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REPORT
TRAINING
Training report on
FABRICATION OF 12.2 M SPAN
COMPOSITE STEEL GIRDER-WELDED TYPE
SUBMITTED BY
SUPERVISOR
REYAZ AHMAD
B.TECH , 4th yr
SECTION ENGINEER
INTEGRAL UNIVERSITY
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ACKNOWLEDGEMENTS
I owe my profound gratitude to my project guide Mr. Vikrma
Prasad who took keen interest on my project work and guided
me all along till the completion of my project work.
The success and final outcome of this project required a lot of
guidance and assistance from many people of the Bridge
workshop and I am extremely fortunate to have got all this all
along the completion of this project work.
Whatever I have done is only due to such guidance and
assistance and I would not forget to thank them.
Finally, I gratefully acknowledge my family members and
my friends for their love, support and constant encouragement
during the study.
REYAZ AHMAD
INTEGRAL UNIVERSITY
INDUSTRIAL TRAINING AT RAILWAY BRIDGE WORK SHOP
INTEGRAL UNIVERSITY
INDUSTRIAL TRAINING AT RAILWAY BRIDGE WORK SHOP
Table of Contents
Acknowledgements2
About North Eastern Railway.3
Table of Contents4
INTRODUCTION
Girder6
Types of Girder.6
Advantages of using steel for Girders..7
Composite steel girder..7
SPECIFICATIONS
Steel ..9
Concrete.....9
Drilling.10
Rivets and Riveting .10
LAYOUT OF COMPOSITE STEEL GIRDER
General..11
Design drawings of Girder11
Part List.18
Shipping List.19
FABRICATION OF JOB
General..20
Items requiring attention before fabrication of girder.21
Tested steel of required quality.21
Roll no. 2300111015
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Manufacture..22
Templates .22
Cutting of plates22
Flattening and Straightening.24
Planning and shearing...24
Jig and fixture making..25
Tack Assembling of job....26
Tack welding...26
Important checks for tack welding..27
Saw Welding.28
Inspection of Weld30
Micro etching test30
Visual Test...31
Weld Gauge 31
DPT test...32
Initial Assembling of job..35
Drilling and Sub punching....36
1.INTRODUCTION
Roll no. 2300111015
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GIRDER
TYPE OF GIRDERS
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2.SPECIFICATIONS
2.1. STEEL
IS:2062 , Quality B Grade Designation E250 (Fe 410 W)
fully killed and normalized/controlled cooled, Plates less than
12mm thick need not be normalized/controlled-cooled.
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2.2 CONCRETE
All RCC work to be done as per IRC-21
C.C mix for substructure M-35 and for superstructure M35.
All structural steel shall conform to IS: 2062-2006 grade B
All RCC work shall be of concrete mix M-35 and reinforcement
bars shall conform to IS: 1786-1985 of minimum grade Fe-415.
2.2. DRILLING
The bores of bushes shall initially have a tolerance of -0mm,
0.1mm. The tolerance shall be checked from time to time and
Roll no. 2300111015
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Here CWG stands for composite steel girder. Its design drawings
includes the elevation , top and cross sectional plan & also the front and
back frame
FABRICATION OF CWG
4.1. GENERAL
The
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i)
Indian Railway Standard specification for fabrication and
erection of steel girder bridges and locomotive turn-tables (B1-2001).
ii)
Indian Railway Standard Code of Practices for metal arc
welding for structural steel bridges carrying rail cum road or
pedestrian traffic (Adopted 1972 Revised 2001).
The officials associated with fabrication work should have
thorough understanding of both the codes i & ii. However, these
guidelines have been prepared for helping the field engineers associated
with execution of the fabrication work through trade. It has been tried to
cover various aspects which require close attention of the field
engineers for ensuring quality of the fabrication work. These guidelines
are just to facilitate and not to supersede the two codes. All engineers
associated with fabrication are advised to understand the provision of
IRS B1-2001 and Welded Bridge Code and take help from these
guidelines. Book published by RETS IRICEN Steel Structure
Fabrication for Railways is also a very good guide for the Engineer
incharge of fabrication. The workshop engineer of contractors should
also have good understanding of various provisions of above Railway
codes and other related codes.
ATTENTION
BEFORE
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4.4. MANUFACTURE
The whole work shall be representative of the highest class of
workmanship. The greatest accuracy shall be observed in the design,
Roll no. 2300111015
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manufacture and erection of every part of the work to ensure that all
parts will fit accurately together on erection. The whole of work to be
erected complete and pieces marked to place
4.5. TEMPLATES
The templates through out the work shall be of steel.
The
template shall be used for marking of cutting material and as well
as profile machining for girders of railway loading.
Templates shall be used for marking of drilling holes in steel
structures other than girder of Railway loadings.
In case where actual materials from a bridge have been used as
templates for drilling similar pieces the Inspecting Officer will decide
whether they are fit to be used as part of the finished structure
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Cutting allowance
3mm up to 12mm thick plates
6mm for than 12mm thick plates
After cutting it should be ensured that all the edges are clean,
reasonably square and true.
