Railroad American Welding Society Compress

AWS SAFETY AND HEALTH
FACT SHEET BUNDLE

FOR RAILROAD WELDING
Includes the following concise and helpful

fact sheets from the American Welding
Society’s Committee on Safety and Health
Fact Sheet 18: Lockout/Tagout

Fact Sheet 20: Thermal Spraying Safety
Fact Sheet 29: Grounding of Portable
and Vehicle Mounted Welding
Generators
Fact Sheet 30: Cylinders: Safe Storage,
Handling, and Use
Fact Sheet 34: Coated Steels: Welding
and Cutting Safety Concerns
The following safety fact sheets and the complete 66-page ANSI Z49.1 Safety in Welding,
Cutting, and Allied Processes are available for free download at www.aws.org/safety:
1: Fumes and Gases 22: Cadmium Exposure from

2: Radiation Welding & Allied Processes
3: Noise 23: California Proposition 65
4: Chromium and Nickel in Welding Fume 24: Fluxes for Arc Welding and Brazing:
5: Electrical Hazards Safe Handling and Use
6: Fire and Explosion Prevention 25: Metal Fume Fever
7: Burn Protection 26: Arc Viewing Distance
8: Mechanical Hazards 27: Thoriated Tungsten Electrodes
9: Tripping and Falling 28: Oxyfuel Safety: Check Valves and
10: Falling Objects Flashback Arrestors
11: Confined Spaces 29: Grounding of Portable and Vehicle
12: Contact Lens Wear Mounted Welding Generators
13: Ergonomics in the Welding Environment 30: Cylinders: Safe Storage,
14: Graphic Symbols for Handling, and Use
Precautionary Labels 31: Eye and Face Protection for Welding and
15: Style Guidelines for Safety and Cutting Operations
Health Documents 33: Personal Protective Equipment (PPE) for
16: Pacemakers and Welding Welding & Cutting
17: Electric and Magnetic Fields (EMF) 34: Coated Steels: Welding and
18: Lockout/Tagout Cutting Safety Concerns
19: Laser Welding and Cutting Safety 36: Ventilation for Welding & Cutting
20: Thermal Spraying Safety 37: Selecting Gloves for Welding & Cutting
21: Resistance Spot Welding Z49.1: Safety in Welding, Cutting, and
Allied Processes
www.aws.org/safety
Safety and Health
Fact Sheet No. 18
© 1998 American Welding Society March 1997
LOCKOUT/TAGOUT
INTRODUCTION
Sometimes work must be performed on equipment, pipelines, and machinery that may
contain moving parts, pressurized gases or liquids, electrical energy, or other hazards.
Contact with any of these may result in injury or death.
DEFINITIONS
“Lockout” means to install a locking device that keeps the switch, valve, or other mecha-
nism from being turned on or opened. “Tagout” means to put a tag on the locking device.
The tag indicates DANGER or WARNING, along with a brief message. It has a place to
put the date and person’s name who lockedout the equipment so that he or she may be
easily found or notified.
STEPS TO FOLLOW
• Train employees in the purpose and methods of lockout/tagout.
• Inform the job supervisor about the proposed work, and obtain permission to lockout
and tagout the equipment.
• Shut down the equipment.
• Place locks and tags on the switches and valves to prevent their use.
Note: If more than one person is performing work on the equipment, it is recom-
mended that they have their own locks and tags on the lockout point.
• Have the operator try to start the equipment or open the valves. If the equipment and
valves are not operable, proceed to the next step. If they are operable, check where
the locks should be placed or, if needed, place additional locks to ensure that equip-
ment or valves are not operable. Check the equipment or valves for operation again.
Fact Sheet No. 18—3/97 Page 1 of 2

• Start the work. If the employees’ shift ends before the work is completed, they must
remove their locks and the next shift’s employees must install their locks before con-
tinuing the work and before the previous shift’s locks are removed.
• When the work is completed, ensure that all employees are clear before removing the
locks and tags, energizing equipment, or opening valves.
INFORMATION SOURCES
Occupational Safety and Health Administration (OSHA). Code of Federal Regulations,

Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5,
available from Superintendent of Documents, U.S. Government Printing Office, Washing-
ton, DC 20402.
Mine Safety and Health Administration (MSHA). Code of Federal Regulations, Parts
1-199, available from Superintendent of Documents, U.S. Government Printing Office,
Washington, DC 20402.
For specific information on recommended lockout points for equipment, machinery, and
valves, contact the manufacturer.
Page 2 of 2 Fact Sheet No. 18—3/97

Safety and Health
Fact Sheet No. 20
© 1998 American Welding Society February 1997
THERMAL SPRAYING SAFETY
INTRODUCTION
Thermal spraying processes use modifications of arc, plasma, and oxyfuel energy
sources to produce the resulting heat, atmosphere, and particle velocity needed to prop-
erly coat an object (a substrate) with the desired thickness and properties of a surfacing
material. The high temperatures, velocity, and projectile distance of the spraying pro-
cesses create a unique set of safety hazards for the operator and those nearby.
DEFINITIONS/PROCESS DESCRIPTIONS
According to ANSI/AWS A3.0, Standard Welding Terms and Definitions, Thermal Spray-
ing (THSP) is a group of processes that deposit molten metallic or non-metallic surfacing
materials onto a prepared substrate. All thermal spraying processes introduce a feed-
stock (usually a powder or wire) into a heating device (combustion or electrical). There
the material is heated, blended into the heat plume, and sprayed onto a prepared
substrate. The molten particles strike the surface, flatten, and form thin platelets that
conform and adhere to the substrate and to one another. As they cool, they build up
a lamellar structure to form the desired coating.
Combustion processes include Low-Velocity Oxyfuel (LVOF) and High-Velocity Oxyfuel

(HVOF) systems. Electrical processes are Arc (two-wire), Plasma Arc (powder), and
Plasma Induction (powder) systems. Typical operating conditions for the various pro-
cesses are shown in the table below.
POTENTIAL HAZARDS AND HAZARDOUS EFFECTS
• Dust—Finely divided airborne solid particulate should be treated as an explosive and

inhalation hazard. Adequate ventilation and wet collection of the overspray should be
provided to minimize these hazards.
• Fumes, Vapors, and Gases—Ventilate and use safe practices according to ANSI
Z49.1, the MSDSs, and AWS Safety and Health Fact Sheet No. 1. In addition, most
spray and abrasive blasting operations require the use of an approved respirator that
complies with requirements of ANSI Z88.2. Also, precautions should be exercised to
avoid the presence of chlorinated hydrocarbon solvent vapor in the area of the arc or
plasma spraying. Hazardous phosgene gas can be produced when hydrocarbon
vapors are exposed to ultra-violet radiation from these processes.

