Indian Institute of Welding ANB

Refresher Course Module 12

Construction And
Design
S.K.GUPTA

7/22/2015 SKG 1
WELDMENT DESIGN
FOR IIW S.K.GUPTA

7/22/2015 SKG 2
7/22/2015 SKG 3
 INTRODUCTION
Welding is one of the most important & versatile
means of Fabrication available to industries.
Welding technologists endeavour to achieve
defect free welds.
Origin of defects can be traced to
Welding Process
Improper design
It is generally acknowledged that defects in
welds are unavoidable
Hence, a good knowledge of influence of defects
on weld joint performance is essential in weld
design.
7/22/2015 SKG 4
 Objectives of Weld Joint Design
The objectives of Weld Joint designs are
ideally to provide an assembly that :
Will perform its Intended Functions
Will have required Reliability & Safety
Is capable of being Fabricated, Inspected,
Transported & placed in service at minimum
total cost.
Minimum total cost includes the cost of :
Design, Materials, Fabrication, Erection,
Inspection, Operation etc.,

7/22/2015 SKG 5
 DESIGN FOR WELDING
Welded Joint is designed to meet a certain
combination of properties required by end use.
Thus, Mandatory requirement are specified in
various Fabrication codes.
The majority of these codes specify the
following in the welded joints :
Type of Joints
Joint details
An allowable design stress based on the material
properties at service temperatures.
Manufacturing & Testing requirements
Mention detailed requirements for specific
environmental conditions.
7/22/2015 SKG 6
 ROLE OF DESIGNER
Depends on Circumstances
Relatively Superficial in established & proven area
Critical application, more wide ranging and profound
range of responsibilities
Designer should be Cost-conscious and avoid
Over Designed Plate / Pipe
Over Sized Fillet weld
Continuous weld when intermittent weld would
suffice
Excess Reinforcement
Expensive welding consumables, etc,.

7/22/2015 SKG 7
 RESPONSIBILITIES OF THE DESIGNER
Component should be designed to meet the
intended functional requirement.
Choose correct Materials
(Knowledge of Materials & their properties)
Choose correct Codes & Standards
(Knowledge of each Document & their limitations)
Detail the Loadings & apply the Design Methodology
(Knowledge of design procedure & failure theories
Choose appropriate Manufacturing methods
(Knowledge of Modern Manufacturing Processes)
Assess integrity of the component after manufacture
(Knowledge of various destructive & NDT techniques)
7/22/2015 SKG 8
Behaviour Of Welded Structures Under Different
Types Of Loading
All composite and fabricated structures work
under different environmental and loading
conditions such as :
Static or dynamic loading
Concentrated or distributed loading
Tension or compression or torsional loading
Combination of above loading
At normal temperature
At sub-zero temperature
At elevated temperature

7/22/2015 SKG 9
 Behaviour Of Welded Structures
Steel structures working under different conditions of
loading and temperatures behave differently due to
variation of the following properties :
Tensile strength
Ductility
Impact strength or toughness
Creep resistance
Brittleness
Variations in the above properties occur mainly due to
the changes in the grain structures and inter granular
grain cohessiveness

7/22/2015 SKG 10
 Static And Dynamic Loading
Under static loading condition the
tensile strength ,
compressive strength ,
shear strength values
are determinants of the section of
the material and that of the weld

7/22/2015 SKG 11
 Static and Dynamic loading
But when the load
varies in value ,
is repeated at relatively high frequency,
constitutes a relatively high frequency

the materials endurance limit must be

substituted for the tensile strength in the
calculations to determine section and weld
dimensions
7/22/2015 SKG 12
 Loading Conditions

7/22/2015 SKG 13
Loading Induced Shear Force and Bending Moment

7/22/2015 SKG 14
 Loading Induced Linear and Angular Strains

7/22/2015 SKG 15
 Loading in Any Axis Induces Stress and Strain
in other Axes

7/22/2015 SKG 16
Three Dimensional Stresses Due to Loading

7/22/2015 SKG 17
7/22/2015 SKG 18
7/22/2015 SKG 19
7/22/2015 SKG 20
 Stress, Strain, Modulus Of Elasticity.
Stress is defined to be the load on a member
divided by the area of cross section and is
expressed in newton per mm sq.
Stress may be tensile or compressive or shear
Elongation or compression per unit length is
termed strain and is a number.
The ratio of stress by strain is called modulus
of elasticity
The endurance limit is the maximum stress to
which the material can be subjected for an
indefinite service life.
SKG 21
 Stress Vs N Curve

S
T
R ENDURANCE
E
S
S

N CYCLES OF STRESS
SKG 22
Elevated Temperature Stresses
Design stresses are usually
limited by yield and tensile
strengths up to a moderate
temperature of about
450 deg. to 535 deg. Centigrade.

