Dik:
It seems to me that we have discussed this project before, you’re moving some heavy equipment in a tunnel or a mine, with tight headroom, or some such, right? I would not cope the one beam end, since that tends to hurt the support of the bottom flange. Why not just use a heavy web plate, welded to one beam end (web) and bolted to the other beam web. Maybe weld a heavy backer plate to the opp. side of web on second beam, then drill/punch the web and backer pl. for the bolted connection. This might also allow you to tighten up the joint gap. The problem with these joints is the differential deflections of the flange tips as the trolley wheels move over the joint gap, and load one flange tip and then try to climb to the other. They actually roll some S shaped (narrower sloped bot. flgs.) Tee sections with thicker flanges and webs to improve this tip deflection problem. A trolley with three axles (six whls.) would be an improvement too; in that more of the load would be further back on the first beam as the leading whl. crossed the slice gap. Are you using off-the-shelf trolleys or are you designing and building your own? Sometimes this gives you some latitude in what you can design around. Also, why not just a WF built-up shape for the hanger with the first (middle) vert. bolts closer to the beam joint. Wouldn’t this reduce the differential deflection btwn. the two beams and through the hanger?
