Would something like this work? Not sure what type of site constraints you have or how big of a moment the conx needs to resist, but you have a lot of options, including end plates, flange plates, direct welding, super glue, etc...
What kind of strength? Global flexure? Shear? Ability to handle concentrated loads/bearing? Serviceability concerns?
Obviously castellating a beam saves weight, but has limits.
Depends on whether it's LRFD or ASD. I'm getting the HSS limit states to squeak by with LRFD. ASD, without a doubt, will have major problems and the lower flange plate would have to be made wider and the HSS split into an upper and lower section. Perhaps the "f" in "Mf" is some indicator I'm...
You have a lot of options. Perhaps something like this? or a field-welded similar option?
Running the W12 continuous over the column is always good, unless it interferes with the perpendicular W12. Resolving the flange force at the top of an HSS is going to be difficult, unless the conx plate...
Uhhhh. A lot of red flags... highly eccentric weld group and possible fatigue considerations. Also, a 2" flat plate is acting as your "hoist/brake beam"....... Unless I'm missing something, I hope I never set foot in this building. Half a mind to report.
One of the other benefits of cap plates, in conjunction with shims/filler plates, is that they can be milled to the required thickness to ensure proper bearing/load-transfer if significant variances in post/column height are discovered during a survey.
For starters:
1) You should ask the design engineer for the bolt hole size & pattern.
2) Tension controlled (TC) bolts can only be turned via shear wrench on one side. If you have architectural requirements, verify which side the TC bolt head is on. Then verify that the erector can get a shear...
From recent memory, the only time I've used double shear plates was beam-to-BU 24x36x4" box columns @ vertical bracing w/ very heavy loads. They're a pain to fabricate because weld access is restricted on the 2nd plate and a CJP (w/ backing bar) is required. Very rarely used.
As a parallel, I think "cracking" was thrust into the limelight relatively recently due the the San Francisco Transit Center fiasco. The plate-girder/built-up node had cracks propagating from welded joints at thick plates. I've noticed greatly increased Charpy V-notch testing requirements...
That was a truly awful job. Had to get on a plane a few time for site inspections to avoid litigation. Can't say much more. If it weren't so embarrassing for every company involved, I would love to give an hour-long case study on the field-fixes and subsequent monetary loss. Overall lesson, if a...
Don't overthink it. Just make sure you line the new holes up carefully. As others said, use some touch-up paint and have QC give the nod.
If you want to feel better, here's a fun photo of when an erector who went wild with new holes on one of my jobs.
Unless your PEMB is actually a Costco shed or something, that's nuts. And I would probably start reconsidering my business relationship with that supplier.
Which AISC Certified fabrication facility in China can the material be traced back to and how would/could you pursue the Chinese company...