Plasma
Induction
LVOF HVOF Arc Plasma Arc (Atmosphere)
Temperature to 5000°F to 6000°F 4000–15,000°F 4000–15,000°F to 30,000°F
Velocity 200–700 ft/sec 2500–4000 ft/sec 800–1100 ft/sec 800–1800 ft/sec 800–1800 ft/sec
(<Mach 1) (to Mach 5) (<Mach 2) (to Mach 2) (to Mach 2)
dBA (Sound 110 150 115 132 132

Level)
Spray Distance 4–10" 6–18" 2-1/2–6" 2-1/2–6" 3–8"
• Noise—The loud noise (high dBA ranges) of these processes must be addressed.
Ear muffs and noise control procedures should be provided to conform to the stan-
dard limits of OSHA 29 CFR 1910.95.
• Radiation—Intense ultraviolet (UV) and infrared (IR) radiation occurs with these
processes. They require total protection of the eyes and all exposed skin to avoid eye
damage and burns. Eye shades of No. 3–6 for combustion and 9–12 for electrical
processes are recommended (see AWS Safety and Health Fact Sheet No. 2).
• Electric Shock—The higher process voltages used in Arc, Plasma Arc, and Plasma
Induction Spraying increase the risk of electric shock. Take precautionary measures
according to ANSI Z49.1 and AWS Safety and Health Fact Sheet No. 5.
• Fire—Use care when handling spray guns during operation to avoid injury to person-
nel or causing fire (see AWS Safety and Health Fact Sheet No. 6).
• Mechanical Hazards—The substrate surface preparation, spraying, finishing, and

post-treatment operations involved with thermal spraying processes present a variety
of mechanical hazards specific to Thermal Spraying. Consult the equipment manufac-
turers’ manuals and material suppliers’ MSDSs for their recommended safe practices.
• Compressed Gases—Compressed gases require safe handling and use as specified

in ANSI Z49.1.
INFORMATION SOURCES
American National Standards Institute (ANSI). Safety in Welding, Cutting, and Allied
Processes, Z49.1, available from American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126.
________. Safety Practices for Occupational and Educational Eye and Face Protection,
Z87.1, available from American National Standards Institute, 11 West 42nd Street, New
York, NY 10036.
Page 2 of 3 Fact Sheet No. 20—2/97

________. Safe Practices for Respiratory Protection, Z88.2, available from American
National Standards Institute, 11 West 42nd Street, New York, NY 10036.
________. Safety Requirements for Industrial Head Protection, Z89.1, available from
American National Standards Institute, 11 West 42nd Street, New York, NY 10036.
Occupational Safety and Health Administration (OSHA). Code of Federal Regulations,

Title 29 Labor, Chapter XVII, Parts 1901.1 to 1910.1450, Order No. 869-019-00111-5,
available from Superintendent of Documents, U.S. Government Printing Office, Washing-
ton, DC 02402.
National Fire Protection Association (NFPA). Standard for Fire Prevention in Use of
Cutting and Welding Processes, NFPA Standard 51B, available from National Fire Pro-
tection Association, One Batterymarch Park, Quincy, MA 02269.
________. National Electrical Code, NFPA Standard 70, available from National Fire Pro-
tection Association. One Batterymarch Park, Quincy, MA 02269.
________. Standard for the Design of Oxygen-Fuel Gas Systems for Welding and Cut-
ting and Allied Process, NFPA Standard 51, available from National Fire Protection Asso-
ciation, One Batterymarch Park, Quincy, MA 02269.
Compressed Gas Association (CGA). Safe Handling of Compressed Gas Cylinders,

CGA P-1, available from Compressed Gas Association, 1725 Jefferson David Highway,
Suite 1004, Arlington, VA 22202.
Robotic Industries Association (RIA). Safety Requirements for Industrial Robots and
Robot Systems. RIA R15.06, available from the Robotic Industries Association (RIA),
P.O. Box 3724, 900 Victors Way, Ann Arbor, MI 48106.
American Welding Society (AWS). Thermal Spraying: Practice, Theory, and Application,
available from American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

Safety and Health
Fact Sheet No. 29 July 2004
© 2004 American Welding Society
Grounding of Portable and Vehicle Mounted Welding

GND/PE Generators
INTRODUCTION
Grounded—Connected to earth or to
Proper grounding and bonding of portable some conducting body that serves in place
and vehicle mounted welding generators of the earth.
that also supply 115 or 230 volts AC
auxiliary power is an on-going topic among Grounded, effectively—Intentionally con-
welders. This Fact Sheet will help you nected to earth through a ground
determine the requirements for bonding connection of sufficiently low resistance
and grounding welding generators. and with adequate current-carrying
Additionally, it will give definitions and capacity to prevent the buildup of voltage
present necessary electrical concepts to that may be hazardous to connected
clarify the requirements for bonding and equipment or to persons.
grounding.
Grounding—The process of bonding one
TERMS or more conductive objects to the ground,
so that all objects are at zero (O) electrical
Sources: ANSI Z49.1, hereafter termed potential; also referred to as “earthing.”
Z49.1, AWS A3.0, and NEC--National
Electrical Code, hereafter termed NEC. Grounding Conductor—A conductor
See Information Sources Section at end for used to connect equipment or the
details. grounded circuit of a wiring system to a
grounding electrode or electrodes [ground
Bonding—The permanent joining of rod(s) or metal water pipe].
metallic parts to form an electrically
conductive path that will ensure electrical Ground Rod—A metal rod, typically
continuity and the capacity to conduct copper, not less than eight feet in length
safely any current likely to be imposed. and 1/2 inch in diameter, driven into the
earth such that at least eight feet of length
Ground—The electrical potential of the is in contact with the soil, to function as a
earth’s surface; a conducting connection, suitable connection point to earth. NOTE:
whether intentional or accidental, between Since different diameters are required for
an electrical circuit or equipment and the different rod materials and the driven
earth, or to some conducting body that length and number of rods used depends
serves in place of the earth. on the special soil conditions and
applications, consult the NEC for the
Ground Connection—An electrical con- specific data for the correct ground rod and
nection of the welding machine frame to method of use for each particular situation.
the earth for safety.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect,
consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this Safety and Health Fact Sheet.
AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.
Fact Sheet No. 29 — 07/04 Page 1

workpiece to an earth ground), the work
Hard Wired—Connected by separate lead will not be grounded.
conductors to a junction point or box—not
to receptacles. NATURE OF THE HAZARD
Metal Water Pipe—Typically an under- Some basics:

ground metal water pipe that supplies • When the generator is running,
water to a building or premises or faucet current can pass through a wire, a
/outlet and that is in contact with the earth ladder, a hoist, your body, or any
for a specified distance. NOTE: Since the other conductor.
metal water pipe has several key • If you become part of an electrical
requirements that must be met before it circuit, current can pass through
complies with regulations, consult the NEC your body causing a shock.
for specific information before selecting
any pipe for a ground connection. Why Grounding is Important: Grounding
the frame of electrical equipment ensures
Portable—Capable of being carried or the following:
moved about; designed for ready • Generators are grounded to prevent
movement and use in field locations. the buildup of voltages that may
result in undue hazards to persons
Separately Derived System--A premises or equipment.
wiring system whose power is derived from • When no voltage difference exists
a battery, a solar photovoltaic system, or between the grounded generator
from a generator, transformer, or converter frame and earth, no electric current
windings, and that has no direct electrical can flow. Therefore, the shock
connection, including a solidly connected hazard is reduced.
grounded circuit conductor, to supply • Since it is the flow of electric current
conductors originating in another system. through the human body that is
hazardous, proper grounding is one
Vehicle Mounted—Equipment installed in of the best ways to prevent
a truck, trailer, or similar wheeled vehicle. unintended electric shock.
Work—The workpiece or metal upon If we don’t ground the generator and
which the welder welds and is normally should have, the results can be
grounded independently of the welding hazardous—here’s why:
leads to a good electrical ground unless a
qualified person assures it is safe to work • If the auxiliary power circuit has a
on an ungrounded workpiece. fault condition (such as a short
caused by bare wires), and there is
Work Lead—The electric conductor be- no safety ground connection to
tween the source of arc welding current protect the user, the result can be
and the work. The work lead should not be an electric shock.
referred to as the ground lead. It is • Additionally, grounding helps
preferable to connect the work lead directly prevent possible fire or explosion
to the work. Unless a separate grounding when fueling by reducing the
conductor is used (to connect the chances for static electricity sparks
from the fuel nozzle to the tank.

