For Official use only

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
(Railway Board)

INDIAN RAILWAY STANDARD

CODE OF PRACTICE FOR

METAL ARC WELDING IN STRUCTURAL STEEL
BRIDGES CARRYING RAIL, RAIL-CUM-ROAD
OR PEDESTRIAN TRAFFIC

(WELDED BRIDGE CODE)

ADOPTED –1972
Revised -2001
INCORPORATING A & C SLIP NO. 2, dt11.7.18
Disclaimer: This Compilation is for educational reference only.
For details refer original correction slips.

ISSUED BY
RESEARCH DESIGNS AND STANDARDS ORGANISATION
LUCKNOW –226011

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 CONTENTS
Page
1. Scope 1
2. Terminology 2
3. Materials 2
4. Drawings and Procedure Sheets 2
5. Butt Welds 2
6. Fillet Welds 4
7. Plug Welds 7
8. Combination of Welds 7
9. Cope Holes 7
10. Preparation of Joint Faces 7
11. Fusion Faces 7
12. Assembly for Welding 8
13. Permissible Stresses in Welds 8
14. Reduction in Permissible Stresses 9
15. Structural Details 9
16. Welding in Solid Web Girders 9
17. Strengthening of Existing Bridges 10
18. Safety Precautions 11
19. Approval and Testing of Welding Procedures 11
20. Approval and Testing of Welders 11
21. Welding Procedures 11
22. Sequence of Welding 12
23. Position of Welding 12
24. Tack Welds 13
25. Inter-Run Cleaning 13
26. Stray Arcing on Work 13
27. Inspection and Testing of Welded Joints 13
28. Inspection Prior to Welding 14
29. Inspection During Welding 14
30. Inspection After Welding 14
31. Acceptance Levels for Quality of Welds 15
32. Non-destructive Tests 15
33. Marking of Defective Welds 15

Appendix –A Procedure for Providing Plug Welds 17

Appendix –B Fillet Weld Gauges and Their Application 18
Appendix –C Acceptance Levels for Welds 19
Figures 1-28 21

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 INDIAN RAILWAY STANDARD CODE OF PRACTICE FOR METAL ARC
WELDING IN STRUCTURAL STEEL BRIDGES CARRYING RAIL, RAIL-CUM-
ROAD OR PEDESTRIAN TRAFFIC

(Welded Bridge Code)

i) B-1 Fabrication and erection of

1. Scope
Steel Girder Bridges
1.1 This Code of Practice shall apply to ii) M-28 Classification, testing and
the design, construction and inspection of approval of metal arc
welds made by Manual, automatic or semi welding electrodes.
automatic metal arc process in new and iii) M-39 Classification, testing and
existing structural steel bridges carrying rail, approval of submerged arc
rail-cum-road or pedestrian traffic. The welding wire- flux
general requirements of design, combinations for use on
construction and inspection of structural Indian Railways.
steel bridges shall comply with IRS Steel
Bridge Code and IRS Fabrication 1.5.2 RDSO/M&C/Specification
Specification.
i) Classification, testing and
1.2 The design and construction of approval of CO2 welding filler
welds in mild steel bars used in reinforced wires for use on Indian
cement concrete, and of welds in high Railways.
tensile steel are not covered by this code. 1.5.3 Indian Standards

1.3 For road bridges, the design, 812 Glossary of terms relating to
construction and inspection of welds shall welding and cutting of
comply with the standard specifications and metals.
code of practice for road bridges issued by 813 Scheme of symbols for
the Indian Roads Congress. welding.
817 Code of practice for training
1.4 Any revision or addition or deletion
and testing of metal arc
of the provisions of this code shall be issued
welders.
only through the correction slip to this Code.
No cognizance shall be given to any policy 818 Code of practice for safety
directives issued through other means. and health requirements in
electric and gas welding
1.5 The Code makes reference to the operations.
following standards: 822 Code of procedure for
inspection of welds.
1.5.1 Indian Railway Standard
Specifications 1179 Equipment for eye and face
protection during welding.

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 2062 Structural steel (fusion shall conform to IRS Specification M-39.
welding quality). Wire for CO2 welding shall conform to
RDSO/M&C/Specification.
3016 Fire precautions in welding
and cutting operations.
3.3 All consumables shall be stored and
4353 Recommendations for handled with care and in accordance with
submerged arc welding of the manufacturers recommendations. This
mild steel and low alloy shall be governed as per relevant para of
steels. IS: 9595.
7307 (Pt-1) Approval tests for
welding procedure. 4. Drawings and Procedure Sheets
7310 (Pt-1) Approval tests for
welders working to approved 4.1 The symbols for welding used on the
welding procedure-fusion drawings and procedure sheets shall be in
welding of steel. accordance with IS: 813. If other symbols
are used, a complete explanation of their
7318 (Pt-1) Approval tests for meaning shall be given.
welders when welding
procedure approval is not 4.2 The fabrication drawings and/or
required – fusion welding of welding procedure sheets prepared for
steel. direction of the welding organisation shall
9595 Recommendations for metal include the following information:
arc welding of carbon and
carbon manganese steel. a) Specification of the parent
metal, and electrodes and/or
NOTE: The latest version of IS Code wire-flux combinations.
/Specifications referred herein, including
their amendments issued from time to time, b) Locations, sizes, actual
are to be followed. lengths and details, i.e. form
of joint, angle between fusion
faces, gap between parts,
2. Terminology
etc., of all welds.

