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his book covers the basics of fabrication of railway steel structures. It covers the various types of steels, steel sections and structures involved along with fabrication methods. Further, some basics of design, handling and launching of fabricated components are covered including case studies
This book covers the basics of fabrication of railway steel structures. It covers the various types of steels, steel sections and structures involved along with fabrication methods. Further, some basics of design, handling and launching of fabricated components are covered including case studies covering the consequences of errors or shortcuts adopted during fabrication. The latest trends in steel construction, adoption of steel for fast-paced construction, pre-engineered structures and use of steel for station redevelopment projects are also covered. This book aims to help the reader deliver economical and good-quality structures speedily without time and cost overruns.
This book:
• Introduces readers to the advantages and challenges of using steel as a material for railway bridges and other structures.
• Covers instructions and practices for fabrication of railway steel bridges duly linking with other aspects like design and erection to provide 3600 view.
• Reviews the latest developments in the field including new materials, fabrication techniques and types of structures being adopted.
• Includes case studies to underline the importance of good fabrication practices and consequences of ignoring the same.
This book is aimed at civil and mechanical engineering professionals connected with fabrication and erection of railway steel structures
Contents
Preface
About the Author .
Chapter 1 Introduction
1.1 Introduction to Steel
1.2 History of Use of Steel in Bridges
1.3 Few Illustrious Indian Railway Structures
1.3.1 The Past
1.3.2 The Present
1.3.3 The Future
1.4 Advantages of Using Steel
1.5 Limitations of Steel
1.6 Situations Where Steel is Preferred ..
Chapter 1 – Summary .
Revision Questions – Chapter 1
Chapter 2 Basics of Steel Structures
2.1 Types of Steel Sections
2.2 Types of Steels
2.2.1 Types of Steel Based on Treatment
2.2.2 Types of Steel Based on Strength
2.3 Common Steel Structures
2.4 Choosing Appropriate STEEL
Chapter 2 – Summary .
Revision Questions – Chapter 2
Annexure 2.1 Material Acceptance:
Steel (Plates and Rolled Sections)
Annexure 2.2 Material Acceptance: Hollow Sections
Chapter 3 Considerations in Steel Fabrication
3.1 Steel Structures – Expectations
3.2 Role of Different Stakeholders
3.3 Safety Considerations
3.4 Geometric Considerations
3.5 Assembly Considerations
3.6 Erection Considerations
3.7 Aesthetic Considerations
3.8 Durability Considerations.
3.9 Economic Considerations
3.10 Principles of “Fatigue”
3.10.1 Importance of Fatigue in Railway Bridges
3.10.2 Role of Fabrication in Ensuring Good Life of Structures under Fatigue Loads
3.11 Proper Detailing in Steel Structures Some Answers to Questions Posed in the Chapter
Chapter 3 – Summary
Revision Questions – Chapter 3
Chapter 4 Introduction to a Steel Fabrication Workshop
4.1 Introduction
4.2 Managing a Workshop
4.3 Workshop Organization
4.4 Different Shops in a Workshop
4.5 Efficient Layout for a Workshop.
4.6 Information Management in Workshop
4.7 Records to Be Maintained in All Shops
4.8 Ancillary Shops/Sections in a Workshop
4.8.1 General Management
4.8.2 Human Resource Management (HRM) Section
4.8.3 Training Section
4.8.4 Marketing and Business Development (BD)
4.8.5 Procurement and Billing Section
4.8.6 Plant and Machinery Repair Shop .
4.8.7 Asset Management Section
4.8.8 Scrap Section
4.8.9 Security Section
4.8.10 Special Sections Like Smithy, Casting, Galvanization Shops
4.8.11 Quality Control (QC) Section
4.8.12 Safety Organization..
4.9 Role of Leadership
Chapter 4 – Summary
Revision Questions – Chapter 4
Annexure 4.1 Organization Structure of a Large Workshop
Annexure 4.2 Equipment, Plant and Machinery in a Typical
Workshop with 4,000 Tonnes Fabrication Capacity per Month
Annexure 4.3 Fabrication Tolerances as per IRS B1.
Annexure 4.4 Records to be Maintained by a Workshop
(Appendix I of IRS B1) .
Chapter 5 Production Planning in a Workshop
5.1 Role of Production Control Office (PCO)
5.2 Production Planning (PP)
5.2.1 Job Analysis
5.2.2 Preparing Quality Assurance Plans
5.2.3 Preparing Fabrication Drawings
5.2.4 Production Planning
5.2.5 Features of Good Production Planning
5.3 Preparing Fixtures, Jigs/CAD Files.
5.4 Production Scheduling (PS)
5.5 Conflict Resolution
5.6 Strategic Direction
5.7 Performance Monitoring
5.7.1 Monthly Workshop Review
5.8 Strategic Reports Issued by the PCO
5.9 Production Control Office Organization
Chapter 5 – Summary
Revision Questions – Chapter 5
Annexure 5.1 Model QAP Issued by RDSO for OWGs
Chapter 6 Materials Shop.
