoid
distortion
• Remove Slag
 4. WELDED GIRDERS
• WELDING
– AS PER IRS WELDED BRIDGE CODE
– ALL THE WELDS SHOULD BE DONE BY
FULLY AUTOMATIC/SEMI AUTOMATIC
SUBMERGED ARC WELDING
– MANUAL METAL ARC WELDING
(MMAW) / CARBON DIOXIDE
WELDING (CO2) FOR WELDS OF VERY
SHORT RUNS/OF MINOR
IMPORTANCE/WHERE LOCATION IS
NOT ACCESSIBLE FOR SAW
PERFORMANCE QUALIFICATION TEST/
WELDER APPROVAL TEST RECORD
– The welder shall undergo different tests
for different variables. The following
variables will require separate
qualification

1. Welding process

2. Welding position

3. Plate thickness

79
 PREPARATION OF SAMPLE JOINT
 IS : 7307 ( Part-1) – Requirements for the approval test
for welding procedure for carbon & carbon manganese
steel. Salient features for welding procedure test records
are as per this specification

 IS : 817 Part-I-1992 – Training of welders, Code of

Practice - Shielded Metal Arc Welding

 IS : 817 Part –II- 1996 – Training of welders, Code of

Practice – Oxy- Fuel welding

 IS : 7310 Part -I-1974 – Approval test for Welders

working to approved Welding procedure

80
APPROVAL TEST FOR WELDERS WHERE
WPQR NOT REQUIRED

 IS : 7318 Part-I-1974 – Approval test for

welders, when welding procedure not
required – Fusion welding of steel.

 IS : 7318 Part-II-1974 – Approval Tests

for welders, when welding procedure
approval is not required – TIG/MIG
welding of Alluminium & its alloy

81
 WELDED GIRDERS
• WELDING PROCEDURES
– PREPARATION OF WELDING PROCEDURE
SPECIFICATION SHEET (WPSS) AS PER
ITEM 1 OF APPENDIX V OF B1-2001
– THE SPECIMEN OF ADEQUATE LENGTH
(300MM LENGTH), USING THE SAME
SECTIONS AS TO BE USED FOR ACTUAL JOB,
ARE PREPARED USING PROPOSED
WELDING VOLTAGE, SPEED OF TRAVEL)
– THESE SPECIMEN ARE TESTED IN
LABORATORY AND IF TEST RESULTS ARE
FOUND OK, THE WPSS WILL BE APPROVED
AND ADOPTED FOR ACTUAL JOBS.
 WELDED GIRDERS
• WELDING PROCEDURES
– THE WELDING PARAMETERS
APPROVED IN WPSS SHOULD BE
FOLLOWED IN ACTUAL WELDING AND
SHOULD BE KEPT WITHIN
FOLLOWING LIMITS.
• WELDING CURRENT ±10%
• ARC VOLTAGE ±7%
• SPEED OF TRAVEL ±15%
 WELDED GIRDERS
• WELDING PROCEDURES
– FOR DIFFERENT SIZES OF WELDS
SEPARATE WPSS WILL BE PREPARED
– FOR DIFFERENT SECTIONS AND
COMBINATIONS, SEPARATE WPSS WILL
BE PREPARED
– WPSS SHOULD INDICATE THE SEQUENCE
OF WELDING AND WELD PASS
Welding Procedure Specification Sheet
(WPSS)(Prepared for each type of Joint seperately)
1. Name of Fabricator
2. Welding Procedure Specification No.
3. Drawing No.
4. Weld Joint Description
5. Base Metal
6. Welding Process
7. Welding Consumables- Electrode/Wire
Flux
 WPSS contd……
8. Joint Details with sketch
9. Welding current: Type- , Polarity-
10. Welder’s Qualification: As per IS:7310 Pt-I-1974
11. Welding Parameters: Weld Pass
Electrode/Wire dia
Current (Amps)
Arc Voltage (Volt)
Wire speed (m/min.)
Travel Speed (m/min.)
Electrode stickout (mm)
 WPSS contd…….
12. Welding Technique:- welding from run-on
to run-off tabs at the free ends
13. Rectification of weld defects-
•By grinding the defective weld
•Rectification by filling the gap using A2 class of electrode
of Specification IRSM 28 after conducting the D.P. test
14. Inspection of weld: Visual,
Dye Penetration Test
Macro Etching Test
 Welding Procedure Qualification Record
(WPQR)(Prepared for each welder)
1. Name & Address of the fabricator
2. Description of weld Joint
3. WPSS No.
4. Name of welder with Photo
5. Date of welding
6. Dimension of test piece
7. Base Metal
8. Welding Process
 WPQR contd……
9. Welding position
10. Welding current- Type & Polarity
11. Joint details with sketch
12. Details of welding consumables- Wire & Flux
13. Welding parameters
14. Testing of weld sample
(a) Non destructive Tests- Visual & DPT
(b) Destructive Tests- Macro Examination & Fillet
weld fracture.
 Re-approval of Welder (IS:-7310 Pt-1)
1. The employer shall certify at every six months about
the reasonable continuity and satisfactory welding
performance for approved welding procedure.
2. Re-approval shall be required if any of following
apply:-
• New welding procedure is to be approved
• Welder changes his employer, without transfer of
his test records
• 6 months or more have elapsed since welder was
engaged for particular procedure
• There is specific reason to question his ability.
 WELDED GIRDERS
• APPROVAL AND TESTING OF WELDERS
– PREPARATION OF WELDING PROCEDURE
QUALIFICATION RECORD (WPQR) AS PER
ITEM 2 OF APPENDIX V OF B1-2001
– WELDING TO BE DONE BY ONLY APPROVED
WELDERS
– COMPETENCY TO BE VERIFIED/ CERTIFIED
BY RDSO
– TEST SPECIMEN TO BE PREPARED USING
APPROVED WPSS
– IF TEST RESULTS ARE FOUND
SATISFACTORY THE WELDER WILL BE
APPROVED
 WELDED GIRDERS
• Welding Procedure Data
Register/Sheet (WPDS) to be
maintained as per item no.5 of
appendix 1 of B1-2001 for all the
welds.
• The welding data to be submitted
to RDSO while offering the girder
for inspection
 WELDED GIRDERS
• SIZE OF THE WELD – IS MIN. LEG LENGTH FOR
NORMAL FILLET WELD
• MIN SIZE OF FILLET WELD

