Preface ‘This Handbook is intended to assist the welder, supervisor, and inspector, as well as engineer, in the proper use, procedures and inspection of welding in structural steel buildings. It is also intended to assist; by providing commonly needed information in a convenient source readily avaiiable to those performing the work, in the application of the governing spacifications cited by the design documents. and project: specifications. In case of conflict of: ‘interpretation, the standards listed below and the . ‘project specifications govern. : we sa on il al 4 Gomimon governing specications are: ‘Ainerican Welding Society (AWS) 1000 - Structural Welding Code - Stee! 4998 Standard Symbols for Welding, 1g arid Nondestructive Testing (WSS AS-series Filler Metal Specifications ‘American Institute of Steel Construction (AISC) “© Load and Resistance Factor Design Specification for ~ hs Structural Stee! Buildings 2 Allowable Stress Design Specification for ‘Structural Steel Buildings “Local and State Building Codes as applied in the project's jurisdiction ‘As this document provides only summaries of ° standards, procedurés and technical information, and also -because codes and specifications change frequently, users of this Handbook are urged to secure further information, including complete specifications and references, and additional competent advice with respect to the information contained herein for a particular purpose. Structural Welding Quality Handbook a reference guide for fabricators, erectors, ironworkers, welders, inspectors, and engineers involved in structural stee! buildings Steel Structures Technology Center, Inc. New Address Effective Feb, 2001: Steel Structures Technology Center, Inc. 24110 Meadowbrook Road, Ste. 104 Novi, Ml 48375-3406 phone (248) 893-0132 fax (248) 893-0134 wwwsteelstructures.com 55S copyright 2000 Stee! Structures Technology Center, inc. ob4 : 4 8 i Table of Contents Organization of AWS 01.1 : 2000 Limitations of AWS D1.1: 2000... Other AWS D1 Structural Welding Codes... Inspection Inspection - General Provisions Inspection Prior to Welding . Inspection During Welding Inspection After Welding Position Position - Fillet Welds - Plate Position - Groove Welds - Plate Position - Fillet Welds - Tubular Product Position - Groove Welds - Tubular Product Welding Procedure Specifications (WPS) Typical Elements ina WPS... Common Tolerances for WPS Adjustment - Filler Motals Notes to Filer Metal Tables FM through IV . Filler Metal Table FM- . 7 Filer Metal Table FM-IN Filler Metal Tables FM-IIl & FM-IV Assembly Fit-Up Tolerances for Fillet Welds . Measurement of Fillet Welds stale Minimum Filet Weld Size .... Minimium Prequalified PJP Groove Weld Siz Fit-Up and Measurement of Groove Welded Joints Tips for Minimizing Distortion . .. Preheat and interpass Temperature Notes to Preheatintepass Tables PHIT -A through D . Preheat/interpass Table PHIT-A . : Preheatfinterpass Table PHIT-B Preheat/nterpass Tables PHIT-C & PHIT-D 8 a7 .7 Table of Contents Weld Discontinuities Engineering information . 232 Fillet Weld Size... 133 Fillet Weld Convexity 34 Fillet Weld Concavity 35 Groove Weld Reinforcoment | 36 Groove Weld Underfil 237 Location 38 Overiap 239 Undercut 40 Undercut Postible Causes / Recommendations’ nial Crater. hat teedede le 42 Spatter 3 Spater Possible Causes / Recommendations 2 Slag Inclusions Piping Porosity... eee cceeeee : Subsurface Porosity . Laz Porosity - Possible Causes / Recommendations ...... 48 Incomplete Fusion ........... 22 50 Incomplete Fusion - Causes / Recommendations |_| 51 Incomplete Joint Penetration 53 Incomplete Joint Penetration - Causes /Recommendations .............. 54 sitet abcbledad ett 256 o7 Prequalified Groove Welds Identification of Prequalified Groove Welds -- 60 Notes on Prequalified Groove Welds : 61 Bia BPIb.BPIc |... 82 63 64 65 166 eer 67 Figure: B-Lia, BLib .-.- 68 BLib : S68 BU2 i dled 270 Figure: B-U2, B-U2a n B-U2a : 172 BUsa 3 Figure: B-U4a, TCUda |) 74 TOU4a ere 175:sen eit inet ee “ath eset si Table of Contents Shielded Metal Arc Welding (SMAW) 8.1 Class. System for Carbon Steel Electrodes 76 ‘A55 Class. System for Low Alloy Steel Electrodes... 77 Electrode Properties -A5.1 7 Electrode Properties - A5.5 7 179 Exposure of Low-Hydrogen Electrodes =.=... 80 ‘Typical Amperage Ranges .. eae Flux Cored Arc Welding (FCAW) ‘AS.20 Class. System for Carbon Stee! Electrodes . ‘A5.29 Class. System for Low Alloy Steel Electrodes... Electrode Properties -A5.20 ‘ Electrode Properties - A5.29 7 Gas Metal Arc Welding (GMAW) ‘AS.18 Class, System for Carbon Steel Electrodes ‘A5.28 Class. System for Low Alloy Steel Electrodes Electrode Properties - A5.18 Electrode Properties - A5.28 Welder Qualification Using Pate Tests ‘On Plate . et 92 On Box Tube 222s 93 On Pipe .. 7 94 FCAW WPS Adjustments, 95 Ait Carbon Arc Gouging - U-Groove Gouging 2.98 Air Carbon Arc Gouging - Current Ranges .......... 97 ‘Thermal Cutting Quality 98 Oxyacetylene Cutting Tip Sizes... cee 89 Beam Copes and Reentrant Comers... 400 Common Access Hole Details... =... 101 Electrode Diameters ........... ceeeee es 102, Metric Conversion Chart 2222s cece eee. 108 Safety Filter Shades for Welding and Cutting 104 Safely Warnings 105 Welding Symbols .......... oy 106 Notes 0.2.22. 7 108 Organizational Structure of AWS D1.1:2000 Structural Welding Code - Stee! General Requirements Design of Welded Connections ‘Common Requirements of Nontubular and ‘Tubular Connections ‘Specific Requirements for Nontubular Connections ‘Specific Requirements for Cyclically Loaded Nontubular Connections ‘Specific Requirements for Tubular Prequalification of WPSs General Requirements ‘Welding Procedure Specification (WPS) Performance Qualification ‘General Requirements ‘Acceptance Criteria Nondestructive Testing Procedures Radiographic Testing Ultrasonic Testing of Groove Welds, ‘Other Examination methods Stud Welding Strengthening and Repairing Existing Structures1p inte seb AWS D1.1:2000 Annexes Mandar Effective Throat Effective Throats of Fliet Welds in Skewed T- soints | Tnformation, Requirements for impact Testing WPS Requirements ‘Weld Quality Requirements for Tension Joints in Cyciically Loaded Structures Flatness of Girder Webs — Statically Loaded Structures Flatness of Girder Webs ~ Cyclicaly Loaded Structures “Temperature-Moisture Content Charts ‘Manufacturers’ Stud Base Quaiffcation, Requitements, ‘Qualfcation and Calibration of Ultrasonic Units with Other Approved Reference Blocks: “Guideline on Altemative Methods for Determining Preheat ‘Symbols for Tubular Connection Weld Design Nonmandatory Information ‘Short Ciculting Transfer “Terms and Definitions Guide for Specification Writers ‘Utrasonic Equipment Qualfication & Inspection Forms ‘Sample Welding Forms forthe Structural Welding Committee Local Dihedral Angle ‘Contents of Prequalified WPS Safe Practices: ‘Guidelines for Preparation of Technical Inquifes Ultrasonic Examination of Welds by Aternative Techniques ‘Ovalzing Parameter Alpha Requiring Qualification per Section 4 st of Reference Documents ‘Code-Approved Base Metals and Filer Metals Filler Metal Strength Properties “6 tations of AWS D1.1:2000 The use of AWS D1.1:2000 is limited to carbon and low-alloy steels, witha specified minimum yield strength ‘of 100 ksi or less, with a thickness of 1/8 inch or greater. It is not intended for pressure vessels or pressure piping. Reference: AWS D1.1:2000, Section 1. SS Other AWS D1 Structural Welding Codes AWS D1.2 Structural Welding Code - Aluminum AWS 01.3 Structural Welding Code - Sheet Stee! AWS D1.3is applicable for structurat sheet steels with ‘a nominal thickness of 3/16" or less, and for the welding of these sheet steels to structural steel. AWS D1.4 Structural Welding Code - Reinforcing Steet AWS D1.4 is applicable to specific reinforcing steels, and to the welding of these reinforcing steels to structural steel AWS D1.5 Bridge Welding Code AWS 01.6 Structural Welding Code - Stainless Steel AWS D1.6 is applicable to stainless steels in various product forms.Inspection - General Pro ‘A general description of a welding inspector's tasks are provided in AWS DI.1, Section 6, Part A. Pertinent provisions of a general nature include Sections 6.1.5, 6. 