2.1 All terms relating arc-welded c) Whether welds are to be

construction shall have, unless specially made in shop or field.
defined in this code, the meaning assigned d) Welding procedure, like
to them in IS: 812. welding sequence, pre-
heating, post heating etc.
3. Materials
e) Details of testing and
inspection requirements.
3.1 Parent metal shall be of fusion
welding quality conforming to IS: 2062. 5. Butt Welds

3.2 Electrodes shall conform to IRS 5.1 Forms and details- All details of
Specification M-28. The filler wire and flux butt welded joints shall be in accordance
combinations for submerged arc welding
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with IS: 9595 and IS: 4353 as applicable. the thinner part or 3 mm whichever is
greater, the dimensions of the wider or
5.2 Unsealed butt welds of single V, U, J thicker parts shall be reduced at the butt
and bevel types and incomplete penetration joints to those of the smaller part, the slope
butt welds shall not be used. Sketches of being not steeper than 1 in 5 (see Fig. 3).
different types of butt weld are given in Where the difference in thickness of the
Fig. 1. parts does not exceed 25% of the thickness
of the thinner part or 3 mm whichever is
5.3 Intermittent butt welds shall not be greater, the transition of thickness shall be
used. accomplished by sloping weld faces (see
Fig. 4) by chamfering the thicker part or by
5.4 Sealing or backing combination of the two methods (see
Fig. 5), at an angle not steeper than 1 in 5.
5.4.1 Single V, U, J bevel or square butt
welds shall generally be completed by 5.5.2 Where the reduction of the
depositing a sealing run of weld metal on dimensions of the thicker part is
the back of the joints. impracticable, and/or where structures are
not designed to withstand dynamic forces,
5.4.2 Where it is not practicable to deposit the weld metal shall be built up at the
a run of weld metal on the back of the joint, junction with the thicker part to dimension
then single V, bevel or square butt welds, at-least 25% greater than those of the
welded from one side only, may be thinner part, or alternatively, to the
permitted, provided that another steel part dimensions of the thicker member (see
of the structure or a special steel backing Fig. 6).
strip is in contact with the back of the joint
and the edges of the steel parts of the joint 5.6 Butt Welded T Joints - Butt weld in
are prepared as specified in IS: 9595 or IS: T joint shall be reinforced by welding as
4353, whichever is applicable, to ensure shown in Fig. 7 Flange to web connection
complete fusion of the parts to be joined. will also fall under this category.

5.4.3 In all full penetration butt welds 5.7 Ends of butt welds - The ends of
which are to be welded from both sides, the butt joint shall be welded so as to provide
back of the first run shall be gauged out by the full throat thickness. This shall be done,
suitable means to clean sound metal, before in all cases of parent metal more than 20
welding is started on the gauged out side mm thick and preferably in other cases also,
(see Fig. 2). by extending the ends of the butt welds past
the edges of the parts joined by the use of
5.5 Butt welding parts of unequal run-on and run-off plates with a similar joint
cross-section preparation and of reasonable thickness not
less than the thickness of the part joined
5.5.1 In butt welding steel parts in line with and of the length not less than 40 mm (see
each other which are intended to withstand Fig. 8) If run on and run off plates are
dynamic forces, and which are of unequal removed after completion of the welds, the
width, or where the difference in thickness ends of the weld shall be finished smooth
of the parts exceeds 25% of the thickness of and flush with the edges of the abutting

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parts. Run on and run off plates are to be minimum nominal leg length plus 2.4 mm
removed after completion of welds by (see Fig. 12) The minimum size of the first
abrasive cut off or by hacksaw blade .To run or of a single run fillet welds shall be as
avoid thermal stress as well as heat given in table-I. Minimum size of fillet weld
affected zone, Oxy-acetylene cut should not shall be as given in table II to avoid the risk
be permitted. If the parent metal is not more of cracking in the absence of pre-heating.
than 20 mm thick, the ends of the butt welds
may be chipped or cut back to sound metal Table-I Minimum size of first run of a
and then filled up with welds having a width fillet weld (Clause 6.2)
not less than one and half time the ‘V’
opening and having the same reinforcement Thickness of thicker part Minimum
as adopted for the faces of the butt weld size
(see Fig. 9)
6 mm up to and including 5 mm.
5.8 Reinforcement of butt welds – 20 mm
Sufficient convexity not exceeding 3 mm,
shall be provided as reinforcement to Over 20 mm up to and 6 mm.
ensure full cross sectional area at the joint. including 32 mm
Where a flush surface is required, the butt
welds shall be first built up as specified Over 32 mm up to and 8 mm.
above and then dressed flush. including 50 mm