THICKNESS OF THICKER PART MIN.

SIZE
UP TO AND INCL. 6MM 3MM
OVER 6MM AND UP TO INCL. 12MM 4MM
OVER 12MM AND UP TO INCL. 18MM 6MM
OVER 18MM AND UP TO INCL. 36MM 8MM
OVER 36MM AND UP TO INCL. 56MM 10MM
OVER 56MM AND UP TO INCL. 150MM 12MM
OVER 150MM 16MM
 WELDED GIRDERS
• ANGLE BETWEEN FUSION FACES SHOULD BE
BETWEEN 60° TO 120° FOR FILLET WELDS
• EFFECTIVE LENGTH OF WELD WILL BE
ACTUAL LENGTH OF WELD MINUS TWICE THE
WELD SIZE
• EFFECTIVE AREA OF A FILLET WELD =
EFFECTIVE THROAT THICKNESS x EFFECTIVE
LENGTH
• MIN. LENGTH OF WELD  FOUR TIMES THE
SIZE OF WELD, SUBJECT TO MIN OF 40 MM.
 WELDED GIRDERS
• EFFECTIVE THROAT THICKNESS – IS
“K” TIMES THE FILLET SIZE WHERE K
IS
 WELDED GIRDERS
• FIELD WELDS ARE NOT PERMITTED FOR
RAILWAY BRIDGES WITHOUT PRIOR
APPROVAL OF RAILWAY BOARD (CL-14.1 OF
WBC)
• ACCUMULATION OF WELD JOINTS IN A
SINGLE LOCATION SHOULD BE AVOIDED
• WELDS SHALL PREFERABLY BE MADE IN
FLAT POSITION
• FOR SAW – F&H POSITION
• FOR MMAW/CO2-H & HV POSITION
 Welding Consumables in SAW
Wire: Class: W1 of IRSM 39-2001
Dia : 3.15mm for weld thickness upto 8mm
: 4mm for weld thickness >8mm
(Dia of wire used is established by fabricator based on
experience, No. of passes & other welding parameters.
For Reference, these values are given in Table 9 of
Annexure A of IS 4353: 1995)
Type: Core Wire Electrode (Copper Coated M.S. Wire)
Brand: From sources approved by RDSO
Flux: A material used to prevent, dissolve or facilitate
removal of oxides and other undesirable substances.
Class: F1 of IRSM39-2001 (Type-Agglomerated)
Grain Size of Flux :- 0.2 to 1.6 mm
Brand: From sources approved by RDSO
 SAW welding

