Welder Qualification Manual Revision 5

WELDER QUALIFICATION
MANUAL
Welder Qualification Manual
Page 2 of 20

Table of Contents
Subject
Work Instruction
Page
Revision History
Welder Qualification Procedure
PR-4003
3
4
Welder Qualification Tests

WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
WQT
1
2
3
4
5
6
7
8
11P
11G
12P
12G
13P-16
13G-16
13P-12
13G-12
Prepared by: Dennis Johnson
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Effective Date: July 16, 2012
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
Revision History
Revision
Effective Date
Number
1
2
April 14, 2010

May 28, 2010
3
4
5
December 16, 2010

November 11, 2011
July 16, 2012
Page 3 of 20
Revision Summary
General Revision to for typographical clarifications
Add revision history
Add vertical tack weld test procedure WQT4
Removed WQT 7 and WQT 8
Revised welding procedure WQT5
Add Gas Flow Rate to WQT1
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
Page 4 of 20
Welder Qualification Procedure

PR-4003 (IAS AC472, 5.1.3.1)
All welders and welder operators will be qualified for the type of weld, process and position that they are
expected to perform.
The weld test as indicated in Table 1 shall be administered by the ACI In-House CWI. Welder Tests shall
be administered according to the procedures indicated in the Welding Operations Manual, Welder
Qualification Procedure PR-4000.
TABLE 1 WELDER, WELDER OPERATOR AND TACK WELDER TEST PROCEDURES
Welder Test
WQT Number
AWS D1.1
WQT 1
WQT 2
WQT 3
WQT4
WQT 5
WQT 6
Process
Thickness
Diameter
Range
Qualified
Qualified
Hot Rolled and Built-Up Members
GMAW
1/8N/A
Unlimited
GMAW
1/8 3/4
> 4 Nominal
Pipe Size
SAW
1/8N/A
Unlimited
GMAW
1/8 N/A
Unlimited
SAW
1/8N/A
Unlimited
GMAW
1/8N/A
Unlimited
Coating
Position Qualified
None
None
2G (Flat and Horizontal Groove)

2F (Horizontal Fillet)
1G (Flat Groove Rotated)
None
2F (Horizontal Fillet)
None
3F Tack (Vertical Down Only) Tack

Weld Only
1G (Flat Groove)
None
None
2F (Flat and Horizontal Only) Tack

Weld Only
AWS D1.3
11P
Cold-Formed Members
GMAW
16 gage to
N/A
Painted
2F (Flat and Horizontal Fillet)
12 gage
11G
GMAW
16 gage to
N/A
Galvanized
2F (Flat and Horizontal Fillet)
12 gage
12P
GMAW
16 gage to
N/A
Painted
2G (Flair V-Groove and Flair Bevel
12 gage
Groove Flat)
12G
GMAW
16 gage to
N/A
Galvanized
2G (Flair V-Groove and Flair Bevel
12 gage
Groove Flat)
Special Note: Qualify Welders for Arc Plug Welds for the full production range of the Welding Procedure by welding
two samples of each Welder Qualification Test WQT 13P-16, 13G-16, 13P-12 and 13G-12
13P-16
GMAW
16 gage
N/A
Painted
1G (Plug Weld)
13G-16
GMAW
16 gage
N/A
Galvanized
1G (Plug Weld)
13P-12
GMAW
12 gage
N/A
Painted
1G (Plug Weld)
13G-12
GMAW
12 gage
N/A
Galvanized
1G (Plug Weld)
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 5 of 20
1
3
Use Figure 4.30 of AWS D1.1 2008 for

Assembly Preparation
Process:
1"
GMAW
1 "
4
2G
Material Type
ASTM A572
Grade 55
Material Thickness:
Diameter:
N/A
Backing:
Yes
Backing Type:
Grade 55
ASTM A572
Welding Procedure:
See Electrical Parameters Below
Gas Flow Rate:
40 CFH
Coating:
None
Acceptance Criteria:
Visual Acceptance
Side Bends (2) or Radiograph
Thickness
Layers
Side
1
2
3
4
5
6
7
1
1
1
1
1
1
1
Number
of
Passes
1-2
2-3
3-4
4-5
5-6
6-7
7-8
Filler
Metal
Size
0.045
0.045
0.045
0.045
0.045
0.045
0.045
6"
45
Position:
(Horizontal)
1 "
4
Amps
Volts
243-297
243-297
243-297
243-297
243-297
243-297
243-297
26-30
26-30
26-30
26-30
26-30
26-30
26-30
UNCONTROLLED
WHEN PRINTED
Wire
Speed
(IPM)
374-458
374-458
374-458
374-458
374-458
374-458
374-458
Travel
Speed
(IPM)
12-20
12-20
12-20
12-20
12-20
12-20
12-20
Position
Revision Number: 5
2G
2G
2G
2G
2G
2G
2G
WQT Number:
Revision:
Page 6 of 20
2
6
Use Figure 4.24 of AWS D1.1 2008 for Assembly Preparation

