Chapter 3 STEEL STRUCTURE Section 1 General Article 1. Application This standard is applicable to steel structures other than those speci- fied in Chapters 1 and 2. Description: Steel structures except steel penstocks, hydraulic gates, and trashracks specified in Chapters 1 and 2 should be in accordance with the standards of this chapter. Various articles not specified in this chapter should con- form with the Articles of Chapters 1 and 2, and welding methods and joints should conform with the Articles of Chapters 4 and 5. Article 2, Definition Steel structures defined in this chapter are stee! linings, hydraulic pres- sure pipes, waterway conduits, steel surge-tanks including their support- ing structures, and aqueducts, bridges for operating hydraulic gates, gantry cranes and lifting beams. Description: Steel linings are lined with steel, used for pressure tunnels, surge-tanks, etc. to prevent water leakage but which are not subject to stresses from internal pressures. Hydraulic pressure pipes are those filled with water, installed in a waterway, which bear internal pressures by the steel pipe itself, and those embedded in a pressure tunnel which bear internal pres- sure partially or wholly by the steel pipe. Syphon pipes, pipe beams, pipe arches, discharge pipes and pressure pipes on an aqueduct, etc., are in- cluded in the above category. Waterway conduits refer to steel waterways having a free water surface like waterway pipes, and include gutters, open conduits, ete., made of steel. = 259 =Section 2 Design Article 3. Material 1, Materials to be used for steel structures shall be of types listed in Tables 1.8-1 and 2.10-1, and shall be those materials which have been tested and passed each corresponding standard. Provided sufficient studies were made, materials other than those shown in Tables 1.8-1 and 2.10-1 may be used. 2. Auxiliary facilities closely related to main structures shall be made of steel. Descriptio Those closely related to main structures means the portions constitut- ing critical parts in terms of strength and having great influence on human lives in view of security if damaged, Article 4. Allowable Stress of Materials Allowable stresses of materials to be used for design computation shall be in accordance with Article 12., Chapter 1 for steel linings hydraulic pressure pipes, waterway conduits and steel surge-tanks, and Article 12., Chapter 2 for other steel structures. Description: Not Applicable. Article 5. Increase in Allowable Stress Allowable stresses of materials taking account of seismic load and/or wind load, and allowable stresses of materials for water-filled pipes may be increased by 50% of the values in the preceding Article. Description: Since a waterway conduit is under normal load conditions when only partially filled with water, an increase in allowable stress is not permissi- ble. And, when taking seismic and/or wind loads into consideration, their combined stress should not exceed 90% of a yield point stress. Article 6. Loads to be Considered In designing structures, the following shall be taken into consideration = 260 =when appropriate; internal pressure, external pressure, the pipe’s own weight, weight of water (including additional weight), seismic load, im- pact load, live load, wind load, snow load, influences of temperature var- ition, ete. Descriptio Wind load, snow load and seismic load should be referred to in Article 13., Chapter I and Article 14., Chapter 2. Article 7. Combination of Loads As for loads in the preceding Article when applied to main structures, the following combination shall be taken into consideration; 1. Steel linings When empty: External pressure 2. Hydraulic pressure pipes When fully filled with water: Internal pressure, pipe’s own weight, weight of water in the pipe and temperature variation ‘When partially filled with water: Pipe’s own weight, weight of water in the pipe and tempera- ture variation When empty: External pressure 3. Waterway conduits: Pipe’s own weight, weight of water in the pipe and temperature var- ition Steel surge-tanks: Internal pressure, tank's own weight, weight of water in the tank and wind load 5. Other steel structures: ‘Own weight, live load, impact load, water pressure and snow load For 2. to 5., seismic load, wind load, snow load, etc., shall also be taken into consideration, if required. Descriptio Depending on types and construction of structure, terrain, ground foun: dation, weather. etc. consideration must be taken in combination with the relevant loads mentioned above. As for wind load and seismic load, the larger of the two