6.5.4, and 6.5.5. Based upon these provisions, a list of commonly accepted inspection tasks has been provided on the following pages, along with reference to pertinent AWS, Code provisions citing the quality and/or inspection requirements. This lst should note considered all-inclusive, as additional requirements may be necessary for specific projects or in certain building code jurisdictions. Rather, i ‘should serve as a guide for both the welder and inspector, as well as all others involved, in the inspection of welding for steel buildings. AWS Section 6.1.5 states “The Inspector shall ascertain that ‘all fabrication and erection by welding is performed in accordance with the requirements of the contract documents.” AWS Section 6.5.1 states “The Inspector shall make certain ‘that the size, length, and location of all welds conform to the requirements of this code and to the detail drawings and that no unspecified welds have been added without approval.” AWS Section 6.5.4 states “The Inspector shall, at suitable intervals, observe joint preparation, assembly practice, the welding techniques, and performance of each weider, welding operator, and tack welder to make certain that the applicable requirements of this code are met.” AWS Section 6.5.5 states ‘The Inspector shalt examine the ‘work fo make certain that it meets the requirements of this ‘code. Other acceptance criteria, different from those specified in the code, may be used when approved by the Engineer. Size and contour of welds shall be measured with suitable gages. .." AWS Code Section 6.1.2 distinguishes between inspection performed by the fabricator / erector, termed “Fabrication / Erection Inspection,” and by the owner, termed “Verification Inspection” AWS Section 6.6.1 states that ‘The contractor shal be responsible for visual inspection and necessary correction of all deficiencies in materials and workmanship in accordance with the requirements of this code.” The term contractor, in this section, refers to the fabricator or erector as the contractor responsible for the welding “8 Inspection Prior to Welding Welding personne! qualified Welding equipmert suitable Proper welding materials selected Proper storage of welding mat Sper storage 19 materials SAW ‘Shielding gas type ( used) Proper WPS selected for joint detail We setings (vote, polariy, Teed speed) on weting equipment ‘Shielding gas flow rate setting Fitof pats Fit of backing bar ( used) Rost cpening and groove ange within tolerance and We toerance > Nn ont pee Conon of stae surtace po ee Wied join surtaces fe of iscontnies Existing tack welds clean and of adequate ex equa Environmental conditions Wind velocity within mits Minimum preheat applied if required Maximum preheat verified, if applicable‘speed, travel speed, stickout, ges flow rate, ‘pase location, ele) Inspection After Welding Inspection delay period satisfied (if required) ait Table 6.4 (5) Control of welding materials exposure ‘maintained ‘Minimum interpass temperature maintained Maximum interpass temperature satisfied No detrimental change to environmental ‘conditions Proper technique used (electrode angle, stringer beads) Interpass cleaning satisfactory Weld size and length verifea Weld within profile limitations Weld appearance indicates thorough fusion Weld craters acceptable 5302 Table 6.1 (1) 51 655 Table 6.1 (6) $24 655 Table 6.4 (4) ‘Table 6.1 (2) Table 6.1 (9) Interpass profies satisfactory ‘Weld passes meet quality requirements Undercut within limitations Porosity within mitatons Ae stikes checked end ground Table 6.1 (7) Table 6.1 (8) NDT, in process, when required -10- Backing bars removed (frequred) Weld tabs removed ( equred) Weld surface contour (requires) ‘Surface rsh required) NOT completed (required) Inspection mark completed Documentation completed alleFillet Weld Positions on Plate Groove Weld Positions on Plate » v Ww Flat Position i 1F : Flat Position v. 1G Horizontal Position ; 2F Horizontal Position 4 2G Vertical Position bs Vertical Position 3G Overhead Position ‘ Overhead Position 4F ae Inclination of Axis orto tse | 150"10 210° Flat orto 1s" | 150°to 210" 125% to 150" orto 15° | 80° to 150° 210° to 235 Horizontal oto | ao 8 astoae | 125"10235° : sstto eo | 80" to 280° D Bortose | Oto 360" Vertical Broro oineer 2 Oto 128" Oto 80" | 235° 360" Overhead ortoaor | oto 80" c 280° 10 360" “12. “1.| Fillet Weld Positions on Tubular Product Groove Weld Positions on Tubular { Product Flat Position Ac Position 1F Rotated Rotated Horizontal Position Horizontal Position 26 2F Not Rotated Not Rotated : Horizontal Position 5G 3F Not Rotated Rotated 6G ar Not Rotated Not Rotated 6GR Not Rotated 5E Restriction Plate Not Rotated Reference: AWS D1.1:2000, Figure 4.4 Reference: AWS D1.1:2000, Figure 4.6 bptenernsoTypical Elements in a Welding Procedure Specification (WPS) Welding process (SMAW, FCAW, GMAW, SA\ Procedure Qualification Record (POR) Number (if qualified) Joint type (Butt, tee, comer, lap, edge) Base metal Material thickness range ‘Welding position Progression (if vertical) Filler metal classification Filler metal brand name (FCAW, GMAW-C, SAW) ‘Shielding gas composition (FCAW-G, GMAW) ‘Shielding gas flow rate (FCAW-G, GMAW) ‘Shielding gas cup size (FCAW-G, GMAW) Flux type (SAW) Groove Welded Joints Root opening Root face Groove angle Groove radius (for J and U joints) Backing requirements and type Backgouging requirements Minimum / maximum preheat temperature Minimum / maximum interpass temperature Number of passes Voltage (except SMAW) Current (amps) or wire feed speed Polarity ‘Travel speed Transfer Mode (for GMAW) Technique requirements (stringer or weave bead) Placement of weld passes Contact tube to work distance (stick-out) Post heating Post weld heat treatment Reference: AWS D1.1:2000, Annex E -16- Common Tolerances for WPS Adjustment Shielding Gas Flow Rate +25%, -10% Heat Input (if controlled) +10%, - not limited Preheat and Interpass Temperature + not limited, -25°F Heat Input = 60 * Voltage * Current / Travel Speed Heat Input in Joules per Inch Travel Speed in Inches per Minute * SMAW range limited to that specified by the electrode manufacturer Reference AWS D1.1:2000, Section 3.6, Table 4.5 aecnet roan nn nse nm aes Notes to Filler Metal Tables FM | through IV ‘These tables include “matching’ filer metal information for structural steels approved by AISC, but not listed as prequalified by AWS D1.1. These steels are identified by the use of italics. Steels not listed as prequalified by AWS D1.1 must be evaluated for their weldabilty, Weldabilty may be evaluated using methods such as carbon equivalency, the performance of WPS qualification testing, or physical testing such as the ‘Tekken test, Lehigh Restraint Cracking Test, or the Varestraint Test. ‘Quenched and tempered steels are not listed in this table, and are not prequalified under AWS Table 3.1. ‘See AWS D1.1:2000, Annex M for these steels. +. Alloy groups 83, B3L, B4, B4L, 85, BSL, BG, BEL, 87, B7L, B8, B8L, B9 are not prequalified. Reference AWS D1.1:2000, Table 3.1 “18. Table FM-1 “Matching” Filler Metal for AISC-approved structural steols, including those prequalified under AWS 01.1, Table 3.1, and those not considered prequalified (shown in italics) ‘Shapes and Plates A368 ‘A529, grade 42 ‘A708, grade 36 48529, grade 46 ‘A283, grade D (plates) Round and Rectangular Sections ‘AS3, grade B (round) ‘A500, grades A and B (round) ‘A500, grades A and B (rectangular) A501 (Found) ‘A500, grade C (round) ABS: ETOXKX! FCAW ‘A5.20: E6XT-X, E6XT-XM ETXT-X, E7XT-XM (Except -2, -2M, -3, -10, -13, -14, GS) 5.28: EGXTX-X', EOXTX.X'M ETXTX-X', ETXTXX'M GMAW ‘A5.18: ER7OS-X, E70C-XC, E70C-XM (Except -GS%)) ‘A5.28: ER7OS-X"XX, E70C-X'XX SAW (AS.17: FOXX-EXXX, FEXX-ECKXK PTXK-EXXX, FTXXECKXXK “19.4 $ Table FM-II “Matching” Filler Metal for AISC-approved structural steels, including those prequalified under AWS D1.1, Table 3.1, and those not considered prequalified (shown in italics) ‘Shapes and Plates ‘A572, grades 42 and 50 ‘A588, 4 in. thick and under ‘A708, grades 50 and 50W A913, grade 50 ‘A992, grade 50 (shapes only) A242, all grades ‘A529, grades 50 and 55 ‘A588, over 4 in. Round and Rectangular Sections ‘A618, grades Ib, I, and til round) ‘A800, grade C (rectangular) ‘A618, grades ib, I and il (round) A847 ‘sMAW ‘A5.1: E7OXX, low hydrogen ‘A5.5: E7OXX-X', low hydrogen FCAW. ‘AS.20: E7XT-X, E7XT-XM (Except -2, -2M, -3, 10, -13, -14, -GS) A629: ETATX.X', E7XTXX'M maw ‘A5.18: ER70S-X, E70C-XC, E70C-KM {Except -GS00)) 5.28: ER7OS-X"XX, E7OC-X'XX SAW AB.AT: ETXX-EXXX, FTXX-ECKXK 5.23: F7XX- BOOK, PECK Table FM4Il “Matching” Filler Metal for AISC-approved structural steels, including those prequalified under AWS D1.1, Table 3.1, and those not considered prequalified (shown in italics) ‘Shapes and Piates ‘AST2, grades 60 and 65 ‘A913, grades 60 and 65 ‘sMAW ‘AS.5: EBOXX-X', low hydrogen FCAW ‘5.29: EBXTXX', EBXTXX'M GMAW ‘A5.28: ERBOS-X"XX, EBOC-X'XX SAW 85.23: FEXX-EXXXX', FEXX-ECKXX' Table FMV Shapes and Plates ‘A703, grade 70W_ A852 ‘SMAW ‘A8.8: EQOXX-X’, low hydrogen E018 FCAW ‘5.29: ESXTX-X', EOXT-X'M GMAW ‘A8.28: ERGOS-X"XX, EQOC-X'XX SAW (95.23: FOXX-EXXX-X", FOXK-ECKXX? 2: Assembly Fit-Up Tolerances Measurement of Fillet Welds 7 for Fillet Welds ‘The gap between assembled parts should be no more than 1/16". Convex Fillet Weld No adjustment to filet leg size is needed i the gap is d Pbhespehetsrel 1/16" or less. 3 f eoeuiatae Zo semrireeetie Ifthe gap is more than 1/16", then the leg of filet weld fee ‘must be increased by an amount equal to the amount of the gap, up to a maximum limit of 3/16" gap. a Ifthe gap is more than 3/16", permitted only i the parts exceed 3" in thickness, then the leg size must be increased accordingly, and a suitable backing material must be used at the root of the fillet weld, ‘Concave Filet Weld Fora concave tet wets, messure the taal of te ey ; ? ‘etwot win aon {fthe gap exceeds 3/16" with thinner materials, consutt £ Pr stiae and vert at ne frost eee ey sue the Engineer. ‘een ened live roots aden eg soe Reference AWS D1.1:2000, Section 5.22.1 te ‘ned rot be messes See Frovous pgeforatabicel ee etwas ee guenieg Measurement of Fillet Welds ‘Unequal Leg Fillet Weld Size Specified Throat = {rounded to nearest 1/32") Foran unequalieg conver ‘et wel, measure each og ‘of he fet wels wih ‘suitable gauge and verty Ahateach eg size spectes 's provided. Fora unequa’ eg tet weid with a concave ofl, measure te tvoat ae above 11182" 17132" For filet welds in skewed joints, see AWS D1. 