Flux WIRE
Submerged Arc Welding Machine
FLUX DRYING
WELDING IN PROGRESS
WELDING IN PROGRESS
MIG Welding in Progress
 Welding Process and Positions

• Control distortions
– Control heat input
– Control speed of welding
– Sequence of welding shall be symmetrical
– Hold the part to be welded mechanically
– Straighten by applying force
 Distortion
Correction
in Jallandhar
Workshop
 Distortion
Correction
in
Mughalsarai
Workshop
 WELDED GIRDERS
• SEQUENCE OF WELDING
– REQUIRED TO AVOID UNDUE
DISTORTION OF THE MEMBERS
– THE WELDING IN THE THINNEST
ELEMENT (USUALLY THE WEB) SHALL BE
DONE PRIOR TO THE WELDING OF THE
THICKER ELEMENTS
– SPLICES IN EACH COMPONENT PART OF A
SOLID WEB GIRDER OR BUILT – UP
MEMBER SHALL BE MADE PRIOR TO
WELDING OF PARTS TOGETHER
 WELDED GIRDER
• SEQUENCE OF WELDING
– A FILLET WELD MAY BE MADE BY SINGLE
PASS OR MULTI PASS WELDING
– FOR BUTT WELDING MIN. 2 SEQUENCES
WITH AT LEAST ONE PASS IN EACH
SEQUENCE
– FOR COMPOSITE GIRDERS, SHEAR
CONNECTORS SHOULD BE WELDED TO
TOP FLANGE PRIOR TO ASSEMBLY OF I
SECTION.
 WELDED GIRDERS

2 4

3 1

SEQUENCE OF BUTT WELD FOR

10-12 MM THICK PLATE
 WELDED GIRDERS
• TACK WELDS
– SIZE SHALL NOT BE LESS THAN THE LESSER
THICKNESS OF THE MEMBERS CONNECTED
– LENGTH = FOUR TIMES THE THICKNESS OF
THE THICKER PART OR 50MM WHICHEVER
IS THE SMALLER
– WHEN INCORPORATED IN A WELDED JOINT
THE SHAPE, SIZE AND QUALITY SHOULD BE
FIT FOR INCORPORATION IN THE FINISHED
WELD
– SHOULD NOT BE MADE AT EXTREME ENDS
OF JOINTS
 WELDED GIRDERS

• VARIOUS TESTS CONDUCTED ON

WELDS
– DESTRUCTIVE TESTS
• ON SAMPLE WELDS
• ON EXTENSION PIECES
• TENSILE TEST, BEND TEST, IMPACT TEST, LOAD
TEST ETC.
• TEST FOR DETERMINING CONTINUITY, FUSION
SOUNDNESS
• MACRO ETCHING TEST FOR DETERMINING
PENETRATION
• TEST FOR DETERMINING METALLURGICAL
PROPERTIES.
 WELDED GIRDERS
NDT TESTS CONDUCTED ON WELDS
• VISUAL EXAMINATION
• WELD DIMENSIONS
• RADIOGRAPHIC EXAMINATION – FOR
BUTT WELDS
• ULTRASONIC EXAMINATION – FOR BUTT
WELDS
• MAGNETIC PARTICLE FLAW DETECTION
• LIQUID PENETRANT FLAW DETECTION
 WELDED GIRDERS

• FOR MEASURING FILLET WELD SIZE AND

SHAPE, FILLET WELD GAUGE AS PER
APPENDIX B OF WELDED BRIDGE CODE TO
BE USED. THIS GAUGE IS SUITABLE FOR:
– NORMAL FILLET WELD OF 5 TO 25 MM WELD
SIZE.
– ANGLE BETWEEN FUSION FACES SHOULD BE 900.
• FOR EACH WELD SIZE SEPARATE GAUGE IS
REQUIRED.
Welding Inspection Gauge

125
Method of Welding Inspection by Gauges

126
 Submerged Arc Welding
• Clean the surface with pneumatic Wire
brush
• Apply adequate flux
• Use proper parameters
• Follow the sequence for better distortion
control
SAW
 DPT & Rectification
• Clean the surface with soft brush
• Apply cleaner
• Apply penetrant, wipe after some time
• Apply developer
• Mark defects
• Remove defects with pneumatic hand
grinder with gouging
• Refill with MMAW & redress with
pneumatic grinding
DP TESTING
DP TESTING ….
DP TESTING ….
DPT & Rectification
Macro Etching Test