6. Fillet Welds Table-II Minimum size of a fillet weld

6.1 Types of fillet welds Thickness of thicker part Minimum

size
6.1.1 Normal Fillet Weld - A normal fillet Upto and including 6 mm 3 mm
weld is one in which the depth of
penetration beyond the root is less than 2.4 Over 6 mm upto and including 4 mm
mm (see Fig. 10). 12 mm
Over 12 mm upto and 6 mm
6.1.2 Deep Penetration Fillet Weld - A including 18 mm
deep penetration fillet weld is one in which
Over 18 mm upto and 8 mm
the depth of penetration beyond the root is
including 36 mm
2.4 mm or more (see Fig. 10). It shall be
used only by agreement between purchaser
Over 36 mm upto and 10 mm
and contractor, and tests shall be agreed
including56 mm
between purchaser and contractor to verify
that the requisite route penetration is being Over 56 mm upto and 12 mm
obtained. including 150 mm
Over 150 mm 16 mm
6.2 Size - The size of normal fillet weld
shall be taken as the minimum leg length
(see Fig. 11). The size of a deep Note: (1) When the minimum size of the
penetration fillet weld shall be taken as the first run of fillet weld and /or minimum size
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of the fillet weld as given in Table-I and loading shall not be less than four times the
Table-II is greater than the thickness of the size of the weld, subject to minimum of 40
thinner part, the minimum size of the weld mm.
shall be equal to the thickness of the thinner
part. The thicker part shall be adequately 6.8 Intermittent fillet welds
pre-heated to prevent cracking of the weld.
(2) Where the thicker part is more than 6.8.1 Intermittent fillet welds may be used
50 mm in case of steel to IS: 2062 special in structures not subjected to dynamic
precautions like pre-heating as per IS: 9595 loading, to transfer calculated stress across
shall be taken to ensure weld soundness. a joint when the strength required is less
than that developed by a continuous fillet
6.3 Effective throat thickness - The weld of the smallest allowable size for the
effective throat thickness of a fillet weld thickness of the parts joined.
shall be taken as ‘K’ times fillet size where
‘K’ is a constant, given in as per Fig. 13, for 6.8.2 Load carrying intermittent fillet welds
different angles between fusion faces. All shall not be used in members subjected to
fillet welds shall have a flat or convex face. dynamic loading, except for connecting
In no case, except at the outside of a corner intermediate stiffeners to webs of beams
joint shall the convexity exceed the value and girders, subject to the provisions of
given by the formula 0.1S + 0.76 mm, clause 16.3.
where S is size of weld in mm.
6.8.3 Intermittent fillet welds shall not be
6.4 Angle between fusion faces - Fillet used where they would result in the
weld shall not be used for connecting parts, formation of rust pockets.
whose fusion faces form an angle of more
than 1200 or less than 600, unless such 6.8.4 Chain intermittent welding is to be
welds are demonstrated by practical tests to preferred to stagger intermittent welding.
develop the required strength.
6.8.5 The distance along an edge of a part
6.5 Effective length - The effective between effective lengths of consecutive
length of fillet weld shall be that length only, intermittent fillet welds, whether the welds
which is of the specified size and required are in line or staggered on alternate sides of
throat thickness. It shall be taken to be the the edge, shall not exceed 12 times the
actual length of the weld minus twice the thickness of the thinner part and shall in no
weld size. This deduction need not be made case exceed 150 mm. This requirement
in the case of end and side fillets, which are shall not be taken into account in complying
returned continuously around the corner for with the requirements of clauses 6.4 and 6.8
a minimum length of twice the weld size. of IRS Steel Bridge Code.

6.6 Effective area - The effective area 6.8.6 In a line of intermittent fillet welds,
of a fillet weld shall be the effective throat there shall be a weld at both ends of the
thickness multiplied by the effective length. parts connected. For staggered welds, this
shall apply to both sides.
6.7 Minimum length - The effective
length of a fillet weld designed to transmit 6.8.7 In built up members in whose parts
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are connected by intermittent filled welds, slot or the hole, but the later shall not be
continuous longitudinal fillet welds shall be filled with weld metal or partially filled in
used at the end for a length not less than such a manner as to form a direct weld
the width of the part concerned. metal connection between opposite wall.

6.9 Fillet welds applied to the edge of 6.11.2 The dimensions of the slot or hole
a plate or section shall comply with the following limits in
terms of the thickness of the steel part in
6.9.1 Where a fillet weld is applied to the which the slot or hole is formed.
square edge of a part, the specified size of
the weld shall generally be at-least 1.5 mm (i) The width or diameter to be not less
less than the edge thickness, in order to than three times the thickness or 25
avoid melting down of the outer corner, (see mm whichever is greater.
Fig. 14). (ii) Corners at the enclosed ends of
slots to be rounded with a radius not
6.9.2 Where a fillet welds is applied to the less than 1.5 times the thickness or
rounded toe of a rolled section, the specified 12 mm whichever is greater.
size of the weld shall generally not exceed
(iii) The distance between the edge of
3/4 of the thickness of the section at the toe
the part and edge of the slot or hole
(see Fig. 14).
or between adjacent slots and/ or
holes not to be less than twice the
6.9.3 Where a fillet weld equal in size to
thickness when measured along the
the thickness of the section at the toe of a
direction of stress and five times the
rolled section or at the square edge of a
thickness when measured normal to
plate is required from design considerations
the direction of stress.
and is specially designated in the drawing,
the toe or edge shall be specially built up 6.12 End Returns - Fillet welds
with weld metal in such a manner as to terminating at the ends or sides of parts or
ensure full throat thickness, full fusion area members shall be returned continuously
and no injury to the parent metal (see Fig. around the corner for a distance of not less
15 & 16). than twice the size of the weld. This
provision shall apply particularly to side and
6.10 End fillets - When end fillets are end fillet welds joining brackets, beam
used alone, each fillet shall be returned as a seatings and similar attachments at the
side fillet for a minimum length equal to tension side of such connections.
twice the size of the weld, and this returned
length shall be disregarded in calculating 6.13 Bending about a single fillet - A
the strength of the joint. single fillet weld shall not be subjected to
bending moment about the longitudinal axis
6.11 Fillet welds in slots or holes of the fillet (see Fig. 17).