should be considered in principle. In designing, corresponding items in Chapter 1 and 2 can be applied = 261Arch-form waterway conduits in particular should be carefully studied in view of seismic and wind loads normal to a longitudinal direction. As for a pipe beam structure, attention should be drawn to the fact that the stress in a longitudinal direction at the bottom of the pipe when par- tially filled with water may exceed the stress calculated for a fully filled pipe. = 262 -Section 3. Fabrication and Installation Article 8. Articles Applied As for fabrication and instaltation, the following articles shall be ap- plied unless otherwise specified: 1. Hydraulic Pressure Pipes: Chapter 1, Articles 30. t0 41. Chapter 5, Articles 7., 10. to 12., 16. to 17., and 20. 2, Waterway conduits: Chapter 1, Articles 30. 10 41. Chapter 5, Articles 7., 10. to 12., 16. to 17., and 20. 3. Stee! surge-tanks: Chapter 1, Articles 30. and 41. Chapter 5, Articles 7., 10. to 12., 16. to 17., and 20. 4, Other steel structures: Chapter 1, Articles 30, 34., 35., 36. (except those embedded in concrete) Chapter 5, Articles 7., 10. to 12., 16, to 17., and 20, Description: ‘Not applicable = 263 —Chapter 4 WELDING Section 1 General Article 1. Application ‘The following standard is applicable when steel materials are to be welded by means of Arc Welding. Description: Welding, generally may be defined as the connection of metals by means of their partial fusion, and includes pressure welding and brazing in addi- tion to fusion welding, but this technical standard applies to Arc Welding. ‘Arc welding is a method to weld joints by fusing the joint with heat generated from an arc between the base metal and an electrode, This arc welding is most extensively used among the various welding methods be- cause high heat energy generated by relatively low electric current can be focused locally and utilized for welds. Carbon, tungsten, etc., may be used as electrodes (non-consumable electrode), but presently metal-arc weld- ing in which metal electrodes, with almost the same composition as the base metal have been most popular (consumable electrode), and so called, ‘arc-welding’ usually refers to the latter. Accordingly, this technical stan- dard specifies the metal-arc welding. Arc welding may be divided into A.C. welding and D.C. welding, depending on the type of electric current used. Due to the efficiency, easy handling and maintenance, and the low cost of equipment, A.C. welding hhas been widely used in Japan. In D.C. welding, an arc is stable and the polarity effect can be utilized. (In A.C., the current alternates in conjunc- tion with its power source frequency, and ions in the arc disappear the instant the current value becomes nil, and so regenerating an arc on the next cycle becomes difficult and the arc is likely to disappear.) Therefore, D.C. is frequently used for welding thin plates and stainelss steels. In D.C. welding, the metallurgical nature of the weld metal is said (0 be better than in A.C., but these problems are almost negligible in the case of weld- ing mild steels and high tensile steels. = 265 -Are welding may be divided in terms of operation types into hand weld- ing, automatic welding and semi-automatic welding performed mecha cally or automatically to improve work efficiency and maintain a uniform quality. In addition, automatic welding may be subdivided into visible arc process and submerged arc process. Semi-automatic welding is generally a visible are process. In the visible arc process, an arc can be seen asin the case of hand weld- ing, but in the submerged arc process no arc can be seen with the naked eye. This submerged arc process utilizes high welding currents in a pre~ positioned powdered flux as shown in Fig. 4.1-1. This process can em- ploy high currents easier than other automatic weldings, thus resulting in better work efficiency. This process is quite extensively used in Japan. As for its power source, A.C. is mainly used but D.C. is also employed. AC. oF D.C. electrode Soliifed fox ‘Welding rod Ground Base metal Deposited metal Base metal Backing strip if required Fig. 4.11 Submerged Are Welding ‘Compared with hand welding, automatic welding has the following ad- vantages and disadvantages: 1 Advantages: (1) High work efficiency because fairly thick plates can be welded a single pass owing to high welding speeds and deep penetration by using high currents. (2) Stable welds obtainable and less variation resulting from welder's skill 3) Less deformation 2.. Disadvantages (1) Accurate preparation of plate edges is required. With inaccurate root gaps and/or groove angles, poorly penetrated sections and/or burn throughs occur, thus making a perfect weld impossible. = 266 =(2) Because the heat effect is so great, careful consideration must be given to the materials of base metals. For example, a sulphur crack is likely to occur if the steel has a segregation of sulphur. 