Fusion into
parent
metal
Macro Etching
Macro Etching
5. JIG FILING & DRILLING SECTION
• Mark using line thread, chalk, tape, t - square
etc as per working drawing

• Put jig on one end & ensure the correctness of

dimensions

• Fix jig in position with either bolts or tacking

• Drill with correct size drill

 Using Jigs
and
Fixtures for
drilling
DRILLING SECTION
• Following sizes are drilled in open web girders

Radial drill machines are used for hole drilling

DRILLING SECTION
• For guidance of drill machine
operator a color codification system
for different dia. Holes may be used
• Jigs should be removed from the
component after all holes are drilled
otherwise it will be very difficult to
drill left over holes at later stage
• Punching of holes is totally
prohibited in open web girder
6. INITIAL ASSEMBLY
SECTION
• After drilling of holes, temporarily
tack assembled drilled component
will be opened. Before taking them
apart proper match marking should
be done to pair the drilled hole
components.
• All burrs left by the drill and sharp
edges of all the rivet holes
completely removed.
INITIAL ASSEMBLY SECTION
• All the surfaces which will be in permanent
contact shall be thoroughly cleaned by
grinding to remove paint, mill scale ,dust
etc.
• One coat of zinc chrome red oxide priming
to is:2074 should be applied immediately
after cleaning.
INITIAL ASSEMBLY
SECTION
• Joint shall normally be made by filling
not less than 50% of the holes with
service bolts & drifts in the ratio of four
to one.
• Service bolt will exert clamping force
while drift will ensure alignment
• Tolerances for dia.
– Drift +0 MM TO – 0.13 MM
– Service bolt 1.5 mm. Less than the hole dia.
– Turned Bolts + 0 MM TO – 0.13 MM
7. RIVETING SECTION

• Steel for rivets should conform to IS:1148 and rivet

should be made conforming to IS:1929
• The rivet hole should be 1.5 mm bigger than the rivet
diameter
• Length of rivets= grip +1.5 d + 1 mm extra to every 4
mm grip
• Compressed air pressure required at the hammer end is
approx. 6 to 7 kg/cm2
• Heating time of rivets is 20 to 25 minutes
• Remove service bolts in sequence one at a time
• Follow the correct riveting procedure
• Test rivets as early as possible
• Remove/ rectify defective rivets
RIVETING SECTION

• All The Rivets Should Be Tested 100% By

A Responsible Supervisor.
• All the defective rivets shall be distinctly
marked on their heads with paint and
promptly replaced.
• When all the rivets of joints have been
finally passed they should be painted
with one coat of ready mixed zinc
chrome primer to IS:104 followed by one
coat of ready mixed paint red oxide zinc
chrome primer to IS:2074.
 RIVETING SECTION
Details of rivet checking to be maintained
as per rivet checking register ( item no. 2
of Appendix I of B1-2001)

COMPONENT DATE OF RIVETING NUMBER NUMBER INITIALS

DESCRIPTIO RIVETIN PARTY AND OF OF
N G NATURE OF DEFECTIV SUPERVIS
DEFECTIVE E RIVETS OR IN
RIVETS REPLACED CHARGE
8. FINAL ASSEMBLY SECTION
• Final finishing of length, profile, notches etc. is
done - use Edge distance gauges for final marking
• Cut excess length with Gas cutter with sufficient
margin for finishing
• Finish with P/ hand grinder or Milling Machine
• Fixing of fitting for site connection
• All the defects should be rectified
• Final check & inspection
• Final assembly includes accurate machining of end
profile of component.
• All the members should be correctly marked
before dispatch to facilitate easier erection.
9. INSPECTION
• After final finishing , identification marking of
component ( shipping mark) is done. After final
inspection by RDSO/inspecting agency the
girder parts are cleared for metallising /
painting.
• Weld quality inspection is done by RDSO (M&C)
based on actual job, test pieces &Other welding
records
• Remaining inspection is done by RDSO (B&S) for
dimensions
• Final pass certificate is issued based on all
records
CAMBER IN GIRDERS

• CAMBER IS PROVIDED IN
– Open web girders as pre-stressing force to
eliminate secondary stresses
– Foot over bridges as geometrical
arrangement for drainage purposes
– Not provided in plate girders (span up to 35
m – no Railway Plate Girders beyond this)

• OPEN WEB GIRDER CAMBER:

