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...
Here's a sketch of your most conservative connection design option.
A 4-plate end "sleeve" w' long slots that's field welded to the HSS (also long slots) & W30 support. This lets you 1) push the "sleeve" inward, 2) swing the HSS system into place between the W30 supports, 3) extend the "sleeve"...
It would probably be best to solidify your thoughts. I'd say make a document clearly articulating the pros and cons of your current situation. Incorporate your thoughts on the direction of current company, with examples, and what you would expect from a new employer.
Regarding the pay cut, I...
Small engineering team, medium-sized company.
The way things are going in my industry (structural steel), we increasingly interact w/ detailing teams all over the globe (India lately). So it’s already sort of remote, whether I'm at home or the office. It's a bit funny (and depressing) knowing...
Axial loads are mostly assumed to transfer via flanges. The shortest explanation is that you should avoid transferring large axial loads into the flimsiest part of a supporting member because of 1) unacceptable structural performance and 2) reinforcement costs.
Also, your latest photos all show...
The yellow plate won't be very efficient because it establishes an alternate load path through the least stiff part of the blue beam, via flexure of the blue beam's flanges. If you consider it like a pair of springs in parallel, where one is much stiffer than the other, the stiffer spring with...
I'd say adding additional length equivalent to the sum of the weld start & stop would be more than sufficient, but not necessary. Imposing another 1" on top of that is too conservative and in some cases might be less efficient (i.e. more time consuming w/ only a little weld material saved) than...
