SUMMER

REPORT

TRAINING

Submitted in partial fulfillment for the award of degree of b.tech

Training report on
FABRICATION OF 12.2 M SPAN
COMPOSITE STEEL GIRDER-WELDED TYPE

North Eastern Railway Bridge Workshop

(Gorakhpur Division)
1st June -30th June 2015

SUBMITTED BY

SUPERVISOR

REYAZ AHMAD
B.TECH , 4th yr
SECTION ENGINEER

MR. VIKRMA PRASAD

SENIOR
BRIDGE WORKSHOP,
GORAKHPUR CANTT

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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

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NORTH EASTERN RAILWAY

The North Eastern Railway is one of the seventeen railway zones in
India. It is headquartered at Gorakhpur and comprises Lucknow and
Varansi divisions as well as reorganized Izzatnagar division.
The North eastern railway was formed on 14 april 1952 by combining
two railway systems the Oudh and trihut railway and Assam railway
and the Canpore-Achnera section of the Bombay, Baroda and Central
India Railway.
NER has 3.042.46 route km with 486 stations. NER primarily serves
the areas of Uttar Pradesh , Uttarakhand & western districts of Bihar.
It has also the longest platform in the world at Gorakhpur Railway
station about 1.3 km in length by combining the platforms 1 &2.
As Gorakhpur is the headquarter of the NER zone therefore it have all
the construction sites i.e. from steel bridges workshop to concrete
yard.

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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
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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
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GIRDER

A girder is a support beam used in construction. It is the main

horizontal support of a structure which supports smaller beams.
Girders often have an I-beam cross section for strength but may
also have a box shape, Z shape and other forms. A girder is
commonly used many times in the building of bridges, and planes.
A girder bridge, in general is a bridge that utilizes girders as the
means of supporting the deck.

TYPE OF GIRDERS

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A Rolled Steel Girder is a girder that has been fabricated by

rolling a blank cylinder of steel through a series of dies to create
the desired shape. These create standardized I-beam and wide
flange beam shapes up to 100 feet in length.
A Plate Girder is a girder that has been fabricated by welding
plates together to create the desired shape. The fabricator
receives large plate of steel in the desired thickness, then cuts
the flanges and web from the plate in the desired length and
shape. Plate girders can be used for spans between 10 meters
and more than 100 meters. Stiffeners are occasionally welded
between the compression flange and the web to increase the
strength of girder.

A Box Girder or tub girder is, as the name suggests, a box

shape. They consist of two vertical webs, short top flanges on
top of each web, and a wide bottom flange connecting the webs
together. A box girder in particularly resistant to torsion and,
while expensive, are utilized in situations where a standard
girder might succumb to torsion or toppling effects.

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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IS:2062 , Quality C Grade Designation E250 (Fe 410 W)

fully killed and normalized/controlled cooled, ensuring
impact properties at (-) 200 C or (-) 400 C shall be used for subzero temperature areas for welded/riveted girders subjected to
Railway loading. Plates less than 12mm thick need not be
normalized/controlled-cooled.

Steel for bolts shall conform to property class 4.6 or 6.6 as

specified in IS:1367 accordingly,
Steel for drifts shall be in accordance with IS:1875 for forged
quality steel or IS:7283 for hot rolled bars.
Steel for rivets shall comply with the requirement of IS:1148 for
hot rolled rivet bars for general structural purposes and IS:1149
for high tensile steel rivet bars for high strength structural
purposes.

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
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when the bores exceed a tolerance of, -0mm, +0.4mm, the

bushes shall be rejected. Tolerances for checking jigs from
master plates shall be +0mm-0.13mm.

2.4. RIVETS AND RIVETING

The rivet holes shall be 1.5 mm greater than the diameter of the
rivet bars used. The rivets shall be made to IS:1929.
Rivets when driven shall completely fill the holes, have the
heads concentric with the shanks and shall be in full contact
with the surface. Driven rivets when struck 12 sharply on the
head with the 110-gm. rivet testing hammer
shall
be free from movement or vibration.