3) Sensitive to moisture, oi, rust, ete. If those are present on the metals to be welded, blowholes are likely to occur. (4) For materials to be welded into complicated shapes, the operation of welding machines would become difficult. (5) On quenched and tempered high tensile steels the heat-affected zones become brittle and soften due to high welding heat. In the ccase of softening, there is no width problem for welded structures (Fig. 4.1-2) but attention should be paid to brittle fractures on 7Okgi/mm? or more high tensile steels. aol Pac wana a (1) Standard tensile strength of hand welding Joint (2) Standard tensile strength ‘of automatic welding Joint (0 © Hand.welding joint 2s ao) TeS piece widtn/est piece thickness (W/T) Fig. 4.1.2 Relationship between W/T and Strength of 60kef/mm? Quenched & Tempered High-tensile Steel Welded Joints ‘The main advantage of automatic welding is high work efficiency, but care should be exercised in the selection of materials and work. manship because of the disadvantages stated above. In addition to the above, various other welding processes have been employed in recent years such as metal inert gas (MIG) welding for stain. tess steel, alloy steel, and thick high tensile strength steel plates; various = 267 —CO, gas shielded arc-welding for mild steel and high tensile steel (by using solid wires or flux cored wires - short-arc welding); electro slag welding and electro gas arc welding (a kind of CO, gas shielded arc’ welding using flux cored wires) as vertical automatic welding; and gravi- ty incline or fire-cracker welding, as semiautomatic welding using shield- ed arc welding machines. Article 2. Welder Steel penstocks, hydraulic gates and steel structures shall be welded by qualified welders. Description: However strictly the work is controlled, good-quality welds cannot be expected if the welder is not capable. Welders engaged in welding major structures such as steel penstock, hydraulic gates, etc., must be qualified in accordance with strict standards. ‘The welder’s qualification test should be in accordance with the JIS Z 3801 (1979) “Standard Qualification Procedure for Welding Technique”, and the JIS Z 3841 (1979) “Standard Qualification Procedure for Semi- automatic Are Welding Technique”. These standards specify the test methods for technical qualification for the purpose of evaluating the welder’s skill; the contents are shown in Table 4.2-1 = 268 =Ve veion i] a a acor - e438 ting pea Tes st a i = = — ee i, aaa Se Eira peer cere | ee er cat A a er i Sea Eee =|! fares —— ae ne ee ee iar gene ner eee ao REI ay teed Sas oe SSE ce PRA Sees oaoeasea eer 2. sae ete 1 BERR oa nem tnt 5. The tangect ica of pane marco te weed by qualified welders are town the et abe Te appation owe only» eure tre maybe op aro aseBread diameter of ine (rum) Chaseation of welding operation Thickness (rm) Thi plate 60 and wr Medium pate as 19 ~ ‘Thick plate 12 and over = ‘Thin wall pipe 6.5 and under 400 and under ‘Medium wall pipe as 400 and under ‘Thick wall pipe 12 and over 400 and under Note: Pipe with diameter of more th ‘00mm is considered to be plate Welders who qualify by passing each type of test are considered to have the skill associated with that particular type. However, as the level of defects in the weld zone may differ due to the types of parent metals and welding materials, the amount of electric currents used, and the manipu- lation of the electrodes even if the same equipment is used, consideration should be made to test welding knowledge, if required. Welder's skills are likely to be affected by physical and mental con: tions, Consequently, it is necessary to hold the skill test regularly once ‘every year if possible, or at least once every three years, and select quali- fied persons. Itis recommended that a perfect welding operation should be carried ‘out by appointing a welding engineer capable of supervising the welders. As for the welding of steel penstocks, hydraulic gates and steel struc- tures, there are (wo types: shop welding (including field shop) and field welding. In addition to the proper selection of welding materials, welding ‘currents and welding speeds, the quality of welds can be influenced depend- ing on the welding positions. The