AWS 01.1/01.1 M:2008 An American National Standard Approved by the American National Standards Institute JUly 2,2008 Structu'ral Welding CodeSteel 21 st Edition Supersedes AWS Dl.l/D1.1M:2006 Prepared by the American Welding Society CAWS) Dl Committee on Structural Welding Under the Direction of the AWS Technical Activities Committee Approved by the AWS Board of Directors Abstract This code covers the welding requirements for any type of welded structure made from the commonly used carbon and low-alloy constructional steels. Clauses I through 8 constitute a body of rules for the regulation of welding in steel construction. There are eight normative and twelve informative annexes in this code. A Commentary of the code is included with the document. . E (!!9 Reproduced by World Engineerin.g Xchange With the Permission of AWS Under Royalty Agreement AWS 01.1/01.1 M:2008 International Standard Book Number: 978-0-87171-090-1 American Welding Society 550 N.W. Lejeune Road, Miami, FL 33126 © 2008 by American Welding Society All rights reserved Printed in Canada Photocopy Rights. No portio.n of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyright owner. 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When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties. AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. 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Such errata, when discovered, are posted on the AWS web page (www.aws.org). Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 550 N.W. Lejeune Road, Miami, FL 33126 (see Annex 0). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation. This standard is subject to revision at any time by the AWS Dl Committee on Structural Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS Dl Committee on Structural Welding and the author of the comments will be informed of the Committee's response to the comments. Guests are invited to attend all meetings of the AWS D 1 Committee on Structural Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. Lejeune Road, Miami, FL 33126. iii AWS D1.1/D1.1 M:2008 This page is intentionally blank. iv AWS D1.1/D1.1 M:2008 Personnel A WS Dl Committee on Structural Welding Rager Consulting, Incorporated The Lincoln Electric Company Alstom Power, Incorporated American Welding Society STV, Incorporated The Lincoln Electric Company Acute Technological Services Strocal, Incorporated Walt Disney World Company Parker Drilling Team Industries, Incorporated Exelon Nuclear Corporation Consultant Massachusetts Highway Department Modjeski and Masters, Incorporated Shell International E & P ConocoPhillips Company Genesis Quality Systems American Engineering & Manufacturing, Incorporated Butler Manufacturing Company Inspectech Consulting and Testing Canadian Welding Bureau Department of the Army MHP Systems Engineering Mayes Testing Engineers, Incorporated D L McQuaid and Associates, Incorporated High Steel Structures, Incorporated MACTEC, Incorporated Minnesota Department of Transportation LTK Engineering Services ITW, Hobart Brothers Company J. W. Post and Associates, Incorporated American Institute of Steel Construction PSI URS-Washington Division Steel Structures Technology Center, Incorporated Greenman-Pederson, Incorporated Massachusetts Highway Department (Retired) Massachusetts Highway Department Federal Highway Administration Advantage Aviation Technologies D. D. Rager, Chair D. K. Miller, 1st Vice Chair A. W. Sindel, 2nd Vice Chair S. Morales, Secretary N. J. Altebrando F. G. Armao E. L. Bickford F. C. Breismeister B. M. Butler H. H. Campbell, III L. E. Collins R. B. Corbit R. A. Dennis M. A. Grieco C. W. Holmes J. J. Kenney J. H. Kiefer V.Kuruvilla J. Lawmon D. R. Lawrence, n N. S. Lindell D. R. Luciani S. L. Luckowski P. W. Marshall M.J. Mayes D. L. McQuaid R. D. Medlock J. Merrill T. L. Niemann J. B. Pearson D. C. Phillips J. W. Post T. Schlafly D. R. Scott D. A. Shapira R. E. Shaw, Jr. R. W. Stieve P. J. Sullivan M. M. Tayarani K. K. Verma B. D. Wright v AWS 01.1/01.1 M:2008 Advisors to the AWS Dl Committee on Structural Welding W. G. Alexander E. M. Beck O. W. Blodgett M. V. Davis G. L. Fox G. J. Hill M. L. Hoitomt W. A. Milek, Jr. J. E. Myers WGAPE MACTEC, Incorporated The Lincoln Electric Company Consultant Consuftant G. J. Hill and Associates, Incorporated Hoitomt Consulting Services Consultant Consuftant AWS DIQ Subcommittee on Steel D. D. Rager, Chair T. Schlafly, Vice C,hair S. Morales, Secretary N. J. Altebrando M. Bemasek E. L. Bickford B. M. Butler 1. W. Cagle B. Capers H. H. Campbell, III L. E. Collins R. A. Dennis D. A. Dunn K. R. Fogleman J. Guili M.J.Jordan J. J. Kenney J. H. Kiefer L. A. Kloiber S. W. Kopp J. E. Koski V.Kuruvilla K. Landwehr D. R. Lawrence, II D. R. Luciani P. W. Marshall R. P. Marslender G. S. Martin M.J.Mayes R. D. Medlock J. Merrill J. 1. Miller S. P. Moran J. C. Nordby J. A. Packer F. J. Palmer J. W. Post D. R. Scott J. G. Shaw R. E. Shaw, Jr. A. W. Sindel Rager Consulting, Incorporated American Institute ofSteel Construction American Welding Society STV, Incorporated C-spec Acute Technological Services Walt Disney World Company C P Buckner Steel Erection, Incorporated Walt Disney World Company Parker Drilling Team Industries, Incorporated Consultant PSI Valmont Industries Tru-Weld Equipment Company Johnson Plate and Tower Fabrication Shell International E & P ConocoPhillips Company Lejeune Steel Company High Steel Structures Stud Welding Products, Incorporated Genesis Quality Systems Schuff Steel Company Butler Manufacturing Company Canadian Welding Bureau MHP Systems Engineering .." Kiewit Offshore Services, LTD GEEnergy Mayes Testing Engineers, Incorporated High Steel Structures, Incorporated MACTEC, Incorporated J. I. Miller Consulting Hobart Brothers Entergy University of Toronto Steel Tube Institute J. W. Post and Associates, Incorporated PSI WSP Mountain Enterprises, Incorporated Steel Structures Technology Center, Incorporated Alstom Power, Incorporated vi AWS D1.1/D1.1 M:2008 AWS DIQ Subcommittee on Steel (Continued) R. W. Stieve S. R. Swartz, Jr. S. J. Thomas w. A. Thornton R. H. R. Tide P. Workman Greenman-Pederson, Incorporated New Age Fastening Systems, Incorporated VP Buildings, Incorporated Cives Corporation Wiss, Janney, Elstner Associates Tru-Weld Advisors to the AWS DIQ Committee on Steel H C Nutting I A Terracon Company Strocal, Incorporated Nelson Stud Welding Exelon Nuclear Corporation Texas Department of Transportation Massachusetts Highway Department Idaho National Laboratory The Lincoln Electric Company High Steel Structures G. J. Hill and Associates, Incorporated Modjeski and Masters, Incorporated Bombardier Transportation Inspectech Consulting and Testing Caterpillar, Incorporated D L McQuaid and Associates, Incorporated PDM Bridge, Eau Clair Wisc Consultant The Lincoln Electric Company Cives Steel Company LTK Engineering Services ITW, Hobart Brothers Company U.S. Army Corps ofEngineers URS-Washington Division Massachusetts Highway Department (Retired) Massachusetts Highway Department Waukesha County Tech College Federal Highway Administration Canadian Welding Bureau Ohmstede Ltd. U. W. Aschemeier F. C. Breismeister H. A. Chambers R. B. Corbit H. E. Gilmer M. A. Grieco M. J. Harker C. W. Hayes C. R. Hess G. J. Hill C. W. Holmes W. Jaxa-Rozen N. S. Lindell H. W. Ludewig D. L. McQuaid 1. K. Mieseke W. A. Milek, Jr. D. K. Miller L. Muir J. B. Pearson D. C. Phillips J. Ross D. A. Shapira P. J. Sullivan M. M. Tayarani J. L. Uebele K. K. Verma D. G. Yantz O. Zollinger AWS DIQ Subcommittee Task Group on Design B. M. Butler, Chair S. J. Thomas, Vice Chair N. J. Altebrando B. Capers W. Jaxa-Rozen M. J. Jordan J. J. Kenney L. A. Kloiber P. W. Marshall L. Muir 1. A. Packer F. J. Palmer Walt Disney World Company VP Buildings, Incorporated STV, Incorporated Walt Disney World Company Bombardier Transportation Johnson Plate and Tower Fabrication Shell International E & P Lejeune Steel Company MHP Systems Engineering Cives Steel Company University of Toronto Steel Tube Institute vii AWS D1.1/D1.1M:2008 AWS DIQ Subcommittee Task Group on Design (Continued) LTK Engineering Services AISC Steel Structures Technology Center, Incorporated WSP Mountains Enterprises, Incorporated Wiss, Janney, Elstner Associates J. B. Pearson, Jf. T. J. Schlafly R. E. Shaw, Jf. J.G. Shaw R. H. R. Tide Advisors to the AWS DIQ Subcommittee Task Group on Design The Lincoln Electric Company Exelon Nuclear Corporation Bombardier Transportation Canada Consultant U.S. Army of Corps ofEngineers Cives Corporation O. W. Blodgett R. B. Corbit J. Desjardins W. A. Milek, Jr. J. D. Ross W. A. Thornton AWS DIQ Subcommittee Task Group on Qualification Consultant ConocoPhillips Company C-spec Acute Technological Services Strocal, Incorporated Exelon Nuclear Corporation Consultant Massachusetts Highway Department Idaho National Laboratory Shell International E & P Genesis Quality Systems Schuff Steel Company Butler Manufacturing Company Kiewit Offshore Services, LTD J. I. Miller Consulting Entergy Hobart Brothers Company J. W. Post and Associates, Incorporated URS-Washington Division Alstom Power, Incorporated Massachusetts Highway Department Waukesha County Technical College Ron Dennis, Chair J. H. Kiefer, Vice Chair M. Bernasek E. L. Bickford F. C. Breismeister R. B. Corbit R. A. Dennis M. A. Grieco M. J. Harker J. J. Kenney V.Kuruvilla K.Landwehr D. R. Lawrence, II R. P. Marslender J. 1. Miller J. C. Nordby D. C. Phillips J. W. Post D. A. Shapira A. W. Sindel M. M. Tayarani J. L. Uebele Advisors to the AWS DIQ Subcommittee Task Group on Qualification M. L. Hoitmont H. W. Ludewig G. S. Martin J. K. Mieseke D. K. Miller K. K. Verma B. D. Wright D. G. Yantz O. Zollinger Consultant Caterpillar, Incorporated GE Energy Consultant The Lincoln Electric Company Federal Highway Department of Transportation Advantage Aviation Technologies Canadian Welding Bureau Ohmstede Limited viii AWS D1.1/D1.1M:2008 AWS DIQ Subcommittee Task Group on Fabrication Genesis Quality Systems Texas Department of Transportation Strocal, Incorporated C P Buckner Steel Erection, Incorporated Parker Drilling Team Industries, Incorporated Consultant Massachusetts Highway Department High Steel Structures G J Hill & Associates Modjeski & Masters, Incorporated Schuff Steel Company D L McQuaid & Associates, Incorporated High Steel Structures, Incorporated Consultant J. I. Miller Consulting Hobart Brothers J. W. Post and Associates, Incorporated AISC URS-Washington Division Alstom Power, Incorporated Federal Highway Administration V. Kuruvilla, Chair H. E. Gilmer, Vice Chair F. C. Breismeister J. W. Cagle H. H. Campbell, III L. E. Collins R. A. Dennis M. A. Grieco C. R. Hess G. J. Hill C. W. Holmes K. Landwehr D. L. McQuaid R. D. Medlock W. A. Milek J. I. Miller S. P. Moran J. W. Post T. J. Schlafly D. A. Shapira A. W. Sindel K. K. Verma Advisors to the AWS DIQ Subcommittee Task Group on Fabrication WGAPE Consultant Acute Technological Services Consultant The Lincoln Electric Company Consultant Wiss, Janney, Elstner Associates W. G. Alexander F. R. Beckmann E. L. Bickford G. L. Fox D. K. Miller J. E. Myers R. H. R. Tide AWS DIQ Subcommittee Task Group on Inspection D. R. Scott, Chair G. S. Martin, Vice Chair U. W. Aschemeier H. H. Campbell, III R. V. Clarke L. E. Collins D. A. Dunn K. R. Fogleman C. W. Hayes R. K. Holbert P. G. Kinney S. W. Kopp N. S. Lindell C. A. Mankenberg P. W. Marshall D. L. McQuaid J. E. Mellinger J. Merrill PSI (Retired) GE Energy H C Nutting I A Terracon Company Parker Drilling St. Louis Testing Laboratories, Incorporated Team Industries, Incorporated PSI Valmont Industries The Lincoln Electric Company FMC Technologies, Incorporated Robert W Hunt Company High Steel Structures Inspectech Consulting and Testing Shell International MHP Systems Engineering D L McQuaid & Associates, Incorporated Pennoni Associates, Incorporated MACTEC, Incorporated ix AWS D1.1/D1.1M:2008 AWS DIQ Subcommittee Task Group on Inspection J. B. Pearson, Jr. R. W. Stieve P. J. Sullivan K. K. Verma D. G. Yantz LTK Engineering Services Greenman-Pederson, Incorporated Massachusetts Highway Department (Retired) Federal Highway Administration Canadian Welding Bureau Advisors to the AWS DIQ Subcommittee Task Group ou Inspection WGAPE MACTEC Engineering & Consulting Consultant Consultant G J Hill & Associates Consultant ConocoPhillips Company Consultant Consultant Welding Consultants, Incorporated W. G. Alexander E. M. Beck F. R. Beckmann G. L. Fox G. J. Hill M. L. Hoitomt J. H. K.iefer D. M. Marudas W. A. Milek, Jr. W. A. Svekric AWS DIQ Subcommittee Task Group on Stud Welding M. M. Tayarani, Chair D. R. Luciani, Vice Chair U. W. Aschemeier H. A. Chambers D. A. Dunn J. Guili B. C. Hobson J. E. Koski S. P. Moran S. R. Swartz, Jr. J. L. Uebele P. Workman Massachusetts Highway Department Canadian Welding Bureau H C Nutting I A Terracon Company Consultant PSI Tru-Weld Equipment Company Image Industries Stud Welding Products, Incorporated Hobart Brothers New Age Fastening Systems, Incorporated Waukesha County Tech College Tru-Weld Equipment Company Advisors to the AWS DIQ Subcommittee Task Group on Stud Welding Nelson Stud Welding Consultant C. B. Champney C. C. Pease AWS DIM Standing Task Group on New Materials D. c. Phillips, Chair T. J. Schlafly, Vice Chair F. C. Breismeister B. M. Butler C. W. Hayes R. D. Medlock J. B. Pearson, Jr. D. Rees-Evans D. A. Shapira Hobart Brothers Company AISC Strocal, Incorporated Walt Disney World Company The Lincoln Electric Company High Steel Structures, Incorporated LTK Engineering Services Steel Dynamics URS-Washington Division x AWS D1.1/D1.1 M:2008 Advisors to the AWS DIM Standing Task Gronp on Materials M. L. Hoitomt J. W. Post A. W. Sindel Consultant J W Post & Associates, Incorporated Alstom Power, Incorporated AWS DIF Subcommittee on Strengthening and Repair VP Bridges High Steel Structures American Welding Society Modjeski & Masters, Incorporated New York State Department of Transportation Greenman-Pederson, Incorporated Massachusetts Highway Department N. J. Altebrando, Chair S. W. Kopp, Vice Chair S. Morales, Secretary C. W. Holmes P. Rimmer R. W. Stieve M. M. Tayarani Advisors to the AWS DIF Snbcommittee on Strengthening and Repair E. M. Beck