“BSI BS*5135 64 MMH 2b24ob9 OOb3Z42 O Pa BS 5135: 1984 {VDC 621,701.76: (0.44 + 009.157.1981 © British Standards Institution. No part ofthis publication may be phatocopie. or otherwise reproduced without the prior permission in writing of BSI British Standard Specification for Are welding of carbonand /\ carbon manganese steels Soudage & I'arc des aciers au carbone et au carbone-manganése — Spécifications Lichtbogenschwei8en von Kolilersstuff- und Kohlenstoff-Mangan-Stahlen — ba British Standards Institution Copyright by The Brith Standards Tastitaion Wed Nov 10 0646-4 1999“BSI BS¥5435 84 MM TG24G69 OOL3243 2 mm Bs 6195: 1984 Contents Foreword 1 Committees responsible Back page Specification ‘Scope 2 2. Definitions 2 1 2 3. 4 6 a 7 8 9. 10. 11 12 13, 4 15, 16 ”. 18. 19, 20. 2 22. 2, 24, 26. 26. 27. 28, 20. 3. Information and requirements to be agraed and to be documented 1. Parent motal 5. Welding consumables Equioment Burt weld details Fillet wald details Wolds in slots }. Preparation of joint faces |. Fusion faces Assembly for weing ‘Alignment of butt joints Fitup of parts joined by fillot wolds Tack welds 3. Temporary attachments Protection from the weather ‘Stray arcing on work Inter-run cleening Deals of welding procedure |. Welding procedures to avoid cracking 2. Approval and testing of welding procedures . Approval and testing of welders }. Identifieation Peening 3. Inspection and testing . Quelity of wolds Corraetion of faulty welde Heat treatment ‘Appendicos A B . Guidance on lamellar * Guidance on design Guidance on butt welds (for other then structural hollow sections) Guidance on typical dotalls for structural hollow sections Guldanee on fracture toughnoss of heat-affected zone end weld metal Guidance on avoidance of hyaragen cracking Guidance on solidification cracking ing Guidance on acceptance lavels Copyright by the ed Nov 10 08:48 Hydrogen scales 2. Carbon equivalent values for BS 4360 steals, 10 Dé used in absone# Of mill sheets Conditions for manual matal-are welding with covered electrodes of fillet welds in stoe! having maximum carbon equivalent of 0:38 Conditions for manual metat-are welding with coverad oleetrodes of fillet wale in etal having maximum carbon equivalent of 0.40 Conditions for manual metal-are wolding ith covered electrodes of fillet welds in stoel, having maximum carbon equivalent of 0.4% Conditions for manuel metal-arc welding with covered electrodes of fillot wolds in stee, having maximum earbon equivalent of 0.43 Sitch Standards Institution 1 1999 REBEBBEBvaaaeoaoorsasseunn 1. Gonditions for manual metalare welding ‘with covered electrodes of fillet welds in steel having maximum carbon equivalent of 0.45 8, Conditions for merual matal-aro welding with covered electrodes of fillet welds in steel having maximum earhon aruvalont of 0.48 9. Conditions for menual meta-are welding ‘with covered eleotrades of fillet welds in stael navi niaximum carbon equivalent of 0.60 10, Run lengths and runout ratios for electrodes uf affiolancy << 110 % complying with BS 639 11, Bun lengths and runout rstios for ooctrodos of efficiency > 110 %and'e 130% complying with 8S 638 12, Run lengths and runout ratios for slectrodes with coverings of oficienay > 130 % complying with 8S 639 18, Values of are energy for the manual metal-arc ‘weIding of single run filet welds 14. Fectors for deriving design throat thickness fof fat or convex fillet weld 18. Typical forms of butt wald preparation [other than structural hollow sections) 16. Typical forms of eutt wold praparation for structural hollow sections 17. Examples of maximum combined thickness ‘woldable without prehsst 18, Guidance on aceoptance levels for butt joints 19, Guidance on acceptance levols for fillet welds Figures 1. Diagrammatic representation of method of {gouging out full penetration butt joints Welded from both sides Fillet welds applied to the edge of a part Exemplos of combinod thickness Conditions for wolding steel of stated carbon caulvalont Butt joints of unequal cross section Branch connections for circular structural ollow sections: burc welds (ahlekness up to 30 mm) 7. Branch connestions for circular structural hollows soetions: fillet welds 8, Branch connections for rectangular structural hollow sections: butt wide ‘9. Branch connections for rectangular structural hollow soetions: fillet welds 10. Short wansverse tensile tst specimen with friction welded extensions 11. Suggested STRA values appropriate to risk of lamellar tearing in joints of differing restraint (values besod on 6.4 mm dlamotor specimen} 12. STRA against sulphur content for plates 12.5 mm to 50 mm thick (inclusivo) 13, Example of restraints in T-oint with flat wel 14, Details and joint configurations in which lamellar teating Is possible when fabricating large structures with a high degroe of restraint from plete Page 13 “ 6 oh 7 > 18 20 31 33 so 46 47 18 10 Ey 3% 38 42 43 230 ofthis British Gtandlrd has been prepared under the direction of the Welding Standards Committee. It's the fist revision of ths standard since the original 1974 edition whieh Is withdrawn. Because of its range of applleablity, it has been used cxtontivoly over a wide fiold of types of fabrication and has recslved due recognition as @ comprehensive welding standard, Experience gained in its use has boon reflected in the changes incorporated in this revision, principally by ‘converting most ofthe previous guidance on the avoldance of hydrogen eracking Intaraquiramants Which have to be followed whenover practicable. Appendices giving recommendstions concerning various modes of cracking and factors to be taken Into account in establishing welding procedures have been retained in updated form. Copyngne by he Brtsh Standaras fesutonon Wed Nov 10 06:49:14 1999 BSI BS*5235 84 MH Ub24b64 OObIZ4% 4 am 8S 6195: 1984 Permissible stresses in welds, nitliods of testing and acceptance levels are not specified because they depend on the service conditions ofthe fabrication. These require ments should be obtained from the relevant application standard of by agreement beivreen the contracting parties, ‘An eppendis. has boon Introduced giving quidanao on four levels of acceptance eritria which may be used to assist in reaching agreement. lt has been assumed in the drafting of ths standard that the execution ofits provisions is entrusted to eppropriataly qualified and experienced people, Compliance with a British Standard does not of itself confer Immunity from tegal obigations.BSI BS*5135 84 mm Bs 6136: 1984 Wb24bb4 OOLIE4S b A British Standard Spedification for Arc welding of carbon and carbon manganese steels T. Scope ‘This arash Standard sfiifies raqutramenis Tor Wie proces ‘of manual, sami-sutomati, automatic and mechanized arc \wolding of carbon and carton manganese steel of maximum ‘arbon equivalontof 0.5 [se claus inal product fora including circular and rectangular holow sections. In addition tothe definitive requirement, it also requires the Items detailed in clause 3 to be documented. For compliance with this standard, Both the definitive requirements and the documented item have ta‘be satlstled.* normal farletion restreint conditions and higher rest situations need higher preheat or other precautions to prevent hydrogen cracking, Sore guidance an ths igen inappendix € ‘The appondoe ae Tanda o als Use OT A stancar™ by ahing guidance on various topes, but echorence to aha. is stated in the eppendizes does not form pert of compliance with this standard, ‘This standard doa not include al the requirements forthe Welding of ste! for coperete reinforcement whieh may be affected by other fasts nat eoered by tis stamens This standard does nat cover requirements for east to cast fabrieations which are specified in BS 4570, INGIe. te Wa of te pbetions fered Io thi stoned hon th nde bok over 2. Definitions For the purposes ofthis Brith Standard, the definitions ivan in BS 499 : Part t apply 8. Information and requirements to be agreed and to be documented 3.1 Information to be supplied by the purchaser ‘Tha following information to be supplied by the purchaser shall be fuily documented. Bath the definitive requirements spocitied throughout the standard and the documented toms shall bo satisfied bofore a claim of compliance with the standard cen be made end verified. (a) The application standard to be used togother with any supplementary requirements (b) Specification ofthe parent metal end of the required wold metal and welded joint properties. {6) Locations, dimensions and detil i. form of joint, angle between fusion feces, gaps betwen parts, tc. of ell welds. NOTE. When symbol ar ua for tandor wale forms, {hey shuleleontorm to BS 499 Part 2, (d) Whether the welds are to be made in the shop or elsovrne (0) Whathor written welding procedures are required {soe louse 20), (1) Whether welding procedure approvel testing required (500 clause 22). (gl Whether means of identification to enable welds to be traced to the welder who made them is required and if s0 the methods to be used (s09 clause 24). 