6.1 Role and Responsibilities
6.2 Material Procurement
6.2.1 Manpower in Procurement Section
6.3 Receipt Section
6.4 Material Storage Section
6.4.1 Prevent Damage during Storage
6.4.2 Principles of Material Handling
6.4.3 Records in Storage Section
6.5 Material Issue Section
6.5.1 Records in the Material Issue Shop.
Chapter 6 – Summary
Revision Questions – Chapter 6 .
Chapter 7 Cutting Shop
7.1 Role and Responsibilities
7.1.1 Process Flow in the Cutting Shop
7.2 Straightening .
7.2.1 Basic Principle of Straightening Steel Members.
7.2.2 Care to Be Taken in Distortion Rectification
7.3 Markings.
7.4 Preparations for Cutting .
7.4.1 Lengths to Be Cut.
7.5 Cutting .
7.5.1 Possible Cutting Techniques
7.5.2 Some Codal Provisions for Cutting
7.5.3 Do’s and Don’ts in the Cutting Section
7.6 Distortion Control during Cutting
7.7 Finishing and Acceptance of Cut Sections.
7.8 Grinding
7.9 End Milling
Chapter 7 – Summary
Revision Questions – Chapter 7
Chapter 8 Theory of Welding and Other Connections
8.1 Introduction
8.1.1 Some Advantages of Welded Connections
8.1.2 Welding, However, Suffers from Some Limitations Also .
8.2 Welding TheoryWelding by Electric Arc Process .
8.3 Classification of Welds
8.4 Welding Notations
8.5 Details of Fillet Welds
8.5.1 Parts of a Fillet Weld .
8.5.2 Classification of Fillet Welds Based on Length
8.5.3 Classification of Fillet Welds Based on Root Penetration
8.5.4 Important WBC Provisions Related to Fillet Welds .
8.6 Details of Butt Welds.
8.7 Commonly Used Electric Arc Welding Techniques .
8.7.1 Advantages of SAW
8.7.2 Disadvantages of SAW
8.8 Comparison of Electric Arc Welding Techniques .
8.9 Different Types of Non?Welded Connections.
8.10 Comparison between Welding and Bolting
Chapter 8 – Summary .
Revision Questions – Chapter 8 .
Annexure 8.1 Technical Specifications of Submerged Arc Welding (SAW)
Annexure 8.2 Technical Specifications of Manual Metal Arc Welding (MMAW)
Annexure 8.3 Technical Specifications of Flux Core Arc Welding (FCAW) and CO 2 Welding
Annexure 8.4 Technical Specifications of Shear Stud Welding (SSW).
Annexure 8.5 Storage and Use of Welding Consumables
Including Electrodes
Chapter 9 Welding Shop
9.1 Role and Responsibilities
9.2 Basics of Fit Up or Tack Welding
9.3 Fit up or Tack Welding Process
9.3.1 Preparing Fixtures
9.3.2 Hold Cut Sections in Position for Tack Welding
9.4 Care to Be Taken in Tack Welding .
9.5 Preparatory Works for Welding.
9.6 Carrying Out Welding
9.7 Post?Welding Activities
9.8 Welding Inspection and Testing Procedures
9.9 Welding Defects and Their Rectification .
9.10 Distortion during Welding and Remedies
9.11 Care Required While Welding
9.11.1 Other Precautions .
9.12 Safety Precautions in Welding
Chapter 9 – Summary
Revision Questions – Chapter 9 .
Annexure 9.1 WPSS Proforma as per IRS B1
Annexure 9.2 WPQR Proforma as per IRS B1 .
Annexure 9.3 Acceptance Criteria for Welds(Clause 31.1 of WBC)
Annexure 9.4 Quality Assurance for Inspection of Automatic
Stud Welding
Chapter 10 Drilling Shop .
10.1 Role and Responsibilities
10.2 Basics of Drilled Holes
10.2.1 Marking Hole Locations
10.3 Identifying Locations for Drilling
10.4 Marking Holes for Camber Lengths in OWGs.
10.5 Drilling Holes
10.5.1 Types of Drilling Machines
10.5.2 Hybrid Methods of Drilling Holes
10.6 Other Methods of Making Holes
10.7 Precautions in Making Holes
10.8 Match Markings
Chapter 10 – Summary
Revision Questions – Chapter 10
Chapter 11 Final Assembly Shop..