C. R. Hess G. J. Hill M. J. Mayes J. W. Post J. D. Ross R. E. Shaw, Jr. W. A. Thornton R. H. R. Tide MACTEC, Incorporated High Steel Structures G J Hill & Associates Mayes Testing Engineers, Incorporated J W Post & Associates, Incorporated U.S. Army Corps ofEngineers Steel Structures Technology Center, Incorporated Cives Corporation Wiss, Janney, Elstner Associates xi AWS D1.1/D1.1M:2008 This page is intentionally blank. xii AWS D1.1 /D1.1 M:2008 Foreword This foreword is not part of AWS Dl.l/Dl.lM:2008, Structural Welding Code-Steel, but is included for informational purposes only. The first edition of the Code for Fusion Welding and Gas Cutting in Building Construction was published by the American Welding Society in 1928. The first bridge welding specification was published separately in 1936. The two documents were consolidated in 1972 into the D1.1 document but were once again separated in 1988 when the joint AASHTO/AWS D1.5, Bridge Welding Code, was published to address the specific requirements of State and Federal Transportation Departments. Coincident with this, the D1.1 code changed references of buildings and bridges to statically loaded and dynaJ;nically loaded structures, respectively, in order to make the document applicable to a broader range of structural corlfigurations. Underlined text in the subclauses, tables, or figures indicates an editorial or technical change from the 2006 edition. A vertical line in the margin indicates a revision from the 2006 edition. The following is a summary of the most significant technical revisions contained in D1.1/D1.1M:2008: Clause 1.2-Revised to clarify limitations of the code. Clause 2.3.5-New section on depth of filling for plug and slot welds added. Clause 2.5.4-Revisions made to clarify the allowable stress for a singular linear fillet weld or fillet weld groups of parallel linear fillet welds. Clause 2.5.4.4-Adds design equation for determining allowable stresses on fillet welds in concentrically loaded weld ~ Clause 2.6.7-Revised provision for calculating the resistance provided by connections sharing the load between welds, bolts, and rivets. Clause 2.7.I-Revised to eliminate transition slope requirements for butt joints of unequal thickness in typical low yield tension load situations. Clause 2, Tables-Tables 2.4 through 2.9 were renumbered to accommodate a new table detailing the strength coefficients for obliquely loaded fillet welds. Table 2.3-New note added to limit allowable stresses for plug and slot welds. Figure 2.2-Revised to apply to cyclically loaded structures. Figure 2.3-Revised to apply to the thickness of statically loaded structures. Figure 2.6-Corrections made to better illustrate holdback dimensions and tension. Figures 2.9 and 2.W-Corrections were made to splice joint thicknesses. Clause 3.7-Adds new provision on prequalified shielding gases. Clause 3.W-Revised to clarify the minimum depth of filling for plug and slot welds. Figure 3.4-Correction made was to the tolerances for B-U7-S. Clause 4.8. I-Term "run-off tab" replaced with "weld tabs." Clauses 4.11.1 and 4.11.2-Qualification testing requirements for fillets clarified. Clause 4.23.2-Revised to clarify welding operator requirements for ESW and EGW. xiii AWS D1.1/D1.1 M:2008 Table 4. I-Note assignments for production pipe butt-grooves clarified. Table 4.5-Revised so that number of electrodes is a FOR essential variable for GTAW. Table 4.6-Changes were made to required FOR supplementary essential variables when for single to multiple electrode, or vice versa, in same weld pool and interpass temperatures. Table 4.10--Note assignments clarified. Figure 4.19-1/8 in [3 mm] weld size added to fillet weld soundness tests for WPS qualification. Figures 4.31 and 4.32-Note added to allow side-bent test substitutions for face- or- root-bend tests for 3/8 in [10 mm] plate. Figure 4.38-Revised to apply to both welder and welder operator qualification as well as WPS qualification. Clause 5.3-Deleted references to shielding gases. Clauses 5.3.4.1 and 5.3.4.2-Revised to clarify low-alloy electrodes by strength and not process. References to A5 specifications corrected. Clause 5. 18-Entire section on temporary welds and tack welds was revised and reorganized while introducing the new term "construction aid welds." Clause 5.22. I-Changed "fillet weld leg" to "fillet weld legs" for clarification. Clause 6.1.4.4-Changed the required visual acuity test from Snellen English test to a Jaeger J-2 test at a distance of 12 in-17 in [300 mm-430 mm]. Clause 6. 12-Entire section RT discontinuity acceptance criteria was reorganized. Clause 6.24. I-Changed the required minimum requalification interval for UT equipment horizontal linearity. Clause 6.25.3-Changed the recalibration interval requirement for UT testing equipment. Clause 6.25.5.2-Revised to establish the required maximized horizontal trace deflection screen height for IT testing procedures. Clause 6, Figures-All figures and cases in Clause 6 have been revised and renumbered. Figures 6.2 and 6.3-Figure on maximum acceptable RT images was moved to the commentary. Clause 7.2.6-Correction made to ASTM specification reference. Clause 7.3.3-Revised to eliminate six-month requirement for quality control tests on studs prior to delivery. Clause 7.8.5-Revised to clarify the Contractor's responsibility for corrective stud welding. Annex C-Content was moved to Clause 6 Commentary. Annex C left blank to avoid confusion with Commentary sections. Annex G-Contents moved into Clause 7 as new Clause 7.9. Text revised so a stud base qualified with an approved grade of ASTM A 108 also meets requirements of 7.3.1. Annex K-Added new term "construction aid weld" and deleted term "temporary weld." Annex N-Sample form N-1 revised to include power source. Annex U-Reference documents have been updated to include applicable year. Annex V-Updated all tables to include most recent A5 Classifications. Clause C-1.2-Content deleted and moved into Clause 1.2. Clauses C-2.5.4, C-2.6.5, C-2.6.7, and C-2.7.1-New commentary added. Clause C-2, Figures-Figures renumbered and new figures added illustrating obliquely loaded weld groups. C-Table 3.7-New commentary added for root pass and fill pass thickness variables. Clause C-5.3.2.1-Revised to clarify "low-hydrogen" term. XIV ~ AWS D1.1/D1.1M:2008 Clause C-6.11.1-New commentary added on tubular connection requirements. Clause C-6, Figures-New figures added illustrating discontinuity acceptance criteria. Clause C-Annex I-Section designations removed for clarification. AWS B4.0, Standard Methods for Mechanical Testing of Welds, provides additional details of test specimen preparation and details of test fixture construction. Commentary. The Commentary is nonmandatory and is intended only to provide insightful information into provision rationale. Normative Annexes. These annexes address specific subjects in the code and their requirements are mandatory requirements that supplement the code provisions. Informative Annexes. These annexes are not code requirements but are provided to clarify code provisions by showing examples, providing information, or suggesting alternative good practices. Index. As in previous codes, the entries in the Index are referred to by subclause number rather than by page number. This should enable the user of the Index to locate a particular item of interest in minimum time. Errata. It is the Structural Welding Committee's Policy that all errata should be made available to users of the code. Therefore, any significant errata will be published in the Society News Section of the Welding Journal and posted on the AWS web site at: http://www.aws.org/technical/dl/. Suggestions. Your comments for improving AWS D1.1/D1.1M:2008, Structural Welding Code-Steel are welcome. Submit comments to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. Lejeune Road, Miami, FL 33126; telephone (305) 443-9353; fax (305) 443-5951; e-mail info@aws.org; or via the AWS web site <http://www.aws.org>. xv AWS D1.1/D1.1 M:2008 This page is intentionally blank. xvi AWS D1.1/D1.1M:2008 Table of Contents Page No. v xi xxii xxiv Personnel Foreword List of Tables List ofFigures 1. General Requirements 1.1 Scope 1.2 Limitations 1.3 Definition.s 1.4 Responsibilities 1.5 ApprovaL 1.6 Welding Symbols 1.7 Safety Precautions 1.8 Standard Units of Measurement. 1.9 Reference Documents , 2. Design of Welded Counectious 2.0 Scope of Clause 2 5 5 Part A-Common Requirements for Design of Welded Connections (Nontubular and Tubular Members) 2.1 Scope of Part A 2.2 Contract Plans and Specifications 2.3 Effective Areas 5 5 5 6 Part B-Specific Requirements for Design of Nontubular Connections (Statically or Cyclically Loaded) 2.4 General 2.5 Stresses 2.6 Joint Configuration and Details 2.7 Joint Configuration and Details-Groove Welds 2.8 Joint Configuration and Details-Fillet Welded Joints 2.9 Joint Configuration and Details-Plug and Slot Welds 2.10 Filler Plates , 2.11 Built-Up Members 8 8 8 9 10 10 11 11 12 Part C-Specific Requirements for Design of Nontubular Connections (Cyclically Loaded) 2.12 General 2.13 Limitations 2.14 Calculation of Stresses 2.15 Allowable Stresses and Stress Ranges 2.16 Detailing, Fabrication, and Erection 2.17 Prohibited Joints and Welds 2.18 Inspection 12 12 12 13 13 14 15 15 Part D-Specific Requirements for Design of Tubular Connections (Statically or Cyclically Loaded) 2.19 General 2.20 Allowable Stresses 2.21 Identification 2.22 Symbols 15 15 15 17 17 xvii 1 1 1 1 2 2 3 3 3 3 AWS D1.1/D1.1 M:2008 Page No. 2.23 2.24 2.25 2.26 Weld Design Limitations of the Strength of Welded Connections Thickness Transition '" Material Limitations 17 18 22 22 3. Prequalification of WPSs 3.1 Scope 3.2 Welding Processes 3.3 Base Metal/Filler Metal Combinations 3.4 Engineer's Approval for Auxiliary Attachments 3.5 Minimum Preheat and Interpass Temperature Requirements 3.6 Limitation ofWPS Variables 3.7 General WPS Requirements 3.8 Common Requirements for Parallel Electrode and Multiple Electrode SAW 3.9 Fillet Weld Requirements 3.10 Plug and Slot Weld Requirements 3.11 Common Requirements of PIP and CJP Groove Welds 3.12 PIP Requirements 3.13 CJP Groove Weld Requirements 3.14 Postweld Heat Treatment 4. Qualification 4.0 Scope 123 123 Part A-General Requirements 4.1 General 4.2 Common Requirements for WPS and Welding Personnel Performance Qualification 123 123 124 Part B-Welding Procedure Specification (WPS) 4.3 Production Welding Positions Qualified 4.4 Type of Qualification Tests 4.5 Weld Types for WPS Qualification 4.6 Preparation of WPS 4.7 Essential Variables 4.8 Methods of Testing and Acceptance Criteria for WPS Qualification 4.9 CIP Groove Welds for Nontubular Connections 4.10 PIP Groove Welds for Nontubular Connections 4.11 Fillet Welds for Tubular and Nontubular Connections 4.12 CIP Groove Welds for Tubular Connections 4.13 PIP Tubular T-, Y-, or K-Connections and Butt loints 4.14 Plug and Slot Welds for Tubular and Nontubular Connections 4.15 Welding Processes Requiring Qualification 4.16 WPS Requirement (GTAW) 4.17 WPS Requirements (ESWIEGW) 124 124 124 124 124 125 125 127 127 127 128 129 129 129 130 130 Part C-Performance Qualification 4.18 General 4.19 Type of Qualification Tests Required 4.20 Weld Types for Welder and Welding Operator Performance Qualification 4.21 Preparation of Performance Qualification Forms 4.22 Essential Variables 4.23 CIP Groove Welds for Nontubular Connections 4.24 PIP Groove Welds for Nontubular Connections 4.25 Fillet Welds for Nontubular Connections 130 130 130 131 131 131 131 132 132 xviii 59 59 59 59 60 60 60 60 61 61 61 61 62 62 63 AWS D1.1/D1.1 M:2008 Page No. 4.26 4.27 4.28 4.29 4.30 4.31 4.32 CJP Groove Welds for Tubular Connections PJP Groove Welds for Tubular Connections Fillet Welds for Tubular Connections Plug and Slot Welds for Tubular and Nontubular Connections Methods of Testing and Acceptance Criteria for Welder and Welding Operator Qualification Method of Testing and Acceptance Criteria for Tack Welder Qualification Retest. 132 132 132 132 132 134 134 Part D-Requirements for CVN Testing 4.33 General 4.34 Test Locations 4.35 CVN Tests 4.36 Test Requirements 4.37 Retest 4.38 Reporting 134 134 134 135 135 135 135 5. Fabrication :.' 5.1 Scope 5.2 Base Metal. 5.3 Welding Consumables and Electrode Requirements 5.4 ESW and EGW Processes 5.5 WPS Variables 5.6 Preheat and Interpass Temperatures 5.7 Heat Input Control for Quenched and Tempered Steels 5.8 Stress-Relief Heat Treatment 5.9 Backing, Backing Gas, or Inserts 5.10 Backing 5.11 Welding and Cutting Equipment 5.12 Welding Environment 5.13 Conformance with Design 5.14 Minimum Fillet Weld Sizes 5.15 Preparation of Base Metal 5.16 Reentrant Comers 5.17 Beam Copes and Weld Access Holes 5.18 Tack Welds and Construction Aids 5.19 Camber in Built-Up Members 5.20 Splices in Cyclically Loaded Structures 5.21 Control of Distortion and Shrinkage ~ 5.22 Tolerance of Joint Dimensions 5.23 Dimensional Tolerance of Welded Structural Members 5.24 Weld Profiles 5.25 Technique for Plug and Slot Welds 5.26 Repairs 5.27 Peening 5.28 Caulking 5.29 Arc Strikes 5.30 Weld Cleaning 5.31 Weld Tabs 191 191 191 191 193 193 194 194 194 195 195 195 195 196 196 196 197 197 198 198 199 199 199 200 202 203 203 204 204 205 205 205 6. Inspection Part A-General Requirements 6.1 Scope 6.2 Inspection of Materials and Equipment 213 213 213 214 xix AWS D1.1/D1.1 M:2008 Page No. 6.3 6.4 6.5 Inspection of WPSs Inspection of Welder, Welding Operator, and Tack Welder Qualifications Inspection of Work and Records Part B-Contractor Responsibilities 6.6 Obligations of the Contractor 215 215 Part C-Acceptance Criteria 6.7 Scope 6.8 Engineer's Approval for Alternate Acceptance Criteria 6.9 Visual Inspection 6.10 PT and MT 6.11 NDT 6.12 RT 6.13 UT ' 7. 