3.LAYOUT OF COMPOSITE STEEL GIRDER

3.1. GENERAL
Layout is drawing of complete structure on full scale. Normally
half span is drawn on a leveled smooth floor.
Nominal as well as camber layout will be drawn on the floor.
Length of the members will be kept as per camber layout. However
the for main gussets will be fabricated using nominal layout.

3.2. DESIGN DRWAING OF CWG

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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

fabrication of steel girder bridges is being done by various

Railway Workshops as well as through trade. The fabrication is
governed by the provisions of:

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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.

4.2. ITEMS REQUIRING

FABRICATION OF GIRDER:

ATTENTION

BEFORE

Inspection of Layout on template floor Field engineer has to ensure

that the Template floor is level. Nominal and camber layout are drawn
with the calibrated steel tape. The certificate of calibration from a

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authorized agency should be kept in record. For squareness, diagonal

measurement are also checked. It should be remembered that tape

4.3. TESTED STEEL OF REQUIRED QUALITY

IS:2062-2011 GR.-B0 FULLY KILLED AND NORMALIZED
FOR WELDED GIRDERS SUBJECTED TO RAILWAY
LOADING
(If Service Temp. does not fall below 0 degree C ).
- PLATES LESS THAN 12mm THICK NEED NOT BE
NORMALIZED.
- PLATES MORE THAN 12mm THICK SHOULD BE
NORMALIZED AND ULTRASONICALLY TESTED.
IS:2062 GR.-C FULLY KILLED AND NORMALIZED FOR
WELDED/ GIRDERS SUBJECTED TO RAILWAY LOADING
(If Service Temp. fall below 0 degree C ).
- PLATES LESS THAN 12mm THICK NEED NOT BE
NORMALIZED.
- PLATES MORE THAN 12MM THICK SHOULD BE
NORMALIZED AND ULTRASONICALLY TESTED.

4.4. MANUFACTURE
The whole work shall be representative of the highest class of
workmanship. The greatest accuracy shall be observed in the design,
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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

4.6. CUTTING OF PLATES

Plates are cut into desired length using

ordinary oxy-acetylene cutting torch

pug cutting machine
profile cutting machine
Galloting shear machine (faster but for plates up to 10mm
thickness)

Angles are cut into desired length using

shaper machine

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shearing and punching machine

circular saw profile cutting machine

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.

4.7. FLATTENING AND STRAIGHTENING

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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

4.8. PLANNING AND SHEARING

Except where otherwise indicated, cutting of all plates and
sections shall be affected by shearing or sawing. All edges shall
be clean, reasonably square and true. Wherever possible the edges
shall be cut in a shearing machine, which will take the whole
length of the plate in one cut.

Should be inspection find it necessary, the cut edges shall be

ground afterwards.

Planning or machining of the edges or surface shall be carried

out
when
so specified in the contract drawings or where
specifically ordered by the Engineer. Where machining is
specified, the plates or all sections shall be cut in the first instance
to such a size so as to permit not less than 3mm of metal being
removed from each sheared edge or end, in the case of plates or
sections of 12mm or less in thickness and not less than 6mm of

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metal being removed in the

exceeding 12mm in thickness.

case

of

plates and sections

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.

4.9. JIG AND FIXTURE MAKING

Jigs are the device used in the mass production of standard jobs for
drilling holes without marking. Jig is the member with drilled
holes of one component, so that by placing this jig over the
component, holes can be drilled in the component
For guiding the drilling toll and to prevent oversizing holes of jig,
bushes or reffules are provided over the jigs. The internal dia. Of
bushes should be within tolerance 0.0mm to +0.1mm. When the
bores exceed a tolerance of -0.0mm to +0.4mm, the bushes shall be
rejected.
For every working jig, one master plate should be fabricated. This
master plates is used only for checking the working jigs. Tolerance
for checking jigs from master plates shall be +0.0mm to -0.13mm.