• Watch out for bed liners in trucks—
securely connect the welding
CONDITIONS WHERE GROUNDING THE generator frame to the frame of the
GENERATOR FRAME TO A METAL vehicle or trailer by a ground wire or
WATER PIPE OR GROUND ROD IS bolted metal-to-metal contact.
REQUIRED BY THE NEC: • Bond the generator to the vehicle
frame or earth.
1. The welding generator is not part of a • When grounding a generator sitting
separately derived system, OR directly on the earth, use a driven
2. It has its neutral conductor solidly ground rod to ensure the earth
interconnected to a service-supplied connection.
system neutral, OR • Keep the fuel nozzle in contact with
3. It supplies auxiliary power output (115 the tank when fueling to prevent
volts AC / 230 volts AC) by means other static sparks and fire.
than cord-and-plug connection through
receptacles mounted on the generator, SUMMARY
such as connections to internal terminals
on the generator—hard wired (see • Proper grounding of the welding
equipment Owner’s Manual for grounding generator frame can help prevent
instructions). electric shock.
When ANY of these conditions are met,
• If your generator is in a truck or
grounding is required.
trailer, and you use power directly
CONDITIONS WHERE GROUNDING THE from the receptacles via plugs,
GENERATOR FRAME TO A METAL connect (bond) the generator frame
WATER PIPE OR GROUND ROD IS NOT to the vehicle frame—be sure there
REQUIRED BY THE NEC: is a good metal-to-metal connection.
• If you hard wire the generator
1. The welding generator has auxiliary auxiliary power to a project or
power output (115 volts AC or 230 volts building electrical system, then you
AC) and the generator receptacles have a must connect the generator frame to
ground pin outlet available for the a driven ground rod or metal water
equipment that plugs into the receptacle, pipe.
AND • The decision is based on what
2. The generator is portable or mounted on you do with your auxiliary power:
a truck or trailer, AND If you just plug equipment into the
3. The auxiliary power is used by cord-and- receptacles, connection to the
plug-connection means through recep- vehicle frame is fine. If you hard
tacles mounted on the generator, AND wire the auxiliary power into another
4. The generator is mounted on a vehicle electrical system, then you must
and the generator frame is bonded to the connect the generator frame to a
vehicle frame. driven ground rod or metal water
pipe.
HOW TO AVOID THE HAZARDS • Remember: The objective is to
keep the frame of the generator at
• Follow the manufacturer’s recom- zero (or earth) voltage.
mended procedures for grounding
the welding generator.

• In simplest terms, grounding the Institute of Electrical and Electronic
welding generator frame provides Engineers (IEEE), IEEE Recommended
an electrical path to ground instead Practice for Grounding of Industrial and
of a possible electrical shock hazard Commercial Power Systems—Green Book,
to the user. ISBN 1-5593-7141-2, Product Number
SH14498-TBR Standard 142-1991,avail-
INFORMATION SOURCES able from IEEE Publications Office, 10662
Los Vaqueros Circle, P.O. Box 3014, Los
American National Standards Institute Alamitos, CA 90720-1264 (phone: 800-
(ANSI). Safety in Welding, Cutting, and 272-6657, website: www.ieee.org ).
Allied Processes, Z49.1, published by the
American Welding Society, 550 NW American Welding Society (AWS).Welding
LeJeune Road, Miami, FL 33126; Terms and Definitions, A3.0, published by
telephone 800-443-9353; Web site: the American Welding Society, 550 NW
www.aws.org. LeJeune Road, Miami, FL 33126;
telephone 800-443-9353; Web site:
Occupational Safety and Health www.aws.org.
Administration (OSHA). Code of Federal
Regulations, Title 29 Labor, Parts
1926.400, 1926.403, 1926.404, 1926.449,
and 1910.302 available from U.S.
Government Printing Office, Super-
intendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250–7954 (phone: 800–
321–6742, website: www.osha.gov).
National Fire Protection Association

(NFPA). National Electrical Code (NFPA
70), available from National Fire Protection
Association, 1 Batterymarch Park, P.O.
Box 9101, Quincy, MA 02269–9101
(phone: 800–344–3555, website:
www.nfpa.org).

Safety and Health
Fact Sheet No. 30 March 2005
Cylinders: Safe Storage, Handling, and Use
INTRODUCTION Compressed Gas Association (CGA)

requirements, the cylinder will rapidly
To use compressed gas cylinders safely, it release all its gas (which could be a health
is important that they are stored properly, and/or flammability concern), cause a
handled correctly, used with the correct whistling sound, and possibly spin
equipment, and that the properties of the uncontrollably. If the valve inlet opening is
gases they contain are fully understood. different from the standard hole size used
in most welding gases, such as those used
OVERVIEW OF CYLINDER PHYSICAL for propane or butane and fire protection
HAZARDS system cylinders, the cylinders may take
off and become airborne. You can check
Physical Damage: Cylinders, with their this size matter by being sure the cylinder
high internal pressure [up to 2,500 pounds meets all V-1 requirements.
per square inch gauge (psig)], are very
hazardous when exposed to damage from Tipping and Falling: The most common
falling over or tipping, heat, electric circuits, major hazard is having a cylinder tip over
motion, or vibration – anything that can or fall on you or another nearby worker.
cause a weakness or crack in the cylinder Since cylinders are heavy and awkward to
wall or shell. Such damage can cause the handle, they require special care and
cylinder to rupture and explode sending equipment in handling and securing so
sharp metal pieces, like shrapnel, blasting they don’t fall or tip over and cause injury.
through the area.
Valve Leakage: Cylinder valves can leak,
Valve Hazard: The CGA (in Pamphlet V-1) causing their contents to discharge. To
has established a 0.300 inch (7.62 mm) minimize hazards from leaks, use proper
maximum valve inlet diameter as a ventilation and storage.
requirement to minimize the propulsion
effect in case the valve is severed. This OVERVIEW OF CYLINDER CONTENTS
standard has the exception of valves used HAZARDS
in liquefied gas services and fire control
systems. Special design requirements and Read, understand, and follow the markings
unique applications such as fire control on the cylinder, the label(s) on the cylinder,
systems, which require a “high blow down and the material safety data sheet (MSDS).
flow”, may dictate greater diameters. The Each compressed gas cylinder has unique
actual outcome of a broken off valve hazards based on contents. Some are
depends on the design and pressure of the filled with inert gases – especially those
valve and cylinder. If the valve is broken used in arc welding. Many gases are
off and the valve inlet opening meets the flammable, explosive, toxic, or a combin-
Fact Sheet No.30 — 3/05 Page 1

ation. Common compressed gases include • Most accidents or injuries involving
acetylene, carbon dioxide, argon, cylinders happen when moving or
hydrogen, nitrogen, air, propane, and handling the gas cylinders.
oxygen.
• Use the right equipment, correct
HOW TO STORE CYLINDERS procedures, and sufficient number of
persons to lift and move cylinders to
• Store cylinders upright and secure them avoid personal injury and cylinder
with a chain, strap, or cable to a damage.
stationary building support or to a proper
cylinder cart to prevent them from • Wear protective footwear, safety
tipping or falling. glasses, and heavy gloves.
• Completely close the valves, and keep • Securely install the valve protection
the valve protection devices, such as devices, such as caps or guards.
caps or guards, securely in place.
• Secure cylinders upright to a proper
• Store cylinders in a dry, well-ventilated hand truck or cylinder cart designed for
area at least 20 feet from combustible the purpose.
materials. Do not keep cylinders in
lockers. If they leak, a buildup of • Don't drag or roll them – use a properly
flammable or other types of gases can designed cart or hand truck.
occur inside the locker.
• When using a crane, be sure to use
• Mark the storage area with proper proper cradles, nets, boats, or special
precautionary signs, such as flammable, platforms designed for this purpose to
oxidizer, or toxic. prevent cylinders from falling.
• Place them in a location where they will • Prevent damage – handle carefully –
not be subject to mechanical or physical avoid dropping or banging them.
damage, heat, or electrical circuits to
prevent possible explosion or fire. Keep • Do not lift by the protective cap/guard or
cylinders away from vehicle traffic. use magnets or slings to lift or move
them since valves may be damaged or
• Store empty cylinders separate from full sheared off.
ones.
HOW TO USE CYLINDERS
• Keep oxygen cylinders 20 feet away
from fuel-gas cylinders, such as • Follow the instructions in the
acetylene, or separate them with a non- Compressed Gas Association (CGA)
combustible barrier (such as a wall) at publication P-1, “Safe Handling of
least 5 feet high with a fire-resistance Compressed Gases in Cylinders.” (The
rating of at least one-half hour. phone number and web site of the CGA
are located at the end of this sheet in
HOW TO TRANSPORT CYLINDERS the Information Sources Section.) Don't
tamper with safety devices.