214 214 214 : 215 215 215 215 215 216 216 217 Part D-NDT Procedures 6.14 Procedures 6.15 Extent of Testing 218 218 219 Part E-Radiographic Testing (RT) 6.16 RT of Groove Welds in Butt Joints 6.17 RT Procedures 6.18 Supplementary RT Requirements for Tubular Connections 6.19 Examination, Report, and Disposition of Radiographs 219 219 219 221 222 Part F-Ultrasonic Testing (UT) of Groove Welds 6.20 General 6.21 Qualification Requirements 6.22 UT Equipment 6.23 Reference Standards 6.24 Equipment Qualification 6.25 Calibration for Testing 6.26 Testing Procedures 6.27 UT of Tubular T-, Y-, and K-Connections 6.28 Preparation and Disposition of Reports 6.29 Calibration of the UT Unit with IIW or Other Approved Reference Blocks (Annex H) 6.30 Equipment Qualification Procedures 6.31 Discontinuity Size Evaluation Procedures 6.32 Scanning Patterns 6.33 Examples of dB Accuracy Certification 222 222 222 222 223 223 224 224 226 227 228 229 230 231 231 Part G-Other Examination Methods 6.34 General Requirements 6.35 Radiation Imaging Systems 6.36 Advanced Ultrasonic Systems 6.37 Additional Requirements 231 231 231 231 232 Stud Welding 7.1 Scope 7.2 General Requirements 7.3 Mechanical Requirements 7.4 WorkmanshiplFabrication 7.5 Technique 7.6 Stud Application Qualification Requirements 275 275 275 276 276 276 277 xx AWS 01.1/01.1 M:2008 Page No. 7.7 7.8 7.9 8. Production Control Fabrication and Verification Inspection Requirements Manufacturers' Stud Base Qualification Requirements Strengthening and Repairing Existing Strnctures 8.1 General 8.2 Base Metal. 8.3 Design for Strengthening and Repair 8.4 Fatigue Life Enhancement 8.5 Workmanship and Technique 8.6 Quality 285 285 285 285 285 286 286 Annexes Annex A Annex B Annex D Annex E Annex F Annex G Annex H Annex I Annex J Annex K Annex L Annex M Annex N Annex a Annex P Annex Q Annex R Annex S Annex T Annex U Annex V 278 279 279 (Normative)-Effective Throat (Normative)-Effective Throats of Fillet Welds in Skewed T-Joints (Normative)-Flatness of Girder Webs-Statically Loaded Structures (Normative)-Flatness of Girder Webs-Cyclically Loaded Structures (Normative)-Temperature-Moisture Content Charts (Normative)-Manufacturers' Stud Base Qualification Requirements (Normative)-Qualification and Calibration ofUT Units with Other Approved Reference Blocks (Normative)-Guideline on Alternative Methods for Determining Preheat... (Normative)-Symbols for Tubular Connection Weld Design (Informative)-Terms and Definitions (Informative)-Guide for Specification Writers (lnformative)-UT Equipment Qualification and Inspection Forms (lnformative)-Sample Welding Forms (Informative)-Guidelines for the Preparation of Technical Inquiries for the Structural Welding Committee (Informative)-Local Dihedral Angle (Informative)-Contents of Prequalified WPS (Informative)-Safe Practices (lnformative)-UT Examination of Welds by Alternative Techniques (lnformative)-Ovalizing Parameter Alpha (lnformative)-List of Reference Documents (Informative)-Filler Metal Strength Properties 287 289 291 295 299 305 309 311 315 325 327 335 337 347 359 361 367 369 373 389 391 393 Foreword 405 407 Index 521 List of AWS Documents on Structural Welding 533 Commentary xxi AWS 01.1/01.1 M:2008 List of Tables Page No. Table 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 5.1 5.2 5.3 5.4 Effective Size of Flare-Groove Welds Filled Flush Z Loss Dimension (Nontubular) : Allowable Stresses Equivalent Strength Coefficients for Obliquely Loaded Fillet Welds Fatigue Stress Design Parameters Allowable Stresses in Tubular Connection Welds Stress Categories for Type and Location or'Material for Circular Sections Fatigue Category Limitations on Weld Size or Thickness and Weld Profile (Tubular Connections) Z Loss Dimensions for Calculating Prequalified PJP T-,Y-, and K-Tubular Connection Minimum Weld Sizes Terms for Strength of Connections (Circular Sections) Prequalified Base Metal-Filler Metal Combinations for Matching Strength Prequalified Minimum Preheat and Interpass Temperature Filler Metal Requirements for Exposed Bare Applications of Weathering Steels Minimum Prequalified PJP Weld Size (E) Joint Detail Applications for Prequalified CJP T-, Y-, and K-Tubular Connections Prequalified Joint Dimensions and Groove Angles for CJP Groove Welds in Tubular T-, Y, and K-Connections Made by SMAW, GMAW-S, and FCAW ; Prequalified WPS Requirements WPS Qualification-Production Welding Positions Qualified by Plate, Pipe, and Box Tube Tests WPS Qualification-CJP Groove Welds: Number and Type of Test Specimens and Range of Thickness and Diameter Qualified Number and Type of Test Specimens and Range of Thickness Qualified-WPS Qualification; PJP Groove Welds Number and Type of Test Specimens and Range of Thickness Qualified-WPS Qualification; Fillet Welds PQR Essential Variable Changes Requiring WPS Requalification for SMAW, SAW, GMAW, FCAW, and GTAW PQR Supplementary Essential Variable Changes for CVN Testing Applications Requiring WPS Requalification for SMAW, SAW, GMAW, FCAW, and GTAW PQR Essential Variable Changes Requiring WPS Requalification for ESW or EGW Table 3.1, Table 4.9, and Unlisted Steels Qualified by PQR Code-Approved Base Metals and Filler Metals Requiring Qualification per Clause 4 Welder and Welding Operator Qualification-Production Welding Positions Qualified by Plate, Pipe, and Box Tube Tests Welder and Welding Operator Qualification-Number and Type of Specimens and Range of Thickness and Diameter Qualified Welding Personnel Performance Essential Variable Changes Requiring Requalification Electrode Classification Groups CVN Test Requirements CVN Test Temperature Reduction Allowable Atmospheric Exposure of Low-Hydrogen Electrodes Minimum Holding Time Alternate Stress-Relief Heat Treatment Limits on Acceptability and Repair of Mill Induced Laminar Discontinuities in Cut Surfaces xxii 24 24 25 26 27 37 39 41 41 .42 64 68 71 71 71 72 73 136 137 139 139 140 143 144 145 146 147 148 152 152 153 153 206 206 206 206 AWS D1.1/D1.1M:2008 Table 5.5 5.6 5.7 5.8 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7.1 7.2 B.1 D.1 D.2 D.3 E.1 E.2 E.3 E.4 E.5 I.1 1.2 S.l Page No. Tubular Root Opening Tolerances Camber Tolerance for Typical Girder Camber Tolerance for Girders without a Designed Concrete Haunch Minimum Fillet Weld Sizes Visual Inspection Acceptance Criteria UT Acceptance-Rejection Criteria (Statically Loaded Nontubular Connections) UT Acceptance-Rejection Criteria (Cyclically Loaded Nontubular Connections) Hole-Type IQI Requirements Wire IQI Requirements IQI Selection and Placement. Testing Angle Mechanical Property Requirements for Studs Minimum Fillet Weld Size for Small Diameter Studs Equivalent Fillet Weld Leg Size Factors for Skewed T-Joints Intermediate Stiffeners on Both Sides of Web No Interme<;liate Stiffeners Intermediate Stiffeners on One Side Only of Web Intermediate Stiffness on Both Sides of Web, Interior Girders Intermediate Stiffness on One Side Only of Web, Fascia Girders Intermediate Stiffness on One Side Only of Web, Interior Girders Intermediate Stiffness on Both Sides of Web, Fascia Girders No Intermediate Stiffeners, Interior or Fascia Girders Susceptibility Index Grouping as Function of Hydrogen Level "H" and Composition Parameter Pem Minimum Preheat and Interpass Temperatures for Three Levels of Restraint Acceptance-Rejection Criteria Commentary C-2.1 Survey of DiameterfThickness and Flat WidthfThickness Limits for Tubes C-2.2 Suggested Design Factors C-2.3 Values of JD C-2.4 Structural Steel Plates C-2.5 Structural Steel Pipe and Tubular Shapes C-2.6 Structural Steel Shapes C-2.7 Classification Matrix for Applications ; C-2.8 CVN Testing Conditions C-3.1 Typical Current Ranges for GMAW-S on Steel C-4.1 CVN Test Values C-4.2 HAZ CVN Test Values C-6.1 UT Acceptance Criteria for 2 in [50 mm] Welding, Using a 70° Probe C-8.1 Guide to Welding Suitability C-8.2 Relationship Between Plate Thickness and Burr Radius xxiii : 207 207 207 207 233 234 235 236 236 237 238 281 281 294 296 296 297 300 301 302 303 303 318 318 378 .430 431 431 432 .433 433 434 434 .452 463 463 .494 511 511 AWS D1.1/D1.1M:2008 List of Figures Figure 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Page No. Maximum Fillet Weld Size Along Edges in Lap Joints Transition of Butt Joints in Parts of Unequal Thickness (Cyclically Loaded Nontubular) Transition of Thicknesses (Statically Loaded Nontubular) Transversely Loaded Fillet Welds Minimum Length of Longitudinal Fillet Welds at End of Plate or Flat Bar Members Termination of Welds Near Edges Subject to Tension : End Return at Flexible Connections Fillet Welds on Opposite Sides of a Common Plane Thin Filler Plates in Splice Joint Thick Filler Plates in Splice Joint Allowable Stress Range for Cyclically Applied Load (Fatigue) in Nontubular Connections (Graphical Plot of Table 2.~) Transition of Width (Cyclically Loaded Nontubular) Allowable Fatigue Stress and Strain Ranges for Stress Categories (see Table 2.7), Redundant Tubular Structures for Atmospheric Service Parts of a Tubular Connection Fillet Welded Lap Joint (Tubular) Tubular T-, Y-, and K-Connection Fillet Weld Footprint Radius Punching Shear Stress Detail of Overlapping Joint Limitations for Box T-, Y-, and K-Connections Overlapping K-Connections Transition of Thickness of Butt Joints in Parts of Unequal Thickness (Tubular) Weld Bead in which Depth and Width Exceed the Width of the Weld Face Fillet Welded Prequalified Tubular Joints Made by SMAW, GMAW, and FCAW Prequalified PJP Groove Welded Joint Details (Dimensions in Millimeters) Prequalified CJP Groove Welded Joint Details (Dimensions in Inches) Prequalified Joint Details for PJP T-, Y-, and K-Tubular Connections Prequalified Joint Details for CJP T-, Y-, and K-Tubular Connections Definitions and Detailed Selections for Prequalified CJP T-, Y-, and K-Tubular Connections Prequalified Joint Details for CJP Groove Welds in Tubular T-, Y-, and K-ConnectionsStandard Flat Profiles for Limited Thickness Prequalified Joint Details for CJP Groove Welds in Tubular T-, Y-, and K-ConnectionsProfile with Toe Fillet for Intermediate Thickness Prequalified Joint Details for CJP Groove Welds in Tubular T-, Y-, and K-ConnectionsConcave Improved Profile for Heavy Sections or Fatigue Prequalified Skewed T-Joint Details (Nontubular) Positions of GroQve Welds Positions of Fillet Welds Positions of Test Plates for Groove Welds Positions of Test Pipe or Tubing for Groove Welds Positions of Test Plate for Fillet Welds Positions of Test Pipes or Tubing for Fillet Welds Location of Test Specimens on Welded Test Pipe Location of Test Specimens for Welded Box Tubing xxiv .43 44 .45 45 .46 .46 47 47 48 48 49 50 50 51 54 54 55 55 56 56 57 74 74 76 92 114 117 118 119 120 121 122 154 155 156 157 158 159 160 161 AWS D1.1/D1.1 M:2008 Page No. Figure 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26 4.27 4.28 4.29 4.30 4.31 4.32 4.33 4.34 4.35 4.36 4.37 4.38 4.39 4.40 5.1 5.2 5.3 5.4 6.1 6.2 6.3 6.4 6.5 6.6 6.7 Location of Test Specimens on Welded Test Plates-ESW and EGW- WPS Qualification Location of Test Specimens on Welded Test Plate Over 3/8 in [10 mm] Thick-WPS Qualification Location of Test Specimens on Welded Test Plate 3/8 in [10 mm] Thick and UnderWPS Qualification Face and Root Bend Specimens Side Bend Specimens Reduced-Section Tension Specimens Guided Bend Test Jig Alternative Wraparound Guided Bend Test Jig Alternative Roller-Equipped Guided Bend Test Jig for Bottom Ejection of Test Specimen All-Weld-Metal Tension Specimen Fillet Weld Soundness Tests for WPS Qualification Pipe Fillet Weld Soundness Test-WPS Qualification Test Plate for Unlimited Thickness-Welder Qualification Test Plate for Unlimited Thickness-Welding Operator Qualification Location of Test Specimen on Welded Test Plate 1 in [25 mm] Thick-Consumables Verification for Fillet Weld WPS Qualification Tubular Butt Joint-Welder or WPS Qualification-without Backing Tubular Butt Joint-WPS Qualification with and without Backing Acute Angle Heel Test (Restraints not Shown) Test Joint for T-, Y-, and K-Connections without Backing on Pipe or Box Tubing-Welder and WPS Qualification Test Joint for T-, Y-, and K-Connections without Backing on Pipe or Box Tubing «4 in [100mm] O.D.)-Welder and WPS Qualification : Comer Macroetch Test Joint for T-, Y-, and K-Connections without Backing on Box Tubing for CJP Groove Welds-Welder and WPS Qualification Optional Test Plate for Unlimited Thickness-Horizontal Position-Welder Qualification Test Plate for Limited Thickness-All Positions-Welder Qualification Optional Test Plate for Limited Thickness-Horizontal Position-Welder Qualification Fillet Weld Root Bend Test Plate-Welder or Welding Operator Qualification~Option 2 Location of Test Specimens on Welded Test Pipe and Box Tubing-Welder Qualification Method of Rupturing Specimen-Tack Welder Qualification ; Butt Joint for Welding Operator Qualification-ESW and EGW Fillet Weld Break and Macroetch Test Plate-Welder or Welding Operator Qualification Option 1 Plug Weld Macroetch Test Plate-Welder or Welding Operator Qualification and WPS Qualification Fillet Weld Break Specimen-Tack Welder Qualification CVN Test Specimen Locations Edge Discontinuities in Cut Material Weld Access Hole Geometry Workmanship Tolerances in Assembly of Groove Welded Joints Acceptable and Unacceptable Weld Profiles Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension (Limitations of Porosity and Fusion Discontinuities) Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Compression (Limitations of Porosity or Fusion-Type Discontinuities) Class R Indications Class X Indications Hole-Type IQI Wire IQI xxv 162 163 164 165 166 167 168 169 169 170 171 172 173 173 174 175 175 176 177 178 179 180 181 182 183 184 185 185 186 187 188 189 208 209 210 211 241 246 251 256 258 259 260 AWS D1.1/D1.1 M:2008 Figure 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 7.1 7.2 7.3 7.4 7.5 F.1 F.2 H.1 I.1 I.2 1.3 1.4 S.l S.2 S.3 S.4 S.5 S.6 S.7 S.8 S.9 S.lO S.lI S.12 S.13 S.14 S.15 T.1 Page No. RT Identification and Hole-Type or Wire IQI Locations on Approximately Equal Thickness Joints 10 in [250 mm] and Greater in Length RT Identification and Hole-Type or Wire IQI Locations on Approximately Equal Thickness Joints '" Less than lOin [250 mm] in Length RT Identification and Hole-Type or Wire IQI Locations on Transition Joints 10 in [250 mm] and Greater in Length RT Identification and Hole-Type or Wire IQI Locations on Transition Joints Less than 10 in [250 mm] in Length RT Edge Blocks Single-Wall Exposure-Single-Wall View Double-Wall Exposure-Single-Wall View Double-Wall Exposure-Double-Wall (Elliptical) View, Minimum Two Exposures Double-Wall Exposure-Double-Wall View, Minimum Three Exposures Transducer