Professional Documents
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Categories A through C
Category A
1
Category A
Poor Quality Surface
Crack Initiating in
Base Metal at Flaw
2
Category A Cont’d
Copes
Bad Good
3
Figure 2.2. Category A – Base Metal
Category B
General
4
Category B
Longitudinal Welds
5
Full Penetration Groove Weld
or Fillet Weld
B
Fillet Weld
Category B
Transverse Welds
6
Example Category B Transverse
Welds
Groove Weld
Web Splice
Ground Flush
B With NDI of
Tension
Portion of
Web
Figure 2.8. Category B – Transverse Groove Weld, NDI and Ground Flush
7
Slope Not Greater
Than 1 in 21/2
B
NDI and
Ground Flush
Base Metal B
Other Than
A514 / A517
NDI and Ground Flush
R ≥ 24”
NDI and
Ground Flush
Category B
Groove Welded Attachments
8
Category B
Groove Welded Attachments
Longitudinally loaded
– Can be full or partial penetration
– Ends ground smooth (minimize SCF at toe)
Transversely loaded
– Full penetration only
– Partial penetration has lack-of-fusion zone
Acts as pre-crack or internal flaw
– Weld reinforcement must be removed
Plates must be of equal thickness
– Weld soundness established by NDT
Category B
Groove Welded Attachments
R ≥ 24”
Groove Weld
End Weld Ground Smooth
R
R
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R ≥ 24”
t = td’
Groove Weld
Reinforcement Removed
td R
R
Category B
Bolted Connections
Example Category B
Bolted Connections
10
Example Category B
Bolted Connections
Gross Section if
Friction-Type Connection
Net Section if
Bearing-Type Connection
11
Full Penetration Groove Weld
With Backing Bar Not Removed
B'
B'
Partial Penetration
Groove Weld
12
Slope not Greater
Than 1 in 21/2
NDI and
Ground Flush
A514 / A517
Base Metal
NDI and
Ground Flush
Category C - General
Short welded attachments
– L < 2.0 in
– Applies to groove or fillet welds
Transverse full pen. groove welds w/o
reinforcement ground smooth
– Susceptibility to weld toe cracking
Groove welded attachment
Shear studs
Influence of Attachment
Length on Detail Category
Short Long
Attachment Attachment
13
Influence of Attachment
Length on Detail Category
Category C
Short Attachments
Example of Crack at
Category C Detail
(Weld Toe Crack Transverse Connection Plate)
14
C
C
Fillet Weld
Continuous Member
L < 2”
C
L
Groove Weld
or Fillet Weld
15
Category C
Transverse Full Pen. Welds
Example Category C
Full Pen. Not Ground Flush
Stress
Range
Note weld
toe
C
Groove Weld
Web Splice Not
Ground Flush
With NDI of
Tension Portion
of Web
16
Slope not Greater
Than 1 in 21/2
C
NDI and
Not Ground Flush C
NDI and
Not Ground Flush
Category C
Groove Welded Attachments
6” ≤ R < 24”
Groove Weld, R
End Weld
Ground Smooth
R
C
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Category C
Groove Welded Attachments
6” ≤ R < 24”
t = td
Groove Weld, R
Ground Smooth
td
R C
C t
6” ≤ R < 24”
t = td
R
Groove Weld
Not Ground Flush
R C
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Example Category C
Shear Studs
C
L C
C if L < 2”
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Example of Category C'
C'
C'
tw
C'
d C'
d C'
d
C'
d = (4 ~6) tw
Categories D through E
20
Category D - General
Category D
Intermediate Welded Attachments
Groove or fillet welded attachments
Parallel to direction of stress
– 2.0” < L < 4.0”
– L < 12 x tattachment
2” ≤ L < 4”
L ≤ 12t
Fillet or Groove Weld
t t
L