flat position is the most desirable one among various welding positions, thus making a finished shape accurate. ‘Therefore, itis desirable that shop welding should be performed in a flat position wherever possible by considering assembly sequences and/or us- ing proper jigs. Field welding requires not only a flat position but also vertical, overhead, and horizontal positions in general. Commpared with the flat welds, these positions are more difficult in application, and so careful welding should be executed by setting up enough scaffolds and ‘making working conditions comfortable. Steel penstocks must be welded by welders who have skill qualifications shown in Table 4.2-2 or equivalent standards as a minimum requirement, depending on the categories of joints or welding positions. Classification ‘Ain this Table should be applied to joints with back welding, joints with - n=back strips and fillet welds, and Classification N should be applied to main structures having one side welding without back welding. Qualified welders of Classification N may cover the work of Classification A. Is preferrable that hydraulic gates and steel structures should be welded by welders who have the skill qualifications of JIS A-2F, 2V or 3F, 3V or the equivalent, depending on plate thickness restrictions shown in Table 4.2-2. ‘Welders having qualification for thick plate (JIS Z3801 A-3, JIS Z3841 ‘SA-3) may weld medium thickness plates (JIS Z3801 A-2, JIS Z3841 SA-2).. Fillet welding can be performed by those who have qualifications for medi- tum thickness plate or higher. When itis required to weld stainless steel, special steet, nonferrous me- tals, etc., well-experienced welders should exclusively be assigned to these materials. ‘Table 4.2.2 Welder's Qualification for Manval and Semiautomatic Welding Corresponding {o Categories of Welds. Ta ‘ualieation ory 7 Jae, | Hand welding orion of | Field welding [r25 | A—3F, 3V, 7H, [SA—2F, Sacre 36 (or 4 post" {or 2 postions ‘sant at remire None] So thr # post ‘weldic y (ray ies 5% or? potion [Oe or field shop None IF, 3V SA—3F | {tor postions) ‘ine an | Main welding] Divided 1 A—3E, 2V oF [SAAR BV or pine het fy'piste |A3E3V [SAF a fBickeess |(for 2 postions) | for2 Flat welding in |A—2F or A—3F ~ shop except ma cane Giana welding sped in Noe, Arik 8. ofthe chapter, by plate 20 or IE, Bidkess [35 30 -m-Article 3. Welding Materis 1, Welding materials to be used shall be those specified in JIS 3211 (1978) “Covered Electrodes for Mild Steel”, JIS 23212 (1976) “Covered Elec- trodes for High Tensile Strength Steel”, JIS 23311 (1976) “Steel Wires and Fluxes for Submerged Arc Welding” and JIS 23312 (1976) “Steel Wires for CO, Gas Shielded Are Welding”, depending on welding materials, welding methods and parent metals used, or those specified in similar standards to the above according to materials. 2. The most suitable welding materials shall be selected taking account of materials and strengths of parent metals and welding conditions. Description: No matter how excellent the weldability of steel may be, its merits can- not be maintained in welding if the welding materials are inappropriate. ‘Therefore, the most suitable welding material must be chosen and used, taking conditions of strength and welding operations into consideration. ‘This standard specifies that electrodes to be used for hand welding should be in accordance with the corresponding JIS. But this JIS classifies vari- ous types of rods based on the kinds of coating materials, thus requiring the use of electrodes according to each characteristic. ‘Types and mechanical properties of covered electrodes for mild steel and high tensile steel are shown in Table 4.3-1 and 4.3-2. The coating material is important as it enables are characteristics to be adjusted and metallurgical and physical properties to be controlled. Its functions are as follow: (1) To prevent oxygen and nitrogen in the atmospheric air from intrud ing by generating neutural or reducing atmosphere, thus protecting melting 2) To stabilize an are G) To produce slag with low melting point, low density and proper viscosity (4) To perform deoxidation (5) To facilitate welding in special positions such as in an overhead position (6) To add alloy elements to deposited metal (1) To reduce cooling and solidifying rates of weld metal (8) To facilitate removal of slag and provide clean welded surfaces (9) To resolve and remove oxide on parent metal, thus making weld ing perfect - m3 -Table 43-1 Classification of Electrodes TiasERON Type of | Welding posiions | Type of Current Blecgdes | Coating Flux ne