• Keep cylinders upright and away from HOW TO MAINTAIN THEM
heat, sparks, fire, physical damage, or
electrical circuits to avoid rupture. • Protect the markings on cylinders that
identify the contents, and mark the
• Use in a well-ventilated area to avoid full/empty status on cylinders (do not
gas accumulation. use color to identify contents). Mark all
empty cylinders (some companies use
• Do not bring cylinders into a confined "MT").
space to avoid inhaling the gas and
possible suffocation from the • Don't use the recessed top of the
accumulation of flammable, toxic, or cylinder as a storage area for tools or
reactive gases. material.
• Read, understand, and follow all • If cylinders are leaking, isolate them
cylinder markings and labels to avoid outdoors and away from sparks or heat.
misuse. Call your gas supplier to send qualified
people to take care of the problem –
• Before connecting a regulator, stand to don’t try any repairs yourself. Tag
one side, and momentarily open the leaking cylinders.
valve and then close it immediately. This
procedure, called “cracking” the valve, is • Never mix gases in a cylinder or try to
done to clear the valve of dust or dirt refill a cylinder – always contact your
that could enter the regulator. gas supplier.
• Open valves slowly by hand to avoid SUMMARY

gauge damage. If a specific tool is
required to open the valve, leave it in Even though high-pressure, compressed
position so that the flow of gas can be gas cylinders are near or part of most
stopped quickly in an emergency. welding and cutting operations, they are
used safely everyday by many people
• Lift and move cylinders properly. throughout the world. To prevent injury,
always store, handle, use, and maintain
• Close the gas cylinder valves when not them properly. Treat them with the respect
in use such as during breaks, lunch, or they deserve.
end-of-shift to avoid leaks.
INFORMATION SOURCES
• Avoid getting any oil or grease on the
cylinders or regulators/gauges, American National Standards Institute
particularly those containing oxygen, to (ANSI). Safety in Welding, Cutting, and
avoid fire or explosion. Allied Processes (ANSI Z49.1), published
by the American Welding Society, 550 NW
• Storage is not required for single LeJeune Road, Miami, FL 33126
cylinders of fuel gas and oxygen ready (telephone: 800-443-9353; web site:
for use with regulators attached secured www.aws.org).
to a proper cart.

Barlen, Bill. “The Significance of the Zero
Occupational Safety and Health Point Three Hundred Hole.” Specialty Gas
Administration (OSHA). Code of Federal Report, Vol. 6, No. 2, Second Quarter
Regulations, Title 29 Labor, Parts 1910.1 2003. (Web site: www.specgasreport.com).
to 1910.1450 and 1919.332, available from
the U.S. Government Printing Office, , 732 Barlen, Bill. “Follow-up on the Linde Hole.
North Capitol Street NW, Washington, DC Plus, Where Did the Three Pounds Go?”
20401 (telephone: 800-321-6742; web site: Specialty Gas Report, Vol. 6, No. 3, Third
www.osha.gov). Quarter 2003. (www.specgasreport.com).
Compressed Gas Association (CGA). Safe

Handling of Compressed Gases in
Cylinders, CGA Pamphlet P-1 (and V-1),
from Compressed Gas Association, 1735
Jefferson Davis Highway, Suite 1004,
Arlington, VA 22202-4102 (telephone: 703-
412-0900, web site: www.cganet. com).
National Fire Protection Association

(NFPA). Standard for Fire Prevention
During Welding, Cutting and Other Hot
Work (NFPA 51B), available from National
Fire Protection Association, 1
Batterymarch Park, Quincy, MA 02269-
9101 (telephone: 800-344-3555; website:
www.nfpa.org).

Safety and Health
Fact Sheet No. 34 September 2009
Coated Steels: Welding and Cutting Safety Concerns
INTRODUCTION Coatings may give off fumes and gases

when welding or cutting is performed. A
Steels are coated to provide a protective health hazard may be created when its
covering or a decorative finish. Protective dusts, fumes or gases get into the air in
coatings are designed to prevent rusting or large enough amounts that safe levels are
to shield the steel from chemical attack. exceeded.
Coatings found on steels can become Protective coatings on steels can contain
airborne or give off fumes, smoke, or dust, chromium, lead, tin, zinc or other materials.
during joining and cutting. Some of the It is always good for the welder to
coating’s dusts, fumes or gases can harm understand the coating types for the
you and their exposure limits should not be materials he works with. If not, the welder
exceeded. Exposure limits include: should get this information from his
supervisor or employer.
• Permissible Exposure Limit (PEL): The
PEL is set by the Occupational Safety Paints are made up of compounds that may
and Health Administration (OSHA) and is release hazardous materials into the air
a legal employee exposure limit in the when heated. Paints are usually used on a
U.S. “phosphated” and passivated (often with
chromium) metal surface. The heat from the
• Threshold Limit Value (TLV®): The TLV® arc can cause paints to give off unsafe
is published by the American Conference amounts of gases like carbon monoxide and
of Governmental Industrial Hygienists carbon dioxide. These also increase the risk
(ACGIH) and is a guideline for employers of suffocation in confined work areas, or
to consider in controlling employee those with poor air movement.
exposures.
Steels coated with plastic materials should
OVERVIEW OF HEALTH HAZARDS not be cut or welded unless proper
precautions are taken. It is best to remove
Employers need to know which chemical coating to a distance away from the weld or
may be released into the air that may injure cut where the temperature won’t go above
welders. Welders must be trained in how to the point where the material starts to break
do each process the correct way, and they down.
shall cut or weld only after proper safety
precautions have been taken. For additional information, see AWS Fact
Sheet 1, Fumes and Gases.

