Method Statement for Site Welding

SCOPE
This procedure is a general welding construction method statement applicable to welding for all
acceptable processes and materials in this project.

Welding Process

According to ER of the contract, Shielded Metal Arc-Welding-SMAW, Gas Metal Arc-Welding-

GMAW is acceptable.

Material:

No Welding Processes Electrodes/Wire Structure Material

J507 (E5015)
1 SMAW
J422 (E4303)
Carbon steel
ER100S-G
Stainless Steel (304L,316L)
2 GMAW ER70S-6
E71T-11 GASLESS

For SMAW, after welding with J507, the weld seam appears less aesthetically pleasing than with
acidic welding rods. If necessary, acidic welding rods (J422) can be used on the steel structure
cover surface.

Equipment:

Welding Equipment:
Welding
No Equipment Model Specification Manufacture
Processes
AC/DC
U=380V Shanghai TAYOR-
ZXE1-500
1 SMAW I=124A/68A CHINA
ZX7-400I
IP21S
Gas-cool
AC 380V
40A/16V-550A/39V
IP21S
2 GMAW PRIMIMIG-550 Pinnacle-SA
Gas-cool
MMA/MIG
3 Phases

Note:
1. CO2 is required for MIG welding when flux-core wire is not available.
2. PPE：Safety equipment will be made available as follows:
 Welding face shield or goggles， Leather gauntlet gloves， Safety boot
Welding Procedure Statement

Material Preparation

Prepare the materials to be welded, ensuring they are clean, free of grease, and devoid of
oxidation. Choose suitable welding materials and electrodes based on the welding type and
requirements. Weld bevels can be prepared through machining or grinding, ensuring the bevel
surface is reasonably smooth and matches the mating surface.

Pre-heating

For the preheating of the base metal for welding, a common practice often involves using a flame
torch, such as an acetylene-oxygen flame, to heat the welding area. Ensure precise control of the
flame's temperature to achieve the required preheating temperature. Typically, preheating
temperatures fall within the range of 150°C to 200°C.

Generally, preheating for electrodes is performed at temperatures ranging from 150°C to 200°C,
with preheat times varying from 15 minutes to 2 hours. Solid wire used in Gas Metal Arc Welding
(GMAW) does not require preheating. An electrode oven for welding shall be provided on-site to
facilitate the activity.

Machine Set-up

Start the welding equipment and configure the appropriate current, voltage, and speed according
to the job requirements. Inspect the welding equipment and electrodes to ensure their proper
operation.

Pre-Welding

Conduct test welding, gradually adjusting the current based on the type and thickness of the base
material to find the most suitable current range. Utilize an ammeter or the current control feature
on the welding equipment to maintain consistent current throughout the entire welding process.
Inspect and make adjustments based on the appearance, quality, and the required mechanical
properties of the weld seam.

Welding Operation

Initiate welding following the welding specifications and procedure. Control the current, voltage,
and welding speed to ensure a high-quality weld seam. Maintain an appropriate arc length and
welding gun angle.

Inspection and Quality Control

Regularly inspect the weld seam to ensure there are no defects or substandard welding. Perform
non-destructive testing if necessary, such as ultrasonic testing. Measure the dimensions and quality
of the weld seam to ensure it complies with the specifications.

Testing

In accordance with Sub-clause 1.5.3 d) of STRUCTURAL WELDING SPECIFICATIONS, on-

site non-destructive testing using an ultrasonic testing instrument is acceptable. Equipment model:
AUT810 Digital Ultrasonic Flaw Detector, made in CHINA.

According to Sub-clause 2.11.3.4 b) of MECHANICAL GENERAL SPECIFICATIONS, the

Engineer may also order additional examinations or testing of welds either by the Contractor or by
others. This may take the form of actual testing or also checking the interpretation of existing test
records.

Post-Welding

Clean the weld by removing slag and spatter. If necessary, perform post-weld heat treatment or
weld seam dressing.

Weld Defects and Repair

The Engineer should be notified of any defects before commencing any repair work, and the repair
technique must be approved by the Engineer. When directed by the Engineer, repairs must
undergo radiographic and/or ultrasonic testing.

If re-radiographing a repaired weld reveals further unacceptable defects, the entire weld should be
removed, re-welded, and re-tested. No weld should undergo repairs more than twice.

Whenever possible, all repairs should use the same process as the original weld. An alternative
repair process may only be used with the full knowledge and approval of the Engineer.