1.2000, s+ Figure 3.41 and Annex I 8eet Minimum Fillet Weld Size imum Size of Fillet Weld” 118" to 1/4" incl over 1/4” to 1/2" incl. over 1/2" to 3/6" incl. *ForSMAWrnon dowhydrogen welding done without preheat calculated in accordance with AWS Section 3.5.2, the thickness shown is the thickness of the thicker par joined, For this application, single pass welds must be used to produce the minimum size noted. For low-hydrogen welding processes (FCAW, GMAW, SAW) and SMAW non-ow hydrogen processes using preheat to avoid cracking following AWS Section 3.5.2, the thickness noted is the thickness of the thinner part. "Except that the weld size need not exceed the thickness, of the thinner part joined. Preheat may be needed to avoid ‘cracking when welds smaller than those shown are used, ‘Minimum size for cyclically loaded structures is 2/16°. Reference AWS D1.1:2000, Section 5.14 and Table 5.8 Minimum Prequalified Partial Joint Penetration Groove Weld Size ‘Minimum Weld Size Base Metal Thickness* 118" t0 3/16" incl. over 3/16" to 1/4" incl. over 1/4” to 1/2" incl. over 1/2" to 3/4" incl. over 3/4" to 1-1/2" incl over 1-1/2" to 2-1/4" incl. over 2-1/4" fo 6" incl. * For SMAWnon ‘ow hydrogen welding done without preheat calculated in accordance with AWS Section 3.5.2, the thickness shown is the thickness of the thicker part joined. For this application, single pass welds must be used to ‘produce the minimum size noted. For low-hydrogen welding processes (FCAW, GMAW, SAW) and SMAW non-ow hydrogen processes using preheat to avoid cracking following AWS Section 3.5.2, the thickness noted is the thickness ofthe thinner par. “Except that the weld size need not exceed the thickness. of the thinner part joined. Preheat may be needed to avoid cracking when welds smaller than those shown are used. Reference: AWS D1.1:2000, Table 3.4 and Section 3.12.21Fit-Up Tolerances and Measurement of Groove Welded Joints Root not backgouged Root face of joint Not limited Root opening of +1ne joints without 18" backing Root openit joints with backing Not applicable | Reference AWS D1.1 2000, Section 5.2.4.1 and Figure i 63 Groove angle Tips for Mi imizing Distortion Q Do notoverweld. Q Contro! the ftup. O Use intermittent welds where possible. Q When filet welding, use the smallest leg size permitted. When groove welding, use the minimum root opening and groove angle permitted Q Select joints that require the least filer metal; for ‘example, a double-V joint instead of a single-V joint. Q. With two-sided multiple-pass welds, weld alternately on either side of the joint Use the minimum number of weld passes. O _Use high deposition rate processes. Q Balance welds about the neutral axis of the member. Q Distribute the welding heat as evenly as possible using planned welding sequence. O Weld from the center of the member's length toward the unrestrained ends of the member. Q_ Useclamps, fixtures, or strongbacks to maintain fitup and alignment. Q Prebend the members or preset the joints to allow ‘shrinkage to pull them back into alignment. O Weld first in the welding sequence those joints that contract the most. Q Weld the more flexible sections fist, then straightening, itmecessary, before final assembly. Sequence subassemblies and final assemblies so that the welds continually batance each other about the neutral axis of the section. 27Notes for Tables PHIT - A through D These tables include minimum prequalified preheat and interpass. temperature. information for structural stock, ‘approved by AISC and lsted as prequalified by AWS Dit bul algo include steels not feted as prequaifed by AWS, 1.1. These steels are identified by the use of italics. Steels not listed as prequalified by AWS D1.1 must be ‘evaluated for the suttablity of the minimum preheat and interpass. temperatures through performance of WPS ‘qualification testing per AWS D1.1, Section 4. Engineering judgment has been used to suggest the appropriate, minimum preheat and interpass temperature, for normal applications, for these non-prequalified steels. * if the steel is below 32°F, the steel, in the vicinity of welding, must be raised to and maintained at a minimum temperature of 70°F prior to and during welding, Minimum preheat and interpass temperatures are to be ‘measured, from the point of welding, at a distance of 3°, unless materials over 3" in thickness are being welded. For thicker materials, the temperature is measured at a distance from the point of welding equal to the thickness of the ‘material, Preheat and interpass temperatures are measured just prior to the initiation of the welding arc for each pass, For A709, grade 7OW and A852, grade 70 steels, a ‘maximum preheat and interpass temperature of 40°F for thicknesses up to 1-1/2" inclusive, and 450°F for thickness, greater than 1-1/2", is applicable. AWS 1.1:2000 contains no provisions specifying the location of measurement or maximum preheat and interpass temperatures. This must be specified in the contract documents. A distance of 1" from the point of welding has ‘been suggested for this purpose. Reference: AWS D1.1:2000, Section 3.5, Table 3.2, Section 5.6 28. . Table PHIT-A. “Matching” Filler Metal for AISC-approved 1 structural steels, including those prequalified under AWS D1.1, Table 3.1, and those not considered prequalified (shown in italics) 7 Category A When using SMAW with other than low-hydrogen electrodes ‘Shapes and Plates A36 A829, grade 42 A709, grade 36 A529, grade 46 A283 (plates) Round and Rectangular Sections ‘ASS, grade B (round) ‘A800, grades A and B (round) A500, grades A and B (rectangular) ‘A5Ot (round) ‘A500, grade C (round) Material Thickness of Minimum Preheat Thickest Part at Point of ‘and interpass Welding Temperature 1/8" to 314" incl. 32%" ‘over 3/4" to 1-1/2" incl 150° over 1-1/2" to 2-1/2" incl 25°F over 2-1/2" 300° 20.e Table PHIT-B “Matching” Filler Metal for AISC-approved structural steels, including those prequalified under AWS D1.1, Table 3.1, and those not considered prequalified (shown in italics) Category B When using SMAW with low-hydrogen clectrodes, ‘or FCAW, GMAW or SAW ‘Shapes and Plates A36 A529, grade 42 A709, grades 36, 50 & SOW ‘A572, grades 42 and 50 ‘A588, 4 inch thick and under A913, grade 50 ‘A992, grade 50 (shapes only) A242, all grades: ‘A529, grades 50 and 55 ‘A588, over 4" thick Round and Rectangular Sections ‘ASS, grade B (round) ‘ASOO, grades A and B (round) ‘ASO0, grades A and B (rectangular) ‘ASO1 (round) ‘A618, grades ib, II, and Ill (round) ‘A500, grade C (rectangular) ‘A618, grades Ib, il, and Ill (round) i Ag47 Material Thickness of ‘Minimum Preheat Thickest Part at Point of ind Interpass Welding Temperature 118" to 3/4" incl. 32°64 34" to 1-1/2" incl. over 1-1/2" to 2-4/2" incl over 2-4/2" Table PHIT-C “Matching” Filler Metal for AISC-approved structural steels, including those prequalified under AWS 01.1, Table 3.1, and those not considered prequalified (shown in italics) Category C When using SMAW with low-hydrogen electrodes, or FCAW, GMAW or SAW. ‘Shapes and Plates AST2, grades 60 and 65 ‘A709, grade 7OW (see notes) ‘A852, grade 70 (see notes) A913, grades 60 and 65 Material Thickness of Thickest Part at Point of Welding Minimum Preheat 118" to 3/4" incl. over 3/4” to 1-1/2" incl over 1-1/2" to 2-1/2" inc over 2-1/2" Table PHIT-D Category D When using SMAW with low-hydrogen electrodes, or FCAW, GMAW or SAW, with electrodes of class H8 or lower ‘Shapes and Plates A913, Grades 50, 60, and 65 Material Thickness of Minimum Preheat Thickest Part at Point of and Interpass Welding tureEngineering Information ‘The Engineer is given considerable discretion by the Code regarding the quality criteria for a given project connection or individual weld. Such discretion granted by AWS D1 1:2000 Section 6.8, which states: “The fundamental premise of the code is to provide jeneral stipulations applicable to most situations ptance criteria for production welds different from those specified in the code may be used fora particular application, provided they are suitably documented by the proposer and approved by the Engineer. These altemate criteria can be based upon evaluation of suitability for service using past experience, experimental evidence or engineering analysis considering material type, service load effects, and environmental factors.” The Commentary to the Code goes onto state that the code provisions are based upon "knowledgeable jement of what is achievable by a qualified