Crystal Qualification Procedure of Search Unit Using nw Reference Block International Institute of Welding (nW) UT Reference Blocks Qualification Blocks Plan View ofUT Scanning Patterns Scanning Techniques Transducer Positions (Typical) Dimension and Tolerances of Standard-Type Shear Connectors Typical Tension Test Fixture Torque Testing Arrangement and Table of Testing Torques Bend Testing Device Suggested Type of Device for Qualification Testing of Small Studs Temperature-Moisture Content Chart to be Used in Conjunction with Testing Program to Determine Extended Atmospheric Exposure Time of Low-Hydrogen SMAW Electrodes Application of Temperature-Moisture Content Chart in Determining Atmospheric Exposure Time of Low-Hydrogen SMAW Electrodes Other Approved Blocks and Typical Transducer Position Zone Classification of Steels Critical Cooling Rate for 350 HV and 400 HV Graphs to Determine Cooling Rates for Single-Pass SAW Fillet Welds Relation Between Fillet Weld Size and Energy Input Standard Reference Reflector Recommended Calibration Block Typical Standard Reflector (Located in Weld Mock-Ups and Production Welds) Transfer Correction Compression Wave Depth (Horizontal Sweep Calibration) Compression Wave Sensitivity Calibration Shear Wave Distance and Sensitivity Calibration Scanning Methods Spherical Discontinuity Characteristics Cylindrical Discontinuity Characteristics Planar Discontinuity Characteristics Discontinuity Height Dimension Discontinuity Length Dimension Display Screen Marking Report ofUT (Alternative Procedure) Definition of Terms for Computed Alpha Commentary C-2.1 Balancing of Fillet Welds About a Neutral Axis C-2.2 Shear Planes for Fillet and Groove Welds 261 262 263 264 264 265 265 266 266 267 267 268 269 271 272 273 282 282 283 284 284 306 307 313 320 320 321 324 379 379 380 381 381 382 382 383 384 384 385 385 386 386 387 388 .435 .435 xxvi AWS D1.1/D1.1M:2008 Figure C-2.3 C-2.4 C-2.5 C-2.6 C-2.7 C-2.8 C-2.9 C-2.lO C-2.1l C-2.12 C-2.13 C-2.14 C-3.1 C-3.2 C-3.3 C-4.1 C-5.1 C-5.2 C-5.3 C-5.4 C-5.5 C-5.6 C-5.7 C-5.8 C-6.1 C-6.2 C-6.3 C-6.4 C-6.5 C-6.6 C-6.7 C-8.1 C-8.2 C-8.3 C-8.4 C-8.5 C-8.6 C-8.7 C-8.8 Page No. Eccentric Loading Load Deformation Relationship for Welds Example of an Obliquely Loaded Weld Group Graphical Solution of the Capacity of an Obliquely Loaded Weld Group Single Fillet Welded Lap Joints Illustrations of Branch Member Stresses Corresponding to Mode of Loading Improved Weld Profile Requirements Simplified Concept of Punching Shear Reliability of Punching Shear Criteria Using Computed Alpha Transition Between Gap and Overlap Connections Upper Bound Theorem Yield Line Patterns Oscillograms and Sketches ofGMAW-S Metal Transfer Examples of Centerline Cracking Details of Alternative Groove Preparations for Prequalified Comer Joints Type ofWelfting on Pipe That Does Not Require Pipe Qualification Examples of Unacceptable Reentrant Comers Examples of Good Practice for Cutting Copes Permissible Offset in Abutting Members Correction of Misaligned Members : Typical Method to Determine Variations in Girder Web Flatness Illustration Showing Camber Measurement Methods Measurement of Flange Warpage and Tilt Tolerances at Bearing Points : 90° T- or Comer Joints with Steel Backing Skewed T- or Comer Joints Butt Joints with Separation Between Backing and Joint Effect of Root Opening on Butt Joints with Steel Backing Scanning with Seal Welded Steel Backing Resolutions for Scanning with Seal Welded Steel Backing Illustration of Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections ., Illustration of Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections 1-1/8 in [30 mm] and Greater, Typical of Random Acceptable Discontinuities Illustration of Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension Microscopic Intrusions Fatigue Life Toe Dressing with Burr Grinder Toe Dressing Normal to Stress Effective Toe Grinding End Grinding Hammer Peening Toe Remelting xxvii 436 436 437 .438 439 .439 440 440 441 442 442 443 452 453 453 463 474 474 475 475 476 477 478 479 .495 495 .496 496 .497 497 498 499 500 512 512 513 513 514 514 515 516 AWS 01.1/01.1 M:2008 This page is intentionally blank. xxviii AWS 01.1/01.1 M:2008 Structural Welding Code-Steel 1. General Requirements 1.1 Scope 7. Stud Welding. This clause contains the requirement for the welding of studs to structural steel. This code contains the requirements for fabricating and erecting welded steeJstructures. When this code is stipulated in contract documents, conformance with all provisions of the code shall be required, except for those provisions that the Engineer (see 1.4.1) or contract documents specifically modifies or exempts. 8. Strengthening and Repair of Existing Structures. This clause contains basic information pertinent to the welded modification or repair of existing steel structures. 1.2 Limitations The following is a summary of the code clauses: The code was specifically developed for welded steel structures that utilize carbon or low alloy steels that are 1/8 in [3 mm] or thicker with a minimum specified yield strength of 100 ksi [690 MPa] or less. The code may be suitable to govern structural fabrications outside the scope of the intended purpose. However, the Engineer should evaluate such suitability, and based upon such evaluations, incorporate into contract documents any necessary changes to code requirements to address the specific requirements of the application that is outside the scope of the code. The Structural Welding Committee encourages the Engineer to consider the applicability of other AWS D I codes for applications involving aluminum (AWS D1.2), sheet steel equal to or less than 3/16 in thick [5 mm] (AWS D1.3), reinforcing steel (AWS D1.4), and stainless steel (AWS D1.6). The AASHTOIAWS D1.5 Bridge Welding Code was specifically developed for welding highway bridge components and is recommended for those applications. 1. General Requirements. This clause contains basic information on the scope and limitations of the code, key definitions, and the major responsibilities of the parties involved with steel fabrication. 2. Design of Welded Connections. This clause contains requirements for the design of welded connections composed of tubular, or nontubular, product form members. 3. Prequalification. This clause contains the requirements for exempting a WPS (Welding Procedure Specification) from the WPS qualification requirements of this code. 4. Qualification. This clause contains the requirements for WPS qualification and the qualification tests required to be passed by all welding personnel (welders, welding operators, and tack welders) to perform welding in accordance with this code. 5. Fabrication. This clause contains general fabrication and erection requirements applicable to welded steel structures governed by this code, including the requirements for base metals, welding consumables, welding technique, welded details, material preparation and assembly, workmanship, weld repair, and other requirements. 1.3 Definitions The welding terms used in this code shall be interpreted in conformance with the definitions given in the latest edition of AWS A3.0, Standard Welding Terms and Definitions, supplemented by Annex K of this code and the following definitions: 6. Inspection. This clause contains criteria for the qualifications and responsibilities of inspectors, acceptance criteria for production welds, and standard procedures for performing visual inspection and NDT (nondestructive testing). 1.3.1 Engineer. "Engineer" shall be defined as a duly designated individual who acts for, and in behalf of, the Owner on all matters within the scope of the code. 1 AWS 01.1/01.1 M:2008 CLAUSE 1. GENERAL REQUIREMENTS ments that govern products or structural assemblies produced under this code. The Engineer may add to, delete from, or otherwise modify, the requirements of this code to meet the particular requirements of a specific structure. All requirements that modify this code shall be incorporated into contract documents. The Engineer shall determine the suitability of all joint details to be used in a welded assembly. 1.3.2 Contractor. "Contractor" shall be defined as any company, or that individual representing a company, responsible for the fabrication, erection, manufacturing, or welding, in conformance with the provisions of this code. 1.3.3 Inspectors 1.3.3.1 Contractor's Inspector. "Contractor's Inspector" shall be defined as the duly designated person who acts for, and in behalf of, the Contractor on all inspection and quality matters within the scope of the code and of the contract documents. The Engineer shall specify in contract documents, as necessary, and as applicable, the following: (1) Code requirements that are applicable only when specified by the Engineer. 1.3.3.2 Verification Inspector. "Verification Inspector" shall be defined as the duly designated person who acts for, and in behalf of, the Owner or Engineer on all inspection and quality matters specified by the Engi~eer. (2) All additional NDT that is not specifically addressed in the code. 1.3.3.3 Inspector(s) (unmodified). When the term "Inspector" is used without further qualification as the specific Inspector category described above, it applies equally to the Contractor's Inspector and the Verification Inspector within the limits of responsibility described in 6.1.2. (3) Verification inspection, when required by the Engineer. (4) Weld acceptance criteria other than that specified in Clause 6. (5) CVN toughness criteria for weld metal, base metal, and/or HAZ when required. 1.3.4 OEM (Original Equipment Manufacturer). "OEM" shall be defined as that single Contractor that assumes some or all of the responsibilities assigned by this code to the Engineer. (6) For nontubular applications, whether the structure is statically or cyclically loaded. (7) All additional requirements that are not specifically addressed in the code. 1.3.50wner. "Owner" shall be defined as the individual or company that exercises legal ownership of the product or structural assembly produced under this code. (8) For OEM applications, the responsibilities of the parties involved. 1.3.6 Code Tenus "Shall," "Should," and ''May.'' "Shall," "should," and "may" have the following significance: 1.4.2 Contractor's Responsibilities. The Contractor shall be responsible for WPSs, qualification of welding personnel, the Contractor's inspection, and performing work in conformance with the requirements of this code and contract documents. 1.3.6.1 Shall. Code provisions that use "shall" are mandatory unless specifically modified in contract documents by the Engineer. 1.3.6.2 Should. The word "should" is used to recommend practices that are considered beneficial, but are not requirements. 1.4.3 Inspector's Responsibilities 1.4.3.1 Contractor Inspection. Contractor inspection shall be supplied by the Contractor and shall be performed as necessary to ensure that materials and workmanship meet the requirements of the contract documents. 1.3.6.3 May. The word "may" in a provision allows the use of optional procedures or practices that can be used as an alternative or supplement to code requirements. Those optional procedures that require the Engineer's approval shall either be specified in the contract documents, or require the Engineer's approval. The Contractor may use any option without the Engineer's approval when the code does not specify that the Engineer's approval shall be required. 1.4.3.2 Verification Inspection. The Engineer shall determine if Verification Inspection shall be performed. Responsibilities for Verification Inspection shall be established between the Engineer and the Verification Inspector. 1.5 Approval 1.4 Responsibilities All references to the need for approval shall be interpreted to mean approval by the Authority having Jurisdiction or the Engineer. 1.4.1 Engineer's Responsibilities. The Engineer shall be responsible for the development of the contract docu- 2 CLAUSE 1. GENERAL REQUIREMENTS AWS D1.1/D1.1M:2008 1.6 Welding Symbols NOTE: This code may involve hazardous materials, operations, and equipment. The code does not purport to address all ofthe safety problems associated with its use. It is the responsibility ofthe user to establish appropriate safety and health practices. The user should determine the applicability ofany regulatory limitations prior to use. Welding symbols shall be those shown in the latest edition of AWS A2A, Symbols for Welding, Brazing, and Nondestructive Examination. Special conditions shall be fully explained by added notes or details. 1.8 Standard Units of Measurement 1.7 Safety Precautions This standard makes use of both U.S. Customary Units and the International System of Units (SI). The measurements may not be exact equivalents; therefore, each system shall be used independently of the other without combining in any way. The standard with the designation D1.1:2008 uses U.S. Customary Units. The standard designation D1.1M:2008 uses SI Units. The latter are shown within brackets [ ]. This technical document does not address all welding and health hazards. However, pertinent information can be found in the following documents: (1) ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes (2) Manufacturer's safety literature on equipment and materials 1.9 Reference Documents (3) Other pertinent documents as appropriate. Annex U contains a list of all documents referenced in this code. These documents shall be referred to and followed as required (also see Annex R, Safe Practices). 3 AWS D1.1/D1.1M:2008 This page is intentionally blank. 