ye [AC or BC (2) —_Daior | Timenite wpe Das0a | Lime-drania 5 pant ia Oe igh celui pe Evo FHF Special wpe mente ps0 | Lime-ttania Low hydrogen ‘Won powder tow | Corde) iaropen Spaalype «dF, VO WRT AC or DET oi ay of above __ postions _ emake 1 Syinbos uid Tor welding poston are Peas Verneal:O Overhead H — Horizontal; H-F — Horizon {al ile AC— Alternate current DC| fod < DCL) ~ De tod 2, Welding postions shown in Table 43-1 apply oeectrodes of ess than Sam dis, TC red = :DC(=)~ DE = 2742.806 gh. m “Table 4.3-2 Mechanical Property of Depositgd Metal comiencn | Tear | Vil ae | gin oy | Vee ae eee Ig x ie oy Vand over F838 and over | Dard over |47 | 4.8 and over DE DAN DBM, 43 and over [535 and over | Wand over [27 | 248 and over dono! Sade fessantow | tinder “ Deis 002 and over [Fors and over | 2Sand over | 47 | 4 and ver paz 1 aand over 035 and over | 25 and over | 27 | 2.8 and over 05000 DSA01 05003 | 50 and over |° 740 and over Ward over | 4? \ 48 and over ‘DSUI6 DS026 ©, SOand over |5740 and over Band over aot and over 300 | Sandover freadand ove | Wand over | 4? | and over ssigpsim | sDandover [bee and ove | abandove | 4? las and oer acest | Stave fysiato | Wandow [Sas esc nt oe ‘Remarks: For D4327, the yield point and tensile strength may be alowed 10 dcevease by 1 kgf/mm as elongation increases by 28, but the yield point must be not less than 33 kgf/mm? and the tensile stength not less than 41 kgf /enm? The following various covered electrodes are in general use in Japan: For mild steel: D4301, D4303, D4313, D4316, D4327 For high tensile strength steel: DS016, D5316, D5026, DS816, DS826 Electrodes widely used for steel penstocks, hydraulic gates and steel structures are as follows: 4301, 4303, D4316 S016, 15316, D5026, Ds816 In addition to the above, D4313 has been used for thin plate structures and D4327, D5026, 5826, etc. for flat and horizontal fillet welding. ‘Characteristics of these covered electrodes in general use are given below’ 1) Himenite Type (e.g. 4301) ‘This electrode contains about 30% ilmenite in its coating material and is most widely used in Japan. This facilitates good welds in all po- sitions, The arc is lightly strong, and penetration is deep. Slag has good shieldability and can easily be removed. Bead is closely waved and looks fine, 2) Lime-titania type (e.g. D4303) This electrode contains about 30% titanium dioxide (TiO,) and about 20% basic substances such as lime (CaO) in its coating. Its arc is somewhat moderate, and penetration is shallower than that of il+ menite. = 2s -Being weldable in all positions, this electrode is suited to flat and vertical filet welding. This contains a large amount of titanium diox- ide, but the mechanical property is superior to that of high titanium dioxide (D4313). As the bead’s appearances are extremely fine, this elec- trode is suitable for portions requiring fine finishes. 3) Low hydrogen type (e.g. D4316, DS016, D5316, D5816) ‘The coating material of this electrode is composed of lime mainly blended with fluorite (CaF,), ferrosilicon, etc. The amount of hydro- gen produced from the coating material is small and the CO; gas generated from the lime shields its arc, thus making the amount of hydrogen in the deposited metal small. ‘Accordingly, even if these electrodes are used for high carbon steel, high tensile strength steel, low alloy steel, etc., underbead cracks sel- dom occur. In additon, blowholes are not likely to be present even if used for steels containing a relatively high content of sulphur. Prior to use, itis necessary to dry them sufficiently. Compared with other electrodes, the arc of this type is unstable and the transfer droplet is big, but satisfactory welds can be expected in all positions by keeping the are short. In addition, cracks seldom occur and preheating temper- atures can be extensively lowered compared to other electrodes. This electrode is used in almost all the cases for high tensile strength steels in particular because the electrodes can prevent possible cracks while welding and provide enough strength ductility for deposited metal 4) Iron powder iron oxide type (e.g. D4327) This electrode is intended to increase deposition rates with iron ox- ide as the main component by filling a large quantity of iron powder to it. The arc is of a spray type and spatter is negligible. Penetration is alittle shallower than that of high iron oxide. This electrode has the advantage of suitability for high efficiency of works and fine appear- ance of bead. 5) Iron powder, low hydrogen type (e.g. D5026, D5826) This electrode contains 25 to 60% of iron powder