At higher temperatures the design

stresses are limited by creep and
creep rupture strength.
SKG 23
 Elevated Temperature Design
In designing apparatus / structures at elevated
temperatures allowance must be made for the
thermal coefficient of expansion of the
component materials.
The tensile modulus of elasticity at room
temperature decreases linearly upto 450 deg.
centigrade and then begins to drop at an
increasing rate.
Creep (continuous non-reversible plastic
deformation with time under load) resistance is
the most important property to consider in
designing a structure to operate at elevated
temperature.

SKG 24
 CREEP STRENGTH

Two standards of creep strengths are

commonly used :

The stress to produce a minimum creep

rate of 0.00001 per cent per hour ( 1 per
cent per 100,000 hours )

The stress to produce a total creep

strain of 1 per cent per 100,000 hours.

SKG 25
 SCHEMATIC CREEP CURVE
A ELASTIC
EXTENSION
E
C B- CREEP AT
DECREASING RATE
EXTENSION PER CENT

B D
C CREEP AT
APPROXIMATELY
F CONSTANT RATE

D CREEP AT
INCREASING RATE
A
E ELASTIC
CONTRACTION

ELAPSED TIME IN HOURS F PERMANENT

CHANGE OF LENGTH

SKG 26
Low Temperature Strength
The terms
low temperature and
cryogenic
may be defined as involving
temperatures to
100 degree and 273 deg.
Centigrade.

SKG 27
 LOW TEMPERATURE STRENGTH

Design of structures operating at

low temperatures are based on
the properties of
yield and tensile strength,
fatigue limit,
ductility and
toughness especially
notch toughness.

SKG 28
 NOTCH TOUGHNESS

Notch toughness is a property

of steel reflected in its resistance
to brittle failure under conditions
of high stress concentration such
as impact loading in the presence
of a notch.

SKG 29
Introduction To Weld Design.
The following notes are general guidance
notes showing methods of calculation of the
strength and size of welds.
Welded joints are often crucially important
affecting the safety of the design systems.
It is important that the notes and data below
are only used for preliminary design
evaluations.
Final detail design should be completed in a
formal way using appropriate codes and
standards and quality reference documents

SKG 30
 Variables related to welded joints
1. Strength of deposited weld material
2. Type of joint and welding
3. Size of weld
4. Location of weld in relation to parts
joined
5. Types of stress to which the weld is
subjected
6. Conditions under which weld is
carried out
7. Type of equipment used for welding
8. Skill of welder
SKG 31
Basic Types of Joints & Terms

SKG 32
Types of joints

SKG 33
 Parts of a weld
Joint root
Groove face
Root face
Root edge
Root opening
Bevel
Bevel angle
Groove angle
Groove radius
SKG 34
Joint root is that portion of a joint to be welded
where the members are closest to each other

The joint root may

be either a point,
line, or an area
The joint roots are
shown as shaded
areas in (A)-(D) and
lines in (E) (F)

SKG 35
Groove Face, Root Face, and Root Edge
Groove face is that
surface of a member
included in the
groove
Root face (land) is
that portion of the
groove face within the
joint root
Root edge is a root
face of zero width

SKG 36
Root Opening and Bevel

Root opening is
the separation
between the work
pieces at the joint
root
Bevel (chamfer)
is an angular
edge preparation

SKG 37
Bevel Angle, Groove Angle, and
Groove Radius
Bevel angle is the angle
between the bevel of a joint
member and a plane
perpendicular to the surface
of the member
Groove angle the total
included angle of the groove
between members
Groove radius applies only to
J-&U- groove welds

SKG 38
Position of Weld Symbols on the Drawings

SKG 39
Elementary welding symbols

SKG 40
Elementary welding symbols

SKG 41
 Position of the symbol

Dual
Ref.Line

To be welded on the arrow

side

To be welded on the other

side

SKG 42
Position of the arrow line

SKG 43
Combination of
Elementary
Symbols

SKG 44
Dimensioning

SKG 45
EFFECTIVE THROAT
LEG

LEG
THEORETICAL
THROAT

ACTUAL THROAT
FILLET WELD
NOMENCLATURE
 Strength of the weld depends on the size of the fillet
Types of Lap Joint Welds subjected to heavy loads, -double-fillet lap joints

Double Fillet Joggle Lap Joint

Double Fillet Welded

Single
Adjacent
Sheet To
Sheet Edges to
Continuous Through- Backing Backing
Welded Lap Joint Structure
Structure
Welding Calculations.