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4.10. TACK ASSEMBLY OF JOB

Steel sections after cutting to required size and straightening will be
brought to this process for temporary assembly with tack welding to
form a member so that it will be placed in fixture will be placed over
tack assembly member and prepared for saw welding.

4.10.1. TACK WELDING

TACK Welding is to be done by AC Welding transformer set as on
following Electrode:- 4 mm dia: Type- A2, 4212X
CLASS- IRS-M-28/2002
Current :- AC
Current IN (amp.) :- 180 (approximate)
Arc Voltage (v)
:- 80 (approximate)

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4.10.2. IMPORTANT CHECKS FOR TACK WELDING

i)
Check that top & bottom flange plate are perfectly
perpendicular with reference to web throughout the length of I Section.
ii) Check the squareness i.e. 900 angle between flange & web of top
and bottom flange plate to avoid out of squares flanges.
iii) Check with filler gauge throughout the length of top & bottom
flange connection for uniform contact throughout the web plate.

4.11. SAW WELDING

Fillet welding 6mm to 10 mm Welding is to be done by automatic
submerged arc welding machine as on following approximate) 4 mm copper coated wire class-IRS- M-39 / 2001 is used.
FLUX Class- IRS- M-39 / 2001is used.
Current IN :- DC
Current IN (amp.) :- 500 to 600
Arc Voltage (v)
:- 32 to 34
Wire feed speed (m/mm) :- 2.550 to 3.200
Travel Speed of SAW (m/mm) :- 0.475 to 0.375
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Thorough cleaning of tack welded member should be done with

appropriate tool like wire brush, before shifting for full welding.
Minimum width of 75mm throughout the length shall be cleaned
to ensure that the surface is free from dust, mill scale, grease, oil
and paint to ensure sound quality of weld.

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

Submerged arc welding

Welded construction work shall be carried out generally in accordance

with the provisions of Indian Railway Standard Welded Bridge Code
and subject to further specifications given in the following paragraphs.
All welds should be done by submerged-arc welding process
either fully automatic or semi-automatic.
Carbon
di oxide
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welding or manual metal-arc welding may be done only for

welds of very short runs or of minor importance or where access
of the locations of weld do not permit automatic or semi-automatic
welding.
Except for special types of edge preparation, such as single and
double U single and double J the fusion edges of all the plates
which are to be joined by welding may be prepared by using
mechanically controlled automatic flame cutting equipment and
then ground to a smooth finish. Special edge preparation should be
made by machining or gouging.

Welding procedures:- The welding procedure shall be such

as to avoid distortion and minimize residual shrinkage stresses.
Properly designed jigs should be used for assembly. The welding
techniques and sequence, quality, size of electrodes, voltage and
current required shall be as prescribed by manufacturers of the
material and welding equipment.
For fabrication of welded composite girders, channel shear
connectors shall be welded on top flange plate prior to
assembly of I-section. This facilitates correction of any distortion
of flange plate developed during the welding of channel shear
connectors.

4.12. INSPECTION OF WELD

MACRO ETCHING TEST

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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)

Dye Penetrant Inspection (DPI) Liquid Penetrant Inspection

(LPI) Liquid Penetrant Testing (PT)

ECE Global Inspection Services offers a complete line of surface

examination techniques including Liquid Penetrant and Magnetic
Particle NDT applications and techniques. The application of these
testing methods by experienced technicians has been proven to give
reliable information as to the shape and length of different defects that
are open to surface.

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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.

Dye Penetrant Inspection (DPI), also called Liquid Penetrant Inspection

(LPI) or Liquid Penetrant Testing(PT),
is a widely applied and low-cost inspection method used to locate
surface-breaking defects in all non-porous materials (metals, plastics, or
ceramics). For applications where a greater sensitivity to smaller defects
is required, the fluorescent penetrant method is preferred.
The Penetrant may be applied to all non-ferrous materials and ferrous
materials, but for inspection of ferrous components magnetic-particle
inspection may be preferred for its subsurface detection capability.

