Central Expressway Section 2 Design by : M.

N
. Design of Welding diapharagm reinforcement
Reference Description Output

WELDING DESIGN FOR DIAPHRAGM REINFORCEMENT.

01. INTRODUCTION
The structural design calculations of the mid and end diaphragm of all bridges and via
ducts have been submitted in the super-structure design reports. However, in skew
spans diaphragms length vary due to skewness of the girders as show in fig 1.1.
Hence some diaphragm reinforcement bars have overlap. Therefore, lapping of the
reinforcement shall not be achieved with full lap length due to high congestion of the
reinforcement. (see figure 1.2) As a solution for this, welding (lap welding) can be
used to connect the reinforcement. Therefore, this design report specially prepared for
presents welding of diaphragm reinforcement using the manual metal arc welding with
cored electrode.

Design is done according to the BS 7123 : 1989 and recommendation given in

26th Edition Machinery’s Handbook

PIER
PIER
Vary Diaphragm

Detail " A "

Figure 1.1: Skew span

Congested
Reinforcement

Figure 1.2: Secton of detail "A" - Congested diaphragrm reinforcement

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
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02. EFFECTIVE THROAT THICKNESS AND WIDTH OF THE WELD

( Assuming same diameter bars are welded)

weld
w

t
s

Reinforcement bars

Figure 2.0: welding throat thickness and width of the weld

BS 7123
cl 10.9.2 d - Diameter of the bar
Figure 07 w - Width of the weld ( 0.6d )
s - Shortest distance from the bar contact to the surface of the weld
T - Effective throat thickness ( s - 0.2d )

Diameter of the bar( mm )

Unit
16 20 32
s mm 8 10 16
w mm 10 12 19
T mm 5 6 10

03. WELD METAL SHEAR STRESS

Refer
Welding Genarally for tore steel welding, E7018 electrode is used.
specification
AWS A5.1:
Tensile strength of the E7018 resulted weld is 70000 psi. ( 482 N/mm 2)
E7018-1
Welding Yeild stress of the E7018 weld 57000 psi. (392 N/mm2)
Electrode
BS 7123 Yeild stress < 410 N/ mm2.
cl 10.9.1 (a) Therefore weld metal shear stress is 115 N/ mm 2

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
Reference Description Output

04. DESIGN CALCULATION FOR MINIMUM WELD LENGTH ( L )

Welding Type is flare - vee fillet welds, Design is done Assuming the total weld length
carry the full tensile load of the bar.

BS 7123
cl 10.9.1 Effective throat thickness ( T ) = 6 mm
Specified characteristic strength of the bar ( fy ) = 460 N/mm2
Weld metal shear stress ( fw ) = 115 N/mm2
Diameter of the bar ( d ) = 20 mm

BS 7123 𝚷 𝐱 𝟎.𝟖𝟕 𝐱 𝐟𝐲 𝐱 𝒅𝟐
cl 10.9.2 L= 𝟒 𝐱 𝐓 𝐱 𝐟𝐰

Minimum weld length ( L ) = 182 mm

Consideration of the safety factor for design weld length.

Though BS7123 does not specify any safety margin for design weld length,as a
satisfactory design, general recommendations which are given in the Machinery’s
Handbook are adoptted.
26th Edition Since, the welded diaphragm reinforcement are not having intence loading and also
Machinery’s the diaphragm reinforcement are having enough covering and favorable
Handbook environmental conditions, it can be considered as non severe condition, therefore
page 200 factor of safety can be considered as 1.5 , as a common safety factor for any diameter
of lap weld joint.

Design weld length ( L ) = 273 mm

05. FULL CALCULATION TABLE FOR MINIMUM WELD LENGTH ( L ) FOR

16mm, 20mm AND 32 mm DIAMETER BARS.