6.11.1 When welding inside a slot or a hole, 6.14 Lap Joints

in a plate or other part, in order to join the
same to an underlying part, fillet welding 6.14.1 The minimum overlap of parts in
may be used along the wall or walls of the stress carrying lap joints shall be four times
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the thickness of the thinner part. Unless disconnect junction of welds(see Fig. 19).
opening out of the parts is prevented, they
shall be connected by at least two 9.2 Provision of cope hole in welded
transverse or two longitudinal fillet welds girders is not required when the following
(see Fig. 18). conditions are satisfied;

6.14.2 If longitudinal fillet welds are used i) Butt welds in flanges and web are
alone in lap joints of end connections, the made by automatic sub-merged
length of each fillet weld shall be not less arc welding prior to assembling web
than the perpendicular distance between and flanges together,
them. The transverse spacing of longitudinal ii) Weld reinforcement is dressed flush
fillet welds used in end connections shall both at top and bottom by
not exceed sixteen times the thickness of grinding/machining and
the thinner part connected. The longitudinal
fillet welds may be in slots in addition to iii) Weld is tested by
those along the edges, to comply with this radiographic/ultrasonic method.
provision.
10. Preparation of Joint Faces

7. Plug Welds 10.1 Preparation of joint faces shall be

done as per IS: 9595.
7.1 Plug welds shall not normally be
provided and in any case shall not be
11. Fusion Faces
designed to carry stresses. Where
unavoidable, the procedure laid down in
Appendix A shall be followed. 11.1 The preparation of fusion faces,
angle of preparation root radius and root
face shall be as specified in IS: 9595 and
8. Combination of Welds IS:4353. Where the gap between the root
faces of a butt joint is excessive, the gap
8.1 If butt and fillet welds are combined shall not be bridged since this procedure
in a single joint, the allowable capacity of often leads to cracking. The fusion faces of
each shall be separately computed with the joint shall be built-up with weld metal to
reference to the axis of the group in order to give the appropriate gap before the weld
determine the allowable capacity of the proper is commenced.
combination.
11.2 The preparation of fusion faces,
8.2 Butt welds in parts or members, angle of bevel, root radius and root face
subjected to dynamic loading, shall not be shall be such that the limits of accuracy
supplemented by splice plates attached by required by the appropriate application
fillet welds. standard can be achieved. When however,
no appropriate application standard exists
9. Cope Holes and this standard is itself to be used, it is
recommended that, for manual welding, the
9.1 Cope hole is a semi circular notch in tolerances on limits of gap and root face
between web plate and flange plate to should be ±1 mm on the specified