SUMMARY
HOW TO AVOID HEALTH HAZARDS
FROM OVEREXPOSURE Coatings on steels may be a source of
exposure to fumes and gases during
The welder should make sure he or she welding, brazing and cutting. Steel coatings
knows what a coating might give off when and paints contain materials that can cause
heated or burned: harmful overexposure when breathed. This
is why coatings must also be looked at in
• Obtain the Material Safety Data Sheets order to remove hazards from welding and
(MSDSs) for all materials used. cutting. The joining of some coated steels
require special types of ventilation. In some
• Read and understand the specification cases, the welder must wear a respirator to
for coating type and coating weights. keep safe.
• Find out what hazardous materials are INFORMATION SOURCES

present or might be given off by the
coating when it is exposed to the arc or American National Standards Institute
high temperatures. (ANSI). Safety in Welding, Cutting, and
Allied Processes (ANSI Z49.1), published
• Use adequate ventilation whenever an by the American Welding Society, 550 NW
airborne fume gas or dust must be LeJeune Road, Miami, FL 33126; telephone
controlled. Use enough ventilation, 800-443-9353; web site: www.aws.org.
exhaust, or both to keep the air the
welder breathes below recommended Occupational Safety and Health
safe levels such as the PEL and TLV®. Administration (OSHA). Code of Federal
Regulations, Title 29 Labor, Parts 1910 and
• Have air monitoring done as necessary 1915, available from the U.S. Government
to test for exposure levels in the Printing Office, 732 North Capitol Street NW,
breathing zone of the welder and other Washington, DC 20401; telephone: 800-321-
persons working nearby. 6742; web site: www.osha.gov.
• Use a respirator when required. American Welding Society (AWS). Safety

and Health Fact Sheets, published by the
• Orient the work so the welder’s head is American Welding Society, 550 NW
kept out of the fume plume. LeJeune Road, Miami, FL 33126; telephone
800-443-9353; web site: www.aws.org.
• See AWS Fact Sheet 1, Fumes and
Gases.
• See AWS Fact Sheet 25, Metal Fume

Fever.
• See AWS Fact Sheet 11, Hot Work in

Confined Spaces.

AWS D15.1/D15.1M:2007
An American National Standard
Railroad Welding
Specification
for Cars and
Locomotives
This is a free preview of an AWS technical standard.
AWS publications for your industry are available at
www.awspubs.com
AWS D15.1/D15.1M:2007
An American National Standard
Approved by the
American National Standards Institute
July 5, 2007
Railroad Welding Specification

for Cars and Locomotives
4th Edition
Supersedes AWS D15.1:2001
Prepared by the
American Welding Society (AWS) D15 Committee on Railroad Welding
Under the Direction of the

AWS Technical Activities Committee
Approved by the
AWS Board of Directors
Abstract
This specification establishes minimum standards for the manufacture and maintenance of railroad equipment. Clauses 4
through 17 cover the general requirements for welding in the railroad industry. Clauses 18 through 24 cover specific
requirements for the welding of base metals thinner than 1/8 in [3 mm].
550 N.W. LeJeune Road, Miami, FL 33126