Total throat thickness is >

than material thickness
T FILLET WELDS Welding Calculation. . .
Throat area is the product of the
throat thickness and the effective
length of the weld.

Welds with effective lengths shorter

than 40mm or 6 times the throat
thickness, whichever is larger, should
be ignored for transmission of forces.

Double fillet welding :Limits

rotation of the member about the
axis of the joint, less tension stress at
the root, can be cyclically loaded
parallel to the weld

Size to carry load &

accommodate shrinkage
during cooling to avoid crack.
SKG 50
 LAP JOINT Welding Calculation.
Weld subject to longitudinal shear

Peak stress tends to equalize during loading by

localized plastic deformation.
Length = 100 x Throat thickness
Welds are sized to
withstand static or cyclic
Loading . . .
 Determining Weld Size :
Fillet welds
RULE OF THUMB FOR FILLET WELD SIZE
In order to develop the full strength of a plate by fillet
weld, it is necessary that the leg size of a fillet be
of the plate thickness
w = t
This assumes that :
1. Fillet welds on both sides of the plate
2. Fillet weld for full length of the plate
3. t = thickness of the thinner plate
 Determining Fillet Weld Size
Rule of thumb for rigidity design
When a member is designed to maintain a
certain degree of rigidity or stiffness, the
stresses are usually of a rather low value, but
the weld size is still dependent on the forces
which must be transferred through them.
The rigidity design would require a fillet leg
length
W = 1/4 t to 3/8 t

1/2 to 1/3 of the full weld size

 Design Example
Consider the two assemblies shown in Figures 1 and 2.
Fig.1. Lap joint with fillet welds loaded in parallel.Fig.2. Lap joint
with fillet welds loaded perpendicularly.
The weld sizes would be computed as follows:
Using an E70 electrode (E48), and with L = 4 (100mm,
0.1m), what weld size is needed to resist the applied load
of 40 kips (180 kN)?

)))))))))))
)))))))))))

))))))))))
))))))))))))

Fig. 1 Loaded in Parallel. Fig.2. Loaded perpendicularly

SKG 54
 In-Plane Centre of Gravity Loading.
The allowable stress in a linear weld group loaded in-plane
through the centre of gravity is the following:
FV = 0.30 FEXX (1.0 + 0.50 sin1.5 Q)
where:
FV = allowable unit stress, ksi
FEXX = electrode classification number, i.e.,
minimum specified tensile strength, ksi
Q = angle of loading measured from the weld
longitudinal axis, degrees
For parallel loading, Q = 0, and the parenthetical term in
the above equation becomes 1, yielding the same allowable
unit stress as has been traditionally permitted.
For perpendicular loading, Q = 90, and the parenthetical
term becomes 1.5, permitting the increased allowable unit stress.

SKG 55
 Figure 1. Lap joint with fillet welds loaded in parallel

FV = 0.30 FEXX (1 + 0.5 sin1.5 Q)

ENGLISH
FV = 0.30 (70 ksi) (1 + 0.5 sin1.5 0) = 21 ksi
F = FV (A) = FV (2 welds) (L) (0.707) (w)
w = F / FV. 2L(0.707) = 40 kips / 21 ksi x 4x 0.707
w = 0.337
Use 3/8 fillet
METRIC
FV = 0.30 (480 MPa) (1 + 0.5 sin1.5 0) = 144 MPa
w = 180 kN / (144 MPa) x 2 x (0.1m) x 0.707
w = 0.0088 m (8.8mm)
Use 10 mm fillet

SKG 56
Figure 2. Lap joint with fillet welds loaded perpendicularly.

