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Detail Classification

CE671 – Lecture 25 & 26

Categories A through C

Category A

Refers to base metal condition


– Plain material
Edges & surfaces of cleaned
– Plates
– Rolled shapes
Flame cut must have ANSI surface
quality of 1000 μ-in or better

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Category A
Poor Quality Surface

Crack Initiating in
Base Metal at Flaw

Plug Welds are Not Base Metal

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Category A Cont’d

Unlikely Category A will ever control


– CAFL = 24.0 ksi
Considerable scatter in the data
– Especially in near threshold
Copes require special consideration

Copes

Copes, although base metal are


subjected to:
– Stress concentrations due to geometry
– Flame cut edges (poor quality)
– Hardened material
– Can reduce to Category B or C
– Must be ground for Category A to apply

Copes Must be Ground to


a Sufficient Radius

Bad Good

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Figure 2.2. Category A – Base Metal

(a) Coped Beam Flange

(b) Blocked Beam Flanges

Figure 2.3. Coped, Blocked, or Short-Cut Flanges

Category B
General

Includes welded and bolted details


Welded details
– Longitudinal & transverse welds
– Includes fillet, partial and full pen.

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Category B
Longitudinal Welds

Primary stresses are parallel to weld and


weld toe
Includes fillet, partial and full pen.
Does not apply to ends of welds

Example Category B Longitudinal


Welds

Full Penetration Groove Weld


With Backing Bar Removed

Figure 2.4. Category B – Longitudinal Full Penetration Groove Weld

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Full Penetration Groove Weld
or Fillet Weld
B

Figure 2.5. Category B – Web-to-flange Connections and Longitudinal Stiffener

Fillet Weld

Figure 2.6. Category B – Longitudinal Fillet Weld

Category B
Transverse Welds

Applies to full penetration groove welds


Weld reinforcement must be removed
and ground smooth
– This removes weld toe
Weld soundness established by NDT
– Internal flaws may result in cracking

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Example Category B Transverse
Welds

Full Penetration Groove Weld


With Backing Bar Removed

Figure 2.7. Category B - Transverse Full Penetration Groove Weld

Groove Weld
Web Splice
Ground Flush
B With NDI of
Tension
Portion of
Web

NDI and Ground Flush

Figure 2.8. Category B – Transverse Groove Weld, NDI and Ground Flush

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Slope Not Greater
Than 1 in 21/2

B
NDI and
Ground Flush

Base Metal B
Other Than
A514 / A517
NDI and Ground Flush

Figure 2.9. Category B – Transverse Groove Weld, Straight Transition

R ≥ 24”

NDI and
Ground Flush

Figure 2.10. Category B – Transverse Groove Weld, Curved Transition

Category B
Groove Welded Attachments

Attached to flanges or webs


Transition radius > 24 inches
– Ensures smooth stress flow
Can be longitudinally or transversely
loaded

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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

Figure 2.11. Category B – Groove Welded Attachment, Weld Parallel to Stress

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R ≥ 24”
t = td’
Groove Weld
Reinforcement Removed
td R
R

Figure 2.12. Category B – Groove-Welded Attachment, Weld Transverse to Stress

Category B
Bolted Connections

Gross section away from fully-tightened


bolts (friction connection)
Net section through bolt holes of bearing
type connection with tight bolts
– Bearing for strength limit state
– Do not apply Cochrane’s Rule (S2/4g)
Should account for shear lag
See “Guide to Design Criteria for Riveted
and Bolted Connections” for more

Example Category B
Bolted Connections

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Example Category B
Bolted Connections

Gross Section if
Friction-Type Connection

Net Section if
Bearing-Type Connection

Figure 2.13. Category B – Bolted Connection

Category B' - General


Introduced in 1987 (NCHRP 286)
– Longitudinally loaded welds w/o backing bars
removed
– Partial and full penetration welds
– A514 and A517 transverse groove welds
Addressed degraded fatigue performance due to
presence of:
– Larger initial defects
– Blow holes
– Root gap flaws

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Full Penetration Groove Weld
With Backing Bar Not Removed

B'

Figure 2.14. Category B' – Longitudinal Full Penetration Groove Weld


Backing Bar not Removed

Partial Penetration Groove Weld

B'