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Commonly, DPI is used to detect cracks, surface porosity, lack of

penetration in welds and defects resulting from in-service conditions
(e.g. fatigue cracks of components or welds) in castings, forgings, and
welding surface defects.

1. Section with a normally not visible surface-breaking crack.

2. Penetrant is applied to the surface.
3. Excess Penetrant is removed.
4. Developer is applied, rendering the crack visible.

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The effectiveness of this method relies on many factors including the

training/skill of the technician, how clean the part is, and the procedure
that is being used to perform the test. DPI is a relatively cost effective
method, considering the amount of training required, and the cost of
materials used. DPI can be used in both manufacturing and in-service
inspections. As with other inspection methods, DPI requires that a
known defect standard has been defined using standard parameters. Thus
indications can be compared to with defined allowable limits.

INITIAL ASSEMBLY OF JOB

All the surfaces which will be in permanent contact shall be throughly
cleaned by grinding to remove paint, mill scale, dust etc. One coat of read
lead to IS:102 or zinc chrome red oxide priming to IS:2074 should be
applied immediately after cleaning.

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DRILLING AND SUB PUNCHING

All holes shall be drilled but the Contractor may, if he/she so prefers
sub- punch them to a diameter 6mm less than that of finished holes, e.g.
a punched hole which is to be drilled out to 25mm in diameter shall
not exceed 19mm in diameter at the die end. When the rivet holes
are to be sub-punched, they shall be marked with a centre punch and
made with a nipple punch or preferably, shall be punched in a machine
in which the position of the hole is automatically regulated. The
punching shall be so accurate that when the work has been put
together before drilling, a gauge 1.5mm less in diameter than the size
of the punched holes can be passed easily through all the holes.

MAKING OF JOINTS

Cleaning of permanent contact surfaces:- Surfaces which will have

permanent contact shall be removed of paints and mill scale down to
bare metal, clean and dried and immediately a coating of zinc chrome
red oxide priming to IS:2074 shall be applied. Care shall be taken to
see that all burrs are removed and no surface defects exist before the
parts are assembled

Bolting and Drifting:

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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.

Plain washers to IS:2016 and IS:5369.

Spring washers - IS:3063.
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Taper washers - IS:5372 and IS:5374.

Manufacture, workmanship, Marking, Packing etc. for Bolts and Nuts
shall comply with the requirements of IS:1367.

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.

For black bolts a clearance (difference in diameter) of 1.5mm

for all sizes of bolts shall be allowed.

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.

FINAL ASSEMBLY OF JOB

RIVETTING SECTION
Details of rivet checking to be maintained as per rivet checking
register (item no.-2 of appendix-i of b1-2008.
FINAL ASSEMBLY SECTION

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Final finishing of length, profile, notches etc.

Fixing of fitting for site connections.
All the defects should be rectified
Final check & inspection.

Final assembly includes acurate machining of end profile of

component.
All the members should be correctly marked before dispatch to
fecilitate easier erection.

INSPECTION OF THE WORK DONE

The
work
shall
be
temporarily erected complete at the
Contractors Works for inspection by the Inspecting Officer, with the
exception of such rivetting as has to be done at site, so that accuracy of
fit and perfection of workmanship may be assured. The work shall be
put together with sufficient numbers of parallel drifts or turned bolts or
both to bring the pieces into place. When so erected all holes left to be
filled at site shall be so fair that a parallel gauge turned to a diameter
0.8mm less than that of the hole, of a length equal to the depth of the
hole, can be passed through them without difficulty.

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FINAL SETTING OF STUD

Studs are the shear reinforcements provided on the top portion of girder.
It can be in the form of a I section that is welded on the top of it. Studs
play an important role in case of composite steel girders. At the time of
erection with concrete they bind up with the reinforcements provided
and increase the load bearing capacity of girder.