Process:
GMAW
Position:
1G (Flat Rotated)
Material Type
ASTM A500 B
Material Thickness:
0.280
Diameter:
6 Nominal (6-5/8 actual)
Backing:
Yes
Backing Type:
ASTM A109
Welding Procedure:
WPS B-L1b-G (For Electrical Parameters Only)

(Use Fit-Up Configuration as shown above)
None
Coating:
Visual Acceptance
Root Bend (1)
Face Bend (1)
Radiograph may be substituted for Root and Face Bends
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 7 of 20
3
4
Use Figure 4.37 of AWS D1.1

2008 for Assembly Preparation
Process:
SAW
Position:
2F (Horizontal)
Material Type
ASTM A572 Grade 55
Material Thickness:
1/2
Diameter:
N/A
Backing:
N/A
Backing Type:
N/A
Welding Procedure:
WPS Fillet-S
Coating:
None
Visual Acceptance
Fillet Weld Break (1)
Macroetch (1)
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 8 of 20
4
0

Process:
GMAW
Position:
3F (Vertical Down)
Material Type
ASTM A572 Grade 55
Material Thickness:
1/2
Diameter:
N/A
Backing:
N/A
Backing Type:
N/A
Welding Procedure:
WPS Fillet-G
Coating:
None
Reasonably Uniform Appearance

Free of overlap, cracks and undercut exceeding 1/32
Free of visible porosity
Tack Weld Break Test per Figure 4.35 AWS D1.1 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 9 of 20
5
3

Process:
SAW
Position:
(Flat)
1G
Material Type
ASTM A572 Grade 55
Material Thickness:
Diameter:
N/A
Backing:
Yes
Backing Type:
Flux
Welding Procedure:
WPS B-U2-S
Coating:
None
Visual Acceptance
Side Bends (2) or Radiograph
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 10 of 20
6
2

Process:
GMAW
Position:
2F (Horizontal)
Material Type
ASTM A572 Grade 55
Material Thickness:
1/2
Diameter:
N/A
Backing:
N/A
Backing Type:
N/A
Welding Procedure:
WPS Fillet-G
Coating:
None
Reasonably Uniform Appearance