in the low hydro- agen coating material and the thickness of the coating is larger than other electrodes. As its deposition rate is high and its slag can be easily re- moved, this electrode is suitable for high efficiency welding operations of high tensile steels. Smooth beads with closely spaced wavy patterns are obtainable. For a submerged arc welding, most extensively used among automatic = 276 ~wweldings today, it was evident from the tests that the mechanical proper- ties of the welded zone were superior to those done by manual welding because of the use of a fusion or sintering type flux without any organic compounds and water of crystallization which are sources of hydrogen generated. In order to make the quality uniform and the control perfect, it is desirable that welded joints should be made by automatic welding wherever possible. The weld results of this automatic welding, however, are influenced by the combination of wires and fluxes to be used, welding ‘equipment and welder's experience, etc., thus requiring careful selection ‘of wires and fluxes taking the following into consideration: a, Welding conditions (welding currents, speeds, arc voltages) 'b. Shape and size of welded items (plate thickness, shape, incline grooving conditions, etc.) 4.0 +k: ©. Materials and surface conditions of welded items (rust, cleanliness, etc.) > ‘There are many kinds of wires presently used for the submerged arc welding in Japan, and their chemical compositions and mechanical proper- ties vary with their respective use. Consequently, the wires should always be selected in combination with the flux, parent metal and welding condi- tions concerned. For a combination of wire and flux for the submerged arc welding of high tensile strength steels 70 kgf/mm? or more in partic- ular should be selected and it is necessary to decide after due considera- tion of their applicability to weld materials, restrictions of heat input, etc HS Z 3311 (1976) “Steel Wires and Fluxes for Submeged Arc Weld- ing” presently specifies a part of the above, which covers just carbon steel wires which do not contain special elements except manganese and sili- con. There are various wires used for submerged arc welding of easily weld- cd steels, such as rolled steel for general structures, rolled steel for boilers, rolled steel for welded structures, carbon steel for machine structure use, carbon steel cast and forgings for general use. Their chemical composi- tions are given in Table 4.3-3. too ket -27-‘Table 4.33 Chemical Composition of Wire for Submerged Arc Welding Gis Z 3311) Gusieton | Symtat | “Chemical composition Ciassifcation e_ [se [Ma | Tso Gia [Ro 1] VEWAT [0.10 [G05 | Over 0.20 0.086 and under] and under| to O80. | and under |and under ewe and under ue Can? | 015 [G05 [Over 6.0 6 and unde | and under | “to 130, and under inde ‘Over 0.05 | Over 0.80, 0.030 Jand under | 19 023" | 10 1.30 and under Jand under |and winder | Did | Over 025 [Over 080 [0030 | “0.30 Jand under] “to 043" | 101.0. [and under [and under | and under |and under |e | Noi] VSWaT [Gis | 005 | Over 10 0.030 | 0.030 and under |and under | 10" 1.80. | and under | and under and undee 15 | Over 0.05 | Over 1.30] 0.030 | 0.030 | and nde [ts 098° | to A8° | and under | and under and wide | an er “Gast Roni] Vewar | O17 005 over LA} 0000, t ‘m0 and nde ander | ts 2 58° | and under | and wader [efoto ca, Generally in the case of a multilayer welding which isnot effected by a parent metal, the combination of YS W 11 with the Mux to increase man- ganese, YS W 21 and YS W 31 with the flux to keep the manganese level constant and YS W 41 with the fux to decrease the manganese content will result in the production of proper welding metals for mild steels. But, in the ease of SOkgf/mm? class stel or both sides/sinlelayer weld which ate greatly effected by parent metal contents, wires should be selected af- ter due consideration of such welding conditions as the characteristics of parent metals and fluxes, grooving shapes and number of layers. When used for the high speed welding of rimmed steel and emi-kiled sec et, YS W 22, YS W 23 and YS W 32 are not likely to produce blowholes even if some rust or mill sealeis adhered to the portion welded and smooth bead surfaces can generally be obtained. However ifthe above YS's are used for multi-layer welding, they may cause trouble depending on the fluxes used Low alloy wires, having mainly molybdenum, may be used for Sokgf/mm? class steel and GOkgf/mm class strength steel (HT-60). Table 4.3-4 shows the chemical composition of these wires. No.3] vswae - 78