PROJECT REPORT

on

Course No. 10109

By-
T.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 spans
for North Eastern Railway is under progress.
3
 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
4
Flow Process Chart for Fabricating Open Web Girder

5
 INSPECTION OF WELDED TYPE
GIRDERS
 INSPECTION BEFORE WELDING

 INSPECTION DURING WELDING

 INSPECTION AFTER WELDING

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 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.
7
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.

8
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.

9
 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.
11
Defects noticed in D.P. Blow hole After rectification of
Test ( Enlarged view ) defects

12
 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 15

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

25
VERTICAL MEMBERS

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FLOOR SYSTEM – CROSS GIRDERS

27
 FLOOR SYSTEM –
RAIL BEARERS OR STRINGERS

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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.

30
 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.
 Contd..
 Levels were taken at top of bottom
chord at every nodal joint

 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 bottom

chords is in one level.

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 camber readings and adjust for correctness.

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) ,L4-
22 mm (21.0 mm) and L5- 10 mm
(13.1 mm).
 COST OF THE GIRDER (Per MT)
Revenue Rate Foreign Rly. Rate
Home Rly. Rate

Descriptio Cost Cost

Cost Description
n (in Rs.) Description (in Rs.)
(in Rs.)
Revenue 101205.0
Stores 41459.0
Revenue 101205.00 Rate 0
4
Rate
Proforma 52906.13
Labour 26791.9
Oncost @
8 Proforma 23836.83 91%
Oncost @ 41%
Labour 31346.6
Oncost 2 Freight 3014.66

Stores 1607.52 Supervision 4608.12

Freight 3014.66
Oncost
Profit 10882.79
Total 128057
Total 101205 Total 172617
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 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.