4 AWS D1.1/D1.1M:2008 2. Design of Welded Connections 2.0 Scope of Clause 2 welds shall be clearly shown on the contract plans and specifications, hereinafter referred to as the contract documents. If the Engineer requires specific welds to be performed in the field, they shall be designated in the contract documents. The fabrication and erection drawings, hereinafter referred to as the shop drawings, shall clearly distinguish between shop and field welds. This clause covers requirements for design of welded connections. It is divided into four parts as follows: Part A-Common Requirements for Design of Welded Connections (Nontubular and Tubular Members) Part B-Specific Requirements for Design of Nontubular Connections (Statically or Cyclically Loaded). The requirements shall apply in addition to the requirements of Part A. 2.2.2 Notch Toughness Requirements. If notch toughness of welded joints is required, the Engineer shall specify the minimum absorbed energy with the corresponding test temperature for the filler metal classification to be used, or the Engineer shall specify that the WPSs be qualified with CVN tests. If WPSs with CVN tests are required, the Engineer shall specify the minimum absorbed energy, the test temperature and whether the required CVN test performance is to be in the weld metal, or both in the weld metal and the HAZ (see 4.1.1.3 and Clause 4, Part D). Part C-Specific Requirements for Design of Nontubular Connections (Cyclically Loaded). When applicable, the requirements shall apply in addition to the requirements of Parts A and B. Part D-Specific Requirements for Design of Tubular Structures (Statically and Cyclically Loaded). When applicable, the requirements shall apply in addition to the requirements of Part A. 2.2.3 Specific Welding Requirements. The Engineer, in the contract documents, and the Contractor, in the shop drawings, shall indicate those joints or groups of joints in which the Engineer or Contractor require a specific assembly order, welding sequence, welding technique or other special precautions. Part A Common Requirements for Design of Welded Connections (Nontubular and Tubular Members) . 2.2.4 Weld Size and Length. Contract design drawings shall specify the effective weld length and, for PJP groove welds, the required weld size "(E)." For fillet welds and skewed T-joints, the following shall be provided on the contract documents. 2.1 Scope of Part A This part contains requirements applicable to the design of all welded connections of nontubular and tubular structures, independent of loading. (1) For fillet welds between parts with surfaces meeting at an angle between 80° and 100°, contract documents shall specify the fillet weld leg size. (2) For welds between parts with the surfaces meeting at an angle less than 80° or greater than 100°, the contract documents shall specify the effective throat. 2.2 Contract Plans and Specifications , 2.2.1 Plan and Drawing Information. Complete information regarding base metal specification designation (see 3.3 and 4.7.3) location, type, size, and extent of all End returns and hold-backs for fillet welds, if required by design, shall be indicated on the contract documents. 5 CLAUSE 2. DESIGN OF WELDED CONNECTIONS PARTA 2.2.5 Shop Drawing Reqnirements. Shop drawings shall clearly indicate by welding symbols or sketches the details of groove welded joints and the preparation of base metal required to make them. Both width and thickness of steel backing shall be detailed. AWS 01.1/01.1 M:2008 beyond the fusion boundary nor suitability of the joint detail for a given application. 2.2.5.5 Special Details. When special groove details are required, they shall be detailed in the contract documents. 2.2.5.1 PJP Groove Welds. Shop drawings shall indicate the weld groove depths "S" needed to attain weld size "(E)" required for the welding process and position of welding to be used. 2.2.5.6 Specific Inspection Requirements. Any specific inspection requirements shall be noted on the contract documents. 2.2.5.2 Fillet Welds and Welds in Skewed T-Joints. The following shall be provided on the shop drawings: 2.3 Effective Areas (1) For fillet welds between parts with surfaces meet- ing at an angle between 80° and 100°, shop drawings shall show the fillet weld leg size, 2.3.1 Groove Welds 2.3.1.1 Effective Length. The maximum effective weld length of any groove weld, regardless of orientation, shall be the width of the part joined, perpendicular to the direction of tensile or compressive stress. For groove welds transmitting shear, the effective length is the length specified. (2) For welds between parts with surfaces meeting at an angle less than 80° or greater than 100°, the shop drawings shall show the detailed arrangement of welds and required leg size to account for effects of joint geometry and, where appropriate, the Z-loss reduction for the process to be used and the angle, 2.3.1.2 Effective Size of CJP Groove Welds. The weld size of a CJP groove weld shall be the thickness of the thinner part joined. An increase in the effective area for design calculations for weld reinforcement shall be prohibited. Groove weld sizes for T-, Y-, and Kconnections in tubular construction are shown in Table 3.6. (3) End returns and hold-backs. 2.2.5.3 Welding Symbols. The contract documents shall show CJP or PJP groove weld requirements. Contract documents do not need to show groove type or groove dimensions. The welding symbol without dimensions and with "CJP" in the tail designates a CJP weld as follows: 2.3.1.3 Minimum Size of PJP Groove Welds. PJP groove welds shall be equal to or greater than the size "(E)" specified in 3.12.2.1 unless the WPS is qualified in conformance with Clause 4. ~CJP The welding symbol without dimension and without CJP in the tail designates a weld that will develop the adjacent base metal strength in tension and shear. A welding symbol for a PJP groove weld shall show dimensions enclosed in parentheses below "(E l )" and/or above "(E z)" the reference line to indicate the groove weld sizes on the arrow and other sides of the weld joint, respectively, as shown below: 2.3.1.4 Effective Size of Flare-Groove Welds. The effective size of flare-groove welds when filled flush shall be as shown in Table 2.1, except as allowed by 4.10.5. For flare-groove welds not filled flush, the underfill U shall be deducted. For flare-V-groove welds to surfaces with different radii R, the smaller R shall be used. For flare-groove welds to rectangular tubular sections, R shall be taken as two times the wall thickness. 2.3.1.5 Effective Area of Groove Welds. The effective area of groove welds shall be the effective length multiplied by the effective weld size. 2.2.5.4 Prequalified 'Detail Dimensions. The joint details described in 3.12 (PJP) and 3.13 (CJP) have repeatedly demonstrated their adequacy in providing the conditions and clearances necessary for depositing and fusing sound weld metal to base metal. However, the use of these details shall not be interpreted as implying consideration of the effects of welding process on base metal 2.3.2 Fillet Welds 2.3.2.1 Effective Length (Straight). The effective length of a straight fillet weld shall be the overall length of the full size fillet, including end returns. No reduction in effective length shall be assumed in design calculations to allow for the start or stop crater of the weld. 6 PART A AWS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS 2.3.2.2 Effective Length (Curved). The effective length of a curved fillet weld shall be measured along the centerline of the effective throat. 2.3.2.9 Maximum Weld Size in Lap Joints. The maximum fillet weld size detailed along the edges of base metal in lap joints shall be the following: 2.3.2.3 Minimum Length. The minimum length of a fillet weld shall be at least four times the nominal size, or the effective size of the weld shall be considered not to exceed 25% of its effective length. (1) the thickness of the base metal, for metal less than 114 in [6 mm] thick (see Figure 2.1, Detail A). (2) 1116 in [2 mm] less than the thickness of the base metal, for metal 114 in [6 mm] or more in thickness (see Figure 2.1, Detail B), unless the weld is designated on the shop drawing to be built out to obtain full throat thickness for a leg size equal to the base metal thickness. In the as-welded condition, the distance between the edge of the base metal and the toe of the weld may be less than 1/16 in [2 mm] provided the weld size is clearly verifiable. 2.3.2.4 Intermittent Fillet Welds (Minimum Length). The minimum length of segments of an intermittent fillet weld shall be 1-112 in [38 mm]. 2.3.2.5 Maximum Effective Length. For end-loaded fillet welds with a length up to 100 times the leg dimension, it is allowed to take the effective length equal to the actual length. When the length of end-loaded fillet welds exceeds 100 but not more than 300 times the weld size, the effective length shall be determined by multiplying the actual length by the reduction coefficient ~. ~ = 1.2 - 0.2C o~J :; 2.3.2.10 Effective Area of Fillet Welds. The effective area shall be the effective weld length multiplied by the effective throat. 2.3.3 Skewed T-Joints 1.0 2.3.3.1 General. T-joints in which the angle between joined parts is greater than 100° or less than 80° shall be defined as skewed T-joints. Prequalified skewed T-joint details are shown in Figure 3.11. The details of joints for the obtuse and acute sides may be used together or independently depending upon service conditions and design with proper consideration for effects of eccentricity. where ~ = reduction coefficient L = actual length of end-loaded weld, in [mm] w = weld leg size, in [mm] When the length exceeds 300 times the leg size, the effective length shall be taken as 180 times the leg size. 2.3.3.2 Welds in Acute Angles Between 80° and 60° and in Obtuse Angles Greater than 100°. When welds are deposited in angles between 80° and 60° or in angles greater than 100° the contract documents shall specify the required effective throat. The shop drawings shall clearly show the placement of welds and the required leg dimensions to satisfy the required effective throat (see Annex B). 2.3.2.6 Calculation of Effective Throat. For fillet welds between parts meeting at angles between 80° and 100° the effective throat shall be taken as the shortest distance from the joint root to the weld face of a 90° diagrammatic weld (see Annex A). For welds in acute angles between 60° and 80° and for welds in obtuse angles greater than 100°, the weld leg size required to provide the specified effective throat shall be calculated to account for geometry (see Annex B). For welds in acute angles between 60 0 and 30°, leg size shall be increased by the Z loss dimension to account for the uncertainty of sound weld metal in the root pass of the narrow angle for the welding process to be used (see 2.3.3). 2.3.3.3 Welds in Angles Between 60° and 30°. When welding is required in an acute angle that is less than 60° but equal to or greater than 30° [Figure 3.1l(D)], the effective throat shall be increased by the Z-loss allowance (Table 2.2). The contract documents shall specify the required effective throat. The shop drawings shall show the required leg dimensions to satisfy the required effective throat, increased by the Z-loss allowance (Table 2.2) (see Annex B for calculation of effective throat). 2.3.2.7 Reinforcing Fillet Welds. The effective throat of a combination PIP groove weld and a fillet weld shall be the shortest distance from the joint root to the weld face of the diagrammatic weld minus 118 in [3 mm] for any groove detail requiring such deduction (see Figure 3.3 and Annex A). 2.3.3.4 Welds in Angles Less than 30°. Welds deposited in acute angles less the 30° shall not be considered as effective in transmitting applied forces except as modified for tubular structures in 4.12.4.2. 2.3.3.5 Effective Length of Skewed T-Joints. The effective length of skewed T-joints shall be the overall length of the full size weld. No reduction shall be as- 2.3.2.8 Minimum Size. The minimum size fillet weld shall not be smaller than the size required to transmit the applied load nor that provided in 5.14. 7 CLAUSE 2. DESIGN OF WELDED CONNECTIONS PARTS A &8 AWS 01.1/01.1 M:2008 sumed in design calculations to allow for the start or stop of the weld. the comers rounded to a radius not less than the thickness of the part in which it is made. 2.3.3.6 Minimum Skewed T-Joint Weld Size. The requirements of 2.3.2.8 shall apply. 2.3.5.3 Effective Area of Plug and Slot Welds. The effective area of plug and slot welds shall be the nominal area of the hole or slot in the plane of the faying surface. 2.3.3.7 Effective Throat of Skewed T-Joints. The effective throat of a skewed T-joint in angles between 60° and 30° shall be the minimum distance from the root to the diagrammatic face, less the Z loss reduction dimension. The effective throat of a skewed T-joint in angles between 80° and 60° and in angles greater than 100° shall be taken as the shortest distance from the joint root to the weld face. 2.3.5.4 Depth of Filing. The minimum depth of filling of plug and slot welds shall meet the following requirements: (1) for slot or plug welds in material 5/8 in [16 mm] thick or less, the thickness of the material. (2) for slot or plug welds in materials over 5/8 in [16 mm] thick, one-half the thickness of the material or 5/8 in [16 mm], whichever is greater. 2.3.3.8 Effective Area of Skewed T-Joints. The effective area of skewed T-joints shall be the specified effective throat multiplied by the effective length. ' In no case is the minimum depth of filling required to be greater than the thickness of the thinner part being joined. 2.3.4 Fillet Welds in Holes and Slots 2.3.4.1 Diameter and Width Limitations. The minimum diameter of the hole or the width of slot in which a fillet weld is to be deposited shall be no less than the thickness of the part in which it is made plus 5/16 in [8 mm]. PartB Specific Requirements for Design ofNontubular Connections (Statically or Cyclically Loaded) 2.3.4.2 Slot Ends. Except for those ends which extend to the edge of the part, the ends of the slot shall be semicircular or shall have the comers rounded to a radius not less than the thickness of the part in which it is made. 2.4 General 2.3.4.3 Effective Length of Fillet Welds in Holes or Slots. For fillet welds in holes or slots, the effective length shall be the length of the weld along the centerline of the throat. The specific requirements of Part B together with the requirements of Part A shall apply to all connections of nontubular members subject to static loading. The requirements of Parts A and B, except as modified by Part C, shall also apply to cyclic loading. 