Web-flange Junction Research Articles

Residual stress tests and predictive model of friction stir welded normal-strength aluminium alloy H-shaped sections

To address the challenges of difficult extrusion for super-large cross-section aluminium alloy members, pairs of T-shaped sections were proposed to be longitudinally friction stir welded (FSW) to form the H-shaped sections widely used in structural engineering. It was significantly different from the previous member forming method that one web plate and two flange plates were welded at the flange-web junctions. To understand the novel FSW-induced residual stress distributions and magnitudes in the H-shaped sections, six specimens made of 6061-T6 and 6013-T6 normal-strength aluminium alloys, including various width-to-thickness ratio and plate thickness, were tested using the sectioning method, leading to over 4000 original readings of compressive and tensile residual stresses. The analysis results showed that great tensile residual stresses were clearly concentrated within the web weld, and then rapidly descended to lower compressive stresses near the weld region, followed by approximately linear regression to zero state from the weld edge to the flange-web junction, while the flange data points were relatively scattered. The compressive and tensile residual stresses in each flange and web plate were observed to be slightly associated with the width-to-thickness ratio and plate thickness. A simplified multi-linear residual stress distribution model, including the magnitudes and ranges of constant and linear variation curves, was proposed for the FSW aluminium alloy H-shaped sections, and good accuracy and consistency were observed between the test and predicted results.

Novel multi-crack damage approach for pultruded fiber-polymer web-flange junctions

This paper aims to propose a novel approach to assess the multi-crack behavior of layered fiber-polymer composites. The Compliance and R-curves generated from this novel approach were useful to understand the multiple delamination process, enabling to evaluate separately the strain energy release rate (SERR) related to each crack. A cohesive zone model was developed to simulate the failure process zone of three parallel cracks in web-flange junction (WFJ) specimens extracted from a pultruded bridge deck system subjected to transverse bending. The fracture parameters estimated based on the proposed approach led to a good agreement between the numerical model and the experiments in terms of load vs. displacement curves. Moreover, it was possible to observe that the formation of new cracks may lead to a significant drop on the R-curve, due to the closure of the former cracks.

Web crippling performance of pultruded GFRP C sections strengthened by fibre-reinforced epoxy composite

This study aims to improve the web crippling performance of pultruded glass fibre-reinforced polymer (GFRP) C sections using fibre-reinforced epoxy composite (FEC). The strengthened GFRP C sections were subjected to two loading conditions: interior-two-flange (ITF) and exterior two-flange (ETF). The parameters considered were bearing lengths, FEC strengthening length and thicknesses. Two failure modes, namely web-flange junction failure and web buckling failure were observed for the pultruded GFRP C sections under ETF loading conditions as the bearing length changed. While the combination of the web-flange junction and FEC crushing failures were observed under ITF loading conditions at 20 mm and 50 mm bearing lengths. Furthermore, the average web crippling capacity of strengthened GFRP C sections improved by up to 426 % and 488 %, in comparison to control samples under ETF and ITF loading conditions, respectively. The average web crippling capacity of pultruded GFRP C sections increased up to 45 % when the bearing length increased from 20 mm to 50 mm. The finite element (FE) outcomes showed an agreement with experimental results in the context of failure patterns, load-displacement profiles and web crippling capacities. Finally, equations were proposed to estimate the web crippling capacity of pultruded GFRP C sections strengthened with FEC.

Shear flow capacity of stiffened flanges in steel box girders

The purpose of this paper is to model the shear flow capacity of stiffened flange in a steel box girder. The present study uses an energy-based variational approach to analyze the steel box girder. A new parameter is introduced that is strongly correlated to the shear lag response of stiffeners to flanges. This parameter is named as shear flow parameter. The shear flow parameter decreases with increasing stiffener area to flange area ratio. Along with increasing the stiffness of the flange, stiffeners also reduce the shear flow capacity of the flange plate. It is observed that the reduced shear flow capacity causes more shear lag in the flange, increasing the stress at the web-flange junction. As a result of a high percentage of longitudinal stiffeners, steel box girders have a small effective width ratio, high negative shear lag effect, and significant deflection. This approach is in close agreement with experimental results, finite element results and theoretical results.

Modelling of Web-Crippling Behavior of Pultruded GFRP I Sections at Elevated Temperatures.