OILING, PAINTING AND METALLIZING

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INTEGRAL UNIVERSITY
INDUSTRIAL TRAINING AT RAILWAY BRIDGE WORK SHOP

No part of the work shall be painted or coated, packed or

dispatched, until it has been finally inspected and approved by the
Inspecting Officer. Dry Film Thickness shall be measured by
elcometer or any other approved method.
When so specified by the Purchaser, the whole of the work
except machined surfaces shall be given protective coating
using one of the systems of painting or metalizing given in
clauses.
Prior to the application of protective coating , the surface of
work shall be carefully prepared removing mill- scale, rust, etc.
using wire brushes, sand or grit blasting as stipulated and approved
by the Purchaser.
For locations where the girders are subjected to salt spray such
as in close vicinity of the sea and/or over creeks etc. the
protective coating by metallizing with sprayed aluminium
followed by painting as per painting schedule given below may be
applied:
(i)

One coat of etch primer to IS:5666.

(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.

Roll no. 2300111015

INTEGRAL UNIVERSITY
INDUSTRIAL TRAINING AT RAILWAY BRIDGE WORK SHOP

For locations where girders are exposed to corrosive

environment i.e. flooring system of girders in all cases, girders in
industrial, suburban or coastal areas etc., protective coating by
metallizing followed by painting or by painting using epoxy
based paints as per the following painting schedule may be
applied:

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

Apply by brush/airless spray two coats of Epoxy Zinc Phosphate

primer to RDSO Specification No. M&C/PCN/102/86 to 60 microns
min, dry film thickness( DFT) giving sufficient time gap between two
coats to enable the first coat of primer to hard dry
(b)

Intermediate Coat

Apply by brush/ airless spray one coat of Epoxy Micaceous Iron

Oxide paint to RDSO Specification No. M&C/PCN/103/86 to 100
microns minimum
DFT of 100 and allow it to hard dry.

(c)

Finishing Coat

Roll no. 2300111015

INTEGRAL UNIVERSITY
INDUSTRIAL TRAINING AT RAILWAY BRIDGE WORK SHOP

Apply by brush/airless spray two coats of polyurethane aluminium

finishing to RDSO Specification No. M&C/PCN-110/88 for coastal
locations or polyurethane red oxide (red oxide to ISO 446 as per
IS:5) to RDSO Specification M&C/PCN- 109/88 for other locations to
40 microns minimum DFT giving sufficient time gap between two coats
to enable the first coat to hard dry. The finishing coats to be applied in
shop and touched after erection if necessary

PRECAUTIONS DURING FABRICATION

DOs Use proper fixtures and clamps to hold the members firmly at
desired location while welding. The clamps and fixtures must be
strong enough to prevent any distortion of the member while
cooling of the welding joint. The clamps and fixtures are only to
be removed when the joint is cooled to ambient temperature.
Do the welding work in a warm and dry place so that rain water or
other atmospheric elements may not come in contact while
welding is in progress.
While welding in very cold weather pre-heat the material before
welding and apply post heating to prevent the weld joint from
rapid cooling and develop stress raiser due to sudden contraction.
Cross level of bearing plates in the welded plate girders should be
checked properly for proper sitting over bed plate.
Drilling of holes through approved set of jig particularly long
members should be ensured. No fabrication should be done with
unapproved jig.
Roll no. 2300111015

INTEGRAL UNIVERSITY
INDUSTRIAL TRAINING AT RAILWAY BRIDGE WORK SHOP

Proper edge finishing with grinding/ special attention in

top chord compression members butting by end milling should be
carried out
Application of paint on permanent contact surface should be
ensured after proper surface preparation visual inspection is very
important tool.
The plates should be perfectly horizontal while drilling the holes
to ensure horizontal verticality of holes.
Consistency of weld quality is higher in Submerged Arc Welding
Process and chances of human errors are also eliminated.
Therefore, welding of the girders should be done by SAW
process. Whenever not possible then only CO2 welding or
MMAW may be adopted if provided in app. WPSS.
DONTS
Use of pitted/ corroded material should not be done because it
gives rise to concentration of stresses and results in poor fatigue
strength.
Do not hammer the distorted joints for rectification. It may lead to
the development of cracks and failure of the joints.

Roll no. 2300111015