Free of overlap, cracks and undercut exceeding 1/32
Free of visible porosity
Tack Weld Break Test per Figure 4.35 AWS D1.1 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
Page 11 of 20
THIS PAGE
INTENTIONALLY
LEFT BLANK
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
Page 12 of 20
THIS PAGE
INTENTIONALLY
LEFT BLANK
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 13 of 20
11P
5
Process:
GMAW
Position:
2F (Horizontal)
Material Type
ASTM A1011 Grade 55
Material Thickness:
16 gage
Root Opening:
Welding Procedure:
WPS 11P-G
Coating:
Painted
Coating Thickness:
0.5 mils per side
Visual Acceptance
Two Assemblies Shall be Tested per
Bend Test indicated in Figure 4.2A of AWS D1.3 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 14 of 20
11G
4
Process:
GMAW
Position:
2F (Horizontal)
Material Type
ASTM A653 Grade 55
Material Thickness:
16 gage
Root Opening:
Welding Procedure:
WPS 11G-G
Coating:
Galvanized
Coating Thickness:
G90
Visual Acceptance
Bend Test indicated in Figure 4.2A of AWS D1.3 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 15 of 20
12P
3
Process:
GMAW
Position:
1G (Flat)
Material Type
ASTM A1011 Grade 55
Material Thickness:
16 gage (both pieces)
Root Opening:
Welding Procedure:
WPS 12P-G
Coating:
Painted
Coating Thickness:
0.5 mils per side
Visual Acceptance
Test indicated in Figure 4.3C of AWS D1.3 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 16 of 20
12G
2
Process:
GMAW
Position:
1G (Flat)
Material Type
ASTM A653 Grade 55
Material Thickness:
16 gage (both pieces)
Root Opening:
Welding Procedure:
WPS 12G-G
Coating:
Galvanized
Coating Thickness:
G90
Visual Acceptance
Test indicated in Figure 4.3C of AWS D1.3 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 17 of 20
13P-16
1
9/16" Hole
First Plug
Weld
1" min.
Special Note:
Arc Plug Welders must be
Qualified by using WQT
13P-16 and 13P-12. This
Qualifies Welders for the
Full thickness range of
The production WPS 13P
10"
to 1
2"
mi n
.
/2 "
2 1 i n.
m
Process:
GMAW
Position:
1G (Flat)
Material Type
ASTM A1011 Grade 55
Material Thickness:
16 gage
Root Opening:
Welding Procedure:
WPS 13P-G
Coating:
Painted
Coating Thickness:
0.5 mils per side
Visual Acceptance
Test indicated in Figure 4.6 of AWS D1.3 2008
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 18 of 20
13G-16
1
9/16" Hole
First Plug
Weld
1" min.
Special Note:
13G-16 and 13G-16. This
The production WPS 13G
10"
to 1
2"
min
.
Process:
GMAW
Position:
1G (Flat)
Material Type
ASTM A653 Grade 55
Material Thickness:
16 gage
Root Opening:
Welding Procedure:
WPS 13G-G
Coating:
Galvanized
Coating Thickness:
G90
Visual Acceptance
UNCONTROLLED
WHEN PRINTED
/2 "
2 1 i n.
m
Revision Number: 5
WQT Number:
Revision:
Page 19 of 20
13P-12
1
9/16" Hole
First Plug
Weld
1" min.
Special Note:
13P-16 and 13P-12. This
The production WPS 13P
10"
to 1
2"
mi n
.
/2 "
2 1 i n.
m
Process:
GMAW
Position:
1G (Flat)
Material Type
ASTM A1011 Grade 55
Material Thickness:
12 gage
Root Opening:
Welding Procedure:
WPS 13P-G
Coating:
Painted
Coating Thickness:
0.5 mils per side
Visual Acceptance
UNCONTROLLED
WHEN PRINTED
Revision Number: 5
WQT Number:
Revision:
Page 20 of 20
13G-12
1
9/16" Hole
First Plug
Weld
1" min.
Special Note:
13G-16 and 13G-16. This
The production WPS 13G
10"
to 1
2"
min
.
Process:
GMAW
Position:
1G (Flat)
Material Type
ASTM A653 Grade 55
Material Thickness:
12 gage
Root Opening:
Welding Procedure:
WPS 13G-G
Coating:
Galvanized
Coating Thickness:
G90
Visual Acceptance
UNCONTROLLED
WHEN PRINTED
/2 "
2 1 i n.
m
Revision Number: 5

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WELDER QUALIFICATION

Welder Qualification Manual

Welder Qualification Manual

Welder Qualification Tests

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

April 14, 2010

December 16, 2010

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Welder Qualification Procedure

2G (Flat and Horizontal Groove)

3F Tack (Vertical Down Only) Tack

2F (Flat and Horizontal Only) Tack

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Use Figure 4.30 of AWS D1.1 2008 for

See Electrical Parameters Below

Gas Flow Rate:

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Use Figure 4.24 of AWS D1.1 2008 for Assembly Preparation

6 Nominal (6-5/8 actual)

WPS B-L1b-G (For Electrical Parameters Only)

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Use Figure 4.37 of AWS D1.1

ASTM A572 Grade 55

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Use Figure 4.39 of AWS D1.1

ASTM A572 Grade 55

Reasonably Uniform Appearance

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Use Figure 4.22 of AWS D1.1

ASTM A572 Grade 55

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Use Figure 4.39 of AWS D1.1

ASTM A572 Grade 55

Reasonably Uniform Appearance

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

Prepared by: Dennis Johnson

Effective Date: July 16, 2012

Welder Qualification Manual

ASTM A1011 Grade 55

0.5 mils per side

Prepared by: Dennis Johnson

Effective Date: July 16, 2012