The concentrated transverse load may lead to the web crippling of pultruded GFRP sections due to the lower transverse mechanical properties. Several investigations have been conducted on the web-crippling behavior of the GFRP sections under room temperature. However, the web-crippling behavior is not yet understood when subjected to elevated temperatures. To address this issue, a finite element model considering the temperature-dependent material properties, Hashin failure criterion and the damage evolution law are successfully developed to simulate the web-crippling behavior of the GFRP I sections under elevated temperatures. The numerical model was validated by the web-crippling experiments at room temperature with the end-two-flange (ETF) and end bearing with ground support (EG) loading configurations. The developed model can accurately predict the ultimate loads and failure modes. Moreover, it was found that the initial damage was triggered by exceeding the shear strength at the web-flange junction near the corner of the bearing plate and independent of the elevated temperatures and loading configurations. The ultimate load and stiffness decreased obviously with the increasing temperature. At 220 °C, the ultimate load of specimens under ETF and EG loading configurations significantly decreased by 57% and 62%, respectively, whereas the elastic stiffness obviously reduced by 87% and 88%, respectively.

Effect of Outstanding Flanges on Stress Concentration in Box Beam

Background of the research: A conventional box-type structure is generally used in constructing the core/shear wall, internal frame, and steel box girders. Tube-in-Tube with single and multiple tubes reduces the shear lag effect and lateral deformation in a tall tubular structure. Purpose: However, the present study focuses on the behavior of a modified form of the conventional box beam, i.e., a box beam with outstanding flanges. Thus, this study analyzes a box beam with outstanding flanges and compares the shear lag effect (Stress concentration) and lateral deformation with a conventional box beam. Methodologies: The minimum potential energy principle is applied to analyze the models and validated with the finite element results. Principal results: The transformation is observed to be reducing the shear lag effect at the web-flange junction and lateral deformations of the beam. In addition, the transformation also controls stress reversal. The modification demonstrated in the present study is stiffer than the conventional box-type structure as a core/shear wall or internal frame. Major conclusions and contributions to the field: This modification may be an integral part of tall tubular buildings producing significantly lowered stress concentration and lateral deformation. The present study is also applicable to strengthening steel box girders. It is possible to extend the bottom plate with the outstanding flange to increase the load-bearing capacity or strengthen the existing steel box girder. Therefore, the transformed box beam can be utilized as an economical alternative in constructing tall tubular buildings and retrofitting the steel box girder bridge. It is convenient and straightforward as there is no need to stiffen any part of the core/shear wall or internal frame. Additionally, there is no need to remove elements from the existing girder or alter its dimensions. Add the remaining flange by welding or bolting it onto the bottom flange to extend it. Limitation of the study and future research: A different assumption of stress function can be used in the flange and web when an orthotropic membrane theory is adapted to analyze the frame tube structure.

Web crippling design of cold-formed steel built-up I-sections

This paper reports the experiments, numerical modelling and design of cold-formed steel built-up I-sections subjected to localised loadings. The built-up I-sections were made up of two equal-sized plain channels fastened back-to-back in the web. The web crippling tests were undertaken on 41 built-up I-section members under Interior-Two-Flange (ITF), End-Two-Flange (ETF), Interior-One-Flange (IOF) and End-One-Flange (EOF) loading conditions. The effects of the arrangement of screws along the web height were investigated. After the experiments, finite element (FE) analyses considering the initial local imperfections of the web of the specimens were performed and the validity of the FE models was assessed using the test results. A parametric investigation including 258 numerical simulations was conducted to expand the database and evaluate the influences of the screw arrangements in the web height. The test and numerical results indicated that the failure modes of the specimens with different screw arrangements were generally similar in each loading condition, and the screws located close to the flange-web junctions of the sections could generally provide maximum web crippling resistances of the built-up I-sections. The design recommendations on the arrangements of screws along the web height were proposed. The experimentally and numerically generated web crippling resistances were utilized to assess the current North American specification (AISI S100), Australian and New Zealand standard (AS/NZS 4600) and European code (EN1993-1-3). The results show that the existing codified design formulas lead to either conservative or highly unsafe results. Therefore, two sets of design formulas were derived on the basis of unified equation and direct strength method.

Review on Local Buckling of Hollow Box FRP Profiles in Civil Structural Applications.