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dimensions for material upto and including 13. Permissible Stresses in Welds
12 mm thick and ±2 mm for material over 12
mm thick. The tolerance on the included 13.1 Since fatigue strength of welded
angle between the fusion faces of a V structures depends upon the constructional
preparation is recommended to be ±5 details, this shall be decided before the
degree and for U and J preparations + 10 permissible stresses and consequently the
degree. For an automatic process, closer size of members and weld sizes are
limits are necessary and particular determined.
requirements depend on the characteristics
of the process. 13.2 Stresses due to dead load, live load
and impact, stresses resulting from
11.3 It shall be ensured, if necessary, by curvature and eccentricity of track, and
suitable non-destructive tests that the fusion secondary stresses as defined in clause
faces and adjacent surfaces shall be free 3.3.2 (a) of IRS Steel Bridge Code, shall
from cracks, notches or other irregularities only be considered for effects due to
which might be the cause of defects or fatigue. All other items mentioned in clause
would interfere with the deposition of the 3.1 of IRS Steel Bridge Code and
weld. secondary stresses as defined in clause
3.3.2 (b) there of should be ignored when
11.4 Fusion faces and the surrounding considering fatigue.
surfaces shall be free from heavy scale,
moisture, oil, paint or any other substance 13.3 Butt welds - Stresses in butt welds
which might affect the quality of the weld or shall not exceed the permissible stresses of
impede the progress of welding. Certain the parent metal as specified in IRS Steel
proprietary protective coatings are specially Bridge Code.
formulated with the intention that they
should not interfere with welding. The use of 13.4 Fillet welds
such coatings is not excluded by the
requirements of this clause but shall be 13.4.1 The basic permissible stress in fillet
demonstrated by means of specimen welds welds based on a thickness equal to the
that the coating complies with the above throat thickness shall be 100 N/mm2 (10.2
requirements. kg/mm2) where a fillet weld is subjected to
shear stress in two directions, the actual
12. Assembly for Welding stress shall be taken as the vector sum of
the separate shear stresses and shall not
12.1 Parts to be welded shall be exceed 100 N/mm2 (10.2 kg/mm2).
assembled such that the joints are easily
accessible and visible to the operator. 13.4.2 Load carrying fillet welds in
dynamically loaded structures shall be
12.2 Jigs and manipulators shall be used, designed such that the stress on the total
where practicable, so that the welding can effective area of fillet welds does not exceed
be carried out in the most suitable position. the relevant values specified in Table for
Jigs shall maintain the alignment with the Class ‘G’ Constructional details, Appendix
minimum restraint so as to reduce the ‘G’ to IRS Steel Bridge Code, subject to a
possibility of locked in-stress. maximum of 100 N/mm2 (10.2 kg/mm2).
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13.4.3 Load carrying fillet welds in 15.3 Packings - Where a packing is used
dynamically loaded structures shall be between two parts, the packing and the
designed so that secondary bending welds connecting it to each part shall be
stresses are not developed (e.g. single lap capable of transmitting the load between the
joints shall not be used). parts, except where the packing is too thin
to carry the load or permit the provision of
14. Reduction in Permissible adequate welds, when it shall be trimmed
Stresses flush with the edges of the narrower part
and the load shall be transmitted through
14.1 The permissible stresses for field the welds alone, the welds being increased
welds of structural members shall be in size by an amount equal to the thickness
reduced to 80% of those specified in of the packing.
clauses 13.3 and 13.4. Field welds shall not
be adopted for bridges carrying road/railway 15.4 Arrangement of welds
loading without the specific approval of the
Board. 15.4.1 Fillet welds at right angles to the
lines of principal stresses in a plate
14.2 If over-head welds are unavoidable, subjected to tension shall be avoided in
the stresses permitted shall be 80% of dynamically loaded structures.
those specified in clauses 13.3 and 13.4
and modified by clause 14.1 if field welding 15.4.2 Accumulation of weld joints in a
is involved. single location shall be avoided (See Fig.
20).
14.3 In structures subjected to dynamic
loading, tensile or shear stresses in butt 15.4.3 Sizes or lengths of fillet welds shall
welds shall not exceed 66°% of the be sufficient to provide for better distribution
permissible stresses as specified in clause of stress. Excessive sizes or lengths shall
13.3 and as modified by clauses 14.1 and not be specified.
14.2 as applicable, unless the welds are
examined radiographically, ultrasonically or 16. Welding in Solid Web Girders
other non-destructive testing methods which
are equally effective and present 16.1 Flange plates
satisfactory evidence to the Engineer that
welds are meeting the quality requirement. 16.1.1 Each flange shall, as far as possible,
particularly in dynamically loaded structures,
15. Structural Details consist of a single section rather than of two
or more sections super-imposed. The single
15.1 Changes in section shall be gradual section may comprise a series of sections
and re-entrant notch-like corners shall be laid end to end and effectively welded at
avoided. their junctions.

15.2 Attachment of fittings and making 16.1.2 If the use of curtailed flange plates
openings at locations of severe fatigue can not be avoided the end of the plate shall
stress shall preferably be avoided. be tapered in plane to a rounded end and
welded continuously round the end.
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16.1.3 In dynamically loaded structures, 16.3.3 Fillet welds placed on one side only
flange plates laid end to end shall be joined of the stiffener shall not be used.
by butt welds, and welded cover plates shall
not be used. Joints in flange plates shall be 16.3.4 Intermediate stiffeners carrying
butt welded and dressed flush before cross bracings or diaphragms shall not be
assembling. connected to the web by intermittent fillet
welds.
16.1.4 Where the flange consists of more
than one section, the butt joints shall be 16.3.5 Intermediate stiffeners shall be
staggered. located away from web splices.

16.1.5 Welded cover plates, where used in 17. Strengthening of Existing Bridges
structures not subjected to dynamic loading,
shall have enough welds on either side to 17.1 All provisions of this code, applicable
develop the load 5% more than that of the to new welded bridge work, shall apply
element spliced. equally to strengthening of existing bridges
except as modified by clauses 17.2 to 17.7.
16.1.6 The flange plate, welded directly to
the web plate, shall not be more than 50 17.2 Where a compression member is
mm thick when steel conforms to IS: 2062. strengthened by welding while under load,
the work shall be carried out in such a way
16.2 Web plates - Splices in the webs of that -
plate girders and rolled sections used, as
beams shall be made by butt welds dressed (a) The least radius of gyration is
flush on all faces, in the case of dynamically substantially increased; and
loaded structures. In the case of structures
(b) Large compression shrinkage
not subjected to dynamic loading, splice
stresses are not induced in the
plates may be used independently and not
extreme fibres.
to reinforce a butt-welded splice.
17.3 Strengthening of existing bridges by
16.3 Intermediate stiffeners welding shall not be done unless tests prove
that the parent metal is suitable for the
16.3.1 Where intermediate stiffeners are purpose.
connected to the web by intermittent fillet
welds placed in pairs, one weld on either 17.4 The details of design for
side of the stiffeners, the effective length of strengthening shall be made taking into
each weld shall be not less than four times consideration the weakening effect of stress
the thickness of the stiffeners, subject to the raisers on the fatigue strength of the parent
provisions of clause 6.7. metal.