welder.” ind “should not be considered a boundary of suitabil for service.” Further, ‘the appropriate quality accepiance criteria and whether a deviation produces a harmful product should be the Engineer's decision.” Substantial research has been performed to establish Teasonable quality acceptance criteria based upon suitability for service, also call “fitness for purpose.” Research papers and guidedocuments are available to document rational quality acceptance based upon performance requirements rather than workmanship expectations. Additionally, numerous international stee! construction codes have adopted such criteria. Frequently, such codes have considerably relaxed ‘quaitty criteria on a fitness for purpose basis, although in some severe loading cases, the quality requirements ate more stringent, Quality criteria may be established in advance for a particular project, or specific decisions regarding weld acceptance may be made when quality fails tomeetthe Code workmanship provisions. -32- Fillet Weld Size Description For equal leg filet welds, the leg length of the largest {isosceles right triangle that can be inscrived within the filet weld cross section. For unequal leg filet welds, the leg lengths of the largest right triangle that can be inscribed within the fille weld cross-section, Measurement AWS D1.1:2000, Section 6.5.1 and 6.5.5 Verify that the size, length, and location conforms to the Code and to the detail drawings. The size and contour of welds must be measured, Unequal Leg Convex nq Acceptance Criteria AWS 01.1:2000, Section 6.9 and Table 6.1 (6) ‘Afillet wold in any single continuous weld shall be permitted {o underrun the nominal filet size shown in the following table, without correction, provided that the undersize portion of the weld does not exceed 10% of the length of the weld. Maximum Permitted Underrun on Leg Si 1116" to 3/16" incl more than 5/16" ‘On web-to-lange welds on girders, no underrun is permitted atthe ends for alength equal to twice the width of the flange. Repair AWS D1.1:2000, Section 5.26.1.2 Prepare surface, then deposit additional weld to achieve acceptable size. “33i ; | | Fillet Weld Convexity Description ‘The maximum distance from the face of a convex filet weld perpendicular to a ine joining the weld toes. Measurement AWS D1.1:2000, Sections 5.24 and 6.5.5, Figure 5.4, Table 6.1 (4) ‘The size and contour of welds must be measured, ia as Acceptance Criteria AWS D1.1:2000, Section 5.24, Figure 5.4, and Table 6.1 (4) Convexity of the overall weld, and of the individual weld beads in a multi-pass weld, shall not exceed the values in the following table: over 5/16" to 1” Repair AWS D1.1:2000, Section 5.26.1.1 Remove excess weld metal “34 Fillet Weld Concavity Description ‘The maximum distance from the face of a concave filet weld perpendicular to a line joining the weld toes. Measurement Need not be measured. Acceptance Criteria ‘There are no limits to concavity, only that the required weld throat is provided. See section on Fillet Weld Size. Repair AWS D1.1:2000, Section 5.26.12 Prepare surface, then deposit additional weld to achieve acceptable size. 35.| i Groove Weld Reinforcement Description Weld metal in excess of the quantity required to fila groove- welded joint Measurement AWS D1.1:2000, Sections 6.5.1 and 6.6.5 Pane T ‘The size and contour of welds must be measured. Acceptance Criteria ‘AWS D1.1:2000, Section 5.24.4, Figure 5.4 (0), Table 6.1 (4) Groove welds must be made with minimum face reinforcement, unless otherwise specified. in the case of butt and comer joints, face reinforcement must not exceed 478" in eight. For TJoints, no maximum groove weld reinforcement provisions apply. ‘All wlds must have a gradual transition to the plane of the steel surfaces, free from undercut except as permitted by this Code, Repair AWS D1.1:2000, Section 5.26.1.1 Remove excess weld metal 236. Groove Weld Underfill Description ‘A condition in which the weld face or root surface extends below the adjacent surface of the base metal. Measurement AWS D1.1:2000, Sections 6.5.1 Verity that the size, length, and location of all welds conform to the requirements of the Code and to the detail drawings. Acceptance Criteria AWS D1.1:2000, Sections 5.13, 5.22.4 and 5.24.4.1 Groove welds should be made with some reinforcement. However, using the acceptance criteria for flush surfaces, underill up to 1/82", or 5% of the steel thickness, whichever is tess, can be permitted. The second criteria is applicable when the steel is 5/8" thick or less. Repair AWS D1.1:2000, Section 5.26.1.2 Prepare surface, then deposit additional weld to achieve acceptable size,i | | Location Description Placement of welds and parts. Measurement AWS D1.1:2000, Section 6.5.1 Verify that the size, tength, and location of all welds conform to the requirements of the Code and to the detail drawings, Acceptance Criteria AWS D1.1:2000 contains no tolerances for weld location, Stifiener location is covered in AWS 1.1:2000, Section 5.23.11, General fabrication and erection tolerances are covered in AWS D1.1:2000 Section 5.23, and in the AISC Code of Standard Practice. ir As required by the E Overlap Description ‘The protrusion of weld metal beyond the weld toe or weld root, also termed “rollover” Measurement AWS D1.1:2000, Section 6.5.5 The size and contour of welds must be measured. An angle between the weld and the steel less than 90° indicates overlap, Acceptance Criteria AWS D1.1:2000, Section 5.4, Figure 5.4 (c), Table 6.1 (4) Overlap is unacceptable. Repair AWS D1.1:2000, Section 5.26.1.1 Remove excess weld metal Overlap Increase travel speed Increase currentiwire feed speed Use smaller electrode Low welding current Large weld size Increase travel speed Incorrect electrode Adjust electrode angle so that angle arc does not push matten puddle over unmelted regions -30-Undercut Undercut Description Agroove melted into the base metal agjacentto the weld toe : or weld roo, left unfilled by weld metal Possible Cause. Recommendation Travel speed too high | Reduce travel speed Measurement — AWS D1.1:2000, Secon 5.24 and 60, Figure 5.4 (C) and Welding vtage 100 | reduce votage Reduce current | | moses eae 7 a Use proper welding current for electrode size and welding position ream ae Reduced are length Acceptance Criteria Electrode angles _| Use proper electrode angles ‘AWS D1.1:2000, Section 6.8, Table 6.1 (7A) - ‘When using aweaving For steel less than 1" thick, undercut up to and including Insufficient dwell | technique pause at each side 1/82" is permitted. A maximum 1/16" undercut is permitted for an accumulated length of 2 in any 12" weld length. For steel equal to or greater than 1” thick, undercut up to ang Including 1/16" is permitted. For cyclically loaded and tubular connections, see AWS Table 6.1.(78) Repair AWS D1.1:2000, Section 5.26.1.2 Prepare surface, then deposit additional weld to achieve acceptable size. -40- ofthe wold bead ‘Adjust location of ground ‘connection Use two or more ground connections Reduce arc length ‘Weld in the direction that the arc blows Use AC polarity Arc blow Reduce current Alea 3 Crater Description ‘A depression in the weld face at the termination of a weld bead. Measurement AWS D1,1:2000, Section 6.5.1 and 6.5.5 ‘The size and contour of welds must be measured. Acceptance Criteria AWS D1,1:2000, Section 6.9, Table 6.1 (3) All craters shall be filled to provide the specified weld size, ‘except for the ends of intermittent filet welds outside of their effective length. Repair AWS D1.1:2000, Section 5.26.1.2 Prepare surface, then deposit additional weld to achieve acceptable size. 42 Spatter Description ‘Metal particles expelied during welding that do not form a part of the weld Measurement ‘No measurement required Acceptance Criteria AWS D1.1:2000, Section 30.2 Tightly adherent spatter remaining after the cleaning operations acceptable, unless its removals required forthe purpose of nondestructive testing. Repair AWS D1.1:2000, Section 5.30.2 {frequired, removed by chipping or grinding, mena curentt©o | Reduce welding curent Too k length Reduce arc length Adjust location of ground connection Use two or more ground connections. Reduce arc length Weld in the direction that the arc blows Use AC polarity Reduce current Wet, dirty or Property maintain and store damaged electrode electrodesard j i i i Surface Slag Description ‘Nonmetallic material on the surface of the weld, generally from flux and impurities in the materials. Measurement No measurement required, Acceptance Criteria AWS D1.1:2000, Section 5.30.1 and 6.30.2 Before welding over previously deposited metal, allslag shalt be removed and the weld and adjacent base metal shall be brushed clean, ‘Slag shall be removed from all completed welds, and the weld and adjacent base metal shall be cleaned by brushing or other suitable means. Repair AWS D1.1:2000, Sections 5.30.1 and 5.30.2. Remove slag from surface, Slag Inclusions Description Nonmetallic material embedded in or below the surface of the weld, generally from the flux and impurities in the materials. Measurement By nondestructive testing technician. ‘Acceptance Criteria AAs required by NDT criteria. See AWS 01.1:2000, Section 6.12 for radiographic acceptance criteria, and Section 6.13 for ultrasonic acceptance criteria Repair AWS D1.1:2000, Section 5.26.1.3. Remove unacceptable slag inclusions and reweld. 