Repairing/Replacing Deformed Member

TB 9-2510-242-40

h. Cracked/Broken Member. Repair a cracked or broken member of a frame by preparing and welding the

crack/break and then adding a reinforcing plate for extra strength. The original strength of the member cannot be

restored by welding the crack/break alone. The reinforcing plate can be internal, external, or a combination of both on a

frame channel member. If a suspension mounting or mounting of another item cannot compensate for or permit addition

of the reinforcing plate, replacement of the entire member shall be considered. The frame shall be considered as non-

repairable when member replacement is not practical. Where repair of the cracked/broken member is practical, proceed

as described in steps a-g above.

5-4 Repairing/Replacing Deformed Member. Frame members deformed in a local area resulting in metal thickness

reduction are also reduced in strength. Straightening such members cannot restore metal to its original thickness.

Original strength cannot be restored; therefore, deformed members shall be removed and replaced. Similarly, at times it

may be more economical to replace the frame member rather than cut out a damaged segment, and fabricate, insert,

and strengthen a replacement segment.

a. Complete Member Replacement. Complete frame members shall be replaced as follows.

(1) Remove Structural Load. The first step to remove a complete frame member is to remove its structural

load. Use jack stands or other cribbing to safely support all frame members that connect to the member to be replaced.

Support the frame at other points to ensure that the frame and its members cannot move with removal of damaged

members.

(2) Remove Damaged Member. Before their removal, measure and record all welds by type, size, length, and

location. For a welded frame member, remove old weld material from all welded joints holding the member. Use a

portable grinder of suitable size. Avoid application of excessive heat to the remaining frame members. Also remove all

paint down to the bare metal a distance of 4 inches from where new welding is to be done, including the back and inside

of all metal surfaces to be welded. For galvanized trailers, the galvanization must first be ground off. Wear an

appropriate respirator and remove zinc coating using a suitable grinder.

(3) Realign Remaining Frame Members. Align remaining frame members to their correct original positions.

Repairs to some existing member may be necessary before the remaining frame members can be correctly aligned.

(4) Fabricate/Obtain Replacement Member. If feasible, obtain a replacement member. If not, fabricate the

replacement member to the design of the original member. The finished member's length can be easily determined by

measuring similar members. Member material shall be the same as the original member (see appendix A and appendix

(5) Install Replacement Member. Clamp the replacement member in position and weld using the skip-weld

procedure specified in paragraph 5-1d.

(6) Treat/Paint New Joints. Treat and paint replacement member and welds