Hollow box pultruded fibre-reinforced polymers (PFRP) profiles are increasingly used as structural elements in many structural applications due to their cost-effective manufacturing process, excellent mechanical properties-to-weight ratios, and superior corrosion resistance. Despite the extensive usage of PFRP profiles, there is still a lack of knowledge in the design for manufacturing against local buckling on the structural level. In this review, the local buckling of open-section (I, C, Z, L, T shapes) and closed-section (box) FRP structural shapes was systematically compared. The local buckling is influenced by the unique stresses distribution of each section of the profile shapes. This article reviews the related design parameters to identify the research gaps in order to expand the current design standards and manuals of hollow box PFRP profiles and to broaden their applications in civil structures. Unlike open-section profiles, it was found that local buckling can be avoided for box profiles if the geometric parameters are optimised. The identified research gaps include the effect of the corner (flange-web junction) radius on the local buckling of hollow box PFRP profiles and the interactions between the layup properties, the flange-web slenderness, and the corner geometry (inner and outer corner radii). More research is still needed to address the critical design parameters of layup and geometry controlling the local buckling of pulwound box FRP profiles and quantify their relative contribution and interactions. Considering these interactions can facilitate economic structural designs and guidelines for these profiles, eliminate any conservative assumptions, and update the current design charts and standards.

Analysis of the impact of shear stress at the flange-web junction on the web behavior under concentrated and patch load

This article focuses on realistic predictions of the buckling of web plates under concentrated and patch load conceptually isolated from I-beams or box-beams. Under certain simplifications (which usually approximate practical conditions), girder web can be treated, for two limiting cases, as simply supported or simply supported and clamped rectangular plate under in-plane non-uniform loads. Any problem, including very demanding patch loading case, can then be tackled accurately using Ritz’s energy technique with double Fourier series for the deflection profile and exact stress distributions throughout the plate. The article firstly explains defined distribution of shear stresses on web-flange junction adopted, for the first time, in the analytical patch load model, and then proceeds to consider two different (but related) thematic problem types which concern various aspects of the introduction of such shear effect on stability problems of webs: firstly, how the shear stresses affect the buckling coefficients of plates and lead to an increase in load capacity due to more realistic web behavior and secondly, is there any influence of shear stresses on the existing values and shapes of interaction curves and surfaces. Analytical results in this article are compared with numerical finite element (FE) values.

Exterior beam-to-column bolted connections between GFRP I-shaped pultruded profiles using stainless steel cleats. Part 1: Experimental study

Beam-to-column connections are very relevant in the design of glass fibre reinforced polymer (GFRP) structures, since they can (i) govern the load capacity and robustness, presenting brittle failure modes, and (ii) reduce the deflections of GFRP flexural members. This paper presents a study about the mechanical behaviour of exterior beam-to-column connections between I-shaped pultruded GFRP profiles using stainless steel cleats. The main objective was to develop a connection system with non-corrodible auxiliary parts and improved ductility, by exploiting the stainless steel properties. For that, full-scale tests were performed to investigate (i) the monotonic response of nine different connection series, and (ii) the cyclic response of four of those series. The series differed in the number of bolts/rods (one or two bolt rows), cleat thickness (3, 6 and 8 mm), position of the cleats (flange or web) and use of column reinforcements, materialized by stainless steel rods and plates connecting the cleats to the columns’ back flange. All series that did not include such reinforcements presented tensile rupture at the columns’ web-flange junction at a very initial stage of the monotonic and cyclic tests, limiting the connections’ strength, ductility and capacity to dissipate energy. In the reinforced series, where this failure mode was avoided, the stiffness, strength, ductility and energy dissipation was highly influenced by the cleats thickness and bolts row number. The series that presented the best overall mechanical behaviour comprised 6 mm thick flange cleats, each with two bolt rows, and column reinforcements; in this series, the intermediate thickness of the cleats provided the best balance between the initial stiffness and non-linear deformation capacity, delaying GFRP local failure and allowing to mobilize the stainless steel ductility — this connection presented the highest strength and energy dissipation capacity. In addition to the experimental study presented herein, Part 2 (Martins et al., 2021) presents predictions of the stiffness and strength of the reinforced connection series using analytical and numerical methods.

Flexural behavior of carbon-textile-reinforced concrete I-section beams

In the present work, the flexural behavior of carbon textile reinforced concrete (TRC) I-beams is investigated. Four-point bending tests were performed in I-beams, considering SBR-laminated textile and the following conditions: (a) plain cementitious matrix; (b) plain matrix and sand-coated textile; and (c) strain hardening cement-based composite (SHCC) matrix. The main goal of the research was to correlate the improvements on interface and matrix properties with the crack pattern, failure mode and ductility. For a comprehensive discussion, full mechanical characterization was performed and a design model is proposed for a better evaluation of the experimental results. Cracking behavior was greatly improved for conditions (b) and (c) with respect to (a), due to enhanced bonding between reinforcement and matrix in the former and due to fiber bridging mechanism in the latter. Beams with plain matrix exhibited brittle failure, whereas the beam having SHCC matrix showed premature local failure near load application point, resulting in an apparent ductility due to concrete softening mechanism. The reduced cracking load and the premature flange detachment along web-flange junction for condition (a) are also discussed. The proposed model is also validated through comparison with experimental results available in the literature.