0h) Surface finish of weld profile 40) Quality control arcangoments, 4) Whether post meld hest treatment is required {see clause 28). NOTE, Th tems rte tn thi effec upon the performance ofthe fabrication andthe ourchese? oul oer tat tho roguremente alate sppropriatly fo the Datel ar Joints and Intended erie ite ofthe faieton 3.2 Requirements to be agreed. The following items to be ‘agreed between the contracting parties, which are specified Inthe clauses referred to, shall be fully documented Both the definitive requirements specified throughout the standard and the following dacumonted itoms shal be ‘atisted before a claim of compliance with the standerd ‘ean be made and verted {6 When no dressing isto be carried out, the per vinld profile ifs not snecifed in the application standard (08 73.2). {0} The use of especial method to achieve full penetration without the Use of backing ateral when bate weld is to be welded from one side only (G90 7-4(0)(20 (c) The material for backing when ths is not part of the structure (see 7.6.2. (6) methods other than those speciried in 10.1 or preperation or cuting of material {sce 10.2). (0) Tha naening of welds (se clause 25). {f) The mathod and extant of inspection and tasting in ‘the absence of a relevant application standard (seo 26.2) {g) The acceptance raquirements for welded joints inthe absence ofa relevant application standard (se2 27,2) (h) Whon postaveld heat treatment is required but there isno application standard, tho details ofthe heat ‘veatment to be appli (see 28.2). ible 4, Paront metal ‘The parent motal shall bea carbon or carbon manaanose steel whose chemical composition, in % (mim), determined 4 maximum carbon aquivalent of 1 using the following formula Moy Gemoty, Niscu Cer aan) NOTE 1. This carbon aqivaont formula may not apply toca eo low eartion cortent or boron conaining ste! Carbon equivalent » C + Coppre by Whe BA STandaras Tsao Wed Nov 10 06:49:14 1999BSI BSx5235 84 MM Ub24bb9 OOLI24b 2 mm NOTE 2. Reauiraments are not scifi for carbon manganese ‘els sbove a carbon equsant of 0.58 bouts febretion fexperensa finite, The sedmaker, welcng consumable supple ‘or other appropriate authoritative vee should be conaulted with ‘gard to tho woldng procedures for there sek 5, Welding consumables 5.1 Hydrogen lovels. When hydrogan-controlled welding consumables are to be used, the contractor shall be able to demonstrate that he has used the consumables in the ‘manner recommended by the consumable manufacturer and that the cansiimablas have been dried or baked to the appropriete temperature levels and times. 52 Manual metaae welding. Electrodes sal be sects having regard to the pertieular application, i. joint design, ‘welding position and tho properties required to meet service conditions (sve 3.1{b}), Whare thera ies British Standard applicable tothe electrodes solected, they shall ‘comply with and be coded in accordance with that standard (e.g. BS 639). 5.3 Covered electrodes for semi-automatic, automatic end imochanlzod motal-are wolding. Tho weld motal produced ‘rom covered electrodes used with semi-automatic, automatic and mechanized metal-are welding processes® shall nave mechanical properties not less than tho ‘minimum specified forthe weld metal praducad by electrodes complying with 8S 639 having regard to tho particular appli Joint design, wolding position and the properties required to moot service conditions fooe 9.1(6)) 5.4 Submerged are wolding. Electrode wire and flux combinations for submerged are welding shall comply with the appropriate sections of BS 4165. The combination shall be selected having regard to the particular appli ke. joint design, welding position and the prow tes Fequired to mect service conditions (se 3.1()). BB Gasshielded processes 6.6.1. Fillo rods and wires. Whore a solid metal filler rod or ‘wire Is used with a ga-shielded proces, it shall comply ‘with BS 2901 : Part 1 and shall be selected having regard to ‘the particular application, ie joint design, welding position and the properties required to meet sarviee conditions (ee 3.1(b)). Cored electrodes, when used with the appropriate shielding {2s or gas mixture, shall be selected having regard to the particular application, ie joint design, welding position ‘and the propertins required ta meat service conditions (ioe 3.1(b)). 5.5.2 Shielding gases. When a ges or gas mixture Is used, It shall bo of the following quality, as appropriate: {@) argon complying with 8S 4365; {U) carbon dioxide complying wlth type 1 specified in BS 4108 (6) gas mixtures that have been proved to be satisfactory 52 result of eithor experince or procedure approval tests, 8.6 Unshielded semi-automatic are welding. Electrodes for tunshialded soml-automatic are welding, which are usually of the cored typa, shall ha salacted having regaed to the particular application, ic. joint design, welding position and the properties required to meet service conditions we 3100). "ne group of processes ambraces raity end suto-contat welding with Iong eight argh of eavered electrode and open with = Continuous covered alctrode, Copyright by the British Slandards Isittion Wed Nov 10 06:49:15 1999 BS 5135: 1984 8.7 Storage and handing 5.7.1. Generat. All consumables shall be stored and handled with care and in accordance with the manufacturer's recommendations. Electrodes, filler wires and rods and fluxes that show signs of damage or deterioration shall not bo weed. NOTE, Exampies of damage or deterioration include ercked or Make costings on covered eloctrodas, runt or ty seetode wie fred he ith faked or Semeped copper Coming 8.7.2 Covered electrodes. Electrodes shall be stored in thee original eontainers in dry, preferably heated placa adoqustely protected from the effects of the weather and accordance withthe manufacturer's recommendations When special protection or other treatment during storage or immodiatsly prior to use is recommended by the slectrods manufacturer, they shal bo treated in accordance with the conditions detailed by the manufacturer In order to ensure that the weld metal deposited by hydroger-controlledsloctrodos falls within the Hints of the appropriate scale as specified in clause 21, the drying or ‘baking conditions indicated by the electrode manufacturer shall be followed. Electrodes shall be removed from thelr original containers before drying or baking. Aftar removal from the oven, the electrodes shal bs protected from exposure to conditions conducive to moisture absorption. NOTE 1 Ifthe lowest hydoge levels raced it may be recesary for welder tobe lave with electrode in quer sealed concanar. Electrodes returned to stores shall be treated in secordance with the electrode manufecturer’s recommendations before NOTE 2. letrodes have ben exposd 1 poor storee conditions ort seuspected that hay have become damp, the edvoe ofthe 8.7.3 Semi-automati, automatic and mechanized welding. Wire or cored eleatrodes shal be suitably packed to guard against damago, including that during transportation, When stored, the wire oF electrode shall be kept in its ‘otiginel bundle wr package in dry atoreroumn NOTE. The performance of eoppor coat wires dapends on the Contuly an asaya copper ann Ti ten not ‘pleats Such coralderetions dnoula be agreed betoan he onvestor ad th ppier. Flux shall bo packad in such a way that its proteoted from moisture pick-up and damege, including that during ansportation. Flux with @ guaranteed moisture level or siving «controlled hydrogen lovel as deposited shall be pecked in moisture resistant containors. When stored, ‘the flux shall be kept in its original contalner in @ dry storeroom, the compostton of the flux Is such thar speotal protection during storage or special trestment before use is desirable, details of such special protection or treatment shall be provided by the manufactur and Implemented by the contractor. 6. Equipment 6.1 Plant. Welding plant, intrumonts, cables end accessories shall comply with the requirements of the appropriate Parts of BS 638. The contractor shall be responsible tor ensuring that the eapacity of the welding vweeingplant and ancillary equipment is edequate for the welding procedure to bo used and for maintaining all welding plant and areillary equipment in good working order. NOTE, The etention of the contactor dra to the ace on Toor no, 98 Clete arc unin” tad by the Heath and Safty Exoctivo and publhed by HM Stationery Office, 6.2 Earthing, All dectica plant in connection with Ue welding operation shall be adequately earthed, The welding return lead from the work shall be adequate in cross ‘s0otion and shall bo correctly eonneotod and earthed. 6.3 Instrumentation. Means of measuring the current shal, bo available, either as part of tha walding pant, or by the provision of g portable ammeter. In the cases of semi-automatic, automatic and mechanized welding, seas shall be provided fox measuring the oe voltage, current and/or wire feed speed. Drying ovens shall be provided with means of measuring the oven temperature, 7. Butt weld details 7A Goneral, The dotalls ofall butt weld, e.g. form of Joint, angle between fusion faces, gap between parts, shalbe arranged to permit the use ofa satisfactory welding procedura and the combination of wold detall and welding procedura shal be such that the resultant joint will comply With the roquirements of the design. [NOTE 1. Guldenoe on design of butt welds Is gen In At opondx Band tablet NOTE 2, Incomol lon but wold Intantonaly hav © throat thickness thats as than the perent mata tlre. “This typo of weld is escoptaba Ir many crcumstoncs, but for rentetdone on eu, S28 A, 7.2 Throat thioknoss. Tho ends of butt joints in plato shall be welded so as to provide the full throat thickness. NOTE. This may be done bythe ute of extension pices or exher ‘eens approved by the purchaer. 