11.1 Role and Responsibilities
11.2 Procedures in Final Assembly Shop
11.3 HSFG Bolts Installation
11.4 Trial Assembly..
11.5 Camber and Its Types
11.5.1 Camber Type?I to Be Provided.
11.5.2 Camber Type?I vs Camber Type?II .
11.5.3 Checking Girders with Improper Camber Type?II
Chapter 11 – Summary
Revision Questions – Chapter 11
Annexure 11.1 Permitted Relaxation in Camber Values
Annexure 11.2 Material Acceptance: High Strength Friction Grip (HSFG) Bolts
Chapter 12 Painting Shop .
12.1 Need for Painting.
12.2 Corrosion – Mechanism and Strategies to Address .
12.2.1 Important Locations for Additional Care in Corrosion Protection
12.3 Surface Preparation for Coatings
12.3.1 Surface Preparation in a Workshop.
12.3.2 Specifications for Blasting.
12.4 Application of Coatings .
12.4.1 Qualities of a Good Coating
12.4.2 Care to Be Taken While Painting
12.4.3 Advantages of Galvanization
12.4.4 Limitations of Galvanization
12.4.5 Care to Be Taken in Galvanization
12.5 Coatings to Be Adopted.
12.6 Care to Be Taken in Painting shop
Chapter 12 – Summary
Revision Questions – Chapter 12
Chapter 13 Dispatch Shop.
13.1 Role and Responsibilities
13.2 Procedures in Loading and Dispatch Shop
13.2.1 Protecting the Members during Transportation
13.2.2 Approvals for Moving Over Dimensioned Consignments (ODCs)
13.2.3 Transfer to Dead Inventory
13.2.4 Loading .
13.2.5 Dispatch
13.2.6 Care during Transportation
13.2.7 Material Rejected at the Site
13.2.8 Material Returned from the Site
13.3 Records in the Dispatch Shop.
13.4 Coordination with Site
13.5 Manpower and Machinery in the Dispatch Shop
Chapter 13 – Summary .
Revision Questions – Chapter 13
Chapter 14 Fabrication for Indian Railways
14.1 Scope
14.2 Sources of Information
14.3 Indian Railway’s Policy and Guidelines for Steel Structures
14.4 Standard RDSO Designs
14.5 RDSO Vendor Registration
Chapter 14 – Summary
Annexure 14.1 Schedule of Technical Requirements for Fabrication of Girders .
Chapter 15 Site Assembly and Erection.
15.1 Receiving the Material at the Site
15.2 Stacking the Material at Site
15.3 Preparations for Assembly/Erection
15.3.1 Assembly/Erection Scheme
15.3.2 Team for Assembly/Erection .
15.4 Carrying Out Site Assembly/Erection .
15.4.1 Work before Starting Assembly/Erection .
15.4.2 Actual Assembly .
15.5 Post?Assembly Work..
15.6 Final Inspections .
15.7 Care to be Taken in Site Assembly/Erection
15.7.1 Correct Site Connections.
15.7.2 Prevent Overstressing of Members
15.7.3 Prevent Damage to Fabricated Members
15.7.4 Keep a Plan B Ready .
15.7.5 Camber in Girders
15.8 Finishing and Handover
Chapter 15 – Summary
Revision Questions – Chapter 15
Annexure 15.1 Method of Assembly of Specific Structures
Chapter 16 Case Studies for Issues Faced After Erection
16.1 Case #1: Lack of Proper Camber in Open Web Girders .
16.2 Case #2: Holes in Open Web Girders Components Not Matching
16.3 Case #3: Top Flange of Plate Girder Found Drooping
16.4 Case #4: Negative Deflection in Composite Girder
16.5 Case #5: Improper Welding
16.6 Case #6: Drawing not Followed Properly
16.7 Case #7: Improper Design and Drawing
16.8 Case #8: Improper Bearing Installation for Skew Girder
16.9 Case #9: Improper Installation of Girder on Piers .
16.10 Case #10: Girder Parts with Fresh Paint.
16.11 Case #11: Girder Hit the Pier during Launching
16.12 Case #12: Wrong Parts Procured for HSFG Bolts
16.13 Case #13: Improper Surface Preparation
16.14 Case #14: Girder Components Damaged in Transit
16.15 Case #15: Girder Fell Off the Supports
16.16 Case #16: Interesting and Unusual Failure
16.17 Case #17: Bolts Insertion not Possible
16.18 Case #18: Durability Considerations in Design
16.19 Case #19: Poor Detailing
16.20 Case #20: Wrong Interpretation of Codal Provisions
16.21 Case #21: Some Common Areas of Dispute
Chapter 16 – Summary
Revision Questions – Chapter 16
Important Technical Terms and Acronyms
Bibliography
Index