FV = 0.30 FEXX (1 + 0.5 sin1.5 Q)

ENGLISH
FV = 0.30 (70 ksi) (1 + 0.5 sin1.5 90) = 31.5 ksi
w = 40 kips / (31.5 ksi) x 2 x 4 x 0.707
w = 0.224
Use 1/4 fillet
METRIC
FV = 0.30 (480 MPa) (1 + 0.5 sin1.5 90) = 216 MPa
w = 180 kN / (216 MPa) x 2 x 0.1m x 0.707
w = 0.00589 m (5.89 mm)

Use 6 mm fillet

SKG 57
 Practical Applications

In order to capitalize upon the additional

allowable stress capacity, the designer
must orient the welds so that they are as
nearly perpendicular to the applied load
as possible.
Notice that the equation permits the use
of any value of Q, even though the
examples have shown the extremes of 0
and 90.

SKG 58
 SHEAR STRENGTH OF WELD

HORIZONTAL SHEAR FORCE ON EACH WELD

r Vay N/m
h = In
WHERE :
V = TOTAL SHEAR ON SECTION AT A GIVEN
POSITION ALONG BEAM, ( N )
2
a = AREA OF FLANGE HELD BY WELD ( m )
y = DISTANCE BETWEEN THE C.G. OF FLANGE AREA
AND N.A. OF THE WHOLE SECTION (m)
4
I = MOMENT OF INERTIA OF THE WHOLE SECTION ( m )
n = NUMBER OF WELDS JOINING EACH FLANGE TO WEB
 250

AREA OF 70
FLANGE
HELD BY
WELDS

860 kN 1200

WELD LEG SIZE w

7/22/2015 SKG 60
V = 860 kN = 860 / 1000 MN = 0.860 MN
Cross-sectional area held by
2
the weld = 70 /1000 x 250 /1000 m
= 0.070 x 0.250 = 0.175 m 2
y = distance between the c.g. of the
flange area and the n.a. of the
whole section = (1200 + 70 )/(2 x 1000) m 15
= 0.635 m
I = the moment of inertia of the section

70
3
= 1/12 { (250/1000) x (1340/1000)
3
- (235/1000) x (1200/1000) }

1200
= 0.16282262 m4
n = number of welds joining
each flange to web = 2

70
Throat area for a parallel loaded fillet weld
= 0.707w 250
Allowable shear strength = 96 MN / m

WORKED OUT EXAMPLE

 WORKED OUT EXAMPLE
GIVEN :
Width of the flange= 250 mm. Thickness of the flange = 70 mm
Thickness of the web = 15 mm. Depth of the web = 1200mm
Total shear on section = 860 Kn
Then : rh = (V.a.Y)/I.n
3 6
(860/10 ) x (70 x 250)/10 x 1270/2000
=
3 3
{( 250/12000) x (1.340 ) 2.35 x 1.2 } x 2/12

= 0.2934712 MN/m

If the size of the fillet is w, and allowable shear strength = 96 MN/m2

Then, 0.707 w x 96 = 0.2934712.
or w = 4.32 mm
THIS SHOULD BE THE MINIMUM LEG SIZE OF THE CONTINUOUS FILLET
WELD
 Minimum size of first run or of a
single run fillet weld

Thickness of thicker part (mm) Minimum size (mm)

t 10 3
10 < t 20 5
20 < t 32 6
32 < t 50 8 (First run)
10 (Minimum size of fillet)

7/22/2015 SKG 63
 Guidance Principles

For the direct loading case the

butt weld stresses are tensile/
compressive t.

For the fillet welds the stresses

are assumed to be
shear s applied to the weld
throat.

7/22/2015 SKG 64
 Guidance Principles
For butt welded joints subject to bending
the butt weld stresses result from a
tensile/compressive stress b and a direct
shear stress s .
In these cases the design basis stress
should be
2 2
r = Sqrt (b + 4s )

7/22/2015 SKG 65
 Guidance Principles
For Fillet welded joints subject to
bending the stresses in the fillet
welds are all shear stresses.
From bending b and from shear s
In these cases the design basis
stress is generally
2 2
r = Sqrt (b + s )

7/22/2015 SKG 66
 How to Calculate Welding Size for
Bending Loads
Calculating correct welding size and specifying it in a
welding drawing is the first important step toward
achieving defect-free welding. This welding design
will explain how to calculate welding size for
bending loads. The procedure for welding size
calculation for bending load is a little different than
calculation of welding size for pure tension. Here we
will discuss the calculation procedure called the
"line method" (BS 5950 Clause 6.8.7.2) along with
examples

7/22/2015 SKG 67
A Typical Example : In the picture below one plate is welded over
the I-beam and a vertically downward load of 10 KN is acting on
the plate.