7.2 Wold profilo 7.3.1 In the aswelded condition, the weld fece shall be proud of the surface of the parent metal. Where a flush surface is required, the excess wald motal shall be dressed ‘off. When no dressing isto be carried out, the weld profile shail be as specified inthe application standard where It exits, 7.8.2 When no dressing is to be carried out and no ‘applioation standard oxiete, tho weld profila call bo ‘agreed between the contracting partie, 7A Full penetration. Full penetration sinao, V, U, J, ‘bevel or square butt welds shal be completed as described in either (a) or (b: (a) by depositing sealing run of weld metal on the back ‘of the joint, (b) whore these or other butt welds are to be wolded from one side only, clther (1) with tho aid of temporary or pormanent backing material, oF (2) by agreement between the contracting partes, by the edontion of an approved special method of welding that gives full penetration without the use of eithar type of backing mater NOTE, Undorfetgueconcttlons, permanent backing materia may boundstabe Copyright by the British Slandards Isittion Wed Nov 10 06:49:16 1999 BST 8S#5235 84 MH Lb24bb9 O0b3247 T me 7.8 Backing material 7.8.1 Backing marorlal shall consist of another steal part of the structure when this is appropriate, 7.8.2 When itis not appropriate to use part of the structure as backing material, the matoral to be used shall be agrood between the contracting parties. NOTE. Gora shouldbe ton wen wang eopper sa backing ‘materiel a theres @rsk of copper lok inthe weld etal. 7.8.3 Where temporary of permanent backing material is, ‘employed, the Joli shall be arranged In such a way a5 10 ‘ensure that complete fuslon of the parts to be joined Is readily obtained. 7.6 Back gouging. In all full penetration butt welds, where ‘these are to be welded from both sides, certain welding pprncadurae allaw thi ta ha dena without hack gouging but where complete penetration cannot be achieved, the back ofthe first run shall bo gouged out by sultable ‘meane to loan eound motal boforo wolding le tartod on. the gougod:-out side (se figure 1), 8, Fillot wold details A filet weld, at dopositad, shall be not less than the specified dimensions (see 3.1(c)) which shal be clearly Indicated as throat thickness and/or leg length as ‘eppropriete, taking into aecount the use of det penetration processes or partial preparations (Gee clause 14 and, for gu'danc, appendix C). For concave filet welds, the actual throat thickness shall be not les than 0.7 times the specified lag langth (see 3.4(c)). For convex fillet welds, the actual throat thickness shall be not more than 0.8 times the actual leg length. Where the specified leg length (see 8.1fc) ofa filet wold at the edge ofa plate or section is sich that the parent metal does not project beyond the weld, melting of the tuter corner oF corners, whish redueos tho throat thiclines shall not be allowed (see figure 2). NOTE, Guldanee onthe dosgn of filet welds is gvon in A.2. 9, Welds in stots Because of the lek of cracking, slots shall not be filled with weld metal unless required by the applicetion standard, Slots that are required to be filled with wold motal shall only be filled efter the fillet weld has been inspected and approved, 10. Proparation of joint facos 10.1 If proparation or cutting of the material Is necessary, ‘this shall be dono by shearing, chipoing, ringing, ‘machining, thermal cutting, thermal gouging or an alternative method agreed in accordance with 10.2. ‘When shearing is used, the effect of work hardening shall be taken into account and precautions shall be taken to ‘ensure that there ls no eracklng of the edos. Inthe eases where the cut edge is not 2 fusion fas, ‘the effect of embrittlement from shearing, thermal cutting (oF thermal gouging shall not be to the detriment of the performenee of the fabrioation,A, IN » o wo (a) Fler sie wolded a wv (©) Beek of frst run gouged Out to cean metal GN a ai 16) Second side weldoe BSI BS#5235 84 MM Ub24LEA OOb3248 L a BS 5135: 1984 S wy ca Figure 1. Diagrammatic representation of method of gouging out full penetration butt joints welded from both sides (0) Desable le} Not sceotabe becauo of reducad thant thickness Figure 2, Fillat welds applied to the edge of a part NOTE, Local hardoning can be reduced by suitable thermal {woatment or ramoved by mashanlel means Te sennrat uf {Tram to 2mm rom et feos normally eliminate the ayer of hatdnas. When using thermal etn, loca hrdning ean be ‘auc by reduction in arma eutng speed or oy preheating bare cutting, The steel supplier shouldbe congue for reeommendations on achleving «redveon in hare 10.2 Methods tor prepatation or cutting of the material other than by shearing, chipping, grinding, machining, ‘thermal cutting or thermal gouging (a rafercad to in 10.1) shall only be used by agreement between the contracting patties. Copyright by the Britis Standards lst Wed Nov 10 06:49:17 1999 (b) Acceptable becauss of fll throat hiker 11. Fusion faces 11.1 Tho proparation of tusion faces, angle of bove, root radius and root face shal be such that the limits of ‘ccuraey required by the appropriete application standard: ‘can be achieved, NOTE. When no appropiate apicetion standard exists, its recommended that, For marwal welding, te toleteness an lit of {9 and root fac shouldbe = Tau an te spesnd dmansione fee 9.4) for material up to and Inclusing 12mm thick and "Zone fr mater over 2mm thick The tolerance on the Inoludae enale batten th fusion fetes ofa V preparation fs recommended to ba #5 and for Uand J preperation: #10", 0°, 1 proces, clone limite ncaery ‘which dopend on th charters of the proces,BS 6135: 1984 11.2. Fusion faces and adjacent surfaces shall be free from cracks, notches or atherirragilarites which weld Interfere with the deposition of the weld or be the cause of fects. Any ropair to fusion feces shall be carried out In asoordance with the roquleemonte of thie etanderd. 11.3 Fusion faces and the surrounding surfaces shall be {oe from heavy scale, moisture, oll, paint or any other substance which might tect the quality of the weld or Impade the progress of welding. NOTE. Thi particularly important winens hydropancontrolled tneidingproois fuses, Certain ropelry protect coatings aro Specially formuleted with se Intention that thay snculd not Interfere th welding, The ute oF eh coating not exeludod by the realnanete ot ti louse bf 9 axlod by the purchoter, the contractor should demonstrate tele seaptebilty by means of ‘peciman vide lve BS 6064) 12, Assembly for welding Parts to be welded shal be assembled such that the joints ‘0 be Welded are easly acezssiole and visibie to the operator. NOTE. Jigs end manipulator should be uted, where pretissbl, at th welding can be cari out in the mast eltebe postion, 13, Alignment of butt joints “Tho root edges or root faces of but joints shall not ba nut of alignment by more than 26 % ofthe thickness of the thinner matorial for materiel up to and including 12.mm thio or by moro than 3 mm fer material thik than 12mm. NOTE. For certain applsations and welding processes, one alr nay be nace 14. Fitup of parts joined by fillet welds “The edges and surfaces to be joined by fillet welds shall bo Iivas close contact as possible sinee any gap increases the rlek of eradking, but In no caso shall the gep exceed 3 mm. NOTE, Consideration should be given tothe noe to irereate the Teg length of te ot wel to corporsts for lage aap (ee clare 8 an for guldsnc, spony 18. Tack welds ‘Tack welds shall be not less dan the throat thickness oF {eg length of the root run to be used inthe joint and shall bb subject to the same welding conditions as those specified inthis standard for the root run, The length ofthe tack Weld shall not be less than four times the thickness of the thicker part er 50.mm whichaver isthe smaller. Where a tack wold is insorporated in s welded joint, the shape of the tack shal be sultable for incorporation in the finished weld, and I shall bo free from eracks end other deposition faults. Tack welds which crack shall be cut out (soe clause 28), In joints welded by an autometic or mechanized process ‘oF where smaller tack wolds are desired, tho conditions for deposition shall be as given in clause 21 16. Temporary attachments 16.1 Wolde for tomporary attashmonte chal bo made In accordance withthe same requirements of this standard that apply 40 permanent welds NOTE, Temporary attachments should be remote from pineal Joint as fr ex practeabie ‘Copyright by the British Standards Institution Wed Nov 10 06:49:10 1999 BSI BS*5135 84 MM Lb24bb9 OOL3245 3 mm 16.2. Whon wolded attachments used to facilitate construction are requlred to be removed, this shall be done carefully by cutting or chipping and the surface of the ‘matetal shal alvvays be finished smooth by grinding fellowod by surface erack detection. Temporary attachments shall not be camoved by hammering. 