16.3.2 Where staggered intermittent fillet 17.5 If material is added to a member

welds are used, the effective length of each carrying dead load stress in excess of 19.6
weld shall be not less than 10 times the N/mm2 (2.0 kg/mm2) for strengthening, it is
thickness of the stiffener, subject to the desirable to relieve the member of dead
provisions of clause 6.7. load stress.
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17.6 In all cases where the dead load peening, painting, etc. In case any of the
stress is not relieved, the permissible stress provisions contained therein contravene the
in the new material added for strengthening provisions made on this code, the latter
shall be the allowable unit stress in the shall be followed.
original member minus the dead load stress
in the original member. 19.3 In addition to the provisions of IS:
4353 the Inspector may, where deemed
17.7 When welding is used for necessary, require a sample joint having the
strengthening an existing riveted or bolted same cross-section as the joint to be used
connection, the rivets shall be assumed to in construction and a length of at least 300
carry the dead load, provided they are mm to be welded with the wire, flux current,
capable of carrying it without overstress and arc voltage and speed of travel that are
welding is carried out without relieving the proposed to be used and a macroetched
dead load stress. The welds in such cases cross section of the welded joint prepared
shall be designed to carry all loads other as a demonstration that the specified
than dead load. In case the rivets or bolts requirements will be met, when the welding
are overstressed even by dead load, or the current, arc voltage and speed of travel are
strengthening is done after relieving the established by a test made in accordance
dead load stress, the weld shall be with requirements of this clause, they shall
designed to carry all loads including the be kept within the following limits of
dead load. variations

Welding current ±10%

18. Safety Precautions
Arc Voltage ± 7%
Speed of travel ±15%
18.1 Provisions of IS: 818, IS: 1179 and
IS: 3016 shall generally apply for safety and
health requirements during welding 20. Approval and Testing of Welders
operations.
20.1 The welders shall be trained in
19. Approval and Testing of Welding accordance with IS: 817. The welders shall
Procedures be subjected to appropriate qualifying tests
specified in IS: 7310 (Pt-I).
19.1 Welding procedure test shall be
carried out in accordance with IS:7307(Part- 21. Welding Procedures
I) to demonstrate, by means of a specimen
weld of adequate length on a steel 21.1 Welding work shall be given to a
representative of that to be used, so as to contractor who does produce satisfactory
confirm that satisfactory weld is achievable evidence of his ability to handle the work in
with the welding procedure to be used for a competent manner. The contractor shall
fabrication. also prove the ability of the
operator/Welders employed by him to
19.2 Provisions of IS: 9595 and IS: 4353, produce welds of the required strength. The
shall generally be followed, as applicable, contractor shall employ a competent
for welding procedure, details of welding supervisor to ensure that quality of
workmanship, correction of weld faults, materials and the standard of workmanship
IVB-11
comply with the requirements laid down in oxide (CO2) welding or manual metal arc
this code. welding may be done only for welds of very
short runs or of minor importance or where
21.2 The sizes and length of welds shall access of the locations of weld does not
not be less than those specified in the permit automatic or semi-automatic welding.
drawings nor shall they be substantially in
excess of the requirements without prior 21.9 Neither the depth of fusion nor the
approval of the Engineer. The location of maximum width in the cross section of weld
welds shall not be changed without prior metal deposited in each weld pass shall
approval of the Engineer. Welds shall exceed the width of the face of the weld
preferably be made in flat position. pass. (see Fig. 21 & 22)

21.3 In case of welds in structures 22. Sequence of Welding

subjected to dynamic loading, adequate
means of identification, either by 22.1 The sequence of welding shall be
identification stamp or other records shall be such that when possible the members,
provided to enable each weld to be traced which offer the greatest resistance to
to the welding operator by whom it was compression, are welded first.
made.
22.2 The welding in the thinnest element
21.4 During the entire welding of cooling of a section (usually the web in case of
cycle, the joints shall not be subjected to beams) shall be done prior to the welding of
any external forces or shocks. the thicker elements (usually the flanges in
case of beams).
21.5 Freedom of movement of one
member of a joint shall be allowed wherever 22.3 In making butt welded joints in rolled
possible. No butt joint shall be welded shapes, the sequence and procedure of
without allowing one component, freedom of welding shall take into account unequal
movement of the order of 1.5 mm. amount of expansion or contraction in
elements being welded.
21.6 In making welds under conditions of
severe external shrinkage restraint, the 22.4 Splices in each component part of a
welding shall be carried out with electrodes solid web girder or built-up member shall be
having type 6 covering as per IRS:M-28 made before such component part is
Specification. welded to other component part of the
member.
21.7 In case of welding using direct
current, earthing on the work piece to be
welded shall be connected carefully at more
than one location with a view to avoid “Arc
Blow” during welding. 23. Position of Welding