L
D
D
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2” ≤ L < 4”
L ≤ 12t
Groove or
D Fillet Weld
L
t
2” ≤ L < 4”
L ≤ 12t
L
D
Category D
Groove Welded Attachments
Attachments with transition radius
between 2.0” < R < 6.0”
– Longitudinally loaded full or partial penetration
welds with ends ground smooth
– Transversely loaded full penetration welds
Applies to base metal of attachment
Plates of equal thickness
Either w/ or w/o reinforcement removed
Soundness established by NDT
22
6” > R ≥ 2” ,
t = td
Groove Weld
End Welds Ground Smooth
R
R
D D
Category D
Groove Welded Attachments
Transversely loaded groove welded attachments
– Base metal of attachment
– Minimum transition radius of 2.0”
– Unequal plate thickness
– Weld reinforcement removed
– Note no NDT required
R ≥ 2” , t ≠ td
td
D
D
23
Category D
Fillet Welded Attachments
R ≥ 2”
Fillet Weld
End Ground Smooth
R R
D D
Category D
Riveted Connections
24
Category D
Common Riveted Details
25
Example of Fatigue Crack
in Riveted Member
I-95 Over
Susquehanna
River
26
Category E or E'
Ends of Partial Length Cover PL’s
Base metal of main member at toe
C.P. narrower than flange (E or E')
– Square or tapered ends
– With or w/o welds across ends
C.P. wider than flange (E or E')
– With welds across ends
C.P. wider than flange (E')
– Without welds across ends
– Coupled with thickness effect may be worse
than E'
Category E or E'
Typical Cover Plate Terminations
Category E or E'
No Welds Across Ends of C.P.
27
E tf ≤ 0.8”
E’ tf > 0.8”
End Welded
tf
Cover Plate
with Square or
Tapered Ends
End Not Welded
tf
Cover Plate
Wider Than Flange
Category E or E'
Longitudinal Welded Attachments
Base metal of main member at toe
Groove or fillet welded attachments
L > 4” or 12 x tplate
Plate thickness
– tplate < 1.0” Category E
– tplate > 1.0” Category E'
28
L > 12t or L > 4” E t < 1.0”
E’ t ≥ 1.0”
Fillet Weld or
Groove Weld
t t
t L
L
E or E’
E or E’
Example Category E
Longit. Welded Attachment
Example Category E
Longit. Welded Attachment
29
Example of Longitudinal
Welded Attachment
I-84 Bridge…
Actually worse
than Category E'
E td < 1.0”
E’ td ≥ 1.0”
Groove or
Fillet Weld
td
L
t
E or E’
Example of Longitudinal
Welded Flange Attachment
30
Category E
Longitudinal Welded Attachments
R R
Longitudinally Welded
Attachment – (Shear Lag)
(Bencia-Martinez Bridge)
Longitudinal
Weld
Chord
Retrofit
Hole
31
Category E
Transversely Loaded Attachments
Category E
Intermittent Fillet Welds
Specifications consider Category E
Test data suggests higher category
– Category D or possibly C
However, not a good details to use
Resistance set at Category E to
discourage use
Applies at weld toe
32
Load Carrying Fillet Welded
Cruciform Connection
Discontinuous
Member
t ≤ 0.5”
Fillet Weld
Satisfies Cat. F
33
Cracking Modes - PJP
Comparison of Welds
1.8
Min Weld (AASHTO)
3/8 Fillet - 1/8 Penetration
1.6 1/2 Fillet - 3/16 Penetration
1/2 Fillet - 1/8 Penetration
Min Weld - 1/8 Penetration
1.4
1.2
Cat C (CJP)
1
0.8
0.6
0.4
0.2
0.375 0.5 0.625 0.75 0.875 1
Plate Thickness (in)
34
Fillet Welded
Cruciform Connection
Reduced fatigue strength
calculated as follows:
2a w
⎛ ⎛ ⎞ ⎛ ⎞⎞
⎜ 0.65 − 0.59⎜ 2a ⎟ + 0.72⎜ w ⎟ ⎟
⎜ ⎜ tp ⎟ ⎜ tp ⎟ ⎟ Sr
S =S ⎜
C ⎝ ⎠ ⎝ ⎠⎟
R R⎜ 0.167
tp ⎟
⎜ ⎟
⎜ ⎟ tp
⎝ ⎠
Where:
Sr = Reduced fatigue strength
SrC = Fatigue strength of Category C
Questions ?
35