17. Protootion from tho woathor Surfaces to be welded shall be dry. Whenever thers is any ‘idence of condensation taking place on metal surfaces, ‘warming shall be carried out to remove such condensation. Inany ease no welding shall be carried out on parent metal below 0 °C, Whon rain or snow is felling, or during periods (of high wind, necessary precautions shall be taken to protect outdoor welding areas. Draughts shall bo prevantad ‘rom blowing along the hares of structural hollow sections when the bore will be penetrated during welding. ‘Where gasshielded welding processes are being used, sir curents at spac Low a 8 kin! can remove the thielding gas, and therefore suffleiontserooning shall bo used to keop winds and draughts away from the welding 18. Stray arcing on work Precautions shall be taken to avoid stray arcing which can (a) between the electrode and the work away from the ‘weld preperation; (b} between the electrode holder and the work: (c) between the work and the welding earth return load connection: {4} botwoon tho work and any part at earth potential (e) with semiautomatic, automatic and machanized Wwalding, between parts of the welding head or torch (9, (0080 contact mie in MIG gun) and the workplecs (f) with TIG welding, between the tungsten electrode and the work. NOTE. Locel hard spots or cracking produce by stray acing may read to be remota by mechanical eens snd ba choekoa Dy Inspection aftr consultation brtunan the contracting partes. Femoved hard soot mey be meds good by tha depostvon of wold ‘meta in socordance wth thie stander Items be) and Copper. Ta contammated ar may be bite and/or cracked due { intergranule panetrtion of coppar, Thee arms shoul be removed by mechenlcl means voided by afm een conmcrion ictsios inthe workpiee, This the inclusion are large ond angulo or sumorous they should be removed by mechanical means 19. Inter-run cleaning whore 2 process generate slag to protect the wold metal, 2.9, manual metal-are and submerged arc welding, this slag shall be removed from each run of weld metal before a further run is superimposed, particular attention being paid ‘0 the junctions between the wold metal and the fusion ‘aces. Visible defects such as cracks, cavities and other deposition faults shall be removed before the deposition of further weld metal.20, Details of welding procedure ‘When written wolding procedures are required by the purchaser they shall include such ofthe following items as are relevent: {a) Welding process or processes when fore then one 's.used in making a complete joint. (©) Paront metal specification, thickness and other levant dimensions. {e) Whethor shop or sito wolding, (a) Cleaning, deareasing, etc. (6) Classification. type and ‘consumables, {f) For manual welding, te size of electrode, welding ‘current and length of run por electrode oF fillet weld eg 2 of electrodes and other automatic and mechenized welding, the size of electrode, ‘welding current, are voltage, spood of travel, wire feed speed, electrode extension of fillet weld log length and ‘number of runs and rate of flow of ges and/or consumption of other process material, a& appropriete. ‘When applicable, the temperature and time adopted for Aous}yJ9 40 ‘seponnsa)9 403 Sona znouny pue sypfu9} uMy “OL a1qeL Vv -| =| os -| = gyn S|) = or -| = st -| = or sel - st se} - zz so} ~ oz oa} ah Copyright by The Bash STandaras Tatton Wed Nov 10 06:49:25 1999BSI BS*S235 64 mH L624G69 0063259 6 mm ag 6196: 1984 Veer eel eo se | oie | ses | ace 80 cis) coc | oze | ocr 60 =| aze | occ | 00s | 10 =| 086 | sve | 000 oro =| czex| oso} ose oe 200 =f | =] 000: oy 08 a wu} wus] aw] ene saa ee a] eof | e[ *| «| « = a{ ee]. 9] os) oe] ze uu “saueyp yo pongo 20} oper noun ‘sess Joaponsep wes gy &J0 wi OLY Waxy Sut un | ABsaus ory [e€9 Sa YIIM BuLAjdUI09 % DEL Spue % OLE <, AoueIOL 30: seponn29j9 40} sojes snouna pue sip6ua] uny “LL ere, Copyright by the British Slandards Isittion Wed Nov 10 06:49:26 1999BST 8S*5135 84 MM 16246649 0063260 2 me BS 5135: 1984 tiiterteies 7 a} es] 9] s| | zl oz ‘anu “siouesp jo eponsae 20 one IouR ‘uur smeumpjo @pessere axa QGy #0 une QL wos AEN] ame | AACS SAY GE9 $a HMA BULA|aWIOD % OGL < AnUaIONJa Jo ‘s9po.n99j9 203 somes anouns pue stpéuo} UNY “Z| O1Ge], V Copyright by the British STandards Tastitotion Wed Nov 10 06:49:26 1999BS 6195: 1904 “BSI BS*5)35 64 MM Lb24E69 OOb32L) 4 mm Table 13, Values of arc energy for the manual ‘motal-are welding of single run fillet walds (sce 21.2.7) ‘Minimum | Are onoray for eectrodos to BS 639 with Toatanath | covering types und electrode efilencles RandAR |B ‘Rend AA 190% mm afm | alm | alm 4 10 13 = 5 14 17 og 6 20 22 rr a 28 a4 16 10 38 50 23 2 55 66 3a ‘combined thleknass = +4 + h 4 = verge thickens here longth of 78m ie T 1+ Da Combines thieknes = 245 P8 Copyright by the British Standards Institution Wed Nov 10 06:4927 1999 t ae 7 vel et, neo 4 es hleh) bleh) 4 or utansouny deposited seareeertarmet LL ee ee 0) Oy Figure 3. Examples of combined thickness 18 Tvojeanae woqo parm jo [55 BuIpjem 4 suoRIpUED “y ainBLy svo| two} ovo] seo 8S 5135: 1984 svo| ovo| sco] veo [e242 205) ono abospAH BSI BS*5135 64 MMH Lbesbb9 OOb32b2 bom « up fBs01 224 uur} KB.oue 22y 1 fo 02 os oot 2inye.pduay Suyeouaud 0 ‘un 22 amnjesaduay [O — Buysnyaud: ‘UR, oe fal 9 uw ssauypius pauiauos ay wu ss@uy2ity pauiquos oot oo 002 OS SE Copyright by The Brtsh Standards Tasitotion ed Nov 10 064920 1999BSI BS#5135 64 MM Ub24G69 OObI2b3 & mm bs 5195: 1984 ww ssaurpiyy pauiquoy 1 ‘Are energy kiln z = ¢ ww sseuqayy peugaoy 20] #2 8 #8 o 20 Copyright by the British Slandards Isittion Wed Nov 10 06:4929 1999 ttt fe. ge itt = & je £ z 3 F — | 4 LSS alee % a Biae #2 ¢@ ¢e 8 ¢ © & o 8 3/8 i g\s i).[3/3 il late 2/ O0b3272 9 “BST BSx5135 64 MM 1L24 Appandix A, Guidance on design [NOTE 1. Typical appliation standards covering wale dasign aspects sre BS 183° Part 3B Bx, and BS 4a0 = Pert 2. NOTE 2, Particular auldance on design to avoid amllrtaring Is ven in appendix G. ‘A.A Butt joints (soe also appendix B). Butt joints between berts of unequal eros section arranged inline wil result in local increase In stress in addltion to the stress concentra ion caused by the profile of the weld itself. Ifthe contre planes of the two parts joined do not coincide, local banding also will be induced atthe joint. Ifthe stresses Induced by theto affeote aro unaeceptable, then the parte chould be shaped so a8 to reduce the strestes, Examples of plain and ped parts are shown in figure 6, where (a) and (b) are ‘te more common types with (c) Beng a special contigur ation to facilitate non-destructive testing. The slope of the ‘taper should be based on design requirements. f no such, Tequitement i stated, its recommended that the slope should not be steeper than 1 in 4. ‘An Incomplete penetration butt weld which Is welded from ‘one side anly should not be subjected to a bending moment. about the longitudinal axis of the weld which would cause the root of the weld to be in tonsion, unloss thi I allowed by the application standard, “The use of Incomplete penetration butt welds to resist repeating or alternating dynamic forces should be avoided where possible but, where they are used, the design stresses should bo suitable forthe loading conditions. Welded joints subjected to fluctuating loads should be designed 90 thatthe stresses satisfy the requirements of [BS 6400 : Part 10, A.2 Fillet walde. The affective longth of an open ended fillet weld should be taken as the overall length less twice the log length, thereby discounting the contribution of the stop and start positions whieh are generally of reduced profile. In any case, the effective length should not be less a wo {c) Specttcontgueation to fetta nondestructive testing. Figura 6. Butt joints of unequal eros section 29 Copyright by The Brith Standard Tstittion ed Nov 10 06:49:96 1999 BS 5136: 1984 than four imet the log length Flt wold terminating at the ends or sides of parts should be returned continuously around the corners fora distanes of not less than twice the Teg length of the wold unless access or the contiguration. render this impracticable. This procedure is particularly Important for fillet welds on the tension side of parts carrying a bending load In fillet welded joints carrying a compressive load, it should ‘not be assumed that the parts jolned are in contact under ‘the joint, For critical applications the use of a partial or ‘ven & full penetration weld should be considered, Asingle fillet weld should not be subjected to a bending ‘moment about the longitudinal axis of tha joint which ‘would eaute the root of the weld to bein tension, ‘Where fillet walds are used in slots or holes through one or ‘more of the parts being joined, the dimensions ofthe slot, ‘or hole should comply with the Following limits in terms of the thlekness ofthe part or parts in which the slot or hole is tormes, (a) The width or diameter should be not lass than three ‘yes the thickest 28 mm, whichavae i Hho greater {b) Corners at the enclosed ends of slots should be rounded with ¢redius of not ass than 1.8 times the ‘thickness or 12 mm, whichever is the greater. (@) The distance between the edge of the part and the 9690 of the slot or hole, oF batween adjacent slots oF