AWS D15.1/D15.1M:2007
Foreword
This foreword is not part of AWS D15.1/D15.1M:2007, Railroad Welding Specification
for Cars and Locomotives, but is included for informational purposes only.
This specification establishes minimum standards for the manufacture and maintenance of railroad equipment. It was
developed and is maintained by the D15 Committee on Railroad Welding of the American Welding Society.
Welding of railroad components is vital to the industry. An investigating committee was formed in 1982 which
recommended a Railroad Welding Committee be formed to establish minimum welding standards for the industry. This
recommendation was made because of confusion and incompleteness of the existing welding specifications and guides
as applied to the railroad industry needs. The committee is made up of individuals from all segments of the railroad
industry: both users and suppliers, the general public, and representatives of the Association of American Railroads.
The purpose of this specification is to provide a single comprehensive document of welding data that will be used
throughout the railroad industry. Also, it should contribute to improvements in welding quality and performance. This
document includes data from AWS D1.1, Structural Welding Code—Steel; AWS D1.2, Structural Welding Code—
Aluminum; AWS D1.3, Structural Welding Code—Sheet Steel; and AWS D1.6, Structural Welding Code—Stainless
Steel.
AWS D15.1-86 was titled simply Railroad Welding Specification. For the 1993 revision, the suffix Cars and Loco-
motives was added because the locomotive section had been introduced. A later revision was published in 2001, AWS
D15.1:2001. The welding of rail is addressed in AWS D15.2, Recommended Practice for the Welding of Rails and
Related Rail Components for Use by Rail Vehicles.
Several significant modifications have been made in AWS D15.1/D15.1M:2007. A vertical line in the margin indicates a
revision from the 2001 edition. The document has incorporated SI Units within the text as well as all figures and tables
in order to create a dual dimension standard. The overall format of AWS D15.1/D15.1M:2007 has changed; thus, all
clauses as well as figure and table notations throughout the document have been altered to comply with the new style.
Also important to note, Annex A—Base Metal Groupings, Annex E—Glossary, Annex F—Safety Considerations, and
finally Annex H—Metric Tables and Figures from AWS D15.1:2001 have all been removed in this edition. Additions in
AWS D15.1/D15.1M:2007 include a new Annex A—Alternate Base Material Specifications (Steel) and a Figure
7.2K—Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details. The section on Inspection—General Re-
quirements, Clauses 14 through 17, has been updated along with Figure 8.1—Weld Pass in Which Depth and Width Ex-
ceed the Width of the Weld Face, Table 8.1—Prequalified Base Metal–Filler Metal Combinations for Matching
Strength, Table 8.2—Prequalified Minimum Preheat and Interpass Temperature (Steel), and Table 10.1—Procedure
Qualification—Number and Type of Specimens and Range of Thickness Qualified—Complete Joint Penetration (CJP)
Groove Weld.
vii
AWS D15.1/D15.1M:2007
Table of Contents
Page No.
Personnel......................................................................................................................................................................v
Foreword .................................................................................................................................................................. vii
List of Tables ............................................................................................................................................................ xiii
List of Figures............................................................................................................................................................xiv
1. Scope.....................................................................................................................................................................1
2. Normative References .........................................................................................................................................1
3. Terms and Definitions.........................................................................................................................................3
4. General Requirements ........................................................................................................................................3
5. Requirements for All Welding ...........................................................................................................................4
5.1 Processes ...................................................................................................................................................4
5.2 Welding Procedure Qualification..............................................................................................................4
5.3 Qualification of Welders and Welding Operators.....................................................................................5
5.4 Design of Welded Joints ...........................................................................................................................5
5.5 Consumables .............................................................................................................................................8
6. Technique and Workmanship..........................................................................................................................19
6.1 General ....................................................................................................................................................19
6.2 Preparation of Base Metal .......................................................................................................................19
6.3 Steel and Aluminum Assembly Criteria..................................................................................................20
6.4 Weld Profiles...........................................................................................................................................21
6.5 Repairs.....................................................................................................................................................22
6.6 Arc Strikes...............................................................................................................................................23
6.7 Cleaning and Protective Coatings ...........................................................................................................23
6.8 Weld Termination ...................................................................................................................................23
6.9 Groove Weld Backing .............................................................................................................................23
6.10 Heat Input Control for Quenched and Tempered Steel...........................................................................24
6.11 Stress Relief Heat Treatment...................................................................................................................24
6.12 Peening ....................................................................................................................................................24
6.13 Workmanship for Stud Arc Welding (SW).............................................................................................24
6.14 Workpiece Leads.....................................................................................................................................24
6.15 Welding Air Brake Pipe ..........................................................................................................................25
7. Prequalified Welding Procedures—Joint Design Details ..............................................................................30
7.1 Groove Weld Size (Effective Weld Size) ...............................................................................................30
7.2 Joint Designs ...........................................................................................................................................30
7.3 Fillet Welds .............................................................................................................................................30
7.4 Details of Plug and Slot Welds ...............................................................................................................30
7.5 Complete Joint Penetration Groove Welds .............................................................................................30
7.6 Partial Joint Penetration Groove Welds ..................................................................................................31
8. Technique for Prequalified Welding Procedures ...........................................................................................59
8.1 Base Metal, Filler Metal, and Related Metal Requirements ...................................................................59
8.2 Preheat, Interpass, and Postweld Heat Treatment (PWHT) Requirements.............................................59
8.3 Shielded Metal Arc Welding (SMAW)...................................................................................................59
ix
AWS D15.1/D15.1M:2007
Page No.
8.4 Submerged Arc Welding (SAW) ............................................................................................................60
8.5 Gas Metal Arc and Flux Cored Arc Welding (GMAW and FCAW)......................................................62
8.6 Plug and Slot Welds ................................................................................................................................63
8.7 Welding Wear Plates and Wear Liners ...................................................................................................63
9. General Requirements for Qualification.........................................................................................................73
9.1 Prequalified Procedures...........................................................................................................................73
9.2 Qualified Procedures ...............................................................................................................................73
9.3 Welders, Welding Operators, and Tack Welders....................................................................................73
9.4 Qualification Responsibility....................................................................................................................73
10. Procedure Qualification....................................................................................................................................74
10.1 Limitation of Essential Variables............................................................................................................74
10.2 Types of Tests and Purposes ...................................................................................................................76
10.3 Base Metal and Its Preparation................................................................................................................77
10.4 Position of Test Welds ............................................................................................................................77
10.5 Joint Welding Procedure .........................................................................................................................78
10.6 Test Specimens: Number, Type, and Preparation ...................................................................................78
10.7 Special Test Conditions...........................................................................................................................79
10.8 Method of Testing Specimens.................................................................................................................80
10.9 Test Results Required..............................................................................................................................81
10.10 Records....................................................................................................................................................82
10.11 Retests .....................................................................................................................................................82
11. Welder Qualification.......................................................................................................................................104
11.1 General ..................................................................................................................................................104
11.2 Limitation of Variables .........................................................................................................................104
11.3 Qualification Tests Required.................................................................................................................104
11.4 Groove Weld Plate Qualification Test for Plate....................................................................................104
11.5 Groove Weld Qualification Test for Pipe or Square or Rectangular Tubing........................................104
11.6 Fillet Weld Qualification Test for Fillet Welds Only ...........................................................................104
11.7 Position of Test Welds ..........................................................................................................................105
11.8 Base Metal.............................................................................................................................................105
11.9 Joint Welding Procedure .......................................................................................................................105
11.10 Test Specimens......................................................................................................................................105
11.11 Method of Testing Specimens...............................................................................................................105
11.12 Test Results Required............................................................................................................................106
11.13 Retests ...................................................................................................................................................106
11.14 Period of Effectiveness..........................................................................................................................107
11.15 Records..................................................................................................................................................107
12. Welding Operator Qualification ....................................................................................................................122
12.1 General ..................................................................................................................................................122
12.3 Qualification Tests Required for Welding Operators ...........................................................................122
12.4 Base Metal.............................................................................................................................................122
12.5 Joint Welding Procedure .......................................................................................................................123
12.6 Test Specimens: Number, Type, and Preparation .................................................................................123
12.9 Retests ...................................................................................................................................................123
12.11 Records..................................................................................................................................................123
x
AWS D15.1/D15.1M:2007
Page No.
13. Tack Welder Qualification .............................................................................................................................125
13.1 General ..................................................................................................................................................125
13.3 Qualification Tests Required.................................................................................................................125
13.4 Base Metal.............................................................................................................................................125
13.5 Test Specimens: Number, Type, and Preparation .................................................................................125
13.8 Retests ...................................................................................................................................................125
13.10 Records..................................................................................................................................................125
14. Inspection—General Requirements ..............................................................................................................127
14.1 Manufacturer’s Responsibility ..............................................................................................................127
14.2 Designated Inspector (Fabrication Inspector) .......................................................................................127
14.3 Inspection of Welding ...........................................................................................................................127
14.4 Weld Size and Location ........................................................................................................................127
14.5 Visual Inspection of Completed Welds.................................................................................................127
14.6 Documentation ......................................................................................................................................127
14.7 Verification Inspection..........................................................................................................................127
14.8 Personnel Qualifications .......................................................................................................................128
15. NDE General Requirements...........................................................................................................................128
15.1 Nondestructive Testing .........................................................................................................................128
16. NDE Methods...................................................................................................................................................128
16.1 Radiographic Testing of Groove Welds in Butt Joints .........................................................................128
16.2 Ultrasonic Testing of Groove Welds.....................................................................................................129
16.3 Liquid Penetrant Testing of Welds........................................................................................................130
16.4 Magnetic Particle Testing of Welds ......................................................................................................130
17. Acceptance Criteria.........................................................................................................................................140
17.1 Temporary Welds..................................................................................................................................140
17.2 Visual Inspection Acceptance Criteria..................................................................................................140
17.3 Radiographic Inspection Acceptance Criteria.......................................................................................140
17.4 Ultrasonic Inspection Acceptance Criteria............................................................................................140
17.5 Liquid Penetrant Inspection Acceptance Criteria..................................................................................140
17.6 Magnetic Particle Inspection Acceptance Criteria ................................................................................140
18. Requirements for Welding Sheet Metal ........................................................................................................143
18.1 Design of Welded Joints .......................................................................................................................143
18.2 Joint and Procedure Qualification for Welding Sheet Metal ................................................................143
19. Welder, Welding Operator, and Tack Welder Qualification—Carbon, Low Alloy, and
Stainless Steel Sheet Metals............................................................................................................................155
19.1 General ..................................................................................................................................................155
19.3 Retests ...................................................................................................................................................156
20. Welder Qualification—Aluminum and Aluminum Alloy Sheet Metals ....................................................158
20.1 Record of Tests......................................................................................................................................158
20.2 Limits of Qualified Positions—Performance Qualification..................................................................158
20.3 Preparation of Test Weldments—Performance Qualification ..............................................................158
20.4 Limitation of Variables—Welder Performance Qualification ..............................................................158
20.5 Limitation of Variables—Welding Operator Performance Qualification.............................................158
xi
AWS D15.1/D15.1M:2007
Page No.
20.6 Limitation of Variables—Tack Welder Performance Qualification .....................................................158
20.7 Acceptance Criteria—Welder, Welding Operator, and Tack Welder Qualification.............................158
20.8 Retests ...................................................................................................................................................158
21. Technique and Workmanship for Welding Sheet Metal.............................................................................159
22. Inspection of Welding Procedure Qualification and Equipment for Welding Sheet Metal.....................159
23. Weld Details—Sheet Metal.............................................................................................................................159
23.1 Groove Welds (Butt Joints)...................................................................................................................159
23.2 Fillet Welds ...........................................................................................................................................159
24. Sheet Metal Weld Quality—Visual Inspection Acceptance Criteria..........................................................159
Annex A (Normative)—Alternate Base Material Specifications (Steel) .................................................................161
Annex B (Informative)—Filler Metal Classifications..............................................................................................163
Annex C (Informative)—Effective Weld Size—Special Cases...............................................................................167
Annex D (Informative)—Sample Report Forms......................................................................................................169
Annex E (Informative)—Gage Thickness of Sheet Metal and Aluminum Filler Alloy Selection Guide................195
Annex F (Informative)—Macroetch Procedures......................................................................................................199
Annex G (Informative)—Guidelines for the Preparation of Technical Inquiries ....................................................201
Index .........................................................................................................................................................................203
xii
AWS D15.1/D15.1M:2007
List of Tables
Table Page No.
5.1 Minimum Weld Size for Partial Joint Penetration Groove Welds...............................................................10
5.2 Allowable Weld Stresses (Steel)..................................................................................................................10
5.3 Allowable Weld Stresses (Aluminum) ........................................................................................................11
5.4 Minimum Mechanical Properties for Welded Aluminum Alloys (Gas Tungsten Arc or
Gas Metal Arc Welding with No Postweld Heat Treatment) ......................................................................12
5.5 Minimum Mechanical Properties for Before Welding ................................................................................13
5.6 Allowable Atmospheric Exposure of Low Hydrogen Electrodes................................................................14
6.1 Limits on Acceptability and Repair of Cut Edge Discontinuities................................................................26
6.2 Joint Dimension Tolerances.........................................................................................................................26
6.3 Maximum Heat Exposure Time at Temperature Preparatory to Forming or Welding of
Aluminum Alloys.........................................................................................................................................27
7.1 Effective Size of Flare-Groove Welds Filled Flush.....................................................................................32
7.2 Minimum Fillet Weld Size...........................................................................................................................32
7.3 Legend for Figures 7.1A–7.1L and 7.2A–7.2K ...........................................................................................33
8.1 Prequalified Base Metal–Filler Metal Combinations for Matching Strength ..............................................64
8.2 Prequalified Minimum Preheat and Interpass Temperature (Steel).............................................................69
10.1 Procedure Qualification—Number and Type of Specimens and Range of Thickness
Qualified—Complete Joint Penetration Groove Weld ................................................................................83
Qualified—Partial Joint Penetration Groove Weld .....................................................................................84
Qualified—Fillet Weld ................................................................................................................................84
10.4 Procedure Qualification Type and Position Limitations..............................................................................85
10.5 As-Welded Strength of Aluminum Alloys (GTAW or GMAW) ................................................................86
11.1 Electrode Classification Groups for Welder and Tack Welder Qualification ...........................................108
11.2 Number and Type of Specimens and Range of Thickness Qualified—Welder and Welding
Operator Qualification ...............................................................................................................................109
11.3 Welder and Welding Operator Qualification—Type and Position Limitation ..........................................110
11.4 Maximum Reinforcement—Pipe Welds ....................................................................................................110
17.1 Undercut and Porosity Tolerances .............................................................................................................141
17.2 Ultrasonic Testing Acceptance-Rejection Criteria ....................................................................................142
18.1 Procedure Qualification Tests ....................................................................................................................147
19.1 Welder Qualification Tests ........................................................................................................................157
A.1 Numerical Indexing of Base Material Specifications (Steel).....................................................................162
B.1 Grouping of Welding Electrodes and Rods for Qualification....................................................................164
C.1 Equivalent Fillet Weld Leg Size Factors for Skewed T-Joints ..................................................................168
E.1 Hot-Rolled and Cold-Rolled Sheet Metal ..................................................................................................196
E.2 Galvanized Sheet Metal .............................................................................................................................196
E.3 Guide to the Choice of Filler Metal for General Purpose Welding of Aluminum.....................................197
xiii
AWS D15.1/D15.1M:2007
List of Figures
Figure Page No.
5.1 Fillers Less than 1/4 in [6 mm] Thick..........................................................................................................15
5.2 Lap Width and Member Axial Load ............................................................................................................15
5.3 Fillers 1/4 in [6 mm] or Thicker...................................................................................................................16
5.4 Details for Fillet Welds ................................................................................................................................17
5.5 Distribution of Mechanical Properties in the Vicinity of an Aluminum Weld ............................................18
6.1 Cut Edge Discontinuity ................................................................................................................................28
6.2 Acceptable and Unacceptable Weld Profiles ...............................................................................................29
7.1A Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................34
7.1B Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................35
7.1C Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................36
7.1D Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................38
7.1E Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................39
7.1F Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................40
7.1G Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................41
7.1H Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................42
7.1I Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................43
7.1J Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................44
7.1K Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................45
7.1L Prequalified Complete Joint Penetration Groove (CJP) Groove Welded Joint Details ...............................46
7.2A Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................47
7.2B Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................48
7.2C Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................49
7.2D Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................50
7.2E Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................51
7.2F Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................52
7.2G Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................53
7.2H Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................54
7.2I Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................55
7.2J Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................56
7.2K Prequalified Partial Joint Penetration (PJP) Groove Weld Joint Details .....................................................57
8.1 Weld Pass in Which Depth and Width Exceed the Width of the Weld Face ..............................................72
10.1 Positions of Groove Welds ..........................................................................................................................88
10.2 Positions of Fillet Welds ..............................................................................................................................89
10.3 Positions of Test Plates for Groove Welds ..................................................................................................90
10.4 Positions of Test Pipe or Tubing for Groove Welds ....................................................................................91
10.5 Test Positions for Fillet Welds (for Plate) ...................................................................................................92
10.6 Test Positions for Fillet Welds (for Pipe and Tubing) .................................................................................93
10.7 Location of Test Specimens on Welded Test Pipe ......................................................................................94
10.8 Location of Test Specimens for Welded Square and Rectangular Tubing ..................................................94
10.9 Location of Test Specimens on Welded Test Plate for 1/8 to 3/8 in [3 mm to 10 mm]
(inclusive) Thick Procedure Qualification ...................................................................................................95
10.10 Location of Test Specimens on Welded Test Plate 3/8 in [10 mm] Thick and Over Procedure
Qualification.................................................................................................................................................96
10.11 Reduced-Section Tension Specimen............................................................................................................97
10.12 All-Weld-Metal Tension Specimen .............................................................................................................98
xiv
AWS D15.1/D15.1M:2007
Figure Page No.