Use of multi-head flame cutting machine having multiple oxy acetylene
torches is desirable for higher productivity and reducing the distortion
due to cutting operation. Plasma-arc cutting method can also be
employed. This process offers less heat input causing less distortion.
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All steel materials, plates, bars and structural shall have straight edges,
flat surfaces and be free from twist. If necessary, they shall be cold
straightened or flattened by pressure before being worked or assembled
unless they are required to be of curvilinear form. Pressure applied for
straightening or flattening shall be such as it would not injure the
material and adjacent surfaces or edges shall be in close contact or at
uniform distance throughout.
Flattening and straightening under hot condition shall not be carried
out unless authorized and approved by the Inspecting Officer
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case
of
The butting ends of all booms and struts where spliced shall be faced in
an end milling machine after members have been completely fabricated.
In the case of compression members the face shall be machined so that
the faces are at right angle to the axis of the members and the joint
when made, will be in close contact throughout. At the discretion of
the Inspecting Officer, a tolerance of 0.4mm may be permitted at
isolated places on the butting line.
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ii) Full welding shall be carried out in flat position with SAW process
as per sequence mentioned in WPSS/WPQR using manipulator/special
welding fixture.
iii) The sequence of welding shall be shown in WPSS/WPQR marked
as 1, 2, 3 & 4 in the order of welding
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Macro etch testing allows the tester to see a cross section of the weld,
and see the arrangement of the grains in the parent metal and the weld
material. This is known as its Macrostructure. Its can also show up
defects such as porosity, inclusions and poor fusion. You need minimal
equipment to perform a macro etch test. Firstly, it involves cutting a
sample from the welded joint. Cold cutting methods are best for this,
such as a bandsaw.
Then the surface needs to be polished. File away any burrs and rough
marks, then use progressively finer grades of emery until a smooth even
polish is obtained.
VISUAL TEST
Fatigue cracks on webs were reported in DOT reports
but couldnt indentify by visual inspection induced by vibration of
lateral bracing due to differential deflection of girders
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WELD GAUGE
To measure fillet welds place irregular curve edge flush to
horizontal toe of weld so the straight edge is in line with the
horizontal member.
To measure weld throat thickness place the 45 angle end flush to
the horizontal and vertical members. Loosen the thumb screw and
slide the pointer until it touches the face of the weld.
DYE PENETRANT TESTING (DPI)
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This can be very important when indications are noted and additional
resources and techniques are needed to assess the overall condition of
your component (e.g. Phased Array Ultrasonic Testing).
Many of the technicians employed by ECE Global are multi-disciplined
and able to apply the other NDT disciplines that may be necessary to
fully determine the suitability of the component for service.
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MAKING OF JOINTS
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Only barrel drifts shall be used in erection. They may be used for
drawing light members into position; but their use on heavy members
shall be restricted to securing them in their correct position. Any
apparent error in shop work, which prevents the assembling and
fitting up of the parts by the proper use of these drifts, shall be
investigated immediately.
SITIFFENERS
Stiffeners are required where factored concentrated loads or reactions
exceed the factored Compressive (vertical) resistance of the plate
girder web.
Failure due to concentrated loads can be as local buckling of the
web in the region where it joins the flange, or overall buckling of
the web throughout its depth
TRANSVERSE STIFFENERS
If a girder has insufficient strength (web local yielding or web
crippling) to support concentrated point loads then a pair of
transverse stiffeners can be added to the web to transfer the
concentrated force to the web.
BEARING STIFFENERS
Bearing stiffeners are placed over the end bearings of welded plate
girders and over the intermediate bearings of continuous welded plate
girders.
They consist of two or more plates placed on both sides of the web.
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RIVETING
BOLTS NUTS AND WASHERS
Bolts, Nuts and Washers shall be in accordance with the following
specifications:
Black hexagonal bolts to IS:6639 and Nuts to IS:1363.
Precision and turned bolts with nuts and hexagonal screws to
IS:1364.
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Where the head and nuts bear on timber, square washers having
the length of each side not less than three diameters of the bolt
and the thickness not less than one quarter of the diameter shall
be provided. Steel, wrought iron or malleable cast iron taper
washers shall also be provided for al heads and nuts bearing
on bevelled surfaces.
Where turned bolts are required they shall be carefully turned and
shall be parallel throughout the barrel. Holes for turned bolts
should be 1mm undrilled in shop and should be reamed at site to
suit the diameter of the turned bolts.
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(ii) One coat of zinc chrome primer to IS:104 with the additional
proviso that zinc chrome to be used in the manufacture of primer
shall conform to type 2 of IS:51.
iii) Two coats of aluminium paint to IS:2339 brushing or spraying as
required. One coat shall be applied before the fabricated steel work
leaves the shop. After the steel work is erected at site, the second
finishing coat shall be applied after touching up the primer and the
finishing coat if damaged in transit.
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I)
SURFACE PREPARATION
a)
Remove oil/grease from the metal surface by using
petroleum hydrocarbon solvent to IS:1745
b) Prepare the surface by sand or grit blasting to Sa 2-1/2
to IS:9954 i.e. near white metallic surface.
(II)
(a)
PAINTING
Primer Coat
Intermediate Coat
(c)
Finishing Coat
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