holes, should be not less than twiee the thickness and not loss than 25 mm for hols. Fillet welds connecting parts, the fuston faces of which form an angle of more than 120° or lass than 60°, should not be raed upon to transmit caleulated loads at the full working stresses unless permitted to do so by the pplication standard. “The design throat thickness ofa flat or convex fillet wold ‘connecting parts, the fusion faces of which form an angle ff hetwann 60" and 120, ray he eerie by multiplying the leg length by the appropriate factor as given in table 14.BSI BS*SL35 64 MM LL24Lb9 003273 0 mm BS 5135: 1984 Table 14. Factors for deriving design throat thiolnoss of flat or convax fillet wolds ‘Angle botwoon fusion tows | Factor degreos 60t0 90 07 81 to 100, 065 101 to 106 08 107 t0 113 oss 114 to 120 05 Due account should be taken of fabrication, transport, and erection stresses particularly for those fillet welds Which have been designed to carry only alight load during servic, Compound welds, consisting of a butt weld plus a fillet wold, should be treated a a fillet weld for fatigue consider ations. Welded joints subjected to fluetuating loads should 'bo designed 20 that tho stresses setafy the requirements (of BS 6400 : Part 10, Appendix B Guidance on butt welds (for other than structural hollow sections) Bt Introduction, Tho recommended dimensions of the Preparations ara intonded primarily for manual welding in ‘the fat position for aonoral tyoes of wolded constructions. Sinoe overhead and vertical wolding require manipulation Of the slectrode, comparatively easy access to the root of ‘the weld is desirable for welding in these positions. Thi le obtained by using a wider angle for the weld preparation, ‘or sometimes by inoreasing the root gap. When using ‘leotrodos with a thick covering, some modification to ‘the root dotails of the weld preparation may be necessary. ‘The dimensions may be different for seml-automatie, automa sd welding. B.2 Suitable methods of making weld proparations. Single and double V and bevel preparations may be machined or machine flamo cut, Single and double U and J preparations usually have to be machined, The cholee of ¢ machined or 30 Copyright by the British Slandards Isittion Wed Nov 10 06:49:27 1999 imechine flame cut preparation should be at the option of the contractor except wien specified by the purchver or inthe appropriate application standard. In ssessing the merits of the two methods of proparation and the type of joint, the relative casts of machining, flame cutting and length of weld should be taken into account, B.8 Selection of wold preparation to control dietortion, U and J preparations as compared with V and bevel preparations serve to reduce distortion by virtue of the leszor amount of wald metel required. Likewize, double proparations are better than single preparations in that the wold metal can be deposited In alternate runs in each side ‘of the Joint, In the contrat of distortion, acouracy ot preparation and fit up of parts are important considerations, az well ssa carefully planned and controlled welding procedure, BA Typical forms of weld ‘mainly on the size and type of electrode and the gap ‘hould be ohoten aceordingly. The two joints (c) and (d) are probably the most common butt weld preparations used in general work. A root face Without a gap usualy taciitates assembly and minimizes Contraction. The production ofa sound weld, with or without gouging out of the back of the first run, Is @ function of the gap, root face and the type of electrode Used, More reliabla production of sound welds can be achieved by using back aouaina. While the double V preparations (e) and (f) usually show & saving in weld meta, itis more difficult in these joints to ‘encure full fusion atthe oontro of the weld. It a root face it provided for assembly purposes and ful fusion isa require- ‘ment, adequate gouging out of the back of the first run may be necessery. ‘The single and double U preparations (a), (h} and () are designed to glvo sasy access for the electrode and to ensure ‘00d arcing conditions particularly forthe first run, ‘Single and double J preparations (k) and (I) and single and double bevel preparations (m) and (n) are used where only ‘one joint member can be prepared. Preparations (m) and (n} ‘are used for lessor thicknossos and where plate edges cannot be machined. To oncure wold goundnoss groat care should be exereised, especially t the root ofthe double bevel butt ‘weld,“BST BS¥535 84 MM LG246L9 OOL3274 2 Ml BS 5135: 1984 Table 16. Typical forme of butt wold proparation (other than structural hollow cootione) ‘wasps Typ jm det oe ia ay Flat poston: Shen square 4 thlekrets 7,9 mm to 6 nm; gep G, 8mm. (without backing) t T Horizontal/vertical or vertical position: Welded from both sides 7 thlckness 7,3 mm to § mm; gap G, 3 mm ' Seo clause 11 for tolerances Se ato cous 7 iB pen square All postions. (wth backing) Fort postion ony ‘es or or i wih rg hicknss 7 Gap 6 Decking which my be mm vn titer temporary or pers | ot mm " sont nich one rey ere 5 be part ofthe stuctre or eens Aa ‘an intogral port of ono: member (c) Single V (without backing) Welded from both sides or ane sido only 11 this preparation is used for material over 16 mm thick the gap may be requited to be Inereeted ‘Soo clause 11 for tolerances. See also clause 7 ‘Al positions i eo For flet position only": 2p G, 2 mm; angle a, 60° thickness 7, 5 mm to 12 mm: toot tana RT mm: thickness T, over 12 mm: root face A, 2 mm, See clause 11 for tolerances, Soe also clause 7 @ All positions Single V thieknoss T, over 10 mm. (with backing) For flat position only" Welded from one side with backing whieh may be lthar tamporary of parm: ‘nent in which case it may bo part of the structure of {an integral part of one member @ Double V Welded trom both sides 2mm nex root face PO; single root run ‘28 G, @ mm; anglo a, 45°; double root run: 92° G, 10 mm; angle, 20°, ‘Soe clause 11 for tolerances S00 also clause 7 All positions: thickness T, over 12 mm, For tlet position only” sep G, 3mm; angle 9, 80 Foot fece R, 2mm. ‘See clause 11 for tolerances, See also clause 7. Asymmetre double V Welded from both sides * Tmo dimonsons ofthe wold prepraton moy heve to be modified fr othr process and for wing in positions other than fh Copyrigt by the British Standards Isittion ed Nov 10 06:49:20 1999 1 lisr 31 All positions: thieknoss 7, over 12 mm, For flet position only’ wep G, Sm angle a, 60° See clause 11 for tolerances. Seo also clause 7, the deoper V is wolded first and full root pponetration is required, the angle f may be increased to 90° to facilitate back gougingBSI BS*SL3S OY MM Lb24Eb9 OOLI275 4 mm BS 5135: 1984 ‘Table 15, (concluded) ‘Typleal joint tat Wold type | _imensions ant aur {a} All positions: Single U thickness T. over 20 mm. Welded rom both sides ier For flat position only": ’ { ing 20; TT Tt radius r, 5 mm; root ace Bim, See lute 1 for tolerant San alo clause 7 th) . All positions: Bout , 1 cere 7, ver 40mm Wolded from both sides ) Asymmetre double U Wolded from both sides w Singlet Welded from both sides 0 Doubio Welded from both sides For flat position oly* ‘angle, 20"; (oot face A, 5 mm. See clause 11 for tolerances. See alto clauso 7 All positions thickness 7, over 30 mm, For flat position only*: land £, 6 mm; angle a, 20°: fagiuer, 5 mm; root face A, 5mm. See clause 11 for tolerances, See also clause 7 All positions thickness, over 20 mm. For flat position only* land, 5 mm; angle a, 20°; radlus r, 8 mm; root face A, 5 mm. Seo clause 11 for tolerances, See also clause 7 ‘All positions ‘thickness 7, over 40 mm. For flat position only*: and 6, 5 mn; angle a, 20°; radius r, mm; root face f, 9 rm. ‘Spe clause 11 for tolerances. See also clause 7 Single bevel a im) my 1, Welded from both sides (n) Double bovs! Welded from both sidos ‘All positions. For flat position only*: 99.6.8 mm; angle e, 46°; thickness 7, 6 mm to 12 mm: root face A, 1 mm; ‘hioknoss 7, over 12 mm: root face A, 2 mm. See clause 11 for tolarences, Sa All positions: ‘thickness 7, over 12 mm, For flat position only": 92 G, Am; ea, 45"; root face F,2mm. See clause 11 for tolerances, See also clause 7 Copyright by the British Slandards Isittion Wed Nov 10 06:49:39 1999BSI BSx5135 84 MH LL24LE9 OOL3276 b mm e Appandix C Guidance on typical details for structural hollow sections BS 5135; 1984 ‘Typicel deteils for butt welds for structural hollow sections are given in table 16, Branch connections for crcular and ‘ectangular structural hollow sections for butt and fillet welds are shown in figures 6 to 9. Table 16. Typical forms of butt weld preparation for structural hollow sections NOTE, All preparation are for welding from one sda only and inal pestons Wald ee | Fret ine et Dimensions fa) ness T, up to 3 mm: ‘Square o gap G, 3 mm max. tate bekn) Seat a (b) Thickness T, 3 mm: Sauere ‘xn G, 3mm min. 8 mm max {with backing) ‘hlokness of booking f,3 mm e Thickness 7 8 mi ep 6, Bimmn min. @ mm mex. thicknoss of backing ¢ 3 mm min. Sram max. Thicke 7, ‘pp 6, Br min. 8mm max. thleknas of backing 3 mm min. 6 mm max. {c) in om ey 4 tnt xr) (ANC Thickness 7, up to 20 mm; 9p G, 2mm min. 3mm max; root face A, 1 mm min, 2.6 mm max. (a ‘Thickness 7, up to 20 mm: Single V 2p G, 8 mm min, 8 mm max.; (with backing) Foot fave A, 2.6 mm mans: thickness of backing x, 3 mm min, 6 mmn max (e) Thickness T, 20 mm to 30 mm: Single V ‘9a G, Bimm min, 10 mmm max. flame cut preparation root face A, 3 mm max.; (with backing) thickness af baking 7, mm min. 10 mm max. 33 Copyright by the British Slandards Isittion Wed Nov 10 06:49:39 1999 Thickness 7, 20 mm and over ‘939 G, Bmam min, 10 ram max root face A, 3 mm max.; thickness of backing ¢, 3 mm min. 10 mmm max.BSI BS*5135 84 MH Lb2ULL9 OOLI27? 