21.8 All welds should be done by 23.1 For fabrication of steel bridge girders
submerged arc welding process either fully the following positions of welding shall be
automatic or semi-automatic. Carbon-di– adopted.
IVB-12
 I) Flat and horizontal position for Submerged cleaning of toes of the welds. Visible defects,
Arc Welding (SAW) and such as cracks, cavities and other deposition
faults, if any, shall be removed to sound metal
II) Horizontal or horizontal-vertical position for before depositing subsequent run or layer of
welding done using manual metal Arc weld.
welding (MMAW) or CO2 welding.
Note – Different positions have been shown 26. Stray Arcing on Work
diagrammatically in Fig. 23. 26.1 Stray arcing shall be avoided as this can
23.2 All butt welds by the submerged arc process leave local hard spots or cracking which are to
shall be made in the flat position. Fillet welds may be removed by mechanical means and be
checked by inspection depending upon the
be made in either flat or horizontal-vertical
application.
position. The size of the single pass fillet welds
made in the horizontal-vertical position shall not 27. Inspection and Testing of Welded
exceed 8 mm.
Joints
24. Tack Welds 27.1 Inspection and Testing of Welded Joints.
Inspection of the welded bridge girders carrying
24.1 Tack welds shall be not less than the rail or rail-cum-road traffic weather of
throat thickness or leg length of the root run to be completely welded type or partially welded type
used in the joint. The length of the tack weld shall shall be done by the RDSO certified
not be less than four times the thickness of the fabrication inspection unit set up in each zonal
railway headed by an officer not below JA
thicker part or 50 mm whichever is the smaller
grade under CBE of that railway. Alternatively
zonal railway may engage specialized third
24.2 Where a tack weld is incorporated in a party (RDSO or any other public sector
welded joint, the shape, size and quality shall be undertaking having expertise in fabrication
suitable for incorporation in the finished weld and inspection) for fabriocation inspection of girders.
it shall be free from all cracks and other welding For ensuring quality of fabrication, QAP to be
defects. Tack welds, which are prone to cracking, prepared by fabricating agency and
shall be cut out and rewelded. approved by the inspecting agency. (ACS
02 dtd 11.07.2018).
24.3 Tack welds shall not be made at extreme 27.2 The Inspector designated by
ends of joints. the purchaser shall ascertain that fabrication
by welding is performed in accordance with
25. Inter-Run Cleaning the requirements of this code. Inspection of
welds shall also be carried out in accordance
25.1 Each run of weld bead shall be thoroughly with this Code. For the provisions which
are not incorporated in this Code, IS:822
cleaned to remove particles of slag, spatters, etc.
“Code of procedure for inspection of
before the subsequent bead is super-imposed welds” shall be followed.
during multi-pass welding. Similarly, each layer of
weld should be thoroughly cleaned of slag,
27.3 He shall be furnished with complete
spatters, etc, before depositing subsequent layers
of weld with particular reference to thorough

IVB-13
detailed drawings showing the size, length, 28.2.2 After the parts are assembled in
type and location of all welds, which are position for welding, the Inspector shall
required to be made. check for incorrect root gap, improper edge
preparation and other features that might
27.4 He shall be notified in advance of affect the quality of the welded joint.
the start of any welding operations.
28.3 Verification of operator’s
27.5 He shall have free access to the qualification - Welding shall be permitted
work being done at all reasonable times by to be performed only by welders and
the contractor and facilities shall be welding operators who are qualified in
provided so that during the course of accordance with requirements of clause 20.
welding he may be able to inspect any layer
of weld metal. He shall be at liberty to reject 28.4 The Contractor shall, if so required,
any material that does not conform to the prescribe the welding procedure to be
provisions of this code and to require any followed. Before any welding on the actual
defective welds to be removed and re- job is allowed under the contract, the
welded. Inspector shall verify, in accordance with the
provisions of IS: 9595 and IS: 4353 as
28. Inspection Prior to Welding applicable, that the procedure prescribed is
satisfactory.
28.1 Parent metal
29. Inspection During Welding
28.1.1 All plates and sections shall be
inspected in the contractor’s works before 29.1 Filler material - Filler material shall
fabrication. Verification of the quality of be tested periodically to ensure that the
parent metal shall be carried out by specified quality is being consistently
reference to the relevant test certificate. The maintained.
Inspector may, at his discretion, ask for spot
checks to be made on the chemical 29.2 While welding is in progress, visual
composition and physical properties of the examination shall be employed to check
material. details of work, such as proper arc, arc
length, speed of weld deposit, sequence of
28.1.2 Freedom from harmful defects such welding, cleaning of slag after each run in
as cracks, surface flaws, laminations, and multi-run welding, electrode spattering,
rough, jagged or imperfect edges shall be manipulation of the electrode, employment
verified by visual examination of the of proper current and voltage etc. Particular
material prior to welding. Dimensions of care shall be taken during the early stages
parts shall be checked by measurement. of the work.

28.2 Edge preparation and set-up of 30. Inspection After Welding

parts.
30.1 For visual inspection of defects, the
28.2.1 Edge preparation shall conform to weld surface shall be thoroughly cleaned of
the relevant drawings and meet the oxide layers and adherent slag. If chipping
requirements of this code.
IVB-14
hammer is used to remove slag, care shall shall be examined by radiographic test
be taken to see that hammer marks do not which will present satisfactory evidence to
obscure the evidence of fine cracks. the Inspector that welds are meeting the
Brushing with a stiff wire-brush or grit quality requirements.
blasting shall normally be followed.
32.2 Other welds may be examined by
30.2 Welding profile - The finished radiographic or any other non-destructive
welds shall be visually inspected and shall method which are equally effective.
conform to the size and contour specified in
the drawings (Acceptable and defective 32.3 Welds shall also be examined by
weld profiles are illustrated in Fig. 24 to 28). liquid penetrant flaw detection method or by
Conformity of fillet welds as to size and magnetic particle flaw detection method as
contour shall be determined by the use of per IS:3658 and IS:3703.
gauges (See Appendix ‘B’) Concavity and
excessive convexity of fillet welds shall be 33. Marking of Defective Welds
marked for correction.
33.1 The marking shall be positive and
31. Acceptance Levels for Quality of clear and in accordance with the method of
Welds marking followed and understood by the
Inspector and shop personnel involved in
31.1 Welds shall meet acceptance levels making the repairs.
as per Appendix C.
33.2 Marking shall be permanent enough
31.2 Dimensional check - The to be evident until the repair is carried out
weldment shall be inspected for dimensional and the inspection completed.
accuracy (including warpage) and shall be
within the tolerances specified. 33.3 After the repair has been done, it
shall be inspected again and properly
32. Non-destructive Tests marked to indicate whether the repair is
satisfactory or not.
32.1 Radiographic tests - Butt welds