44. Slag Inclusions Possible Cause Recommendation Incomplete interpass. slag removal Remove slag between passes Use stringer passes Too wide a weaving motion Reduce width of weaving technique Use a smaller electrode size {for better access to joint Improper joint design Erratic travel speed Increase groove angle of joint Use a uniform travel speed Reposition work to prevent toss of siag control Change electrode or flux to improve slag control Increase travel speed Slag flooding ahead of the welding arc Change electrode angles Reduce arc length Entrapped pieces of lecttode covering | US® undamaged electrodes Oxide inclusions. Provide proper gas shielding 45-tae ste i Piping Porosity Description Elongated porosity whose major dimension lies in adirection ‘approximately normal to the weld surface, frequently called pin holes when extending to the weld surface, Measurement AWS D1.1:2000, Sections 6.5. and 6.9 Visual. Use gauge for measuring diameter when needed. Acceptance Criteria ‘AWS 01,1:2000, Section 6.9, Table 6.1 (8A) Visual piping porosity is prohibited in complete joint penetration groove welds in butt joints transverse to the direction of computed tensile stress. Except as noted below, groove welds and filet welds whose the sum ofthe visible Biping porosity 1/92" or greater in diameter does not exceed 3/8" in any linear inch of weld, and does not exceed 3/4” in ‘any 12" length of weld, are acceptable For cyclically loaded and tubular connections, see AWS Table 6.1 (8B) and (8C). Repair AWS D1.1:2000, Section 5.26.1.3 Remove unacceptable porosity and reweld. -46- Subsurface Porosity Description Cavity-type discontinuities formed by gas entrapment during solidification. Measurement By nondestructive testing technician. ‘Acceptance Criteria See AWS D1.1:2000, Section 6.12 for radiographic acceptance criteria, and Section 6.13 for ultrasonic acceptance erteria, Repair AWS D1.1:2000, Section 6.26.1.3. Remove unacceptable porosity and reweld.Porosity Porosity (Continued) Possible Cause Recommendation Store and maintain electrodes in aclean, dry area nat lt Possible Cause Recommendation Eliminate drafts blowing into the welding arc Electrode contamination Protect electrodes from excessive exposure to dirt and grime when in use Inadequate shielding | !nerease Gas flow rate gas coverage Decrease excessive gas flow ‘ Userecinininged to avoid turbulence in the weld procedures for drying and zene . storing electrodes Reduce nozzle-to-work distance Protect weld region from wind and drafts Reduce travel speed Wind and drafts Reduce fume exhaust system Verify use of welding grade flow rate shielding gas Gas contamination Moisture on joint (Check for leaks in supply eee Use preheat system Remove all grease, oll, moisture, rust, paint, and dirt 7 from work surface before Workpiece ‘contamination welding Excess contact tube- to-work distance Reales sao Arc voltage too high Use filler metals high in deoxidizers Use electrodes with basic High sulfur steet Sagoing reactions Use preheat Rapid solidification rate Increase welding heat input Use low-hydrogen welding processes Excessive hydrogen, nitrogen, or oxygen in | Use filler metals high in welding atmosphere | deoxidizers Increase shielding gas flow rate. 48- 49.Incomplete Fusion Incomplete Fu: sc ie Description Recommendation Location where filer metal and base metal, orfiller metal and previously deposited weld load, fail to melt together and coalesce, Foliow welding procedure specification Increase arc voltage dpaslaiolndnt: Insufficient heat input For surface visual inspection, no measurement is required, For subsurface nondestructive testing, by nondestructive testing technician. Increase currentwire feed speed Reduce travel speed Maintain proper electrode angles Acceptance Criteria AWS D1.1:2000, Section 6.9, Table 6.1 (3) ‘When using a weaving technique, dwell momentarily Visual thorough fusion shail exist between adjacent layers of on the side walls of the groove weld metal and between weld metal and base metal. Improper weld technique Keep electrode directed at the As required by NOT criteria. leading edge of the puddie Minimize weaving for better control Repair T 5 AWS D1.1:2000, Section 5.26.1.3 ee Puddle Increase the travel speed Remove unacceptable portions and reweld Reposition work Weld metal running ahead of the arc Reace care Increase weld travel speed Trapped oxides or —_| Clean weld surface prior to slag on weld groove | welding ‘or weld face (Also see Slag Inclusions)Inadequate gas shielding Improper joint design ‘Adjust location of ground ‘connection Use two or more ground connections Reduce arc tength . ‘Weld in the direction that the arc blows. Use AC polarity Reduce current Increase flow rate Reduce electrode extension Use groove angle and root . opening with adequate access to bottom of the groove and sidewalls Use smaller electrode Use proper electrode extension Incomplete Joint Penetration Description A groove-welded joint root condition where the weld metal does not extend fully to the required depth. Measurement AWS D1.1:2000 Section 6.5.1 Verify thatthe size, length, and location of all welds conform to the requirements of the Code and the deta drawings. No measurement is required. Verified by nondestructive testing technician, unless visible from the root side of weld Acceptance Criteria AWS D1.1:2000 Section 5.24, Figure 5.4(E) Incomplete joint penetration is unacceptable, as insufficient throat is provided. Repair AWS D1.1:2000 Section 5:26.1.2 Remove existing weld metal or backing, as required, to ‘expose portion of root requiring weld. Prepare surface and deposit required weld. Ifthe root is inaccessible, see AWS Section 5.26.4. 53.Incomplete Joint Penetration Insufficient groove angle Excessively thick root face Failure to backgouge when specified Electrode diameter too large Use proper joint geometry Use wider root opening Use smaller electrode in root pass Backgouge to sound metal when required Use smalter electrodes Increase joint access Improper weld technique Maintain electrode angle ‘normal to work surface to achieve maximum penetration Keep arc on leading edge of puddle Decrease arc length Check electrode polarity Slag flooding ahead of welding arc Adjust electrode or work position Reposition work to prevent loss of slag contrat Change electrode or fux to improve siag control Increase travet speed Change electrode angle Reduce arc length Incomplete Joint Penetration (Continued) Insufficient heat input Follow welding procedure specification Increase voltage Increase currentiwire feed speed Reduce travel speed 55Cracks Description ‘A frecture type discontinuity with a sharp tip and a high ratio of length and depth to width Measurement AWS D1.1:2000 Section 5.26.1.4 Visual - No measurement is required, except that the crack tips must be located using MT, PT or other reliable method. Nondestructive Testing - by the NOT technician. Accoptance Criteria AWS D1.1:2000 Section6.9, Table 6.1(1) Visual - Any crack is unacceptable, regardless of size or location, Radiographic Testing - See AWS 6.12.1.1 for statically loaded nontubular connections. All cracks are unacceptable. Uttrasonic Testing - See AWS 6.13 and Table 6.2for statically loaded nontubular connections. Acceptance is ‘based upon indication rating, length and focation. Repair AWS D1.1:2000, Section 5.26.1.4 After locating the tips of the crack, begin 2" beyond the tips of the crack and remove the crack! Starting at each fend reduced the risk of lengthening the crack from the heat of removal. After removal, prepare the surface and reweld. Cracks in the steel, and major or delayed weld and heat- affected zone cracking must be reported to the Engineer {or approval of the repair. See AWS 5.26 3. -56- Cracks Preheat to retard cooling rate Hardening in the heat-affected zone ‘from rapid cooling Follow minimum weld size provisions Maintain required interpass temperatures Use low-hydrogen welding vse Postheat immediately upon weld compton Use dry shielding gas Hydrogen in welding almosphere Remove contaminants and ‘moisture from the steel surface Hydrogen ‘embrittlement Hold weld at elevated temperatures before cooling to difluse hydrogen Redesign the joint or assembly Revise welding sequence stresses : Apply intermediate stross- relief treatment, ether using heat or mechanically it Use matching or Qvermatching filer | ndermatching filer metal, when permitied Reduce excessive preheat Excessive preheat or interpass temperature, causing a coarse-grained HAZ ‘Allow adequate cooiing time between passes to re ‘excessive interpass. temperature “57Cracks (Continued) Cracks (Continued) Possible Cause Recommendation Possible Cause Recommendation Heat-Affected Zone Cracking - Continued Weld Metal Cracking - Continued i Postheat