Figure 2.15. Category B' – Partial Penetration Groove Weld

Partial Penetration
Groove Weld

Figure 2.16. Category B' – Partial Penetration Groove Weld Connections

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Slope not Greater
Than 1 in 21/2

NDI and
Ground Flush

A514 / A517
Base Metal
NDI and
Ground Flush

Figure 2.17. Category B' – Transverse Groove Welded Connections,


A514 or A517 Steel

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

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Influence of Attachment
Length on Detail Category

Longer attachments “attract” more stress


Increases stress concentration at ends

Category C
Short Attachments

Transverse connection plates


– Attached to flange or web
Short attachments on flange or web
Groove or fillet welded
Weld toe cracking is concern

Example of Crack at
Category C Detail
(Weld Toe Crack Transverse Connection Plate)

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C

Figure 2.19. Category C – Transverse Gusset Plate on Web

C
Fillet Weld

Continuous Member

Figure 2.27. Category C – Fillet Welded Connection (Not Load Carrying)

L < 2”

C
L

Groove Weld
or Fillet Weld

Figure 2.22. Category C – Groove of Fillet Welded Short Attachment

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Category C
Transverse Full Pen. Welds

Full penetration groove welds


Weld soundness established by NDT
Flange or web splices (same thickness)
Butt joints with transition no > 1 to 2.5
Weld reinforcement not ground smooth

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

NDI and Not


Ground Flush

Figure 2.20. Category C – Transverse Groove Welded Splice,


NDI but Not Ground Flush

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Slope not Greater
Than 1 in 21/2

C
NDI and
Not Ground Flush C

NDI and
Not Ground Flush

Figure 2.21. Category C – Transverse Groove Welded Flange Splice,


NDI but Not Ground Flush

Category C
Groove Welded Attachments

Longitudinal groove welded


attachments
Plates of equal thickness
Transition radius between 6” & 24”
End welds ground smooth

6” ≤ R < 24”
Groove Weld, R
End Weld
Ground Smooth
R
C

Figure 2.23. Category C – Longitudinal Groove Welded Attachment,


Intermediate Transition Radius

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Category C
Groove Welded Attachments

Base metal of transversely loaded groove


welded attachments
Plates of equal thickness
Weld soundness established by NDT
– Transverse direction
Transition radius between 6” & 24”
End welds may or may not be ground
smooth

6” ≤ R < 24”
t = td
Groove Weld, R
Ground Smooth
td
R C

C t

Figure 2.24. Category C – Transverse Groove Welded Attachment,


Intermediate Transition Radius

6” ≤ R < 24”
t = td
R
Groove Weld
Not Ground Flush
R C

Figure 2.25. Category C – Transverse Groove Welded Attachment,


Weld Not Ground Flush

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Example Category C
Shear Studs

C
L C

C if L < 2”

Figure 2.28. Category C –Shear Connectors

Category C' - General

Only applies to transverse stiffeners


Applies stiffener-to-web & stiffener-
to-flange welds
Applies to groove or fillet welds
– Weld toe condition is critical
Does not apply to transverse
connection plates

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Example of Category C'

C'

C'

tw
C'

d C'

d C'

d
C'
d = (4 ~6) tw

Figure 2.18. Category C' – Transverse Stiffeners on Web

Categories D through E

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Category D - General

Intermediate welded attachments


Welded connections with sharp
transitions
Riveted members and joints

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

Figure 2.29. Category D – Groove or Fillet Welded Attachment,


Intermediate Length

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2” ≤ L < 4”
L ≤ 12t

Groove or
D Fillet Weld

L
t

Figure 2.30. Category D – Welded Gusset Plate, Intermediate Length

2” ≤ L < 4”
L ≤ 12t

Groove or Fillet Weld

L
D

Figure 2.31. Category D – Welded Gusset Plate on Rolled Shape,


Intermediate Length

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

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6” > R ≥ 2” ,
t = td
Groove Weld
End Welds Ground Smooth

R
R

D D

Figure 2.32. Category D – Longitudinally Welded Attachment,


Short Transition Radius

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

Ground Flush, Groove Weld


t
R R

td
D
D

Figure 2.34. Category D – Transversely Welded Attachment,


Unequal Plate Thickness

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Category D
Fillet Welded Attachments

