CLAUSE 5. FABRICATION
1M:2015
5.25.1.1 Overlap, Excessive Convexity, or Excessive
Reinforcement. Excessive weld metal shall be removed.
5.25.1.2 Excessive Concavity of Weld or Crater,
Undersize Welds, Undercutting. The surfaces shall be
prepared (see 5.29) and additional weld metal deposited.
5.25.1.3 Incomplete Fusion, Excessive Weld Poros-
ity, or Slag Inclusions. Unacceptable portions shall be
removed (see 5.25) and rewelded.
5.25.1.4 Cracks in Weld or Base Metal. The extent
of the crack shall be ascertained by use of acid etching,
MT, PT, or other equally positive means; the crack and
sound metal 2 in [50 mm] beyond each end of the crack
shall be removed, and rewelded.
5.25.2 Localized Heat Repair Temperature Limita-
tions. Members distorted by welding shall be straight-
ened by mechanical means or by application of a limited
amount of localized heat. The temperature of heated
areas as measured by approved methods shall not exceed
1100°F [600°C] for quenched and tempered steel nor
1200°F [650°C] for other steels. The part to be heated for
straightening shall be substantially free of stress and
from external forces, except those stresses resulting from
a mechanical straightening method used in conjunction
with the application of heat.
5.25.3 Engineer’s Approval. Prior approval of the En-
gineer shall be obtained for repairs to base metal (other
than those required by 5.14), repair of major or delayed
cracks, repairs to ESW and EGW with internal defects,
or for a revised design to compensate for deficiencies.
The Engineer shall be notified before welded members
are cut apart.
5.25.4 Inaccessibility of Unacceptable Welds. If, after
an unacceptable weld has been made, work is performed
which has rendered that weld inaccessible or has created
new conditions that make correction of the unacceptable
weld dangerous or ineffectual, then the original con-
ditions shall be restored by removing welds or members,
or both, before the corrections are made. If this is not
done, the deficiency shall be compensated for by addi-
tional work performed conforming to an approved revised
design.
5.25.5 Welded Restoration of Base Metal with Mis-
located Holes. Except where restoration by welding is
necessary for structural or other reasons, punched or
drilled mislocated holes may be left open or filled with
bolts. When base metal with mislocated holes is restored
by welding, the following requirements apply:
(1) Base metal not subjected to cyclic tensile stress
may be restored by welding, provided the Contractor
prepares and follows a repair WPS. The repair weld
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soundness shall be verified by appropriate NDT, when
such tests are specified in the contract documents for
groove welds subject to compression or tension stress.
(2) Base metal subject to cyclic tensile stress may be
restored by welding provided:
(a) The Engineer approves repair by welding and
the repair WPS.
(b) The repair WPS is followed in the work and
the soundness of the restored base metal is verified by
the NDT method(s) specified in the contract documents
for examination of tension groove welds or as approved
by the Engineer.
(3) In addition to the requirements of (1) and (2),
when holes in quenched and tempered base metals are
restored by welding:
(a) Appropriate filler metal, heat input, and
PWHT (when PWHT is required) shall be used.
(b) Sample welds shall be made using the repair
WPS.
(c) RT of the sample welds shall verify that weld
soundness conforms to the requirements of 6.12.2.1.
(d) One reduced section tension test (weld metal);
two side bend tests (weld metal); and three CVN tests of
the HAZ (coarse grained area) removed from sample
welds shall be used to demonstrate that the mechanical
properties of the repaired area conform to the specified
requirements of the base metal (see Clause 4, Part D for
CVN testing requirements).
(4) Weld surfaces shall be finished as specified in
5.23.3.1.
5.26 Peening
Peening may be used on intermediate weld layers for
control of shrinkage stresses in thick welds to prevent
cracking or distortion, or both. No peening shall be done
on the root or surface layer of the weld or the base metal
at the edges of the weld except as provided in 9.2.7.6(3)
for tubulars. Care should be taken to prevent overlapping
or cracking of the weld or base metal.
5.26.1 Tools. The use of manual slag hammers, chisels,
and lightweight vibrating tools for the removal of slag and
spatter is allowed and shall not be considered peening.
5.27 Caulking
Caulking shall be defined as plastic deformation of weld
and base metal surfaces by mechanical means to seal or