Galvanizing-Induced Distortion in Steel Plate Girders. II: Effects of Welding and Galvanizing Practices
Publication: Journal of Bridge Engineering
Volume 24, Issue 12
Abstract
This paper, the second of a two-part series, presents a parametric study investigating the influence of welding and galvanizing practices on the susceptibility of welded plate girders to distortion during and after galvanizing. Three methods of welded fabrication were studied: welding in lay-down position, welding in the trough, and welding in the vertical position. In addition, galvanizing dipping and extraction speed, dwell time in the zinc bath, and dipping angle were examined as parameters. It was found that welding in the vertical position corresponded to the least distortion during galvanizing, especially for unstiffened plate girders. Dipping speed was also identified as an important parameter for reducing distortion, and faster dipping and extraction speeds resulted in less distortion during and after galvanizing. The results of this study provide guidance to engineers, galvanizers, and fabricators to minimize steel plate girder distortion so that they can more confidently use hot-dip galvanizing to protect their bridges, and the paper describes a modeling methodology that will enable future research in this field.
Get full access to this article
View all available purchase options and get full access to this article.
References
AGA (American Galvanizers Association). 2017. Hot-dip galvanized steel bridges: A practical design guide. Centennial, CO: AGA.
Asada, H., Y. Fujiwara, and T. Tanaka. 2018. “Controlling LMAC occurrence at drain holes during hot-dip galvanizing.” In Proc., 25th Int. Galvanizing Conf. Reddicroft, UK: European General Galvanizers Association.
ASTM. 2013. Standard practice for safeguarding against warpage and distortion during hot-dip galvanizing of steel assemblies. ASTM A384. West Conshohocken, PA: ASTM.
ASTM. 2014. Standard practice for safeguarding against embrittlement of hot-dip galvanized structural steel products and procedure for detecting embrittlement. ASTM A143. West Conshohocken, PA: ASTM.
Ault, P., and J. Dolph. 2018. Corrosion prevention for extending the service life of steel bridges. NCHRP Synthesis 517. Washington, DC: Transportation Research Board.
AWS (American Welding Society). 2010a. Bridge welding code. AASHTO/AWS D1.5M/D1.5:2010. Miami: AWS.
AWS (American Welding Society). 2010b. Structural welding code—Steel. AWS D1.1/D1.1M:2010. Miami: AWS.
BCSA (British Constructional Steelwork Association). 2005. Galvanizing structural steelwork—An approach to the management of liquid metal assisted cracking. London: BCSA.
Carpio, J., J. A. Casado, J. A. Álvarez, F. Gutiérrez-Solana, and F. Gutierrez-Solana. 2009. “Environmental factors in failure during structural steel hot-dip galvanizing.” Eng. Fail. Anal. 16 (2): 585–595. https://doi.org/10.1016/j.engfailanal.2008.02.006.
Carpio, J., J. A. Casado, J. A. Álvarez, D. Méndez, and F. Gutiérrez-Solana. 2010. “Stress corrosion cracking of structural steels immersed in hot-dip galvanizing baths.” Eng. Fail. Anal. 17 (1): 19–27. https://doi.org/10.1016/j.engfailanal.2008.11.005.
Cresdee, R. B., W. J. Edwards, P. J. Thomas, and G. F. Voss. 1993. “Analysis of beam distortion during hot dip galvanising.” Mater. Sci. Technol. 9 (2): 161–162. https://doi.org/10.1179/mst.1993.9.2.161.
DiGiovanni, C., L. Li, R. Driver, and L. Callele. 2017. “Cracking in welded steel platform structures during hot-dip galvanization.” Eng. Fail. Anal. 79 (Sep): 1031–1042. https://doi.org/10.1016/j.engfailanal.2017.06.021.
Feldmann, M., T. Pinger, D. Tschickardt, W. Bleck, A. Volling, and L. Peter. 2008. “Analysis of the influencing parameters on cracking due to liquid metal embrittlement during hot dip galvanizing.” Der Stahlbau 77 (1): 46–61. https://doi.org/10.1002/stab.200810007.
Gannon, L., Y. Liu, N. Pegg, and M. Smith. 2010. “Effect of welding sequence on residual stress and distortion in flat-bar stiffened plates.” Mar. Struct. 23 (3): 385–404. https://doi.org/10.1016/j.marstruc.2010.05.002.
Iezawa, T., T. Yamashita, S. Kanazawa, Y. Toi, and K. Kobashi. 1994. “Thermal-elasto-plastic analysis on occurrence of liquid zinc induced cracking in bridge girder under hot-dip galvanising.” Iron Steel Inst. Jpn. 80 (12): 950–955. https://doi.org/10.2355/tetsutohagane1955.80.12_950.