2.3.4.4 Effective Area of Fillet Welds in Holes or Slots. The effective area shall be the effective length multiplied by the effective throat. In the case of fillet welds of such size that they overlap at the centerline when deposited in holes or slots, the effective area shall not be taken as greater than the cross-sectional area of the hole or slot in the plane of the faying surface. 2.5 Stresses 2.5.1 Calculated Stresses. The calculated stresses to be compared with the allowable stresses shall be nominal stresses determined by appropriate analysis or stresses determined from the minimum joint strength requirements that may be specified in the applicable design specifications which invoke this code for design of welded connections. 2.3.5 Plug and Slot Welds 2.3.5.1 Diameter and Width Limitations. The minimum diameter of the hole or the width of slot in which a plug or slot weld is to be deposited shall be no less than the thickness of the part which it is made plus 5/16 in [8 mm.]. The maximum diameter of the hole or width of slot shall not exceed the minimum diameter plus 1/8 in [3 mm] or 2-1/4 times the thickness of the part, whichever is greater. 2.5.2 Calculated Stresses Due to Eccentricity. In the design of welded joints, the calculated stresses to be compared with allowable stresses, shall include those due to design eccentricity, if any, in alignment of connected parts and the position, size and type of welds, except as provided in the following: for statically loaded structures, the location of fillet welds to balance the forces about the neutral axis or axes for end connections 2.3.5.2 Slot Length and Shape. The length of the slot in which slot welds are to be deposited shall not exceed ten times the thickness of the part in which it is made. The ends of the slot shall be semicircular or shall have 8 l AWS 01.1/01.1 M:2008 PARTB = Moment of internal forces about the instantaneous center of rotation p = I::./I::.m ratio of element "i" deformation to deformation in element at maximum stress I::.m = 0.209 (8 + 6)-0.32 W, deformation of weld element at maximum stress, in [mm] I::.u = 1.087 (8 + 6)-0.65 W, < 0.17 W, deformation of weld element at ultimate stress (fracture), usually in element furthest from the instantaneous center of rotation, in [rom] W = leg size of the fillet weld, in [mm] I::. i = deformation of weld elements at intermediate stress levels, linearly proportioned to the critical deformation based on distance from instantaneous center of rotation, in [rom] = ril::.u/rerit. x Xi component of ri y = Yi component of ri rerit. = distance from instantaneous center of rotation to weld element with minimum I::.u/ri ratio, in [mm] of single-angle, double-angle, and similar members is not required. In such members, weld arrangements at the heel and toe of angle members may be distributed to conform to the length of the various available edges. M 2.5.3 Allowable Base Metal Stresses. The calculated base-metal stresses shall not exceed the allowable stresses specified in the applicable design specifications. 2.5.4 Allowable Weld Metal Stresses. The calculated stresses on the effective area of welded joints shall not exceed the allowable stresses given in Table 2.3 except as allowed by 2.5.4.2,-).5.4.3, and 2.5.4.4. The use of 2.5.4.2 shall be limited to the analysis of a single linear fillet weld or fillet weld groups consisting of parallel linear fillet welds all loaded at the same angle. 2.5.4.1 Stress in Fillet Welds. Stress in fillet welds shall be considered as.shear applied to the effective area for any direction of applied load. = 2.5.4.2 Alternative Allowable Fillet Weld Stress. For a single linear fillet weld or fillet weld groups consisting of parallel linear fillet welds all loaded at the same angle and loaded in plane through the centroid of the weld group, the allowable stress may be determined by Formula (1): Formula (1) 2.5.4.4 Concentrically Loaded Weld Groups. Alternatively, for the special case of a concentrically loaded weld group, the allowable shear stress for each weld element may be determined using Formula (2) and the allowable loads of all elements calculated and added. Fy = 0.30 FEXX (1.0 + 0.50 sin1.58) Formula (2) where r:y ~xx C 2.5.4.3 Instantaneous Center of Rotation. The allowable stresses in weld elements within a weld group that are loaded in-plane and analyzed using an instantaneous center of rotation method to maintain deformation compatibility and the nonlinear load-deformation behavior of variable angle loaded welds shall be the following: Fvx = Fyy = Fvi = F(p) = M = Fy = 0.30 C F EXX where Fy = allowable unit stress F EXX = electrode classification number, i.e., electrode strength classification 8 = angle between the direction of force and the axis of the weld element, degrees = allowable unit stress = nominal tensile strength of filler metal = the equivalent strength coefficient for obliquely loaded fillet weld, chosen from Table 2.4. 2.5.5 Allowable Stress Increase. Where the applicable design specifications allow the use of increased stresses in the base metal for any reason, a corresponding increase shall be applied to the allowable stresses given herein but not to the stress ranges allowed for base metal or weld metal subject to cyclic loading. L Fvix LFyiy 2.6 Joint Configuration and Details 0.30 FEXX (1.0 + 0.50 sin I.58) F(p) [p (1.9 - 0.9p)] 0.3 L [Fyiy (x) - Fyix (y)] 2.6.1 General Considerations. Welded connections shall be designed to satisfy the strength and stiffness or flexibility requirements of the general invoking specifications. where Fyx Fyy F yix F yiy CLAUSE 2. DESIGN OF WELDED CONNECTIONS 2.6.2 Compression Member Connections and Splices = = = = Total internal force in x direction Total internal force in y direction x component of stress FYi Ycomponent of stress FYi 2.6.2.1 Connections and Splices Designed to Bear Other than Connections to Base Plates. Unless otherwise specified in contract documents, column splices which are finished to bear shall be connected by PJP 9 CLAUSE 2. DESIGN OF WELDED CONNECTIONS PARTB AWS D1.1/D1.1M:2008 groove welds or by fillet welded details sufficient to hold the parts in place. Where compression members other than columns are finished to bear at splices or connections welds shall be designed to hold all parts in alignment and shall be proportioned for 50% of the force in the member. The requirements of Table 3.4 or 5.8 shall apply. 2.6.6 Weld Access Holes. When weld access holes are required, they shall be sized to provide clearances necessary for deposition of sound weld metal. The shape and size requirements of 5.17.1 shall apply. The designer and detailer shall recognize that holes of the minimum required size may affect the maximum net area available in the connected base metal. 2.6.2.2 Connections and Splices Not Finished to Bear Except for Connections to Base Plates. Welds joining splices in columns and splices and connections in other compression members which are not finished to bear, shall be designed to transmit the force in the members, unless CJP welds or more restrictive requirements are specified in contract documents or governing specifications. The requirements of Table 3.4 or Table 5.8 shall apply. 2.6.7 Welds with Rivets or Bolts. Connections that are welded to one member and bolted or riveted to the other shall be allowed. When bolts and welds share the load on a common faying surface, strain compatibility between the bolts and welds shall be considered (see commentary). 2.7 Joint Configuration and Details-. Groove Welds 2.6.2.3 Connections to Base Plates. At base plates of columns and other compression members, the connection shall be adequate to hold the members securely in place. 2.7.1 Transitions in Thicknesses and Widths. For statically loaded structures, surface contouring fillet welds need not be provided. When surface contouring fillet welds are required by the Engineer, they shall be specified in the contract documents (see Figure 2.3). 2.6.3 Base Metal Through-Thickness Loading. T- and comer joints whose function is to transmit stress normal to the sUlface of a connected part, especially when the base metal thickness of the branch member or the required weld size is 3/4 in [20 mm] or greater, shall be given special attention during design, base metal selection and detailing. Joint details which minimize stress intensity on base metal subject to stress in the through-thickness direction shall be used where practical. Specifying weld sizes larger than necessary to transmit calculated stress shall be avoided. 2.7.2 Partial Length CJP Groove Weld Prohibition. Intermittent or partial length CJP groove welds shall be prohibited except that members built-up of elements connected by fillet welds may have groove welds of limited length at points of localized load application to participate in the transfer of localized load. The groove weld shall extend at uniform size for at least the length required to transfer the load. Beyond this length, the groove shall be made with a transition in depth to zero over a distance not less than four times its depth. The groove shall be filled flush before application of the fillet weld. 2.6.4 Combinations of Welds. Except as provided herein, if two or more welds of different type (groove, fillet, plug, slot) are combined to share the load in a single connection, the capacity of the connection shall be calculated as the sum of the individual welds determined relative to the direction of applied load. This method of adding individual capacities of welds does not apply to fillet welds reinforcing PJP groove welds (see Annex A). 2.7.3 Intermittent PJP Groove Welds. Intermittent PJP groove welds, flare bevel, and flare-groove welds may be used to transfer shear stress between connected parts. 2.7.4 Weld Tab Removal. For statically loaded nontubular structures, weld tabs need not be removed. Wher removal is required, or when finishing to surface requirements other than that described by 5.15.4, the requirements shall be specified in the contract documents. 2.6.5 Butt, Corner! and T-Joint Surface Contouring. Fillet welds may be applied over CJP and PJP groove welds in butt joints joining parts of unequal width or thickness, comer, and T-joints for the purpose of contouring weld face or to reduce stress concentrations. When such surface contouring fillet welds are used in statically loaded applications, the size need not be more than 5/16 in [8 mmL The fillet-like reinforcement on the surface ofT- and comer joint groove welds that naturally occurs shall not be cause for rejection nor need it be removed provided it does not interfere with other elements of the construction. No minimum contour radius need be provided. 2.8 Joint Configuration and DetailsFillet Welded Joints 2.8.1 Lap Joints 2.8.1.1 Transverse Fillet Welds. Transverse fille welds in lap joints transferring stress between axiall) loaded parts shall be double-fillet welded (see Figun 10 AWS 01.1/01.1 M:2008 PARTB 2.4) except where deflection of the joint is sufficiently restrained to prevent opening under load. 2.8.4 Fillet Welds in Holes or Slots. Fillet welds in holes or slots in lap joints may be used to transfer shear or to prevent buckling or separation of lapped parts. Minimum spacing and dimensions of holes or slots for fillet welds shall conform to the requirements of 2.3.4.1, 2.3.4.2, 2.8.1, 2.8.2, and 2.9. These fillet welds may overlap subject to the limitation provisions of 2.3.4.4. Fillet welds in holes or slots are not considered to be plug or slot welds. 2.8.1.2 Minimum Overlap. The minimum overlap of parts in stress-carrying lap joints shall be five times the thickness of the thinner part, but not less than 1 in [25 mm]. Unless out-of-plane deflection of the parts is prevented, they shall be double fillet welded (see Figure 2.4) or joined by at least two transverse lines of plug or slot welds or two or more longitudinal fillet or slot welds. 2.8.5 Intermittent Fillet Welds. Intermittent fillet welds may be used to transfer stress between connected parts. 2.8.2 Longitudinal Fillet Welds. If longitudinal fillet welds are used alone in lap joints of end connections of flat bar or plate members, the length of each fillet weld shall be no less than the perpendicular distance between them (see Figure 2.5). The transverse spacing of longitudinal fillet welds used in end connections shall not exceed 16 times the thickness of the thinner connected part unless suitable proviSion is made (as by intermediate plug or slot welds) to prevent buckling or separation of the parts. The longitudinal fillet welds may be either at the edges of the member or in slots. The design of connections using longitudinal fillet welds for members other than flat bar cross sections shall be as provided in the general design specifications. 2.9 Joint Configuration and DetailsPlug and Slot Welds 2.9.1 Minimum Spacing (Plug Welds). The minimum center-to-center spacing of plug welds shall be four times the diameter of the hole. 2.9.2 Minimum Spacing (Slot Welds). The minimum center-to-center spacing of lines o(slot welds in a direction transverse to their length shall be four times the width of the slot. The minimum center-to-center spacing in a longitudinal direction shall be two times the length of the slot. 2.8.3 Fillet Weld Terminations 2.8.3.1 General. Fillet weld terminations may extend to the ends or sides of parts or may be stopped short or may have end returns except as limited by the following cases: 2.9.3 Prequalified Dimensions. Dimensions for prequalified plug and slot welds are described in 2.3.5 and 3.10. 2.8.3.2 Lap Joints Subject to Tension. In lap joints in which one part extends beyond the edge or side of a part subject to calculated tensile stress, fillet welds shall terminate not less than the size of the weld from the start of the extension (see Figure 2.6). 2.9.4 Prohibition in Quenched and Tempered Steels. Plug and slot welds shall be prohibited in quenched and tempered steels with specified minimum Fy greater than 70 ksi [490 MPa]. 2.8.3.3 Maximum End Return Length. Welded joints shall be arranged to allow the flexibility assumed in the connection design. If the outstanding legs of connection base metal are attached with end returned welds, the length of the end return shall not exceed four times the nominal size of the weld (see Figure 2.7 for examples of fl~xible connections). 