7/22/2015 SKG 68
 Input Data: Load F= 10000 N
Desired Output:
Throat thickness (t) and leg length (s)
Steps for Welding Size Calculation by Line Method
As the load is acting at a distance from the I-beam, the
weldment will experience two kinds of stresses, namely
bending stress and shear stress.
Bending moment (M) of the force can be calculated as:
M = 10000 * 60 N-mm = 600000 N-mm
Length or height of the weld H = 100 mm
Width of the weld B = 75 mm
Design stress of the filler material Fw = 220 N/mm2
Y= H/2 =50 mm

7/22/2015 SKG 69
 Input Data: Load F= 10000

Desired Output:
Throat thickness (t) and leg length (s)
Steps for Welding Size Calculation by Line Method
As the load is acting at a distance from the I-beam, the
weldment will experience two kinds of stresses,
namely bending stress and shear stress.
Bending moment (M) of the force can be calculated
as:
M = 10000 * 60 N-mm = 600000 N-mm
Length or height of the weld H = 100 mm
Width of the weld B = 75 mm
Design stress of the filler material Fw = 220 N/mm2
Y= H/2 =50 mm

SKG 70
 Desired Output:
I = a *(1/6)* (3*B + H )* H Eqn.1

Where,
a is the height of weld section.
For line method height (a ) is assumed to be one and
for such case moment of inertia is called unit moment
of inertia (Iu), so for line method Eqn.1 become

Unit moment of inertia

=Iu = (1/6) * (3*B + H ) * H Eqn.2

7/22/2015 SKG 71
 Desired Output
From Eqn.2 calculate the unit moment of inertia (Iu )
of the joint as:
4
Iu = 541667.67 mm
Calculate bending stress ( Tb) on the welding joint as:
Tb = M * Y / Iu
2
= 55.384 N/ mm
Calculate unit area of the welding (Au) as:
Au = (B+H)*2
2
= 350 mm
Calculate shear stress ( Ts) on the welding joint as:
Ts = F/Au
2
= 28.571 N/ mm
7/22/2015 SKG 72
 Desired Output:
Calculate resultant (T) of bending stress
and shear stress on welding as:
2 2 1/2
T = (Tb+Ts)
2
=62. 32 N/ mm
Next, calculate throat thickness (t) as:
t = T/Fw
= 0.283 mm
Finally, calculate welding leg length (s)
using the following equation:
s = 1.414 * t
= 0.4 mm (approximately 0.5 mm)

7/22/2015 SKG 73
 Example of Weld in Torsion..

P = Applied load = 10 000N

P w = Design Strength = 220 N/mm 2 (Electrode E35 steel S275)
Design Strength
b = 120mm.
d = 150 mm
x = b2 / 2(b+d) = 27mm.
y = d2 / 2(b+d) = 42mm.
SKG 74
Simple Method as BS 5950 clause 6.8.7.2

The vector sum of the stresses due to forces and

moments should not exceed the design strength Pw

A u = Unit Throat Area

2
= b + d = (120 + 150) = 270mm
To obtain radius of Force from weld centre of gravity
A = 250 - 27 = 223mm 6
Moment M = P*r 4
= 10000 x 223 = 2.23 x 10 N.mm
2 6
J u = [(b+d) - 6b2d] /12 (b+d) = 1.04 x 10

SKG 75
 Simple Method as BS 5950 clause 6.8.7.2
First considering point Z

Horizontal distance from centroid

r zh = 120 27 = 93mm
Vertical distance from centroid r z v = 42mm

The vertical stress v = sv + tv 2

sv = P /A u = 10000/270 = 37 N/mm
tv = M * r * zh /J u 2
= 2.23x106x93/1.04x106 = 199 N/mm
2
v = 236.45 N/mm

SKG 76
Simple Method as BS 5950 clause 6.8.7.2
First considering point Z
The horizontal stress
h = sh + th
sh = 0
th = M*r*zv /J u
2
= 2.23 x 106x42/1.04x106 = 90 N/mm
2
h = 90 N/mm

The resultant stress

2
on the weld at z
2 2
r = Sqrt (h + v) = 253 N/mm

SKG 77
 Simple Method as BS 5950 clause 6.8.7.2
Now considering point w

Horizontal distance from centroid rwh = 27mm

Vertical distance from centroid
rwv = 150 42 = 108mm

The vertical stress v = sv - tv 2

sv = P /A u = 10000/270 = 37 N/mm
tv = M*rwh /J u 2
= 2.23x106x27/1.04x106 = 57.9 N/mm
2
v = 20.86 N/mm