– In open web girders, members fabricated with
camber lengths and gussets with nominal length.
– Bottom boom has same camber and nominal
lengths.
 CAMBER and PREDEFORMATION
Why Camber?
• To have theoretical or nominal shape of truss after all
loads – thus only axial forces – Avoiding Secondary
stresses in OWG
• Indication of soundness of Structure
• Ensuring level track under load
• Near about design camber indicative of quality of
work
• Drainage in case of FOB’s
 Assumptions in OWG
• All members are straight and free to rotate at
joints
• All joints lie at the intersection of the
centroidal axis of the members
• All loads/forces including the dead weight of
the members is applied at panel points/joints
 Pre-deformation
• Concept of deformation stresses – Rigid joints,
rotation and deflection distorting the nominal
shape of the truss
• Wind load and dead load not only at joints but
all along the member
• Eccentricities due to the manufacturing defects
All these factors induce additional stress called
secondary stresses
 Pre-deformation
• These can be accounted for either by
– Computing and incorporating in the design
– By taking some lump sum value 16⅔% stresses on account
of this
• All bridge OWG 30.5 m and above span are pre-
stressed by fabricating members to longer or shorter
length to induce deformation in unloaded condition
and nominal shape when loaded
• Concept of force fit during assembling
CAMBER LENGTHS
CAMBER LENGTH and CAMBER AT PANEL POINTS
CAMBER IN GIRDERS
• PROCEDURE FOR PROVIDING CAMBER
– Prepare 600 mm high assembly platforms at all
node points
– Provide camber jacks (preferably screw) with ram
out for lowering at all platforms.
– Assemble the bottom chord members stringers
and cross girders on camber jacks at level surface.
– Assemble the verticals and diagonals on the
bottom chords, rivet the connections with bottom
boom.
– Top end of the verticals/ diagonals shall be
connected with temporary gussets or permanent
gussets with smaller bolts.
Assembling of Open Web Girder

2
Assembling of Open Web Girder
3

4
CAMBER IN GIRDERS
• PROCEDURE FOR PROVIDING CAMBER
– Lower the camber jacks, except the central jack,
by the calculated amount to provide camber
desired.
– Check the levels and adjust for any settlements
etc.
– Force Fit The Proper Gusset Plates One By One.
No Reaming To Be Done. Lightly Hammer The
Drifts With 1 Kg Hammer Simultaneously In No
Of Holes. Start From The Center Of The Girder
Outwards
– Force fit the end rockers Connect top end and
then the lower end
– Remove the camber jacks and measure the
camber
Assembling of Open Web Girder
5

6
Assembling of Open Web Girder
7

8
TRIAL ASSEMBLY
JOINTS IN TRIAL ASSEMBLY
 CAMBER FOR OWG – 25 T
CLEAR Loading PANEL POINTS (All dimensions are in mm) RDSO
SPAN Condition Drawing
(m) L0 L1 L2 L3 L4 L5

30.5 A 0.00 12.53 20.64 25.40 - - RDSO-B-

11680
B 0.00 10.99 18.10 22.28 - -
45.7 A 0.00 16.29 29.44 40.16 41.93 - RDSO-B-
17003
B 0.00 13.50 21.38 33.27 34.73 -
61.0 A 0.00 27.16 46.20 62.47 65.41 - RDSO-B-
17023
B 0.00 21.30 36.23 48.99 51.29 -
76.2 A 0.00 31.00 55.09 76.20 87.11 94.15 RDSO-B-
17043
B 0.00 23.39 41.56 57.48 65.72 71.03
A – Theoretical Camber due to DL + LL + IL (Full) for full span (No
Load/Design Camber)
B – Theoretical Camber due to LL + IL (Full) for full span (Dead Load
Camber)
CAMBER DIAGRAM
10. PAINTING SECTION
• AFTER FINAL INSPECTION BY
RDSO/INSPECTING AGENCY, THE GIRDER
PARTS ARE CLEARED FOR METALLISING /
PAINTING.
• NO PART SHALL BE PAINTED UNLESS
INSPECTED & PASSED BY INSPECTING
OFFICIALS.
• DRY FILM THICKNESS SHALL BE
MEASURED BY ELCOMETER.
• BEFORE PAINTING THE SURFACE TO BE
PAINTED SHOULD BE PREPARED
CAREFULLY.
Metallising Gun
Digital Elcometers
 CHECKING OF GIRDER
Fabrication Tolerances (IRC-24)
• Length: +/- 2 mm upto & including 12 m
span, +/- 3.5 mm over 12 m span