10.13 Side-Bend Specimens ..................................................................................................................................99
10.14 Face- and Root-Bend Specimens ...............................................................................................................100
10.15 Fillet Weld Soundness Test for Procedure Qualification...........................................................................101
10.16 Location of Test Specimens on Welded Test Plate 1 in [25 mm] Thick—Consumables
Verification for Fillet Weld Procedure Qualification ................................................................................102
10.17 Pipe Fillet Weld Soundness Test Procedure Qualification ........................................................................103
11.1 Test Plate for Unlimited Thickness Welder Qualification.........................................................................111
11.2 Test Plate for Unlimited Thickness Horizontal Position—Welder Qualification......................................112
11.3 Test Plate for Limited Thickness—Welder Qualification .........................................................................113
11.4 Test Plate for Limited Thickness Horizontal Position—Welder Qualification .........................................114
11.5 Tubular Butt Joint—Welder Qualification Without Backing ....................................................................114
11.6 Tubular Butt Joint—Welder Qualification with Backing ..........................................................................114
11.7 Fillet-Weld-Break and Macroetch Test Plate Welder and Welding Operator Qualification—
Option 1......................................................................................................................................................115
11.8 Fillet Weld Root-Bend Test Plate Welder and Welding Operator Qualification—Option 2 ....................116
11.9 Fillet Weld on Pipe—Welder and Welding Operator Qualification—Option 3........................................117
11.10 Location of Test Specimens on Welded Test Pipe and Square or Rectangular Tubing—
Welder Qualification..................................................................................................................................118
11.11 Guided-Bend Jig ........................................................................................................................................119
11.12 Guided-Bend Wraparound Jig ...................................................................................................................120
11.13 Guided-Bend Roller Jig .............................................................................................................................121
12.1 Test Plate for Unlimited Thickness—Welding Operator Qualification.....................................................124
13.1 Fillet-Weld-Break Specimen—Tack Welder Qualification.......................................................................126
13.2 Method of Rupturing Specimen—Tack Welder Qualification ..................................................................126
16.1 Weld Quality Requirements for Discontinuities Occurring in Cyclically Loaded
Nontubular Tension Welds (Limitations of Porosity and Fusion Discontinuities)....................................131
16.2 Weld Quality Requirements for Discontinuities Occurring in Cyclically Loaded
Nontubular Compression Welds (Limitations of Porosity or Fusion-Type Discontinuities) ....................132
16.3 Weld Quality Requirements for Elongated Discontinuities as Determined by RT of
Tubular Joints.............................................................................................................................................133
16.4 Maximum Acceptable RT Images .............................................................................................................138
16.5 For RT of Tubular Joints 1-1/8 in [30 mm] and Greater, Typical of Random Acceptable
Discontinuities ...........................................................................................................................................139
18.1 Square-Groove Weld in Butt Joint.............................................................................................................148
18.2 Arc Spot Welds ..........................................................................................................................................148
18.3 Arc Spot Weld Using Washer ....................................................................................................................148
18.4 Edge Distances for Arc Spot Welds...........................................................................................................148
18.5 Lap-Fillet Welds ........................................................................................................................................149
18.6 Fillet Welds in T-Joints..............................................................................................................................149
18.7 Single-Flare-Bevel-Groove Weld—Horizontal .........................................................................................149
18.8 Single-Flare-V-Groove Weld—Flat ..........................................................................................................149
18.9 Square-Groove Butt Joints .........................................................................................................................150
18.10 Test for Arc Spot Weld ..............................................................................................................................150
18.11 Fillet Weld Test Assembly.........................................................................................................................151
18.12 Extent of Fillet Weld Qualifications ..........................................................................................................152
18.13 Standard Test Assembly for Flare-Bevel-Groove Welds; Test C—Sheet-to-Sheet ..................................152
18.14 Standard Test Assembly for Flare-Bevel-Groove Weld; Test D—Sheet-to-Supporting Plate..................153
18.15 Standard Test Assembly for Flare-V-Groove Welds .................................................................................153
18.16 Flare-Groove Weld Qualification ..............................................................................................................154
xv
AWS D15.1/D15.1M:2007
Railroad Welding Specification

