- -

5 Application
(3) Lealage from flanges
(1) Prepare a flat bar to make a band Fill sealant Fill sealant

which fits the periphery of the flange.

(2) Make 2 to 3 holes on the band to fill
II
sealant (It is recommended to use
bolt & nut).
(3) With a lead plate or a packing put
under it, tighten the band.
(4) Fill quick drying sealant (silicon, etc.).
(5) Check that sealant comes out from
III
underside. L Check that
~ I
I
(6) When sealant is sufficiently filled, plug the holes. sealant is filled
(7) If necessary, weld the bolt and nut mounted on both sides of the band or on the filling
!
,I
port. II
I
I
I
II
,t) Leakage from the boot of flange or bolt holes of flange
(1) Prepare 2 pieces of steel blank
Joint two flanges by flat bar
flange which are the same in
t Iii
I

thickness as the flange of the

broken pipe but are large in size. I
(2) Bore the blank flanges, aligning I
II

them with the leaking pipe.

(3) After boring the blank flanges,
prepare 2 pairs of split pipe for
strapped joint which fit the
I

outside diamater of the broken

pipe and are 50 to 100 mm long, Prepare 2 pairs of ,It

and weld them on the bored split

blank flanges (the above sight
i
Drain hole
split blank flange-
pipe assemblies

figure). (bolt and nut)

(4) Prepare a pair of split blank
flange-pipe assembly as shown in
the figure below, put them on the III

broken pipe, and weld them.

(5) It is recommended to tack-weld
III
the strapped joint assembly at
many points, but be small as ..
possible. I
Prepare a pair of strapped joint assembly
(upper and lower)
(Mount a drain plug on the lower assembly)

Chapter3 8
y ~'I'j~lIIl~

5.7 How to Prevent Weldment from Deforming

(1) Mount the strong back at an angle of approximately 45 deg. against weld line.
l
5.8

\
\

"
Reinforcement (strongback)
\
(I)
.
(2) In welding the doubling plate, make the deformed original plate come in close contact
with the strong back. .
Dog
/
v
~~ Wedge

Strong back
(2)
.

-~(I./..--
.One-side welding is enough for the strong back and dog.

(3) Eliminating the clearance between the original plate and the strong back one after
another, tack weld all around. Then execute regular welding. . It
Dog 8
Wedge I

.
Make no clearance here

I 8 Chapter 3
 :> . \pplitation
---
j.SArc Welding with Coated Electrode of Galvanized Steel
In general, galvanized steel is hard to be electric welded with covered electrode because
of poor usability of welding and poor appearance of weldment.
This is because the coated zinc has a bad influence on the arc and the physical property of
deposited metal. t I
Galvanized steel is roughly classified into two groups according to coating method:
galvanized steel and electro-galvanized steel (coated amount: amount of coated zinc per
surface area of steel). ! II
Coated amount of zinc has a large influence on weldability. The more the coated amount is I I
added, the more notable the following phenomena appears. I I

II) Influence on usability

II
8Arc becomes unstable and deposited metal is insufficiently covered by slag, resulting in 1,1
poor conformability of bead and rough surface.
8Excess spatter and fume H
Spatter: Metal particles which fly during arc or gas welding and which do not become
deposited metal.
Fume : Smoky gas

(2) Influence on the performance of weldment ,I,

I
8Generates pits and blowholes, lowering mechanical performance. I
Pit : Small dent generated at the end point of weldment
Blowhole: Cavity generated by gas included in molten metal ii,

Pit
Blowhole
~

a.'mI:.J,...,
It is hard to completely eliminate the above mentioned bad influences.
But it can be relieved to a certain deg. by the following measures:
8Execute welding after removing the galvanized zinc layer along weld line by a grinder or
sander.
8When high strength is not required, execute brass soldering instead of arc welding with
covered electrode.

E--

3e
Chapter