SKG 78
Simple Method as BS 5950 clause 6.8.7.2
Now considering point w

The horizontal stress

h = sh + th
sh = 0
th = T*r wv /J u 6 6
= 2,23 x 10 x 108/1.04 x 10
2
= 231.6 N/mm2
h = 231.6 N/mm

The resultant stress on the weld at w

2 2 2
r = Sqrt (h + v) = 232.5 N/mm

SKG 79
Simple Method as BS 5950 clause 6.8.7.2
The horizontal stress h = sh + th
sh = 0
th = T.r wv /J u = 2.23x106x108/1.04.106
= 231.6 N/mm2
h = 231.6 N/mm2
The resultant stress on the weld at w
r = Sqrt ( h2 + v2) = 232.5 N/mm2
The maximum stress is similar but greatest at z ....
The design strength p w for the weld material is 220
N/mm 2
The weld throat thickness should be
253 /220 = 1.15 mm .
The weld size is therefore 1.414 x 1.15 = 1.62 mm
use 3mm fillet weld
SKG 80
Direction Method as BS 5950 clause 6.8.7.3

L = Length of weld 1 unit thick

= (From table below) b + d = (120 + 150)
= 270mm
To obtain radius of Force from weld Centre of Gravity
(COG) .
A = 250 27 = 223mm
Moment M = P*r = 10000 x 223
6
= 2.23 x10 N.mm
Ju = Polar Moment of inertia for weld 1unit(mm) thick.
2 2 6 4
= [(b+d)4 6bd ] /12 (b+d) = 1.04 x10 mm /mm.

SKG 81
Direction Method as BS 5950 clause 6.8.7.3
First considering point Z

Horizontal distance from centroid r zh = 120-27= 93mm

Vertical distance from centroid rzv= 42 mm

The vertical force /mm run Fv = Fsv + Ftv

Fsv = P /L = 10000/270 = 376
N/mm run6
Ftv = M *rzh /J u = 2.23x10x93/1.04x10 = 199 N/mm run
Fv = 236.45 N/mm run

The horizontal force /mm run for unit (mm) weld width
Fh = Fsh + Fth
Fsh = 0 6 6
Fth = M*rzv /J u = 2.23*10*42/1.04*10 = 90 N / mm run
Fh = 90 N / mm run
The resultant force on2 the weld/mm run at z
2
Fr = Sqrt (Fh + Fv) = 253 N / mm run

SKG 82
 Direction Method as BS 5950 clause 6.8.7.3
Horizontal distance from centroid r wh = 27mm
Vertical distance from centroid r wv = 150-42= 108mm
The vertical forces per mm F v = F sv - F tv
F sv = P /L = 10000/270 = 37 N/mm run
F tv = M.r wh /J u = 2.23x106x27/1.04x106 = 57.9 N/mm run
F v = 20.86 N/mm run
The horizontal force /mm run = F h = F sh + F th
F sh = 0
F th = M.r wv /J u = 2.23x106x108/1.04x106 = 231.6 N/mm run
F h = 231.6 N/mm run
The specific force on the weld at w
F r = Sqrt (F h2 + F v2) = 232.5 N/mm run

The maximum specific is greatest at z = 253 N/mm run....

SKG 83
 Direction Method as BS 5950 clause 6.8.7.3
Horizontal distance from centroid r wh = 27mm
Vertical distance from centroid r wv = 150-42= 108mm
The vertical forces per mm F v = F sv - F tv
F sv = P /L = 10000/270 = 37 N/mm run
F tv = M.r wh /J u = 2.23x106x27/1.04x106 = 57.9 N/mm run
F v = 20.86 N/mm run
The horizontal force /mm run = F h = F sh + F th
F sh = 0
F th = M.r wv /J u = 2.23x106x108/1.04x106 = 231.6 N/mm run
F h = 231.6 N/mm run
The specific force on the weld at w
F r = Sqrt (F h2 + F v2) = 232.5 N/mm run

The maximum specific is greatest at z = 253 N/mm run....

SKG 84
Direction Method as BS 5950 clause 6.8.7.3

The maximum specific is greatest at z

= 253 N/mm run.

Referring to weld capacities for longitudinal

stresses PL for fillet welds
Capacities of Fillet Welds

The weld capacity for a 3mm weld with E35

Electrode on S275 Steel is
462N /mm run.