8 mw BS 6135: 1984 Table 16, (concluded) Weld type ‘Typleal joint deal Dimensions (a) Single bevel (without backing) Thickness 7, up to 20 mm: 920 G, 2.6 mm min. 4 mm max.; foot face R, 1 mm min. 3 mm max. Double angle bevel {with becking) Copyright by the British Slandards Isittion Wed Nov 10 06:49:40 1999 34 (hy ‘Thickness T, up to 20 mm Single bevel 989 G, 5 mm min, 8 mm max.; (with backing) root fa09 A, 3 mm max; thickness of backing t, 3 mm min. 6 mm mex. a ‘Thickness 7, 20 mm to 30 mm: Elingle bevel 2p @, 8 nam main. 10 mm man. flame cut preparation root face A, 3 mm max.; (with backing) | thickness of backing z, 8 mm min, 10 mm max, 0 ‘Thickness T, 20 mm and over: thickness of backing t, 3 mm min. 10 mm max.BSI BSxS135 84 MM Lb24Lb9 003278 7 BS 5135: 1984 tte25ag vozsaa my bt to25 mn i 7 ut ten stan ae 2to 3mm ooo taa0 woe ner oe woe beatert nite Ea tama a — fale coe 7 125 an Y ae rh ae i oS { wo | \ aco Dew at ¥ NOTE, Tho angle of intoresotion 9 of the axes ofthe ereuler hollow ae Inetion has buen demonstrated, ns shoulé net bo lets than 90° unlosadaqusteoffiieny ofthe e@ Figure 6. Branen connections for circular structure! hollow setions: but welds (thikness up to 30 mm) 35 Copyright by Ue Britis Standards Institution Wed Nov 10 064941 1999BSI BS*SL3S 64 MMH LL24bb9 0063279 1 mm BS 5135: 1984 L a vee 2, L bora atx Detain at Dotaitat 2 Forth omar angles = Les tonath Intended proved ‘hore adequate. {host tleenes Cried or engi ut branch Filet weld Gap 3mm mex. NOTE 1. Leg lengths shoul be such that the strates fot wal ara in aocordane with th permis steteglven Inthe eovent eran thatthe welde wil rane the ‘pplication st NOTE 2. The argo of Intersection ofthe exe f the citculaehalow sections sould not beets than 20" unlesedsauate etisiany of the juetion Figure 7. Branch eonneotions for lroular structural hollow szetions: fillet welds 36 Copyright by the British Slandards Isittion Wed Nov 10 064942 1999BSxS135 84 MM L24Lb9 003280 6 mm BS 5135: 1984 a Re 1 trod + 2to3mm 2to3mm Winere d= D fea Forte solo andes full pene trim anne lon 0 ofthe exee ofthe rectangular hollow section should not be les than 20" ules aqua officloncy of the junetion has boon demonstrated Figure @. Branch connections for rectangular structural hollow sections: butt welds 37 CCopynet by Ue Betis STandards stitution Wed Nov 10 06:49: 1999BSI BSx5135 64 MM DL24b69 OOL326) T A BS 6135: 1984 A bk £ ie ' AL 2mm max. os i) 4 ee 0-60" tooo" Werod9 >15 25 60 45 20 <9 <15 35 70 60 > 100 <6 <10 45 80 a > 100 <3 <5 5 > 100 > 100 > 100 “ppm mime 30BSI BSx5135 84 MM LE24b9 O0b3263 3 mm BS 5135; 1984 E.2 Hydrogen seales. The following is general guidance on ‘tha soloction of the appropriate hydrogen scale for processes other than manual metal-are welding Solid electrode wire for gasshielded aro welding should be ‘ured with reale C unless otherwise assessed, This sale should be used also with other sultably assessed consum- ables after appropriate drying treatments, as rexommended bby tne manutacturer. TIG welding should be used with seale D, This sale should flzo be used with other suitably assess consumables after drying or othor treatments, eg. clean solid electrode wires for gas-shielded aro welding, and some basié covered slectrodes after drying at temperatures recommended by the manufecturer. It should be noted that on occasions these temperatures could exceed 400 °C, ‘Submerged are welding, flux cored wire welding end ‘continuous covered wire welding consumables can have hhydrogen levels corresponding to any of the scalar A 10 0 ‘and therefore need assessing in the case of each named product. .3 Conditions roquiting more stringent procedures. Welds made involving any ofthe following fectors may require the use of more stringent welding procedures than. ‘those dorived from 21.2. {a) high restraint; (©) thick sections; (c) low carbon equivalent steels; (A) alloyed wold mota; (eh ‘lean’ or low sulphur steels, ‘Adequate quantification of the effeots ofthese factors on ‘the need for a more stringent procedure and on the chang to the welding procedure required to avotd cracking cannot ‘ba male at the present time. The fallowing should therefore bb considered a8 guidelines only. Joint restraint isa complex function of section thickness, ‘Wold preperation, geometry, and the sittness ot the fabrication. Welds made in section thicknesses above approximately 60 mm and root runs in double bevel butt Joints may require mare stringent procedures. For carbon manganese stels of low earbon content {lees than sbout 0.10 51) the earbon equivalent formula specified in clause 4 does not adequataly indicate the risk. . Thus welding procsdures for suah stools may ro modification, In adtion, welding procedures ved from 21.2may not be adequate for avoiding weld ‘motal hydrogen oracking when welding steels af low carbon ‘equivalent (less than approximately 0.42). This is more Tikely to be the casa wihon welding thick sections ‘greater than about 60 mm) and with highar yi ‘Tho uss of alloyed weld meta or carbon manganese weld ~ metal with a manganese content above, ely 1.5% _may load to higher operative stresses. Whi pot Ts aes an inereasad rk of heataffecweszone cracking, the sid pam ld oneal be hraerand more sssetbe Recent experience and research has Indicated that loworita: the inclusion content ofthe steel, principally by lowering the sulphur content (but also the oxygen content) may. increase the hardenability of tho steel. From a practical point of View this effect may result in an ineraase inthe hardness of the heat-ffected zone, and possibly a smell Incroaee in the risk of heat-effected cone hydrogen erucking. Accurate quantification of the effect is not presently practicable but some increase in hardness (and risk of heat: tp. = 1 enim? Copyright by the British Standards Isittion Wed Nov 10 084045 1999 atfacted zone hydrogen cracking) might be observed In ‘stools with sulphur loves loss than approximately 0.008 % (nimi. ‘Although modifications to the procedures derived trom 21.2 ‘to deal with welds involving the above factors can, in principle, be obtained through a charge in arc energy of reheat or weld hydrogen level, the most effective malt cation is to lower the weld hydrogen level. This can be done either directly, by lowering the hydrogen input to the weld (uzo of lower hydrogan welding processes oF consumables), ‘or by increasing hydrogen loss from the weld by diffusion through the use of higher preheat and interpass tempera: tures, and/or by maintaining the preheat 38 a post hoat for a pariod of time after welding. The roquired post heat time ‘will dopend on many factors, but a period of 2h to 3h has “been found to be beneficial in many instances. It is Fecommended that the required modifications to the procedurar be derived by tho ues of adoauats joint simulation weld testing. Ed Relaxations. Relaxations of the welding procedures determined from 21.2 may be possible under the following (8) General preheating. \f the whole component or @ width more than twice that stated in 21.2 is preheated, itis generally possible to reduce the preheating tomporature by up to 50 °C. (6) Limited hoot sink. Ifthe hoot snk is imited in one ‘or more directions (e.g. when the shortest heat path is less than ten times the fillet leg Length) especially in the thicker plate (eg. inthe case ofa lap joint where the cutstand is only marginally greater than the fillet weld leg length, tis possibie to reduee preheating levels (c) Austenitic electrodes. In some circurnstances where tulfielent preheating to ensure erack-free welds is impracticable an advantage may be gained by using certain austenitic electrodes, for example class 19.12.3 ‘r 26,20 in BS 2926 o high nickel alloy. In such cases prehest may not be necessary, especially It te condition Of the electrode coating is such as to deposit weld metal ( containing very low levels of hydrogen. (a) Joine geometry. Close fit fillet welds (whore the gap 1s 0.6 mm or less) and root runs in single V butt wolds may justify relaxations in the welding procedure. £5 Example Stop 1. Deide carbon oquvelent value using tebe 2, 24.241, 2.22 and E:3. Assume soli BS 4960: Grade 0G, not contralled rated “Table 2 gives a carbon equivalent of 0.45. Stop 2. Decide provisionally on walding proces ard ‘consumables Classify ashydrogen scaleA, 5, C of D using 21.2.5 and] tablet to determine which earbon equivalent sel to use. ‘came manual meta are welding ting hydrogen con tell electrodes complying with BS 638, end that the weld hydrogen ove! s appropriate to scale B in sabe 1 Stop 3. Decide whether filet or butt wed and efor to table 2 : Acsime fillet ws ATBST BS*5135 64 MM Lb24bb9 OOb3284 S mm “Toblo 2 rofrs to table 7. ‘Stop 4, Decide minimum specified