immediately upon High hardenabilty n steel (high carbon or | Weld completion Co Decrease penetration by us composition) Shall elecrodes and heat pat imdate ule ipbed Use low-hydrogen electrodes soso manraan Use low heat input permitted Deposit thin layers. ‘Small weld bead fillet welds and groove | Increase size of weld deposit Tool passes Decrease currentiwire feed speed Preheat to reduce magnitude of fosual sresses Increase travel speed Minimize shrinkage stresses Use balanced welding on both Highty joint rigidity | using backstep or block sides of int welding sequences - Reduce groove angle Relieve residual stresses mechanically or with heat Use correct root opening Increase arc volt sgn ag arto. | Retna zee Fill crater before extinguishing width ratio the weld bead or the are penetration Use back-stepping technique Hainiain proper groove Medea 7" i iensions to allow depos! Ise welding current decay improper joint design | Of" weld cross-section fo device when terminating the overcome restraint conditions weld bead Change to new electrode; bake High sullurstee! oe filer metal iow in sulfur tleetodes fo remove maisture = woe Me ett ow a say Store and maintain electrodes. Defective electrodes | ina clean, dry area Protect electrodes from, excessive exposure to dirt and grime when in use ~58- -59-ass lt | Identification of Prequalified Groove Welds Butt joint ‘Comer joint Tee join 4oo P_ Partial joint penetration groove weld LL. Complete joint penetration groove weld, Limited thickness U_ Complete joint penetration groove weld, Unlimited thickness 4 square groove weld 2 single V groove weld 3. double V groove weld 4_ single bevel groove weld 5 double bevel groove weld 6 single U groove weld 7 double U groove wold 8 single J groove weld 9 double J groove weld 10 flare bevel groove weld F flux cored arc welding G gas metal arc welding 'S_ submerged arc welding Example C-U2aF Comer joint with Unlimited thickness, made as a single V groove weld, using Flux cored are welding ‘The a" is used to distinguish this joint detall from the C-U2-F detail See AWS D1.1:2000 Figures 3.3 and 3.4 for complete details. -60- Notes - Prequalified Groove Weld Details The following prequalified groove weld detail information is intended to provide convenient, basic, essential information for use by welding and inspection personnel. It should not be used for design or detailing of groove welded joints. Users should refer to AWS D1.1:2000, Figures 3.3 & 3.4, a8 well as the notes for those Figures found on page 88 of AWS D1.1:2000, for complete details. Special details that require the use of gas shielding when performing Flux Cored Arc Welding (FCAW-G) are not shown, See AWS D1.1:2000 for these details. GMAW-S, Gas Metal Arc Welding using the Short Circuiting Transfer, is not prequalified under AWS D1.1:2000, Section 43, References to GMAWare applicable to globularand spray transfer modes. ‘When groove detail dimensions are provided for Shielded Metal Arc Welding (SMAW), FCAW and GMAW processes may be substituted for SMAW. For details specifying FCAW or GMAW, SMAW may not be substituted. itshould be noted thatthe detail requirements are often the same for allthree processes. For details using the Submerged Arc Welding (SAW) process, see AWS D1.1:2000, ‘Additional detail requirements may apply when these joints are used in a cyclically loaded (fatigue) application, -61-ona B-Pla Thickness limit T, Groove Preparation Fitup Oto 116" B-P1b Permitted Positions Thickness limit T, As Detailed Tolerance +h ane Fitup Tolerance +1116", -0° Permitted Positions ess limit T, 44" max. Ne As Detailed Tolerance Groove Preparation Fitup Tolerance +116", -0" +16" ‘Thickness leit T, befrstceng Reinforcement between 1/32" and 1/8" required B-P1b ‘Thickness leit T, Root opening B-Pic fFeitercement ‘Thickness lint, i Reinforcement between 1/32" and 1/8" requiredBC-P2 sess BC-P2 / In tc As Fit-up Groove Preparation | Detaled | clorance Bee ng ane bowane| Leal recesses, | +U, -0" Brora py YN 10°, 0° Permitted Positions Thickness limit T, 114" min. 4 “S Thickness limit T, Untimited Groove Preparation | Detaited | {CUP Tolerance | Tolerance Root sane ter |euer Gpening o ane 0° | +418", 1/16" Root Face | 1/8" min. | +U,-0" +116" Groove 7 ota oeel ae Snete 60" 40%, -0 10°, -5 64. -65-B-Lia BTC-P4 bs Permitted Positions _| All Thickness limit T, 4/4" max As ' Fit-up Groove Preparation | Detailed Tolerance | Tolerance Thickness limit T, Unlimited Thickness limit T, Untimited As Detailed Fitup Tolerance | Tolerance sine", 0" | +114", 1116" +1ne" 0° | +178", 116" Root Face Unlimited | _+/- 1/16" Thickness limit T, anor 107,07 | +10%,.5° Angle As Detailed Tolerance 9S=E,F &Hony HS. 178" =€, VEOH ‘Thickness fimit T, Thickness limit T; Unlimited As Fitup Tolerance Groove Preparation | Detailed Tolerance sine ,-or | +118", 116" Unlimited | +/- 1116" 107,07 | +10%,-8°BLia ‘ B-L1b 4 Thickness i Stet: | + | permitted Positions t {| thickness tit, “VA" max . As ‘ : Fitup : | GieoveReraion | eld, | roorance j + [Root 7 ae © [Beng sine -oF | +416, 17" BLib . Thickness tint, | «| Thickness limit T, 378" max, + | Groove Preparation | Detailed Tate : Tolerance j ; 69.inn iis il B-U2 Permitted Positions Thickness limit T, Unlimited Groove Preparation As Detailed Tolerance "to 178" 41/16", -0" +16", 18" Or to 178" +116", 0° B-U2 Permitted Positions Thickness limit T, 10°, 0° Unlimited Groove Preparation AS Detailed | toranee Fitup Tolerance Root Opening orto 18" +1N6",-0" +16", 8" Root Face O"to 1/8" +116", 0" Not limited Groove Angle 60° +10", 0° -70- +109, 6° “TeB-U2a SMAW aon B-U4a Permitted Positions" | (A)- All ®- Unlimited Thickness Groove Preparation Root Opening - Groove Angie _(A) Root Opening - Groove Angle _(B) Root Opening - Groove Angle _(C) Permitted Positions Thickness limit T, Groove Preparation Root Opening - Groove Angle Root Opening - Groove Angle 114" 45° Asdeiaied [Aste | [rostrening | sino.or [svn | = “72 Thickness limit T, Unlimited Groove Preparation Root Opening - Groove Angle FCAW & GMAW Permitted Positions (a)-all Thickness limit T, Groove Preparation Root Gpening “Groove Angle (8) [Root Opening -Groove Angle (6) | 36-20" | [tolerances [As betaied | Asritue | [sroove ange [sion [vos | 73.anal bie ec B-Uda aR natal 1 Groove angle F Thickness it T, TC-U4a . TC-U4a Permitted Positions (a)- All (®)-F, V,Honly + [ices [uns | FCAW & GMAW Permitted Positions ~All (®)-F only Thickness limit T, Uniimited Groove Preparation Root Opening - Groove Angle (A) Root Opening - Groove Angle_(B) 4" 45° Root Opening +1116", -0" +1/4" , 16" [sroove angie [soo [sions | “75.AS.1 Classification System for Carbon Steel Electrodes for SMAW EXXPYM-1HZR ‘Minimum tensile strength in units of ksi ‘60 = 60 ksi TO= 70 ksi Generally, welding positions permitted for use, but may be ada med by electrode diameter and Te postions , H, V, OF) 25, Hfilets 4= FH, V-down, OH of covering igh cellule sodium (E6010) 0 = high ren oxide (E6020) igh callulose potassium high tania sodium 3 = high titania potassium tow byaregen sod an Se ron ponder a= low tm, Fen powder eon Evbi eid = ton one tana potassium {f present, meets special Miltary specifications, afi covering tow hyorogen Ror powder It present, indicates improved notch toughness {see AWS A5.1, Table 3) for 7016-1, average CVN of 20 fibt for E7018-1, average GVN of 20 fbi for 7024-1; average CVN of 20 flibt © -OF Optional supplemental diffusible hydrogen designator (iS = maximum 16 ml 100 9 deposited weld metal HE. = mainum 8m | 1009 deposted weld meta maximum 4 mL! 100 g deposited weld metal (ote: E7018M meets H4 requirements, but the 14 designation is not used) Ifpresent, indicates electrode has lower moisture content and meets absorbed moisture test requirements (note: E7018M must meet more stringent requirements, but the R designation is not used) 76. AS5.5 Classification System for Low-Alloy Steel Electrodes for SMAW EXXPYM-AHHZR ‘Minimum tensile strength in units of ksi 70=70ksi 100 = 100 ksi 80=80ksi 110 = 110k 90=90ksi 120 = 120 ksi fan ral Idi itions ited for use, eran diameter: ‘and class zall 2 positions (F, H, V, OH) Tieton high cellulose sodium (except E7020) eee tapas cr, ore Seats ‘except exe) {= toro ana potassium if present, meets special Miltary specifications, and covering is low hydrogen, iron powder [ia sron-molybd¢ teal Witton moidenum x Stonuuneoyoaerum dee! cel stee! Optional supplemental diffusible hydrogen. designator HIB = maximum 16 mi. / 100 g deposited weld metal HS = maxirum gmt 100 gdevosted wid etal maximum 4 mL / 100 deposited weld metal (pote: EXXt8M meets 4 requirements, bulthe 14 designation is not used) present, indicates electrode has lower moisture Content and meets absorbed moisture test requirements 7SMAW Electrode Properties - A5.1 + SMAW Electrode Properties - A5.5 AWS AS.t Carbon Stee! Electrodes for SMAW "AWS AS.5 Low-Alloy Stee! Electrodes for SMAW [Low Hydrogen, 70 ksi . [Low Hydrogen, 70 and 80 ksi] 4 a 4 zonEt@.20F E7015-X one @-20F E7016-X Zonet @ 20 E7018-X SOR @-20F E8015-X* DK @OF ona @.20F ae) E8018-x? onwt@.soF ONG GOF ‘- B3, B3L, BL, 85, 86, B7, B7L 88, BBL, and B9 series electrodes are not prequalified under AWS D1.1 ‘+0 H designation used for E7O18M 2. ETOXX-XR and E7OXX-X-HZR series Moisture Content Limit (as received) = 0.3, -78- -79.Permissible Atmospheric Exposure of Low-Hydrogen SMAW Electrodes Over 4 to 10 max Over 4 to 10 max Over 2 to 10 max Over 4 to 5 max Over 1/2 to.4 max Over 1/2 to.4 max Electrodes exposed to the atmosphere for time periods longer than shown above must be redried before use. If redrying facilities are not available, the electrodes should be disposed of. Electrodes should be issued and held in quivers, or other small open containers. Heated containers are not mandatory. ‘The optional supplemental designator, R, designates a low- hydrogen electrode which has been tested for covering moisture content after exposure to a moist environment for hours and has met the maximum level permitted in ANSAWS A5.1, Specification for Carbon Stee! Electrodes for Shielded Metal Arc Welding. 