Shear Response of Glass Fibre Reinforced Polymer (GFRP) Built-Up Hollow and Lightweight Concrete Filled Beams: An Experimental and Numerical Study.

This paper investigated the static behaviour of glass fibre reinforced polymer (GFRP) built-up hollow and concrete filled built-up beams tested under four-point bending with a span-to-depth ratio of 1.67, therefore focusing their shear performance. Two parameters considered for hollow sections were longitudinal web stiffener and strengthening at the web–flange junction. The experimental results indicated that the GFRP hollow beams failed by web crushing at supports; therefore, the longitudinal web stiffener has an insignificant effect on improving the maximum load. Strengthening web–flange junctions using rectangular hollow sections increased the maximum load by 47%. Concrete infill could effectively prevent the web crushing, and it demonstrated the highest load increment of 162%. The concrete filled GFRP composite beam failed by diagonal tension in the lightweight concrete core. The finite element models adopting Hashin damage criteria yielded are in good agreement with the experimental results in terms of maximum load and failure mode. Based on the numerical study, the longitudinal web stiffener could prevent the web buckling of the slender GFRP beam and improved the maximum load by 136%. The maximum load may be further improved by increasing the thickness of the GFRP section and the size of rectangular hollow sections used for strengthening. It was found that the bond–slip at the concrete–GFRP interface affected the shear resistance of concrete–GFRP composite beam.

Influence of manufacturing technique and autoclaving curing rate on the non-linear behaviour of thin-walled, GFRP channel columns – Experimental studies

The target of this research is to investigate the influence of manufacturing technique and autoclaving process parameters on the buckling and post-buckling behaviour of thin-walled, GFRP laminates. We investigated the compression of channel cross-section profiles with the following dimensions of the inner perimeter: (web × flange × length of the profile): 80 mm × 38 mm × 240 mm. The nominal wall thickness of the columns was equal to 1.2 mm. The inner radius at the web-flange junction was equal to 2 mm. The material used to produce the samples was eight-layered pre-preg tape with an angle-ply, symmetric layer arrangement: [45/−45/45/−45]s. The columns were manufactured using two different techniques. The first technique was to form the channel cross-section profile by draping over an aluminium mandrel, while the second was to form square cross-section profiles, by winding around an aluminium mandrel, which are then cut into two channel-cross sections. Moreover, two curing process types were applied. The first is a nominal (suggested by the pre-preg producer) curing cycle on a hollow section aluminium mandrel, while the second is a modified curing cycle on a solid aluminium mandrel. In total, four different sets of specimens were produced and subjected to static compression. Higher buckling strength (denoting critical loads and post-buckling behaviour) is shown to be a result of internal, after curing stresses in the composite – the highest buckling resistance is achieved for the columns manufactured as square hollow sections and machined into channel sections. This solution is the most economically efficient. Additionally, the samples were 3D scanned in order to assess post-manufacturing distortions and the deviations from the nominal geometry.

Optimal design of cold roll formed steel channel sections under bending considering both geometry and cold work effects