Diameter of the weld bar (

Unit mm )
16 20 32
T kNm/m 5 6 10
fy mm 460 460 460
fw mm 115 115 115
SF - 1.5 1.5 1.5
L mm 219 273 437

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
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06. WELDING DETAIL

06.1. WELDING DETAIL FOR 16mm DIAMETER BAR

BS 7123 Required Minimum weld length = 219 mm

cl 10.9.2 The maximum allowble length for welding = 5d (d - Diameter )
= 5 x 16
= 80 mm
Hence, weld shall be divided in to 3 section ( L ) = 219 / 3
= 73 mm
The minimum allowble length for welding = 1.5d (d - Diameter )
= 1.5 x 16
= 24 mm
Hence OK

The minimum allowble interval for welding = 5d (d - Diameter )

= 5 x 16
= 80 mm

Required minimum overlap length (l ) = 399 mm

Additional Re-bar/ Diaphragm R/F Diaphragm R/F

required overlap length - l (Minimum)

L Min 5d L Min 5d L

Min 10mm
Min 10mm

LxwxT

Figure 06.2 : Welding detail for 16 mm dia. lap weld

w

Sectional veiw at the weld

Recommended
Unit value
value
L mm 73 75
w mm 10 10
T mm 5 5
l mm 399 405

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
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06.2. WELDING DETAIL FOR 20mm DIAMETER BAR

BS 7123 Required Minimum weld length = 273 mm

cl 10.9.2 The maximum allowble length for welding = 5d (d - Diameter )
= 5 x 20
= 100 mm
Hence, weld shall be divided in to 3 section ( L ) = 273 / 3
= 91 mm
The minimum allowble length for welding = 1.5d (d - Diameter )
= 1.5 x 20
= 30 mm
Hence OK

The minimum allowble interval for welding = 5d (d - Diameter )

= 5 x 20
= 100 mm

Required minimum overlap length (l ) = 493 mm

Additional Re-bar/ Diaphragm R/F Diaphragm R/F

required overlap length - l (Minimum)

L Min 5d L Min 5d L

Min 10mm
Min 10mm

LxwxT

Figure 06.2 : Welding detail for 20mm dia. lap weld

w

Sectional veiw at the weld

Recommended
Unit value
value
L mm 91 95
w mm 12 12
T mm 6 6
l mm 493 505

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
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06.3. WELDING DETAIL FOR 32mm DIAMETER BAR

BS 7123 Required Minimum weld length = 437 mm

cl 10.9.2 The maximum allowble length for welding = 5d (d - Diameter )
= 5 x 32
= 160 mm
Hence, weld shall be divided in to 4 section ( L ) = 437 / 4
= 109 mm
The minimum allowble length for welding = 1.5d (d - Diameter )
= 1.5 x 32
= 48 mm
Hence OK

The minimum allowble interval for welding = 5d (d - Diameter )

= 5 x 32
= 160 mm

Required minimum overlap length (l ) = 399 mm

Additional Re-bar / Diaphragm R/F Diaphragm R/F

required overlap length - l (Minimum)

L Min 5d L

Min 10mm
Min 10mm

LxwxT
Figure 06.3 : Welding detail for 32mm dia. lap weld
w

Sectional veiw at the weld

Recommended
Unit value
value
L mm 109 110
w mm 19 20
T mm 10 10
l mm 399 400

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
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07. WELDING ARRAGEMENT FOR OVERLAP DIAPHRAGM REINFORCEMENT

BARS
If girder protrude reinforcement bars are overlapped satisfing the required minimum
length for welding. Those bars can be welded as shown in figure 07.1

Detail "B "

Girder protrude bars

Weld

Figure 07.1 : Detail " B "

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 Central Expressway Section 2 Design by : M.N
. Design of Welding diapharagm reinforcement
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08. WELDING OF DIAPHRAGM REINFORCEMENT BARS WITH ADDITIONAL

REINFORCEMENT BAR.

If the requirement of the part 07 is not satisfied, additional reinforcement bar shall be
used with required minimum length for welding.see figure 08.1

Detail "C "

Diaphragm rf

Weld Additional Re-bar

Figure 08.1 :Detail " C "