This weld would be more than sufficient.

SKG 85
 Guidance Principles
The stresses from joints subject to
torsion loading include shear stress
from the applied load and shear
stresses from the torque loading.
The resulting stresses should be
added vectorially taking care to
choose the location of the highest
stresses.

7/22/2015 SKG 86
7/22/2015 SKG 87
 The table below provides approximate stresses
Stress in Weld
Method of b
Weldment
Loading s
Weld size (h)

7/22/2015 SKG 88
 Stress in Weld
Method of b
Weldment
Loading s
Weld size (h)

7/22/2015 SKG 89
 Stress in Weld
Method of b
Weldment
Loading s
Weld size (h)

7/22/2015 SKG 90
 Stress in Weld
Method of b
Weldment
Loading s
Weld size (h)

7/22/2015 SKG 91
7/22/2015 SKG 92
 WELDING PROCEDURES.
The code says that all the details of the
welding procedure should be listed in a document
known as
WELDING PROCEDURE SPECIFICATION (WPS).
Each of these welding procedure specifications
shall be qualified by welding of the test coupons.
And the mechanical testing of the specimen cut
from these coupons, as required in this code.
The welding data for these coupons and the
results of these tests shall be recorded in a
document known as
PROCEDURE QUALIFICATION RECORD (PQR).
SKG 93
 SCOPE OF WPS AND PQR

A Welding Procedure Specification (WPS) is

written qualified Welding Procedure prepared
to provide direction for making production
welds to code requirements.
A Procedure Qualification Record (PQR) is
essentially a record of welding data used to
weld a test coupon. It also contains the test
results of the tested specimens. Recorded
variables normally fall within a small range of
the actual variables that will be used in
production welding.

SKG 94
 SCOPE OF WPS AND PQR

Changes to PQR are not permitted

except in the cases of editorial corrections to
the entries or the case of an addenda being
added.
All changes in PQR would call for a
re-qualification. When more than one welding
process or filler metal is used to weld a test
coupon, the deposit weld metal thickness of
each process and filler metal would be
recorded. Several WPS, may be prepared
from the data on a single PQR
SKG 95
 Production Welding Positions

Fillet Welds
Groove Welds

7/22/2015 skg 96
 Why Codes and Standards

We use codes and standards to

manufacture many things that have
been built many times before.
The lessons of failure, over and under
design are generally incorporated into
the next revised edition.

SKG 97
 Code and Standards
A Code of Practice is generally considered
as a legally binding document, containing
all obligatory rules to design, build and
test a specific product.
As per English dictionary, A code is a set
of laws or rules that shall be followed
when providing a service or a product.

SKG 98
The Bureau of Indian Standards (BIS)
The Bureau of Indian Standards (BIS) is the
national standards body of India working
under the aegis of Ministry of Consumer
Affairs, Food & Public
Distribution, Government of India. The
organization was erstwhile known as
the Indian Standards Institution which was
founded in the year 1947.
SKG 100
 ISO (International Organization
for Standardization)
ISO (International Organization for
Standardization) is the world's largest
developer and publisher of International
Standards. ISO is a network of the
national standards institutes of 162
countries, one member per country, with
a Central Secretariat in Geneva,
Switzerland, that coordinates the system.
SKG 101
 "British Standards"

Formally, as per the 2002 Memorandum

of Understanding between the BSI and
the United Kingdom Government,
British Standards are defined as:
"British Standards" means formal
standards as based upon the principles
of standardisation recognised inter
alia in European standardisation policy.

SKG 102
 BS EN Specifications
BS EN Specifications have largely
replaced the more familiar British
Standards that most of us were familiar
with but some important solely British
Standards do remain.These "BS EN"
documents are as the name implies
European specifications and therefore
embrace a wide area.

SKG 103
DIN Deutsches Institut fr Normung
2011 DIN e. V.
Standardization and Research Projects
Reason for Standardization in Research
Projects
Ensuring fitness for purpose
Establishment/codification of best practice
Reducing variety and eliminating waste
Establishing compatibility and
interchangeability
Developing self-regulation of a market
Eliminating (technical) barriers to trade
SKG 104
BRIDGE GIRDER FAILURE ANALYSIS

SKG 105
Failure of Pressure Vessel during
Hydro-test

SKG 106
106
LONGITUDINAL STRESS DISTRIBUTION IN
WELDING

SKG 107
 THANK YOU

7/22/2015 SKG 108