• Width of Built up Girder: +/- 3 mm

• Depth :- +3mm/-2mm

• Deviation of centre line of web from centre

line of flanges in built-up members at contact
surfaces is 3 mm.
Fabrication Tolerances (IRC-24)….
• Deviation from flatness of plate webs of
built-up members in a length equal to the
depth of the member is 0.005 b to max. of 2
mm.
• Tilt of flange plate girders
(i) At splices & stiffners, at supports, at the top
flanges of plate girders, at bearings 0.005 b to
max. of 2 mm.
(ii) At other places 0.015 b to a max. of 4 mm.
 HSFG Bolts for Splice : Quality & Inspection
(IS:4000)

1. Property class of bolts 8S or 10S shall be embossed or

indented on bolt.
2. Nominal height of nut shall be 0.8 times the nominal
bolt diameter.
3. Each bolt shall be provided with min. one washer.
4. Use calibrated mechanical torque wrenches for
Tightening of bolts
 HSFG BOLTS, Nuts and Washers

DTI Washer (Direct

Tension Indicator)

Plain Washer
DTI Washers
Chemical composition limits of Bolts
(For carbon steel with additives (e.g. B, Mn,Cr) quenched and tempered) (IS-1367 pt-3)

property
class
C P S Ba Tempering
temperature
(Boron
content)

8.8 min 0.15 0.035% 0.035% 0.003 425oC

% max
0.40 %.

10.9 min 0.15 0.035% 0.035% 0.003 340oC

% max
0.35 %.
Physical properties of bolts as per IS 1367 pt 3
PROPERTY CLASS 8.8 CLASS 10.9

Nominal tensile strength N/mm2 800 N/mm2 1000 N/mm2

Brinnell hardness HB min 242, max min 304, max

318 361
Stress at 0.2% non proportional nominal 640 nominal 900
elongation (Min. Yield stress) N/mm2, min N/mm2, min
660 N/mm2 940 N/mm2

Percent elongation after fracture min 12 % min 9 %

 Important tests of bolts

• Tensile test for full size bolts, screws & studs.

• Torsional test
• Hardness test
• Proof load test for full size bolts & screws
Torque wrench
 Mechanical Properties & chemical composition
of washers
• Washers shall be made from 45C8 steel according to IS 1570-pt 2

• For steel designation 45C8 : C= 0.40-0.50%, Mn= 0.60-0.90%,

• Contents of Sulphur and Phosphorus not exceeding 0.06% in the
check analysis
• Washer shall be thorough hardened and tempered.
• For hardened and tempered steel designation 45C8
Tensile strength Yield stress Elongation
600-750MPa 380MPa 17% min
700-850MPa 480MPa 15% min
SPECIAL THROUGH GIRDERS OF
LONGER SPANS
BRIDGE (No.20) ON JHAZZAR KHAD ON UDHAMPUR-
KATRA SECTION
Tallest pier of bridge on Indian Railway-85 M

Taller than Qutab Minar (72 M)

Longest single span of bridge on Indian Railway-154 M

 IMPORTANT ON-GOING BRIDGE
PROJECTS ON IR
• Ganga Bridge near PATNA (1x64 m + 36x123 m
+1x64 m) – Rail cum Road Bridge
• Ganga Bridge near MUNGER (29x125 m) – Rail
cum Road Bridge
• Jubilee Bridge near KOLKATA on Hooghly River –
three continuous spans (132.65 m + 150.0 m +
132.65 m)
• Bogibheel Bridge near DIBRUGARH on River
Brahmaputra (1x32.5 m + 34x125 m +1x32.5 m) –
Rail cum Road Bridge
 ENGINEERING WORKSHOPS – IR
SN WORKSHOP RLY CAPABILITY
1 ARAKONAM SR PG, OWG up to 61.0 m
2 BONGAIGAON NFR PG
3 GORAKHPUR NER PG, OWG up to 61.0 m
4 JALANDHAR NR PG, OWG up to 61.0 m
5 LALAGUDA SCR PG
6 LUCKNOW NR PG
7 MANMAD CR PG, OWG up to 76.2 m
8 MUGHALSARAI ECR PG, OWG up to 61.0 m
9 SABARMATI WR PG, OWG up to 45.7 m
10 SINI SER PG
PROPOSED BOGIBEEL BRIDGE
Composite, Span=125m
ARTISTIC IMPRESSION OF CHENAB BRIDGE – 467 m span