individual filet lg length required by design drawing. Assume 5 mm, ‘Table 7, HysroganSCATE'B, 8 MIATTED TengUT MENT raqUIes step 5 ‘Step 6, Decide combined thickness of joint to be welded singla run fillet of 5 mm leg lencth. Rotor to 2 ‘Assume caleuleted combined thiekness of 70 mm. ‘Step 6. Return to table 7 and read off the minimum praheat raqulred:hydragen scale B, 5 mm fillet, 70 mim (Gorin thickets reat 100 °C proeat ‘Stop 7, Tables 7 and 13 give arc energy values {see 21.2.6) ‘corresponding to the § mm fillet using the particular ‘electrode chosen (1.7 ks/mm). ‘Tablos 10, 11 and 12 give the electrode size and runout ccanditions which correspond, Thus tabla 11 offers chain Of olactrode sizes and run lengths from 450 mm of electrode ranging trom 3.2 mm dlameter end 148 mm run tength 08 mm diameter and 810 mm run longth. Practical eonsidoratione would probably limit this toa maximum diameter of 6 mm olactrode and corresponding run length of 366 mm, Varietion at stop 3 Step A. Assume bute Wald Table 2 refers to figures 4(3),4T@V-ATaT ane aD, Figure 4(q) s rolovant to 0.48 carbon equivalent ahd fyarogen scale 8. Stap 8. Decide mii i dinenelon to bo used ‘making butt weld, Thigwil most often be the root ru ‘Assume 4 mm electrode to be run out in about 320 mm of tun langth Rotor to table 11. This gives minimum are energy for Individual runs forming the butt weld of 1.2 kJ/mm. ‘Step C. Decide combined thickness of butt joint, referring to 21.28. ‘Assume calculated combined Uhicknwss of 60 mm. ‘Step D, Return to figure 4(g) and plot coordinates of 1.2 kl/mm are energy and 60 mm combina! thickness. Read off minimum preheating and interpass temperature required (by Interpolation, if necessary, or by reading the preheat line Immadiately above or tothe let of the ‘egordinatod point) which in this example is 100 °C. Veriotion at althar step 7 or steo D. tn the event that preheat is undesirable, proceed as follows. ‘Stop W. Re-exemine figure 4(q) to determine minimum are energy Yor no preheat (20°C line, normally). For fillet example: 2.2 ki/mm For butt examples 1.6 kifmm ‘Stap X. If by reference to table 11 these aro energis are ‘easble, proceed using electrode diameter and run length chosen from table 11 If not feasible, proceed to steo Y. ‘Stap V. Using table 7 for tho fillet weld exemple and figures 4[a) and 4{e) for tho butt weld example, examine the feesbility of using lower hydrogen levels (by the use of higher eleowode drying temperatures or change of corsutn ables) to avold the need for preheat at acceptable arc energy ovals. BS 5195: 1984 Appendix F Guidance on solidification cracking F.1 Solidification cracking of the wold motal is usually found as contraline cracking. Ite mors often found In root runs and, although frequently open at the surfeoe and visible after deslagging, may be just belove the surface and Covered by up t0 0.8 mm of sound metal. Solcifieation cracks can be deep and can soriously reduce the efficiency ‘of a joint. When welding caroon manganese steels, this type ‘of eracking Is most commonly found in submerged arc welds, rarely with manual metal-are welding but can sometimes be a problam with gat and salf.shlided processes. F.2 Solidification cracking is xsociated with impurities, pertioulerly sulphur and phosphorus, and is promoted by catbon picked up from the parent metal at high dilution levels whilst manganese reduces the risk of cracking Bocause welding consumables are gonerally purer than the ‘materials boing wolded, impurity levels and crack. susceptibilities are usualy greatest in wld runs of high. dilution, e.. root runs of butt welds. To minimize the risk ‘of etacking, consumables ae praferred with low carbon {and Impurity lovle and relatively high manganese contonts. F.3 For submerged arc welds a formula” has be ‘davelopeet in ihich the soliditicatlon crack susceptibllty In arbitrary units known as units of erack susceptibility (UCS) hae boon related to the composition of the weld metal (in % (m/m)) as follows: 230C + 1905+ 76P + 4BNb~ 12.38i~ 8.4Mn=T" “This formula Is vad Tor weld metal containing he following: © — 003t 100.28 3 0.01010 0.050 P 0.0100 0.048 Si 18 190.85 Mn 04610 1.8 No 0t0007 ‘Alloying elements and imauritis in the weld matal up to the following limits do not exert a marked effect on values of UCs, 1%Ni 0.02% Ti 05 % Cr 0.03 % Al 0.4% Mo 0.002% 8 007 %V 0.01 %Pb 03%Cu 0.08 % Co Inthe above formula, values of less than 10 UCS indicate a high rotiatanco to orooking and above 30 a low recietance. Within these approximate limits the risk of eracking is higher in weld runs with a high depth/width ratio, made athigh welding speeds or where fleup Is near the maximum allowable. For flat wold runs having a depth /width ratio of about 1.0, UGS values of 20 and above indicate @ risk of cracking whilst for butt welds tho valuos of about 25 UCS are critical. Decreasing the depth/ovidth ratio from 1.0 to 0.8 in fll ‘welds may inerease the allowable UCS by sbout 8. However, very low depth/width ratios, such as are obtained when wetvation into the root isnot achieved, also promote cracking, + ee BAILEY, N, end JONES, 8.8, Solldifization creaking of ferrite tals dirng submerged are velng. The Weng Insti, 197, 1 contort of lee than 0.08 Sta akon a eel 10 O08 %. pat {Coppi by the Bi Staaten Wed Nov 10 084946 1999BSI BS*5135 64 MMH LL24bL5 0063265 7? mm BS5135: 1984 Appandix G Guidance on lamellar tearing G.1. Ganoral, in certain types of joint, where the welding contraction strains actin the through-thickness (short transverse) direction ofa plat, lamellar tearing may ceour, Lamellar tearing ie 2 parent metal phenomenon which ‘occurs mainly In plate material. The risk of eracking is influenced by two fectors: plate suscaptibility and straln ‘across the Joint, With vary susceptibie plate, tearing can ‘cour evan if strains are low, le, in Joint of low restraint, More resistant materials might not tear unless used in situations which impoted very high through-thickness sal G.2 Plate suscepuiity. Since lamellar tearing occurs when ‘the non-metallic inclusions ina plate link up under the influence of wolding strains, plate susceptibility is controlled bby the quantity and distribution of the inclusions it contains. At present there is no reliable non-destructive tachnique for dletecting those inclusions, The short transverse tensle test ‘can be used to assess susceptibility (see figure 10) and the short trarsverse reduction of ares (STRA) has been corre. lated with the incidence of lamellar tearing in different. ‘types of fabrication (se figure 11), In the case of low oxy- ‘00n steals (aluminium treated or vacuum degasted typo), sulphur content has been found to be @ useful quide to the Inclusion content and thus to the STRA. Figure 12 gives tho lTkely lowest and highest values of STA to be expected Ian aluminium treated steel of a glvon sulphur content. ‘The deta are for plate 12.6 mm to 0 mm thick but It should be noted that the relationship of STRA {in %) to sulphur content (in %) Is to some extent thickness dependant Steels giving reduction of area values of over 20% STRA, are considered lamellar wearing resistant and materials with quaranteed STRA are available, Thete are usually eluminium treated steels of low sulphur content, although additions of rare earth or ealeium compounds may also be mede both to Feduee the inclusion content and to favourably altr the Inclusion shap When appropriate, the contractor should discuss with the steelmaker the supply of lamellar tearing resistant ste _Friction welded —“extension stabs Plate material Final short transverse tensile specimen Figure 10. Short transverse ter friction welded extensions ile test specimen with Copynne by the Sntsh Stanaaras Tesutonon Wed Nov 10 064947 1999 G.3 Joint configuration and through-thickness strains, ‘The rick of lamellar tearing fora given steel Increases with through-thickness strain, and the latter is usually high in joints of high tensile restraint. However, tearing may also ‘occur i the bending restraint is low, sinoe angular distortion ‘can ineresse the strain in weld root or toe areas (see figure 13). n some esse, design changes een be made which reduce the through-thicknass strain, Examples ofthe types of detall and joint configuration in which lamellar testing is possible are show in figure 14, typical locations of the cracks being illustrated. If the plate susceptibility is suspected to be high, susceptible joints and detalls should ‘be modified or avoided, For example, the T-ilet (figure 14{a)) is ess susceptible than the T-butt (figure 14(e)) and the set on nozzle Islets eusceptibie than tho ect through ‘nozzle. Also chamfor could be applied to the horizontal plate in figure 141) so that welding stresses would no longer ‘be perpendicular to the plate. Replacing a susceptible plate connection by a easting or forging may also be possible, {In most structures of any size and complexity, some joints will have to be mede in such a way that considerable ‘throughthickness strains ae present. In such cases, lamellar tearing resistane plae Is advisable, If this Is not done and the ‘material is found to be susceptible, buttering with weld ‘metal may enable a sound joint to be achieved by taking un contraction