Hello all. We are working on widening the deck of a retired flatbed railroad car to be used as a vehicular bridge. This involves welding gusset plates to the side sills of the railcar, then welding 12" C-channel to the ends of the gusset plates, and finally welding 1/4" plate steel over the gusset plates from the existing deck to the flange of the C-channel (see attached picture; note that C-channel is not yet attached as everything is just spot welded in for fitment). The question is what is the most efficient yet sufficiently strong way to weld the 1/4" plate steel to the upright gusset plate supporting it underneath. The plate steel is 12" wide and will be stitch welded to the deck and to the C-channel flange. For the connection to the gusset plate we're looking at probably 3" welds. There are 100 gusset plate connections like this to be made.
To be clear, I'm not the welder. I'm immensely interested in learning how to weld, but we have a very competent welder who has been working with us on this project. We're just trying to get multiple experience-based opinions on which of the two proposed solutions would be the best route.
Option 1: Make the 3" welds upside down in the boxes created by the rail car, gusset plates, and C-channel. I'm told upside welding is difficult and time consuming.
Option 2: Slot weld from above, cutting the slot in the plate steel right over the edge of the gusset plate, filling with weld, then grinding down before painting.
Would love to hear your thoughts on which route you would go and why. Thank you!
To be clear, I'm not the welder. I'm immensely interested in learning how to weld, but we have a very competent welder who has been working with us on this project. We're just trying to get multiple experience-based opinions on which of the two proposed solutions would be the best route.
Option 1: Make the 3" welds upside down in the boxes created by the rail car, gusset plates, and C-channel. I'm told upside welding is difficult and time consuming.
Option 2: Slot weld from above, cutting the slot in the plate steel right over the edge of the gusset plate, filling with weld, then grinding down before painting.
Would love to hear your thoughts on which route you would go and why. Thank you!