**********

IVB-15
 Appendix-A
(Ref. Clause 7)

Procedure for Providing Plug Welds

A-1 The holes shall be tapered to ensure adequate root penetration.

A-2 Welding shall generally be carried out in flat position using a copper block plate of
25 mm minimum thickness as a backing surface. This plate shall have a depression
of about 3 mm at the center and in the line of the hole.

A-3 Electrodes conforming to IRS M-28 with type-I covering shall be used.

A-4 For welds to be made in the flat position, the arc shall be carried round the root of
the joint and then carried along spiral path to the center of the hole fusing and
depositing a layer of weld metal in the root and bottom of the joint. The arc shall
then be carried to the periphery of the hole and the procedure repeated, fusing and
depositing successive layers to fill the hole. The slag covering the weld metal shall
be kept molten, or nearly so, until the weld is finished. If the arc is broken, except
briefly for changing the electrodes, the slag must be allowed to cool and be
completely removed before starting the weld.

A-5 For welds to be made in the vertical position, the arc shall be started at the root of
the joint, at the lower side of the hole, and carried upwards along a zig zag path
depositing a layer about 5 mm thick on the exposed face and fused to the side of
the hole. After cleaning the slag from the weld, subsequent layers shall be similarly
deposited to fill the hole.

A-6 For welds to be made in the overhead position, the procedure shall be the same as
for the flat position except that the slag shall be allowed to cool and shall be
completely removed after depositing each layer until the hole is filled.

A-7 All plug welds shall be finished with reinforcement of about 3 mm which shall then
be dressed flush.

IVB-17
IVB-18
 Appendix-C
(Ref. Clause 31)
Acceptance Levels for Welds

Defect Type Permitted, Maximum

1) Planar defects

a) Cracks and lamellar tears not permitted

b) Root concavity 0.1t or 1.2 mm whichever is less
c) Lack of root fusion not permitted
d) Lack of side fusion not permitted
e) Lack of inter-run fusion not permitted
f) Lack of root penetration not permitted
2) Cavities

a) Isolated pores ∅≤t/4 and also less than

(or individual pores in a group) (i) 1.5 mm for t upto and including 25 mm;
or
(ii) 3.0 mm for t over 25 mm upto and
including 50 mm; or
(iii) 4.5 mm for t over 50 mm upto and
including 75 mm; or
(iv) 6.0 mm for t over 75 mm
b) Uniformly distributed or localized One percent by area (as seen in a radio
porosity graph) for t≤25 mm and pro-rata for greater
thicknesses
c) Linear porosity Linear porosity parallel to the axis of the
weld may indicate lack of fusion or lack of
penetration and is, therefore, not permitted
d) Worm holes, isolated l≤6 mm w≤1.5 mm
e) Worm holes, aligned same as for linear porosity
f) Crater pipes l≤6 mm w≤1.5 mm
3) Solid Inclusions (Slag Inclusions)
a) Individual and parallel to weld axis (as seen in the radiograph)

IVB-19
 t l w
i) ≤18 mm ≤ t/2 and ≤6 mm ≤1.5 mm
ii) >18 mm and ≤75 mm ≤ t/3 ≤1.5 mm
iii >75 mm ≤ 25 mm ≤1.5 mm
b) Linear group* Aggregate length should not exceed 8 percent of
length of group, which in turn should not exceed
12t in length
c) Individual and randomly Maximum dimension in any direction: 6 mm
oriented (Not parallel to weld axis)
4) Copper inclusions
(Detected by visual examination or Not permitted
by radiography)
5) Profile defects
a) Undercut Slight intermittent undercut permitted, provided it
does not form a sharp notch ; depth should not
exceed 0.4 mm
b) Shrinkage grooves and root Same as for under cut, depth should not exceed 1.2
concavity mm
c) Excess penetration h≤3 mm. Occasional local slight excess is
allowable
d) Reinforcement shape The reinforcement shall blend smoothly with the
parent metal and dressing shall be as specified in
drawing or required for NDT techniques.

e) Overlap Not permitted

f) Linear misalignment h≤t/10 and ≤ 3 mm
g) Other profile defects As per Clause 30.2
Symbols:
t = Thickness of parent metal. In the case of dissimilar thicknesses t applies to the
thinner component
w = Width of defect
l = Length of defect
h = Height of defect
∅ = Diameter of defect
• Individual inclusions within the group should not exceed the sizes in 3(a) above. A linear
group is defined as a number of inclusions in line and parallel to the weld axis where the
spacing between their adjacent ends does not exceed 6 times the length of the longest
inclusion within the group. With parallel groups, all inclusions count towards the
aggregate.
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