If a defective part has been removed, the Engineer is entitled to inspect before re-welding
commences.

Repaired sections of welds must be re-subjected to radiographic examination, with radiographs

identified as post-repair.
 焊接施工方案
范围
本方案适用于本项目所有焊接工艺和材料的通用焊接施工。

焊接工艺

根据合同规定，现场被允许的焊接工艺包括保护金属电弧焊（SMAW）、气体金属电弧焊/
二保焊（GMAW）。

材料：
No 工艺 焊条/焊丝 母材
J507 (E5015)
1 普通焊
J422 (E4303) 低碳钢
ER100S-G 中碳钢管材管件
2 二保焊 ER70S-6 镀锌钢
E71T-11 GASLESS

对于普通焊，使用 J507 焊条焊接后，焊缝的外观不如使用酸性焊条美观。如有必要，可以

在钢结构覆盖面上使用酸性焊条（J422）。

焊接设备
Welding equipment:
Welding
No Model Specification Manufacture
Processes
AC/DC
U=380V Shanghai TAYOR-
ZXE1-500
1 SMAW I=124A/68A CHINA
ZX7-400I
IP21S
Gas-cool
AC 380V
40A/16V-550A/39V
IP21S
2 GMAW PRIMIMIG-550 Pinnacle-SA
Gas-cool
MMA/MIG
3 Phases

备注：
在没有药芯焊丝的情况下，MIG 焊接需要二氧化碳（CO2）。
个人防护装备（PPE）：安全装备将提供如下：焊接面罩或护目镜，皮革手套，安全靴。
焊接施工方法说明

材料准备

准备待焊接的材料，确保其清洁，不含油脂，无氧化物。根据焊接类型和要求，选择合适
的焊接材料和电极。可以通过机械加工或磨削准备焊接坡口，确保坡口表面相对光滑并与
相配合的表面相符。

预热

用于焊接基材的预热常常使用火焰枪，例如乙炔氧火焰，来加热焊接区域。确保精确控制
火焰的温度，以达到所需的预热温度。通常，预热温度范围在 150°C 到 200°C 之间。

一般来说，电焊条的预热温度在 150°C 到 200°C 之间，预热时间因焊条的不同而有所变化，

从 15 分钟到 2 小时不等。在气体金属弧焊（GMAW）中使用的焊丝不需要预热。现场一般
设置焊条预热保温桶。

焊接设备调试

启动焊接设备，并根据工作要求配置适当的电流、电压和速度。检查焊接设备和电极，确
保正常运行。

焊前操作

进行试焊，逐渐根据基材的类型和厚度调整电流，以找到最适合的电流范围。利用焊接设
备上的电流控制功能或电流表来确保整个焊接过程中的恒定电流。根据焊缝的外观、质量
和所需的机械性能进行检查和调整。

焊接操作

按照焊接规范和工序开始焊接。控制电流、电压和焊接速度，以确保高质量的焊缝。保持
适当的电弧长度和焊枪角度。

检查和质量控制

定期检查焊缝，确保没有缺陷或次品焊接。如有必要，进行非破坏性检测，如超声波检测
测量焊缝的尺寸和质量，以确保符合规范要求。

测试

根据 STRUCTURAL WELDING SPECIFICATIONS 的第 1.5.3 d)款规定，使用超声波检测仪

进行现场非破坏性测试。设备型号：AUT810 数字式超声波探伤仪，产自中国。
根据 MECHANICAL GENERAL SPECIFICATIONS 的第 2.11.3.4 b)款规定，工程师还可以要
求承包商或其他人对焊缝进行额外的检查或测试。可以采取实际测试的形式，也可以检查
现有的测试记录的解释。

焊后处理

通过去除渣和飞溅物来清理焊缝。如有必要，进行焊后热处理或修整焊缝。

焊缝缺陷和修复

在开始任何修复工作之前，应通知工程师有关任何缺陷，并修复技术必须经工程师批准。
如果工程师要求，修复必须经过射线和/或超声波测试。

如果重新射线检查修复后的焊缝显示出不可接受的进一步缺陷，整个焊缝应被切除、重新
焊接并重新测试。任何焊缝不得进行超过两次的修复。

在可能的情况下，所有修复工作应使用与原始焊接相同的工艺。仅在工程师的充分了解和
批准下才可使用替代修复工艺。

如果有缺陷的部分被切除，工程师有权在重新焊接开始之前进行检查。

修复后的焊缝部分必须重新进行射线检查，并将射线检查标识为修复后进行。