2.10 Filler Plates Wherever it is necessary to use filler plates in joints required to transfer applied force, the filler plates and the connecting welds shall conform to the requirements of 2.10.1 or 2.10.2, as applicable. 2.8.3.4 Transverse Stiffener Welds. Except where the ends of stiffeners are welded to the flange, fillet welds joining transverse stiffeners to girder webs shall start or terminate not less than four times nor more than six times the thickness of the web from the web toe of the web-to-flange welds. I CLAUSE 2. DESIGN OF WELDED CONNECTIONS 2.10.1 Thin Filler Plates. Filler plates less than 1/4 in [6 mm] thick shall not be used to transfer stress. When the thickness of the filler plate is less than 1/4 in [6 mm], or when the thickness of the filler plate is greater than 114 in [6 mm] but not adequate to transfer the applied force between the connected parts, the filler plate shall be kept flush with the edge of the outside connected palt, and the size of the weld shall be increased over the required size by an amount equal to the thickness of the filler plate (see Figure 2.9). 2.8.3.5 Opposite Sides of a Common Plane. Fillet welds on the opposite sides of a common plane shall be interrupted at the comer common to both welds (see Figure 2.8). 11 CLAUSE 2. DESIGN OF WELDED CONNECTIONS PARTSB& C AWS 01.1/01.1 M:2008 2.11.2.3 Unpainted Weathering Steel. For members of unpainted weathering steel exposed to atmospheric corrosion, if intermittent fillet welds are used, the spacing shall not exceed 14 times the thickness of the thinner plate nor 7 in [180 mm]. 2.10.2 Thick Filler Plates. When the thickness of the filler plate is adequate to transfer the applied force between the connected parts, the filler plate shall extend beyond the edges of the outside connected base metal. The welds joining the outside connected base metal to the filler plate shall be sufficient to transmit the force to the filler plate, and the area subject to applied force in the filler plate shall be adequate to avoid overstressing the filler plate. The welds joining filler plate to the inside connected base metal shall be sufficient to transmit the applied force (see Figure 2.10). PartC Specific Requirements for Design ofNontubular Connections (Cyclically Loaded) 2.10.3 Shop Drawing Requirement. Joints reqUlrmg filler plates shall be completely detailed on shop and erection drawings. 2.12 General 2.12.1 Applicability. Part C applies only to nontubular members and connections subject to cyclic load, within the elastic range, of frequency and magnitude sufficient to initiate cracking and progressive failure (fatigue). The provisions of Part C provide a method for assessing the effects of repeated fluctuations of stress on welded nontubular structural elements which shall be applied to minimize the possibility of a fatigue failure. 2.11 Built-Up Members 2.11.1 Minimum Required Welding. If two or more plates or rolled shapes are used to build up a member, sufficient welding (fillet, plug, or slot type) shall be provided to make the parts act in unison but not less than that which may be required to transmit the calculated stress between the parts joined. 2.12.2 Other Pertinent Provisions. The provisions of Parts A and B shall apply to the design of members and connections subject to the requirements of Part C. 2.11.2 Maximum Spacing oflntermittent Welds 2.11.2.1 General. Except as may be provided by 2.11.2.2 or 2.11.2.3, the maximum longitudinal spacing of intermittent welds connecting a plate component to other components shall not exceed 24 times the thickness of the thinner plate nor exceed 12 in [300 mm]. The longitudinal spacing between intermittent fillet welds connecting two or more rolled shapes shall not exceed 24 in [600 mm]. 2.12.3 Engineer's Responsibility. The Engineer shall provide either complete details, including weld sizes, or shall specify the planned cycle life and the maximum range of moments, shears, and reactions for the connections in contract documents. 2.11.2.2 Compression Members. In built-up compression members, except as provided in 2.11.2.3, the longitudinal spacing of intermittent fillet weld segments along the edges of an outside plate component to other components shall not exceed 12 in [300 mm] nor the plate thickness times 0.730 JEfFy (Fy = specified minimum yield strength and E is Young's modulus of elasticity for the type of steel being used.) When intermittent fillet weld segments are staggered along opposite edges of outside plate components narrower than the width provided by the next sentence, the spacing shall not exceed 18 in [460 mm] nor :the plate thickness times 1.10 JEfFy. The unsupported width of web, cover plate, or diaphragm plates, between adjacent lines of welds, shall not exceed the plate thickness times 1.46 JEfFy. When unsupported transverse spacing exceeds this limit, but a portion of its width no greater than 1.46 JEfFy times the thickness would satisfy the stress requirement, the member shall be considered acceptable. 2.13 Limitations 2.13.1 Stress Range Threshold. No evaluation of fatigue resistance shall be required if the live load stress range is less than the threshold stress range, FTH (see Table 2.~). 2.13.2 Low Cycle Fatigue. Provisions of Part C are nol applicable to low-cycle loading cases which induce calculated stresses into the inelastic range of stress. 2.13.3 Corrosion Protection. The fatigue strengths described in Part C are applicable to structures with suitable corrosion protection, or subject only to mildly corrosive environments such as normal atmospheric conditions. 2.13.4 Redundant-Nonredundant Members. This codf no longer recognizes a distinction between redundant and nonredundant members. 12 AWS 01.1/01.1 M:2008 PART C CLAUSE 2. DESIGN OF WELDED CONNECTIONS 2.14 Calculation of Stresses 2.14.1 Elastic Analysis. Calculated stresses and stress ranges shall be nominal, based upon elastic stress analysis at the member level. Stresses need not be amplified by stress concentration factors for local geometrical discontinuities. In which: FSR = Allowable stress range, ksi [MPa] Cf = Constant from Table 2.~ for all categories except category F. N = Number of cycles of stress range in design life. = Cycles per day x 365 x years of design life. FTH = Threshold fatigue stress range, that is the maximum stress range for infinite life, ksi [MPa] 2.14.2 Axial Stress and Bending. In the case of axial stress combined with bending, the maximum combined stress shall be that for concurrent applied load cases. 2.14.3 Symmetrical Sections. For members having symmetrical cross sections, the connection welds shall preferably be arranged symmetrically about the axis of the member, or if symmetrical arrangement is not practical, the total stresses including those resulting from joint eccentricity shall be included in the calculation of the stress range. For stress category F, the stress range shall not exceed FSR as determined by Formula (3). Formula (3) 2.14.4 Angle Members. For axially stressed angle members, the center of gravity of the connecting welds shall lie between the line of the center of gravity of the angle's cross section and the center of the connected leg, in which case the effects of eccentricity may be ignored. If the center of gravity of the connecting weld lies outside this zone, the total stresses, including those resulting from eccentricity of the joint from the center of gravity of the angle, shall be included in the calculation of the stress range. F SR c l°.167 ( r!J ~FTH Cfx 11 F SR = [( X N (ksi) 10 4 0.167 ) ~ FTH (MPa)] In which: Cf = Constant from Table 2.~ for Category F For tension-loaded plate elements at cruciform, Tand corner joint details with CIP welds, PIP welds, fillet welds or combinations of the preceding, transverse to the direction of stress, the maximum stress range on the cross section of the tension-loaded plate element shall be determined by (a), (b), or (c) as follows: 2.15 Allowable Stresses and Stress Ranges 2.15.1 Allowable Stresses. The calculated unit stresses in welds shall not exceed the allowable stresses described in Table 2.3. (a) For the cross section of a tension-loaded plate element, the maximum stress range on the base metal cross section at the toe of the weld governed by consideration of crack initiation from the toe of the weld, the stress range shall not exceed FSR as determined by Formula (2), Category C, which shall be equal to: 2.15.2 Allowable Stress Ranges. Stress range is defined as the magnitude of fluctuation in stress that results from the repeated application and removal of the live load. In the case of stress reversal, the stress range shall be computed as the numerical sum of the maximum repeated tensile and compressive stresses or the sum of maximum shearing stresses of opposite direction at a given point, resulting from differing arrangement of live load. The calculated range of stress shall not exceed the maximum computed by Formulas (2) through (5), as applicable (see Figure 2.11 for graphical plot of Formulas (2) through (5) for stress categories A, B, B', C, D, E, E', and F). ~ 0.333 F SR = (44~10_) ~ 10 (ksi) 11 0.333 FSR = [e4.4~ 10) ~68.9 (MPa)] (b) For end connections of tension-loaded plate elements using transverse PJP welds, with or without reinforcing or contouring fillet welds, the maximum stress range on the base metal cross section at the toe of the weld governed by consideration of crack initiation from the root of the weld shall not exceed F SR as determined by Formula (4). For categories A, B, B', C, D, E, and E', the stress range shall not exceed FSR as determined by Formula (2). Formula (2) F SR = c lo.333 = ( r!J ~ F TH (ksi) 13 CLAUSE 2. DESIGN OF WELDED CONNECTIONS PARTe AWS D1.1/D1.1M:2008 Formula (4) 2.16 Detailing, Fabrication, and Erection ~ 0.333 F SR = RpJP(44~1O_) F SR = [ RPJP ( 14.4 X 10 N (ksi) 11 )°.333 (MPa) 2.16.1 Transitions in Thickness and Width ] 2.16.1.1 Butt-Joint Thickness Transitions. Butt joints between parts having unequal thicknesses and subject to cyclic tensile stress shall have smooth transitions between offset surfaces at a slope of no more than 1 in 2-112 with the surface of either part. The transition may be accomplished by sloping the weld surfaces, by chamfering the thicker part, or by a combination of the two methods (see Figure 2.3). In which: R pJp = Reduction factor for reinforced or nonreinforced PJP joints RpJp = 0_._65_-_0_.5_9_(2_a_/t.<:..p)_+_0_._72_(_w_/t....r:....p) < . _ 1.0 (for Ill.) t 0.167 p 2.16.1.2 Butt-Joint Width Transitions. Butt joints between parts of unequal width subject to cyclic stress into the tensile range shall have a smooth transition between the offset edges at a slope of not more than 1 on 2-1/2 with the edge of either part or shall be provided with a transition having a 24 in [600 mm] minimum radius tangent to the narrower part at the center of the butt joint (see Figure 2.12). An increased stress range may be used for steels having a yield stress greater than 90 ksi [620 MPa] with details incorporating the radius. _1._12_-_1_.0_1...:...(2_a_/tLP)_+_1._24_(_w_/t....r:....p) ~ 1.0 (for mm) t 0.167 p 2a tp w = the length of the nonwelded root face in the direction of the thickness of the tensionloaded plate = the thickness of tension loaded plate element (in or mm) = the leg size of the reinforcing or contouring fillet, if any, in the direction of the thickness of the tension-loaded plate (in or mm) 2.16.2 Backing 2.16.2.1 Welds for Attaching Steel Backing. Requirements for welds for attaching steel backing and whether the backing shall be removed or left in place shall be determined as described in 2.16.2.2, 2.16.2.3, 2.16.2.4, and the stress range categories of Table 2.~. The Engineer shall note the fatigue stress category on the contract drawings. The Contractor shall note on the shop drawings the required location, the weld detail to be used, whether the tack welds shall be inside the groove or shall be allowed to be outside the groove, and whether the backing shall be allowed to remain in place or whether it shall be removed to provide for the intended stress range category. (c) For end connections of tension-loaded plate el- ements using a pair of fillet welds, the maximum stress range on the base metal cross section at the toe of the weld governed by consideration of crack initiation from the root of the weld due to tension on the root shall not exceed F SR as determined by Formula (5). Additionally, the shear stress range on the throat of the weld shall not exceed F SR by Formula (3) Category F. Formula (5) F SR = R FIL ( . 44 x 1O~ 0.333 N -) (ksl) F SR = [ R FIL ( 14.4 X 10 N 11 )°.333 (MPa) 2.16.2.2 CJP T- and Corner Joints Made from One Side. Welds for attaching backing may be made inside or outside the joint groove. Backing for joints subject to cyclic transverse tension (fatigue) loading shall be removed and the back side of the joint finished consistent with face weld. Any unacceptable discontinuity discovered or caused by removal shall be repaired to the acceptance criteria of this code. ] In which: RFIL = Reduction Factor for joints using a pair of transverse fillet welds only 0.06 + 0.72(~) 0167 t . P 2.16.2.3 CJP Butt Splices. Welds for attaching backing may be inside or outside the groove unless restricted in the stress category description. Tack welds located outside the joint groove shall terminate not closer than 112 in [12 mm] from the edge of the connected part. Backing may remain in place or be removed unless restricted in the stress category used in design. ~ 1.0 (for in) p 0.10 + 1.24 ° t . 167 (~) t p ~ 1.0 (for mm) p 14 A.WS 01.1/01.1 M:2008 PARTSC& 0 CLAUSE 2. DESIGN OF WELDED CONNECTIONS 2.18 Inspection 2.16.2.4 Longitudinal Groove Welds and Corner Joints. Steel backing, if used, shall be continuous for the full length of the joint. Welds for attaching backing may be inside or outside the groove (see 5.10.2). Fatigue categories Band C require that the Engineer ensure that CJP groove welds subject to cyclic transverse applied stress into the tensile range be inspected using RTorUT. 