Optimal design of a structural member is a design process of selecting alternative forms to obtain its maximum strength while maintaining the same weight, leading to the most economical and efficient structure. Amongst steel structures, cold rolled steel ones can effectively gain this requirement as they are thin-walled structures that offer the high ratio of strength over weight. However, the design is very challenging as these members are prone to buckling and failure at low loads. In this paper, the buckling and ultimate strength of cold rolled channel sections was studied using numerical modelling. In order to improve the section strength, the development of various alternative cold rolled formed sections included additional bends such as intermediate stiffeners. The section strength was optimised through a practical approach which altered the stiffener's position and shape and searched for maximum buckling and ultimate strength under bending. In this approach, a nonlinear Finite Element model was first developed for an industrial channel beam subjected to four-point bending tests and this model was validated against experimental test data. The verified model was then used to conduct a parametric study in which the effects of a stiffener's properties on the section strength including its position, shape, size and material properties by the cold work at bends were investigated in detail. Several different cold rolled channel sections having intermediate stiffeners at web and flanges with and without the cold work effect on material properties at the stiffener's bends were considered for this investigation. In addition, a design method, the Direct Strength Method (DSM), was utilised to take into account the effects of a stiffener's properties on the section strength and results were compared with the Finite Element modelling results. It was found that some significant improvements were obtained for the section strength of the optimised sections in comparison to the original sections. An optimal shape for the channel section with maximum ultimate strength in distortional buckling could be obtained with both the stiffeners' position, shape, size and quantity, and the cold work effect. The cold work effect was found most significant in the cases of changing the width of the web stiffeners and the position of the flange stiffeners. It also revealed that, the currently available DSM beam design curve for distortional buckling provided good agreement in predicting buckling load and ultimate strength capacity for most of the considered sections with and without the cold work effect included; however, the DSM provided overestimate results compared to the Finite Element model results in the sections with web intermediate stiffeners, in particular, when the tip of web intermediate stiffener moved away from the web-flange junction in the horizontal direction.

Novel progressive failure model for quasi-orthotropic pultruded FRP structures: Application to compact tension and web-crippling case studies (Part II)

Part I [1] of this two-part paper presented the formulation of a novel progressive failure model for pultruded fibre reinforced polymer (FRP) composites, allowing for the 3D simulation of quasi-orthotropic FRP plates as a homogenized material, as well as the model calibration based on a set of standardized material characterization tests. Part II presents the application of that (calibrated) model to the simulation of two case studies: (i) transverse compact tensile (CT) tests; and (ii) web-crippling tests for two load configurations, external two-flanges (ETF) and internal two-flanges (ITF). The CT test, which is often used to determine the (tensile) fracture energy of FRP materials, is especially interesting as it allows assessing the quality of the simulations for a combination of in-plane transverse tensile and shear stresses in a geometry with a sharp singularity. The web-crippling test, on the other hand, is often used to determine the strength of FRP shapes under concentrated transverse loads, a real structural problem involving combined in-plane compressive and shear stresses. In this paper these two relatively complex case studies are used to assess the quality of the simulation in the presence of combined in-plane stresses. The numerical results showed an excellent agreement with their CT test counterparts; the simulation of these experiments were also used to demonstrate the need for using a mesh regularization scheme when modelling problems with singularities. The models were also well able to simulate both web-crippling load configurations, only slightly underestimating the maximum load – this was likely due to the slight underestimation of shear strength for combined in-plane shear and moderate transverse compressive stresses, as discussed in Part I [1], and/or non-quasi-orthotropic behaviour of the web-flange junction. Overall, the numerical results showed a good agreement with the experimental data, even for relatively coarse meshes, attesting the feasibility and precision of the proposed damage progression model.

Experimental investigation on the bearing behaviour of aluminium sub-heads in façade systems

In the building sector, the application of aluminium alloys in load carrying structures as well as building envelopes has received attention over the past decades. Under wind loading, the vertical members of window walls known as mullions, carry the horizontal load transferred from the glass panels. This load is then transferred to the sub-heads at the top and the sub-sills at the bottom which are connected to the structure. The aluminium sub-head flange due to its long length is susceptible to bending (bearing failure) under this loading condition, a phenomenon that has hitherto not been adequately researched. Hence the performance of aluminium sub-head sections subjected to bearing failure was investigated through a series of 42 tests. This study mainly explores the impacts of parameters such as the bearing width, the loading and boundary conditions, as well as various geometric sections, on the bearing failure of aluminium sub-heads. The significant failure modes observed in the tests were yielding at web-flange junction and slipping of the bearing plate. Currently, no design rules are available to predict the bearing capacity of aluminium sub-heads. Hence a comparison of the ultimate bearing capacities of the test results and the design capacities obtained using the available cold-formed steel design specifications was performed. The code-predicted design strengths were found to be overly conservative for aluminium sub-head sections in window walls. Therefore, new design equations were developed to ensure safe, economic and reliable design of aluminium sub-heads using a wide range of bearing capacity data obtained from the experimental studies. The proposed design rules were found to be in precise agreement with the experimental values.