James, M. N. 2009. “Designing against LMAC in galvanised steel structures.” Eng. Fail. Anal. 16 (4): 1051–1061. https://doi.org/10.1016/j.engfailanal.2008.05.019.
Kikuchi, M. 1982. “Liquid metal embrittlement of steels during hot dip galvanizing.” Iron Steel Inst. Jpn. 68 (14): 1870–1879.
Kikuchi, M., and T. Iezawa. 1981. “Liquid metal embrittlement cracking of steels in molten zinc.” J. Soc. Nav. Archit. Jpn. 1981 (149): 298–305. https://doi.org/10.2534/jjasnaoe1968.1981.298.
Kikuta, Y., T. Araki, M. Yoneda, and K. Uchikawa. 1986. “Effect of fabrication procedure on liquid metal embrittlement cracking in welded steel structures by molten zinc.” Q. J. Jpn. Weld. Soc. 4 (4): 747–753. https://doi.org/10.2207/qjjws.4.747.
Kleineck, J. R. 2011. “Galvanizing crack formation at base plate to shaft welds of high mast illumination poles.” Master's thesis, Dept. of Civil, Architectural, and Environmental Engineering, Univ. of Texas at Austin.
Kogler, R. 2015. Steel bridge design handbook: Corrosion protection of steel bridges. Washington, DC: Federal Highway Administration.
Krausche, T., B. Launert, and H. Pasternak. 2017. “A study on the prediction of welding effects in steel box girders.” In Proc., 8th European Conf. on Steel and Composite Structures, 4400–4406. Berlin: Ernst and Sohn.
Kuklik, V. 2012. “Post on the issue of safety of steel structures of hot dip galvanized structural components.” Procedia Eng. 40: 241–246. https://doi.org/10.1016/j.proeng.2012.07.087.
Ling, Z., M. Wang, and L. Kong. 2018. “Liquid metal embrittlement of galvanized steels during industrial processing: A review.” In Transactions on Intelligent Welding Manufacturing, 25–42. Singapore: Springer. https://doi.org/10.1007/978-981-10-8330-3_2.
Nguyen, K., R. Nasouri, C. Bennett, A. Matamoros, J. Li, and A. Montoya. 2017. “Sensitivity of predicted temperature in a fillet weld T-joint to parameters used in welding simulation with prescribed temperature approach.” In Proc., Science in the Age of Experience, 232–247. Waltham, MA: Dassault Systemes.
Nguyen, K., R. Nasouri, C. Bennett, A. Matamoros, J. Li, and A. Montoya. 2019. “Galvanizing-induced distortion in steel plate girders. I: Effects of girder geometry.” J. Bridge Eng. 24 (12): 04019110. https://doi.org/10.1061/(ASCE)BE.1943-5592.0001444.
Nguyen, K., R. Nasouri, C. R. Bennett, A. Matamoros, J. Li, and A. H. Montoya. 2018. “Thermomechanical modeling of welding and galvanizing of a steel beam connection detail to examine susceptibility to cracking.” Mater. Perform. Charact. 7 (2): 165–190. https://doi.org/10.1520/MPC20170115.
Rudd, W. J., et al. 2008. Failure mechanisms during galvanizing. Brussels, Belgium: European Commission Research Fund for Coal & Steel.
Seleš, K., M. Perić, and Z. Tonković. 2018. “Numerical simulation of a welding process using a prescribed temperature approach.” J. Constr. Steel Res. 145 (Jun): 49–57. https://doi.org/10.1016/j.jcsr.2018.02.012.
Shibayama, H. 2018. “Galvanized bridges in Japan.” In Proc., 25th Int. Galvanizing Conf. Reddicroft, UK: European General Galvanizers Association.
SIMULIA. 2017. Abaqus Welding Interface (AWI) user's manual. Waltham, MA: Dassault Systemes.
Sun, M., and J. A. Packer. 2017. “Hot-dip galvanizing of cold-formed steel hollow sections: A state-of-the-art review.” Front. Struct. Civ. Eng. 13 (1): 49–65. https://doi.org/10.1007/s11709-017-0448-0.
Toi, Y., K. Kobashi, and T. Iezawa. 1994. “Finite element analysis of thermal elasto-plastic behaviours of bridge girders in hot-dip galvanization.” Comput. Struct. 53 (6): 1307–1316. https://doi.org/10.1016/0045-7949(94)90398-0.
Information & Authors
Information
Published In
Journal of Bridge Engineering
Volume 24 • Issue 12 • December 2019
Copyright
© 2019 American Society of Civil Engineers.
History
Received: Aug 10, 2018
Accepted: Feb 26, 2019
Published online: Sep 17, 2019
Published in print: Dec 1, 2019
Discussion open until: Feb 17, 2020
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.