8 Reference: AWS D1.1:2000, Table 5.1 and Sections 5.3.2.2 and 5.3.2.3 -80- SMAW Typical Amperage Ranges [Low-Hydrogen, 70 ksi] “81.A5,20 Classification System for Carbon Steel Electrodes for FCAW EXPT-YMJHZ Electrode A5.29 Classification System for Low Alloy Steel Electrodes for FCAW EXPTY-AM Electrode ‘Minimum Tensile Strength in units of 10 ksi 6 = 0 ksi 7= 70 ksi Position of welding permitted = flat and horizontal position only 1 = all positions, Tubular electrode: ‘Type of electrode, numbered 1-14, or letter G or Gs H used, electrode has been classified using 75- 80% Ar, with balance CO, If used, electrode has toughness of 20 ftibf @ -40°F. If not used, electrode has toughness as listed in A5.20, table ¢ Optional supplemental diffusible hydrogen designator HI6 = maximum 16 mL / 100 g deposited weld metat 18 = maximum 8 mL / 100 g deposited weld metal H4_= maximum 4 mL / 100 g deposited weld metal -§2- Minimum Tensile Strength in units of 10 ksi 6= 60ksi T= 7Oksi B= 80ksi 9= SOksi 10= 100 ksi 14 = 110 ksi 42= 120 ksi Position of welding permitted (= flat and horizontal position only 1 = all positions Tubular electrode Type of electrode, numbered 1, 4, 5, or 8 1&5 -gas-shielded 488. self-shielded Alloy type ‘A carbon-molybdenum stee! B chromium-molybdenum steel © nickel steel 1D manganese-molybdenum steet K other alloy steels W weathering steel I used, electrode has been classified using 75- 180% Ar, with balance CO,FCAW Electrode Properties - A5.20 AWS A5.20 Carbon Steel Electrodes for FCAW [70 ksi, Multipass Only} E70 20 RO @ OF ETOT-AM 20n@ OF ents ' om @ OF errr 208M OOF enra | none spactiag evors 20RIM @ 20° rors 20 Rt @ 20% Ens 20 Rib @ 20°F erin 20 Riot @ 20° Evor-e Zonet @ 20% ‘one spectied ‘one specie’ 20m bt @ 20°F 20 @ 20°F evore [FH co, | ocep | 2onme 20% crore Ten | rsaneae | over | onare cor ents [ruv. | co, | vce | 2onut@20° 0H ents 2oRibt @ 20° 7seo%a | cer CO, FW set] OCEN | none spestes sates emmar fem [ser | oceN | none spected gn, OH stvelded a fe 0, | coer | zoner@ 20% Bene 20 May be either 6 or 7, for 60 ksi or 70 ksi tensile strength. - Use of this electrode on materials over 3/4 inch thick is not recommended. «Electrodes with ‘J’ at the end of the designator (e.g. E7XT-9J) have minimum CVN Toughness of 20 fHbf @ - 20°F 4. Electrodes classified using the shielding gas listed shall not be used with any other shielding gas mixture without first ‘consulting the manufacturer. Note - EXXT-2, 3, -10, 13, -14, and -GS electrodes are not permitted by AWS D1.1 because they are limited to single ass welds, Note - EXXT-3, EXXT-11, and EXXT-14 are for imited thickness applications only, and the manufacturer's recommendations should be consulted.pa ek. FCAW Electrode Properties - A5.29 AWS A5.29 Low Alloy Stee! Electrodes for FCAW 160 to 80 ksi, Multipass Only} — errant woe [rn co, | ocep | samearr core | rm co, | ocr | merearr eormma [ruvon | co, | ocer | soatt@aor reorina | FH co _|_ocep_| waweawr eerrene [rnv.on | co, | ocer | zontie-arr eorew | rm co, | ocer | conee@aor worse [ew co, | acer | nenesecote eeorsea_| eH co, | nese | ronespeted eoorset | RH co | coer | sonsrecor -86- 4 Electrodes classified using the shielding gas listed shall not be used with any other shielding gas mixture without first ‘consulting the manufacturer. Note - EXXT-XM electrodes, a subclass of the gas-shielded electrodes listed above, are tested using 75-80% Argon shielding, with the balance CO, Note - 83, B3L, BAL, 85, 86, 87, B7L, BB, BBL, and BO series electrodes are not prequalified under AWS D1.1 87a ei i AWS A5.18 Classification System for Carbon Steel Electrodes for GMAW ERXXS-AGNHZ ERXXC-AGNHZ AWS A6.28 Classification System for Low Alloy Steel Electrodes for GMAW ER XXS-AAAHZ ER XXC-AAAHZ Electrode Electrode R__| fused, designates that electrode may also be used as filer rod for GTAW XX | Minimum Tensile Strength in units of 1 ksi 70 = 70 ksi Sor | S= Solid wire C__| C=Composite (metal cored) wire A | Chemical composition of solid wire, or of weld deposit of composite wire G = unspecified composition fused, designates that electrode may also be used as filler rod for GTAW Minimum Tensile Strength in units of 1 ksi Composite (metal cored) wire 6 _| Shielding gas used for classification testing C= CO, shielding gas M= 75-80% Ar, balance CO, N_ | tfused, indicates composition timits for nuclear ccore belt applications HZ__| Optional supplemental dusible hydrogen designator 16 = maximum 16 mL / 100 g deposited weld metal 1H = maximum 8 ml / 100 g deposted weld metal 4 = maximum 4 mL / 100 g deposited weld metal H2 = maximum 2mL / 100 g deposited weld metal -88- Chemical composition of solid wire, or of weld deposit of composite wire ‘A = carbon-molybdenum steel B = chromium-molybdenum stee! Ni= nickel steel 1D = manganese-molybdenum stee! 1. = olher alloy steels G = not specified ‘Optional supplemental diffusible hydrogen designator 16 = maximum 16 mL / 100 g deposited weld metal Ha) = maximum 8 ml./ 100 g deposited weld metal Ha. = maximum 4 mL / 100 g deposited weld metal H2_= maximum 2 ml/ 100 g deposited weld metalGMAW Electrode Properties - A5.18 Carbon Steel Electrodes for GMAW [70 ksi only] Zon @ 20% ZR @ OF not requited cee not requios ocer | zonwr@.20°F Onde 20°F as agreed 20nd @ OF 20 Rr O% *.- Electrodes classified using the shielding gas listed shall ‘not be used with any other shielding gas mixture without first consulting the manufacturer. Notes: + E70C-GS(X) electrode is limited to single pass applications, and is not prequalified. * Allabove electrodes optionally available as H16, H8, and Héfor diffusible hydrogen requirements. -0- GMAW Electrode Properties - A5.28 Low Alloy Stee! Electrodes for GMAW [70 to 80 ksi, Multipass Only} 20 RIE @ 20°F not roquied ereos.nit | Ar/1-s% 0, 20M @ 50% 2 nse @ 80°F DRG 100% 20 @ 20°F ersosn2 | arit-s% 0, ERAOS-NIS ALI1-5% 05 eRe0s-02 0, eeoc-B2 ALI. 0, rotreguied Ee0C-Ni A145 0, Zon @ 50°F 20 @ 80° Eecn2 | ar/t5% 0, AL15-5% 05 ‘- Electrodes classified using the shielding gas listed shell not be used with any other shielding gas mixture without first cconsutting the manufacturer. Notes: + B3, BSL, B6, BB and B9 classification electrodes are not prequalified + Allabove electrodes optionally available as H16, H8, H4 and H2 for diffusible hydrogen requirements. 91.Welder Qualification Using Plate Tests Reference AWS D1.1:2000, Table 4.8 Production Plate Welding Qualified ‘isites Pa & St Woking For Onl The Postins Tested Qualification Test Notes: (@) See AWS es 4.3, 4.4, 45, and 456. (b) Groove Weld qualification also qualifies plug and slot welds for the test positions indicated. (See AWS Table 4.9 for dihedral angle restrictions for plate joints, $2- Welder Qualification Using Plate Tests Reference AWS D1.1: 2000, Table 4.8 Production Box Tube Welding Qualified Qualifes Plug and Slot Welding For Only The Positions Tested 5 3 3 Qualification Weld Type Notoer (a) See AWS Figures 43, 4.4, 4.5, and 46. (©) Groove Wel qualifcation also qualifies plug and stot welds for the test positions indicated. (@) Not qualified for joints welded from one side without backing, or welded from two sides without backgouging {e) Not qualified for welds having groove angles less than 20° (see AWS Section 4,124.2) (f See AWS Table 49 for dihedral angle restrictions for plate joints -93-{ Welder Qualification Using Plate Tests Reference AWS D1.1:2000, Table 4.8 Qualified z & é § 3 i ‘Qualifies Plug and Sit Weng For Only The Postions Tested Qualification Test Weld | [ss pe Notes: (@) See AWS Figures 43, 44,45, an 45, (©) Groove Weld qualita aso cuales pug and slot welds forthe test positon ineeated (6) Only uated for pipe over 24 in. (610 min in iarater with backing, ‘backgooging, oben (@) Not qualited for welds raving groove angles less than 20° (soe AWS Section 41242) (See AWS Table 4.9 for dinedtal angle estictons for ae joins 94 FCAW Welding Procedure Adjustments V= Voltage WES = Wire Feed Speed 80 = Stickout TS= Travel Speed oA Or eased of steel) ‘A= increase Y= decrease Reduce porosity VY¥.50 ¥, 04 a, TS, WES VA.DAY, SOY, WES ¥, 1S Reduce convexity VA, SV, DAA, WES ¥, TS Reduce arc blow DA A, $0 A.V. WES W, 7S VYV.S0 A. DA A. WES A. TS Eliminate stuboing VA, DAY, SO, WES ¥ VA,DA 4, SO¥ Increase penetration SOV, WFS AVY. TS AOA Decrease penetration ‘Suggested changes to Welding Procedure Specification (WPS) and techniques are listed in order of effect. Note that changes to essential welding parameters such as voltage, wire feed speed, stickout and travel speed, must be coordinated to ensure that the adjusted procedure stil falls within the intial WPS, or is qualified by testing. Also refer to listing of specific discontinuities for additional ‘suggestions for resolving specific welding problems. 