for Cars and Locomotives
1. Scope 2. Normative References

1.1 This specification covers the minimum welding The standards listed below contain provisions, which,
requirements applicable to welded structures used in the through reference in this text, constitute mandatory pro-
railroad industry. It is not intended to apply to tank car visions of this AWS standard. For undated references,
tanks nor to the welding of rails. Recommended prac- the latest edition of the referenced standard shall apply.
tices for welding railroad rails and related components For dated references, subsequent amendments to, or revi-
are included in D15.2, Recommended Practice for the sions of, any of these publications do not apply.
Welding of Rails and Related Rail Components for Use
by Rail Vehicles. Specifications for welding tank car AWS documents:1
tanks and components welded directly thereto are out- AWS A2.4, Standard Symbols for Welding, Brazing,
lined in the AAR Manual of Standards and Specifications and Nondestructive Examination
for Welding, Section C—Part III, Specification M-1002
(AAR M-1002 C-III). AWS A3.0, Standard Welding Terms and Definitions
Including Terms for Adhesive Bonding, Brazing, Solder-
1.2 Welding symbols shall be those shown in the latest ing, Thermal Cutting, and Thermal Spraying
edition of AWS A2.4, Standard Symbols for Welding,
AWS A5.01/A5.01M, Filler Metal Procurement
Brazing, and Nondestructive Examination.
Guidelines
1.3 This standard makes use of both U.S. Customary AWS A5.1/A5.1M, Specification for Carbon Steel
Units and the International System of Units (SI). The lat- Electrodes for Shielded Metal Arc Welding
ter are shown within brackets [ ] or in the appropriate
columns in tables and figures. The measurements may AWS A5.5/A5.5M, Specification for Low-Alloy Steel
not be exact equivalents; therefore, each system must be Electrodes for Shielded Metal Arc Welding
used independently. AWS A5.9/A5.9M, Specification for Bare Stainless
Steel Welding Electrodes and Rods
1.4 Safety and health issues and concerns are beyond the
scope of this standard and therefore are not fully AWS A5.10/A5.10M, Specification for Bare Alumi-
addressed herein. Safety and health information is avail- num and Aluminum Alloy Welding Electrodes and Rods
able from other sources, including, but not limited to,
AWS A5.17A5.17M, Specification for Carbon Steel
ANSI Z49.1, Safety in Welding, Cutting, and Allied Pro-
Electrodes and Fluxes for Submerged Arc Welding
cesses, and applicable federal, state, and local regulations.
AWS A5.18/A5.18M, Specification for Carbon Steel
1.5 This specification may involve hazardous materials, Filler Metals for Gas Shielded Arc Welding
operations, and equipment. The specification does not
purport to address all of the safety problems associated AWS A5.20/A5.20M, Specification for Carbon Steel
with its use. It is the responsibility of the user to establish Electrodes for Flux Cored Arc Welding
safety and health practices. The user should determine
1 AWS standards are published by the American Welding Society,
the applicability of any regulatory limitations prior to
use. 550 N.W. LeJeune Road, Miami, FL 33126.

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AWS SAFETY AND HEALTH

FACT SHEET BUNDLE

Includes the following concise and helpful

Fact Sheet 18: Lockout/Tagout

1: Fumes and Gases 22: Cadmium Exposure from

• Train employees in the purpose and methods of lockout/tagout.

• Shut down the equipment.

Fact Sheet No. 18—3/97 Page 1 of 2

Occupational Safety and Health Administration (OSHA). Code of Federal Regulations,

Page 2 of 2 Fact Sheet No. 18—3/97

THERMAL SPRAYING SAFETY

Combustion processes include Low-Velocity Oxyfuel (LVOF) and High-Velocity Oxyfuel

POTENTIAL HAZARDS AND HAZARDOUS EFFECTS

• Dust—Finely divided airborne solid particulate should be treated as an explosive and

Fact Sheet No. 20—2/97 Page 1 of 3

Temperature to 5000°F to 6000°F 4000–15,000°F 4000–15,000°F to 30,000°F

dBA (Sound 110 150 115 132 132

Spray Distance 4–10" 6–18" 2-1/2–6" 2-1/2–6" 3–8"

• Mechanical Hazards—The substrate surface preparation, spraying, finishing, and

• Compressed Gases—Compressed gases require safe handling and use as specified

Page 2 of 3 Fact Sheet No. 20—2/97

Occupational Safety and Health Administration (OSHA). Code of Federal Regulations,

Compressed Gas Association (CGA). Safe Handling of Compressed Gas Cylinders,

Fact Sheet No. 20—2/97 Page 3 of 3

Grounding of Portable and Vehicle Mounted Welding

Fact Sheet No. 29 — 07/04 Page 1

Metal Water Pipe—Typically an under- Some basics:

Fact Sheet No. 29 — 07/04 Page 2

Fact Sheet No. 29 — 07/04 Page 3

National Fire Protection Association

Fact Sheet No. 29 — 07/04 Page 4

Cylinders: Safe Storage, Handling, and Use

INTRODUCTION Compressed Gas Association (CGA)

Fact Sheet No.30 — 3/05 Page 1

Fact Sheet No.30 — 3/05 Page 2

• Open valves slowly by hand to avoid SUMMARY

Fact Sheet No.30 — 3/05 Page 3

Compressed Gas Association (CGA). Safe

National Fire Protection Association

Fact Sheet No.30 — 3/05 Page 4

Coated Steels: Welding and Cutting Safety Concerns

INTRODUCTION Coatings may give off fumes and gases

Fact Sheet No. 34 — 9/09 Page 1

• Find out what hazardous materials are INFORMATION SOURCES

• Use a respirator when required. American Welding Society (AWS). Safety

• See AWS Fact Sheet 25, Metal Fume

• See AWS Fact Sheet 11, Hot Work in

Fact Sheet No. 34 — 9/09 Page 2

Railroad Welding Specification

Supersedes AWS D15.1:2001

Under the Direction of the

550 N.W. LeJeune Road, Miami, FL 33126

Figure Page No.

Railroad Welding Specification

1. Scope 2. Normative References

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