Stability performance of thin-walled pultruded beams with geometric web-flange junction imperfections

The current paper investigates the role of initial imperfections at web-flange junction on the lateral torsional buckling behavior of pultruded fiber reinforced polymeric beams. This study is based on experimental and numerical results, which are developed in two main steps: perfect beams and beams with initial imperfections at the web-flange junction. In the first step, small-scale tests are carried out to calculate the mechanical properties of the composite section. Perfect and imperfect pultruded I- and C- shaped beams are subjected to full-scale experimental tests under an applied four-point bending load with a total lengths varying from 1500 to 3000 mm, and 2500–3500 mm for the I- and C-beams, respectively. The end conditions of all beams studied are simply supported. Perfect beams are tested to investigate their dominant failure mode, as well as the impact of lateral bracing on the failure modes. While, imperfect beams are tested to determine the effect of initial imperfections on the lateral-torsional buckling capacity and failure mechanisms.

Improved method for shear lag analysis of thin-walled box girders considering axial equilibrium and shear deformation

Abstract The conventional method (CM) for shear lag analysis of thin-walled box girders supposes that the neutral axis coincides with the centroidal axis of the whole cross section, and thus neglects the axial equilibrium condition. An analytical method considering axial equilibrium and shear deformation, which is referred to as PM, is proposed for overcoming the defect of the conventional method. The longitudinal displacement of the web is introduced to satisfy the axial equilibrium condition and locate the neutral axis automatically. The shear deformation is considered according to the Timoshenko beam theory. Three independent shear lag functions are adopted for describing different shear lag intensities of the top, bottom and cantilever slabs. The governing differential equations for the displacement variables are deduced by means of the virtual work theorem and solved with the relevant boundary conditions. The analytical solution is then derived for the distance from the neutral axis to the top fiber of the cross section. The accuracy of the proposed method is validated by comparisons with the available experimental data as well as the finite element analysis results. Moreover, the distances from the neutral axis to the top fiber, axial forces, and stress difference ratios are analyzed for typical thin-walled box girders to quantify the influence of the axial equilibrium condition. Finally, an extensive parametric study is conducted to examine the effects of various geometric parameters on the stress difference ratio under different load types. The results show that the proposed method can provide good predictions for both deflections and axial stresses, and neglecting axial equilibrium leads to considerable underestimations of axial stresses especially at the top flange-web junctions over the interior support of the continuous box girder.

Determining rotational stiffness of flange-web junction of pultruded GFRP I-sections

In this work, the rotational stiffness of flange-web junctions of pultruded GFRP I-sections is investigated through an experimental program. Flange-web junctions of GFRP profiles are found to be non-rigid, contradicting typical design assumptions. Accounting for flange-web rotational stiffness reduces the rotational restraint of the flange/web junction; often by 15% or more, although more modest reductions were observed in this study. A discussion of different test methods for assessing flange/web junction stiffness is provided. A simple method that mitigates unfavorable effects is recommended. The effectiveness of the selected test method is demonstrated through 25 experimental tests which also serve to augment the limited data available in this area. Finite element modeling is conducted to simulate the experimental test and investigate parameters impacting the experimentally-determined rotational stiffness. Recommendations are made to standardize test parameters. Findings from this study directly support the developments of evaluation criterion for flange-web junctions and design equations; particularly those intended to capture the local buckling behavior of pultruded GFRP beams.

Design of Composite I-Beam Section to Prevent Web-Flange Junction Failure and Improving Its Axial Load Carrying Capacity

Most of the chemical industries are used with Polyurethane (PU) coated steel sample which is found that some chemical reaction and rusted in acidic bath solution becomes a problem in industry. For such problems composite materials can be of good solution which does not possess any reaction with working fluids (acids in our case). With composites there is complexity of manufacturing and high cost involvement, so as to avoid those simplified approach is used to get Flat plates made of Glass fiber reinforced in epoxy which is best solution for any acidic bath as it possesses high resistance to any reaction with itself. Glass fiber plates are cut into the size of dimension and with the help of adhesives joint the WFJ of I-Beam, there are two different types of adhesives used, araldite 2015 and Hundsman araldite are used. The hundsman araldite is found to get better performance of Web-Flange junction (WFJ) joint. Finite element analysis (FEA) is used to get initial validation and further it’s observed that Hundsman araldite failure strength on the web-flange junction is better. Also, additional cleat used with 4 mm, 12 mm for increasing the Web-Flange junction (WFJ) area to improve the Load carrying capacity of the Beam. The experimental analysis results clearly indicate that the emersion of the reinforced epoxy glass-fiber in the acidic bath solution for a certain period, there is no any reaction formed in the acidic bath and improved the behavior of the specimen. Results from FEA and experimental test have shown good correlations are obtained with improvement of failure strength on WFJ.