strains in the non-susooptible buttering layer, although this method cannot be guaranteed to prevent lamellar tearing, G4 Hydrogen orecking and lamellar tearing. Although lameller tearing can oceut even wien very low hydrogen, levels (caie D) are achiovad, defects can be formed by combination of the two mechanisms, so low-hydragen precautions {scale D conditions), e.9, very law hydrogen rocesses, or high temperatura crying of covered electrodes, In accordance with manufacturars racommendations, are ‘advisable when dealing with susceptible material, particu lariy in the case of repairs. Excessive preheating is often ‘rot beneflelal and preheat snould be applied in ich @ way ‘that it does not increase the amount of contraction across ‘the weld, e.g. avoid preheating only the nozzle In figure 14\a) Plate thickness“BST BSx5135 64 MH De24b69 OOL325 9 Ml es e130: 1964 Probst freedom from teering In any Joint yD ‘Some risk in shiy reine joints, 20 tg. nog irs, joints botwoan sub ly fae STRA% Sarna Tak i oderaly 15 rontrined ints, n box eolumns| al San ik in ay eatbame TY Figura 11. Suggested STRA values appropriate to risk of lamellar tearin (values besed on 6.4 mm diameter specimen) joints of differing restraint Tensile restraint Yeper bound ~ Bending restrai Lower bound fr e 001.020 0.080 O00 Sulphur content % (mim) Figure 12. STRA sant sulphur content for oats Fair 12. Example of etalna in Tol w 12.5 mm to 50 mm thick (inolusive) . : Semana 4 Copyright by The Bats STandards Taittion Wed Nov 10 064040 1999BSI BSx5135 64 MM b24G69 003267 O Mm 2s 5195: 1984 Nozzle fabricated from J rolled plate Rigid plate (a) wozzle treugh 9 ld pte Critical joints Circumferentiat stiffener Cytindriedt vessel Rigid end {b) eeitoner or righ ond ino oyndriol fbiation —=_ aA Critical foin ) gid box section 7 {f1 Comer joint with butt vl (6) Tyolnt with lot welds (6) TJolnt with compound but and filet wolds Figure 14, Details and joint configurations in which lamellar ts hgh dagree of restraint from plats Copyright by the British Slandards Isittion Wed Nov 10 06:49:49 1999BSI BS*5235 64 MMH Lb24bb9 OOb3208 2 A ‘Appendix H Guidance on acceptance levels ‘To feellitte agreement between th ‘where no acceptance levels are specified in an application standard, the arbitrary levels given in tables 18 and 19 may be used for yuldance, bearing iv mind that standard higher than quality category A may be essential for fetique situations in butt joints when surface grinding of welds may be required, ‘These quality categories relate to individual joint, not the complete fabrication. Itis emphasized that the consequences of failure inservice of the particular welded joint in e structure should be the ‘essential basis for deciding which quality category to use and the extent of appropriate non-destructive testing, taking into account whether the weld is designed as a partial-penetration joint. Copyrights by The Bath STandarasTastittion ed Nov 10 06:4950 1999 BS 5135: 1984 {n general, defects buried within the inner half of the cross saotion of a Jalnt are love clgifloant than thoco In the outer quarters, ¢ feature which should be borne in mind when considering rejection of joints that appear to be borderline. ‘Although arbitrary, these estogorles have baen applied successfully in practice and ere besed on other British Standerds as follovre: Quality category A: Similar to the level required for procedure and welder approval (8S 4870 : Part 1 and BS 4871 Pert 1) {class I welding (8S 2633) Class II welding (8S 2971) Similar to the level required for general-purpose welders when ‘there is no approval of procadures (88 4872 : Part 1) ‘uatity caregory 8: uatity category C: Quality sategory 0 46BSI BS*5235 84 MH De24LL7 OOb3269 4 RS 5135: 1984 Table 18. Guidance on acceptance levels for butt joints Notation: Is parant meta thickness 1 Telength of dofct fr Iehignt of aatect vw tawetn of tect usin | a . e > atoaory Winimum | 100% TOS each waldo 10% overa® ane mount of 100 3 vinsl only Vvolumetie hon-datracti tering Creake Not permitted Not permitiedt Not permitted? Not permitted Laokof | Not permit? 6 20 mm: < 10mm 128mm many 100mm | 1 28 Kof length fusion hezmm length of weldorm to erm “Goal say penetration he 2mm rooints welsed fom one ide individual |< 18mmi/ 18mm <7 mam > 20.mm:/ © 20mm wet5iem Tee we 1.5mm weet8 mm £78 mm: 26m wetsmm Une Aearepstolongth < 8% of | Any lenge of group provided | Any ongth of group providea | Notepolieale troup ot | lengthoteroun wnion in turn_| acfacont groupe ore epereted re separated Frater | tenatemauonad 2 Fle lngth | hyiavtonc af tat ‘isthe length of longest date fort 20 rom and by 8 ‘stone of lar 6 th fo tngth of longest detect fore> 20mm Poromty + | Indivigvol poros<2mm | Individuel paras <25inm | Tndiviuel pow <3 wn | Sarfeae porony diameter diameter, diameter <0.25 ¢domoter. | ndvdual por: Localized: <2%by area § | Localized: <8. by area § | Loclizad: <4% by aoa f | <3mm dlomoter for grantor thicknoses Lecalced <4 byeras & UUnaecat | itermitent, O8 mm Tearmittent, 05 rom Intermittent, OS mm Depth <0. ‘maxim Indepth ‘maximum in depth ‘maximum inept 110% ane’ {mn the entry for table 12, dolote ‘with coverings type R and type RR’. Mo ort2 Clause 1. Scope sly 1987 In ines 1 and 2, delete ‘the process of, Alter perograph 2 insert the following new paragraph: “The requirements given in clause 21 aro appropriate only to ‘normal fabrication restraint conditions anc higher restraint situations need higher prehest or other precautions to prevent hydrogen cracking. Some guianes on this i given In appendix E*. aMo 5712, Clause 21.2.3 Hydrogen scales ice In tine 1, befor Mo s712 Clause 21.2.6 Arc energy ae Inthe note delete ‘MAG welding (solid wire): 1.0" and ‘MIG welding: 1.0" and suetitite the following: "MIGIMAG wang (ole, cored Mo 6712 Table 1. Hydrogen scales Ed In the heading of column 3, delete ‘Seale’ and substitute ‘Hydrogen scale’ Copyright by Tie Brits STandards lsittion Wed Nov 10 064954 1999BSI BS*5335 84 BM Ub24bb9 OOb3274 & Ml | erect AMO 5712 Tables 3 to 9 sty 87 In the heading of column 1, delete ‘Seale! andl cubetitute “hydrogen scala” amo 6712 Table 10, Run lengths and runout ratios for electrodes with coverings type R uly 1087 and [I of efficiency < 110 % complying with BS 639 In tho ttl, delta ‘with coverings type R and RR’. ano 5712 Table 11. Run lengths and runout ratios for electrodes with covering type B of uty 18 efficiency < 130 % complying with BS 639 In tho tite, delete ‘with covering type B” and after ‘efficiency’ insert > 110% anc’. amo 6712 Table 12. Run lengths and runout ratios for electrodes with coverings type R. duty 1087 and RR of efficiency > 130 % complying with BS 639 In the ttl, delete ‘with coverings type R and RA’. ano 6712 Figure 4. Conditions for welding steel of stated carbon equivalent sly 1087 For cach of the nino tables associated with nemagrame (2) to (n), in the column headings, olote ‘Seale (see 21.2.3) and substitute Hydrogen scale (seo 21.2.3). ‘uly 1967, iny more stringent procedures {In paragraph 6, delete the first santence and substitute the following: “Tho uso of alloyed weld metal or carbon manganese weld ‘metal with @ manganese content above approximately 1.5 % ‘may lead to higher operative stresses” Delete the last two paragraphs and substitute the following: “Although modifications to the procedures derived from 21.2 ‘0 deal with welds involving the sbove fectors can, in principle, be obtained through a change in are energy or proheat or wold hydragon loval, the most effective modifi cation isto lower the weld hydrogen level. This ean be done either directly, by lowering the hydrogon input to tha weld. (use of lower hydrogen welding processes oF consumable), or by increasing hydrogen loss from the wald by diffusion ‘through the use of higher praheat and interpass temaera- ‘tures, and/or by meintaining the preheat as e posthect for 1 period of time after welding. The required post-hest time will depend on many factors, but a period uF 2 fh wo 8 thas ‘been found to be beneficial in mary instonces. It is recommendad that the required modifications to the procedures be derived by the ute of adequate joint simulation weld testing ano 5712 Clause E.5 Example a Under the heading ‘Step 2', inline 2, after ‘es! insert ‘hydrogen scale’ Under the heading ‘Step 4’, Inline 4, before ‘scale’ insert ‘hydrogen’. ‘Undar the heading ‘Stop 6’, inline 2, before “scala” Insort“hydroger Under the heading ‘Step A’, inline 3, bofore “scale” insert ‘hydrogen. Copyright Dy The BATS STandardsTstitotion Wed Nov 10 06:95 1999BST BS*5135 64 MM LL24Eb9 OOb3295 T am! [Ree = AMO 5712, Clause F.3 ‘uly 1987 In arearaph 1. In the formula, aftor "6.4 Mr insert = wo s712 Appendix H. Guidance on acceptance levels suv 1867 Ator the list of quality eateyories sett Uv folowing ‘NOTE. Thre ino relationship between the ote dslgnations for ‘ality categories end those uted for hydrogen seles” ano 6712 Table 18. Guidance on acceptance levels for butt joints sy 87 In the row for ‘Lack of fusion’ and “Leek of root penetration’, after the entry in column & ‘or quality category D, insert the following oppieble only toloins weld from one vie) oro eas 3 ween Copyright by Ue British Standards lsittion Wed Nov 10 06:4956 1999