Transversely loaded fillet welded


attachments
– Base metal of attachment
– Minimum transition radius of 2.0”
– Unequal plate thickness
– End welds ground smooth (Difficult)
– Note no NDT required
Should also check as cruciform
– To be discussed

R ≥ 2”

Fillet Weld
End Ground Smooth

R R

D D

Figure 2.35. Category D – Fillet Welded Attachment,


Transition Radius 2” or More

Category D
Riveted Connections

Applies to net section of connection w/o


application of S2/4g
Category D for resistance

Note that full-scale test data suggests:


– Category D for CAFL
– Category C for finite life
Not a lower-bound curve
– Not permitted in AASHTO

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Category D
Common Riveted Details

Example of Fatigue Crack in


Riveted Member

Example of Fatigue Crack in


Riveted Member

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Example of Fatigue Crack
in Riveted Member
I-95 Over
Susquehanna
River

Base Metal at Net Section


of Riveted Connections

Figure 2.36. Category D – Riveted Connections

Category E and E'


General

Lowest fatigue strength details


Category E' generally applies to similar
category E details w/ thicker plates
– Flanges greater than 0.8 in
– Attachment plate > 1.0 in
– Introduced 1974

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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.

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E tf ≤ 0.8”
E’ tf > 0.8”

End Welded
tf
Cover Plate
with Square or
Tapered Ends
End Not Welded

Figure 2.37. Category E or E’ – Ends of Welded Cover Plate

E tf ≤ 0.8” and With End Weld


E’ tf > 0.8” or Without End Weld

tf

Cover Plate
Wider Than Flange

Figure 2.38. Category E or E’ – Ends of Welded Cover Plate

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'

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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’

Figure 2.39. Category E or E’ – Longitudinally Welded Attachment

Example Category E
Longit. Welded Attachment

Example Category E
Longit. Welded Attachment

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Example of Longitudinal
Welded Attachment
I-84 Bridge…
Actually worse
than Category E'

L > 12t or L > 4”

E td < 1.0”

E’ td ≥ 1.0”

Groove or
Fillet Weld

td
L
t

E or E’

Figure 2.40. Category E or E’ – Longitudinally Welded Attachment


(Lap Joints)

Example of Longitudinal
Welded Flange Attachment

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Category E
Longitudinal Welded Attachments

Base metal of main member at toe


Groove or fillet welded attachments with
curved transitions
– Transition radius 0” < R < 2.0”
– With or w/o end welds ground smooth

Groove or Fillet Welds,


Weld Ends not Ground Flush

R R

Figure 2.42. Category E – Longitudinally Welded Attachment,


Any Transition Radius

Longitudinally Welded
Attachment – (Shear Lag)
(Bencia-Martinez Bridge)

Longitudinal
Weld

Chord
Retrofit
Hole

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Category E
Transversely Loaded Attachments

Base metal of groove welded attachment


with weld soundness established by NDT
– Transition radius 0” < R < 2.0”
– Equal plate thickness
OR
– Unequal plate thickness
– Weld reinforcement not removed
– Transition radius less than 2.0”

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

Figure 2.45. Category E – Intermittent Fillet Welds

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Load Carrying Fillet Welded
Cruciform Connection

Fillet welded intersecting plates


If discontinuous plate is less than 0.5”
thick than Category C applies
– Lack of fusion zone is small
– Weld toe cracking will control
– Appropriate weld size must be used
If discontinuous plate is > 0.5” than
fatigue strength is reduced

Discontinuous
Member
t ≤ 0.5”

Fillet Weld
Satisfies Cat. F

Figure 2.26. Category C – Fillet Welded Connection (Load Carrying)

Cracking Modes - CJP

CJP is susceptible to toe cracking


Can be compared to category C

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Cracking Modes - PJP

PJP is susceptible to throat cracking


Use equation provided in ballot to
determine fatigue resistance

Objective is to design the


fatigue strength of PJP to
match CJP – i.e., toe cracking

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)

Cracking Modes – CJP or PJP

If load induces twisting about web,


toe cracking will likely control

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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 ?

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