95-Ase see debs, Air Carbon Arc Gouging U-Groove Gouging Conditions If the groove depth desired is more than 1-1/2 times the electrode diameter, use multiple passes to prepare the groove. Air Carbon Arc Gouging Suggested Current Ranges Diameter finches) DC Electrodes, DCEP Polarity Sa {amperes) 30 60 97.Thermal Cutting Quality Thermal cutting processes included in AWS 01.1:2000 include oxyfuel gas cutting, electric are cutting, and electric are gouging, also commonly referred to as ait carbon are gouging AWS Section 5.15 generally addresses the ‘preparation of base metal AWS Section 5.15.4.2 states “Stee! and weld metal may be thermally cut, provided a smooth and regular surface free from cracks and notches is secured, and provided that an accurate profile is secured by the use of a mechanical guide. For cyclically loaded structures, freehand thermal cutting shall be done only where approved by the Engineer.” ‘The surface roughness requirements for a thermally cut surface are contained in AWS Section §.15.4.3. + For materials up to 4 inches in thickness, the surface roughness must not exceed 1000 microinches (AWS Surface Roughness Guide Sample No. 3) + Formaterials 4 inches to 8 inches in thickness, inclusive, the surface roughness must not exceed 2000 microinches (AWS Surface Roughness Guide Sample No.2) + The ends of members that are not subjected to calculated stress (suchas typical beam ends), regardless ‘of material thickness, are permitied to have a surface roughness not to exceed 2000 microinches (AWS ‘Surface Roughness Guide Sample No. 2). ‘Surface roughness values are as defined in ASME B46.1, ‘Surface Texture (Surface Roughness, Waviness, and Lay). ‘The AWS Surface Roughness Guide for Oxygen Cutting, a plastic model containing four representative surface Toughness values, is AWS item C4.1-77. ‘The depth of gouges and notches made by thermal cutting ate limited in AWS Section 5.15.4.4. Gouges and notches of 3/16 inch in depth and less are permitted without repair. Deeper notches and gouges must be removed by grinding or machining, although they may also be repaired by welding with the approval of the Engineer. When removal is performed, the nominal cross-sectional area must not be Teduced by more than 2%. AISC Specifications prohibit sharp V-shaped notches in thermal cut surfaces subjected {0 calculated tensile stress, Cut surfaces and the areas adjacent to them must have all slag removed. 98. Oxyacetylene Cutting Tip Sizes for Cutting of Structural Steels 0.060 - 0.080 0.080 - 0.090 0.098 - 0.110 0.095 -0.110 0.110 -0.130 99.Beam Copes and Reentrant Corners Beam copes occur where the top or bottom flange are removed, along with a portion of the web, to avoid ‘assembly interference with the member into which itis framing, AISC and AWS recommend the practice of cutting the flange first, along a bevel, to minimize the ‘chance of leaving notches at the corner of the beam cope. ce A aS ecrrmanage ~ | ‘eoepiabie Tesepabe AWS D1.1: 2000, Section 5.17 addresses beam copes. 'No minimum radius is required for beam copes, nor grinding, only that: there is a smooth transition free of notches, there is no cutting past the points of tangency (where the radius meets the straight portion of the cut), and + the thermal cut surface meets the surface roughness. requirements of AWS Section 5.15.4.3. AWS D1.1:2000, Section 5.16 addresses reentrant corners. A reentrant comer would include holes cut in ‘members to provide web openings. Similar to beam copes, the following requirements apply: + there is a smooth transition free of notches, + there is no cutting past the points of tangency (where the radius meets the straight portion of the cut), and + the thermal cut surface meets the surface roughness requirements of AWS Section 5.15.4.3. In addition, for reentrant comers, there is a minimum radius of 1 inch, For fatigue applications, the contract may establish more stringent requirements, -100- >ty 23/4" radius 2 3/8" (1/2" typical) Shown are typical details used for joints welded from one ‘side against steel backing, using rolled shapes. The radiused portion of the access hole radius must be a Smooth, notefee ranstion wih a minimum rods of 38 For ASTM A6 Group 4 and 5 shapes and welded built-up shapes with @ web thickness more than 1-1/2 inches, preheating to 150°F prior to thermal cutting is required. Afier cutting, grind and inspect the thermally cut edges of the access hole using magnetic particle or dye penetration methods. AISC Specifications contain adaitional provisions regarding welding preheat requirements. Reference: AWS Df.1:2000, Section 5.17, Figure 5.2 -10l-ay Electrode Diameters Metric Conversion Chart 3 4 } To Convert From + Approximate Conversion Factors Approximate Equivalents for Standard AWS: Electrode Diameters ton (2,000 lbs) kg 7164 (4108) 120 118 (4125) metric ton (2,200 tbs) arte (168) F782 (219) 174 (260) -102- -103-ilter Shades for Welding and Cutting Minimum Protective ‘Shade Number Electrode Diameter {inenes) Recommended Shade less than ‘382 5/32. more than 1/4 Minimum Protective ‘Shade Number legs than 500 600 ~ 1000 tess than 300, ‘300 - 400 4400 - 800, Reference: OSHA regulations (Standards-29 CFR) Eye and Face Protection 910.139. -104- Safety Warnings Protect yourself and others. Read and understand this information. FUMES AND GASES canbe dangerous to your heatth. ARC RAYS can injure eyes and burn skin. ELECTRIC SHOCK can kill. + Before use, read and understand the manufacturer's instructions, the Material Safety Data Sheets (MSDSs), and your employer's safety practices. + Keep your head out of the fumes. + Use enough ventilation, exhaust at the arc, or both, to keep fumes and gases away from your breathing zone and the general area + Wear correct eye, ear, and body protection. + Do not touch live electrical parts. + See American National Standard 249.1, Safety in Welding, Cutting, and Allied Processes, published by the American Welding Society, 550 N.W. LeJeune Road, Miami, Florida 33126; and OSHA Safety and Health Standards, 29 CFR 1910, available from the U.S. Govemment Printing Office, Washington, D.C. 20402. -105-9 4\9\f Atier i Welding Symbols ‘Other: Weld or Supplementary Item ret ‘Square Groove Veo Groove ‘Bevel Groove UGeove ‘JGroove Fare Vee Groove Flare Bavel Groove Plug or Sot Weld Lal S492 908 3} BRI TEICT RICE spasieeairaayoe ‘Back or Backing Weld ‘Spot Weld (Sheet Steel) ‘Seam Weld (Sheet Stet) ‘Sud Weld Flush Contour ‘Convex Contour RA (Concave Contour -106- Welding Symbols other side ‘reference fine Welding Symbol Root Opening (depth off for plug and sot welds} Groove Angle Finish Depth of Preparation Weld Size, Eftective Throat for Groove Weld Length Pict Tall Information Number ofWelds Pointing straight tothe joint from Ng the reference tine indicates that ‘itver part may receive the joint preparation. Placing a "break in the arrow line indicates that the part belog pointed to isto receive the joint preparation zaormonag For complete detalls on the use of welding symbols, AWS A2.488, Standard Symbols for Welding, Brazing and Nondestructive Examination. -107-4 { Notes -108- This Structural Welding Quality Handbook is published by: ‘Steel Structures Technology Center, Inc. 42400 W. Nine Mile Road Novi, Mi 48375 phone (248) 344-2010 fax (248) 344-2011 www.steelstructures.com info@steetstructures.com Copyright 2000 by the Steel Structures Technology Center, inc. Permission to reproduce this material must be acquired by writing the SSTC at the above address. Material may not be reproduced in whole or in part in any’ form without the written permission. of the ‘publisher, with the exception of information drawn from, readily available standard specifications. ‘As this document provides only ‘summaries of procedures and. technical. information, and also because codes and specifications change frequently, users of this Handbook are urged to secure further. information, including complete specifications and references, and. additional competent: advice _with respect to’ the information ‘contained herein for a particular purpose. SSTC provides no warranty respecting the use of the material contained herein, and the user assumes all liability arising from such use. Your comments and suggestions for improving this Handbook are encouraged. Thank you. List price $ 15.00 Please see our website at www.steelstructures.com for other publications.