2.16.3 Contouring Weld at Corner and T-Joints. In transverse comer and T-joints subject to tension or tension due to bending, a single pass contouring fillet weld, not less than 1/4 in [6 mm] in size shall be added at reentrant comers. PartD Specific Requirements for Design of Tubular Connections (Statically or Cyclically Loaded) 2.16.4 Flame-Cut Edges. Flame-cut edges need not be dressed provided they meet the roughness provisions of 5.15.4.3. 2.16.5 Transversely Loaded Butt Joints. For transversely loaded butt joints, weld tabs shall be used to provide for cascading the weld termination outside the finished joint. End d~s shall not be used. Weld tabs shall be removed and the end of the weld finished flush with the edge of the member. 2.19 General The specific requirements of Part D apply only to tubular connections, and shall be used with the applicable requirements of Part A. All provisions of Part D apply to static applications and cyclic applications, with the exception of the fatigue provisions of 2.20.6, which are unique to cyclic applications. 2.16.6 Fillet Weld Terminations. In addition to the requirements of 2.8.3.3 the following applies to weld terminations subject to cyclic (fatigue) loading. For connections and details with cyclic forces on outstanding elements of a frequency and magnitude that would tend to cause progressive failure initiating at a point of maximum stress at the end of the weld, fillet welds shall be returned around the side or end for a distance not less than two times the nominal weld size. 2.19.1 Eccentricity. Moments caused by significant deviation from concentric connections shall be provided for in analysis and design [see Figure 2.14(H) for an illustration of an eccentric connection]. 2.20 Allowable Stresses 2.17 Prohibited Joints and Welds 2.20.1 Base-Metal Stresses. These provisions may be used in conjunction with any applicable design specifications in either allowable stress design (ASD) or load and resistance factor design (LRFD) formats. Unless the applicable design specification provides otherwise, tubular connection design shall be as described in 2.20.5,2.20.6, and 2.24. The base-metal stresses shall be those specified in the applicable design specifications, with the following limitations: 2.17.1 One-Sided Groove Welds. Groove welds, made from one side only without backing or made with backing, other than steel, that has not been qualified in conformance with Clause 4 shall be prohibited except that these prohibitions for groove welds made from one side shall not apply to the following: (1) Secondary or nonstress carrying members. (2) Comer joints parallel to the direction of calculated stress between components of built-up members 2.20.2 Circular Section Limitations. Limitations on diameter/thickness for circular sections, and largest flat width/thickness ratio for box sections, beyond which local buckling or other local failure modes shall be considered, shall be in conformance with the governing design code. Limits of applicability for the criteria given in 2.24 shall be observed as follows: 2.17.2 Flat Position Groove Welds. Bevel-groove and J-groove welds in butt joints welded in the flat position shall be prohibited where V-groove or U-groove joints are practicable. 2.17.3 Fillet Welds Less than 3/16 in [5 mm]. Fillet welds less than 3/16 in [5 mm] shall be prohibited. (1) circular tubes: D/t < 3300IFy [for F y in ksi], 478IFy [for Fy in MPa] 2.17.4 T- and Corner CJP Welds with Backing Left in I Place. T- and comer CJP welds subject to cyclic transverse tension stress with the backing bar left in place shall be prohibited. (2) box section gap connections: D/t :::; 210/ JF;, [for F y in ksi], 80/ JF;, [for F y in MPa] but not more than 35 15 CLAUSE 2. DESIGN OF WELDED CONNECTIONS PART 0 (3) box section overlap connections: D/t :s; 190/ IF; [for F y in ksi], 72/ IF; [for F y in MPa] 2.20.6.5 Critical Members. For critical members whose sole failure mode would be catastrophic, D (seel 2.20.6.4) shall be limited to a fractional value of 1/3. 2.20.3 Welds Stresses. The allowable stresses in welds shall not exceed those given in Table 2.§., or as allowed by 2.5.4.2 and 2.5.4.3, except as modified by 2.20.5, 2.20.6, and 2.24. 2.20.6.6 Fatigue Behavior Improvement. For the purpose of enhanced fatigue behavior, and where specified in contract documents, the following profile improvements may be undertaken for welds in tubular T-, Y-, or K-connections: 2.20.4 Fiber Stresses. Fiber stresses due to bending shall not exceed the values described for tension and compression, unless the members are compact sections (able to develop full plastic moment) and any transverse weld is proportioned to develop fUlly the strength of sections joined. (1) A capping layer may be applied so that the aswelded surface merges smoothly with the adjoining base metal, and approximates the profile shown in Figure 3.10. Notches in the profile shall not be deeper than 0.04 in or 1 mID, relative to a disc having a diameter equal to or greater than the branch member thickness. 2.20.5 Load and Resistance Factor Design. Resistance factors, cD, given elsewhere in this section, may be used in context of load and resistance factor design (LRFD) calculations in the following format: cD x (Pu or Mu ) AWS D1.1/D1.1M:2008 (2) The weld surface may be ground to the profile shown in Figure 3.10. Final grinding marks shall be transverse to the weld axis. =L,(LF x Load) (3) The toe of the weld may be peened with a blunt instrument, so as to produce local plastic deformation which smooths the transition between weld and base metal, while inducing a compressive residual stress. Such peening shall always be done after visual inspection, and be followed by MT as described below. Consideration should be given to the possibility of locally degraded notch toughness due to peening. where Pu or Mu is the ultimate load or moment as given herein; and LF is the load factor as defined in the governing LRFD design code, e.g., AISC Load and Resistance Factor Design Specification for Structural Steel in Buildings. 2.20.6 Fatigue 2.20.6.1 Stress Range and Member Type. In the design of members and connections subject to repeated variations in live load stress, consideration shall be given to the number of stress cycles, the expected range of stress, and type and location of member or detail. In order to qualify fatigue categories Xl and Kl, representative welds (all welds for nonredundant structures or where peening has been applied) shall receive MT for surface and near-surface discontinuities. Any indications which cannot be resolved by light grinding shall be repaired in conformance with 5.26.1.4. 2.20.6.2 Fatigue Stress Categories. The type and location of material shall be categorized as shown in Table 2.7. 2.20.6.7 Size and Profile Effects. Applicability of welds to the fatigue categories listed below is limited to the following weld size or base-metal thicknesses: 2.20.6.3 Basic Allowable Stress Limitation. Where the applicable design specification has a fatigue requirement, the maximum stress shall not exceed the basic allowable stress provided elsewhere, and the range of stress at a given number of cycles shall not exceed the values given in Figure 2.13. Cl C2 D E ET F FT 2.20.6.4 Cumulative Damage. Where the fatigue environment involves stress ranges of varying magnitude and varying numbers of applications, the cumulative fatigue damage ratio, D, summed over all the various loads, shall not exceed unity, where 2 in [50 mm] thinner member at transition 1 in [25 mm] attachment 1 in [25 mm] attachment 1 in [25 mm] attachment 1.5 in [38 mm] branch 0.7 in [18 mm] weld size 1 in [25 mm] weld size For applications exceeding these limits, consideration should be given to reducing the allowable stresses or improving the weld profile (see Commentary). For T-, Y-, and K-connections, two levels of fatigue performance are provided for in Table 2.§.. The designer shall designate when Level I is to apply; in the absence of such designation, and for applications where fatigue is not a consideration, Level II shall be the minimum acceptable standard where n = number of cycles applied at a given stress range N = number of cycles for which the given stress range would be allowed in Figure 2.13 16 AWS D1.1/D1.1M:2008 PART 0 2.21 Identification CLAUSE 2. DESIGN OF WELDED CONNECTIONS 2.23.2.2 Prequalified CJP Groove Weld Details Welded from One Side without Backing in T -, Y-, and K-Connections. See 3.13.4 for the detail options. If fatigue behavior improvement is required, the details selected shall be based on the profile requirements of 2.20.6.6 and Table 2.8. Members in tubular structures shall be identified as shown in Figure 2.14. 2.22 Symbols 2.23.3 Stresses in Welds. When weld allowable stress calculations are required for circular sections, the nominal stress in the weld joining branch to chord in a simple T-, Y-, or K-connection shall be computed as: Symbols used in Clause 2, Part D, are as shown in Annex I. .{" 2.23 Weld Design Jweld 2.23.1 Fillet Welds = ~[fa (r~ + (fb) r~] K r K 2 t w a b rw where 2.23.1.1 Effective Area. The effective area shall be in conformance with ?3.2.10 and the following: the effective length of fillet welds in structural T-, Y-, and Kconnections shall be calculated in conformance with 2.23.4 or 2.23.5, using the radius or face dimensions of the branch member as measured to the centerline of the weld. tb = thickness of branch member tw = effective throat of the weld fa and fb = nominal axial and bending stresses in the branch For rm and r w , see Figure 2.16. Ka and Kb are effective length and section factors given in 2.23.4 and 2.23.5. 2.23.1.2 Beta Limitation for Prequalified Details. Details for prequalified fillet welds in tubular T-, Y-, and K-connections are described in Figure 3.2. These details are limited to ~ ::; 1/3 for circular connections, and ~ ::; 0.8 for box sections. They are also subject to the limitations of 3.9.2. For a box section with large comer radii, a smaller limit on ~ may be required to keep the branch member and the weld on the flat face. In ultimate strength or LRFD format, the following expression for branch axial load capacity P shall apply for both circular and box sections: Pu = Qw' Leff where Qw = weld line load capacity (kips/inch) and L eff = weld effective length. For fillet welds, 2.23.1.3 Lap Joints. Lap joints of telescoping tubes (as opposed to an interference slip-on joint as used in tapered poles) in which the load is transferred via the weld may be single fillet welded in conformance with Figure 2.15. Qw = 0.6 t w F Exx with <I> = 0.8 where FEXX = classified minimum tensile strength of weld deposit. 2.23.2 Groove Welds. The effective area shall be in conformance with 2.3.1.5 and the following: the effective length of groove welds in structural T-, Y-, and Kconnections shall be calculated in conformance with 2.23.4 or 2.23.5, using the mean radius r m or face dimensions of the branch member. 2.23.4 Circular Connection Lengths. Length of welds and the intersection length in T-, Y-, and K-connections shall be determined as 21trKa where l' is the effective radius of the intersection (see 2.23.2, 2.23.1.1, and 2.24.1.3(4)). 2.23.2.1 Prequalified PJP Groove Weld Details. Prequalified PIP groove welds in tubular T-, Y-, or Kconnections shall conform to Figure 3.5. The Engineer shall use the figure in conjunction with Table 2.2. to calculate the minimum weld size in order to determine the maximum weld stress except where such calculations are waived by 2.24.1.3(2). x = 1/(2 1t sin e) where , The Z loss dimension shall be deducted from the distance from the work point to the theoretical weld face to find the minimum weld size. e ~ 17 = the acute angle between the two member axes = diameter ratio, branch/main, as previously defined CLAUSE 2. DESIGN OF WELDED CONNECTIONS (1) Punching Shear Format. The acting punching shear stress on the potential failure surface (see Figure 2.17) shall not exceed the allowable punching shear stress. NOTE: The following may be used as conservative approximations: 8 ~~or aXla . 11oad K a -_ 1 + l/sin 2 Kb = Kb = AWS 01.1/01.1 M:2008 PARTD The acting punching shear stress is given by acting V p = 'tin sin 8 3 + l/sin 8 . . 4 ' 8 for m-plane bendmg sm The allowable punching shear stress is given by 1 + 3/sin 8 . 4 for out-of-plane bendmg allow V p = Qq' Qf' F yo /(0.6 y) The allowable V p shall also be limited by the allowable shear stress specified in the applicable design specification (e.g., 0.4 F yo )' 2.23.5 Box Connection Lengths 2.23.5.1 K- and N-Connections. The effective length of branch welds in structural, planar, gap K- and Nconnections between box sections, subjected to pr~domi­ nantly static axial load, shall be taken as: Terms used in the foregoing equations are defined as follows: 2ax + 2b, for 8 ~ 50° 8, y, ~ and other parameters of connection geometry are defined in Figure 2.l4(M). 2ax + b, for 8 ~ 60° in is the nominal axial (fa) or bending (fb ) stress in.the 1:, branch member (punching shear for each kept separate) Thus for 8 ~ 50° the heel, toe and sides of the branch can be considered fully effective. For 8 ~ 60°, the heel is considered ineffective due to uneven distribution of load. For 50° < 8 < 60°, interpolate. F yo = The specified minimum yield strength of the main member chord, but not more than 2/3 the tensile strength. 2.23.5.2 T-, yo, and X-Connections. The effective length of branch welds in structural, planar, T-, Y-, and X-connections between box sections, subjected to predominantly static axial load, shall be taken as: Qq, Qf are geometry modifier and stress interaction terms, respectively, given in Table 2.10. For bending about two axes (e.g., y and z), the effective resultant bending stress in circular and square box sections may be taken as 2ax + b, for 8 ~ 50° 2ax' for 8 ~ 60° For 50° < 8 < 60°, interpolate. For combined axial and bending stresses, the following formula shall be satisfied: 2.24 Limitations of the Strength of Welded Connections JI.75 Acting V [ allow V pP axial 2.24.1 Circular T -, Y-, and K-Connections (see 2.26.1.1) 2.24.1.1 Local Failnre. Where a T-, Y-, or Kconnection is made by simply welding the branch member(s) individually to the main member, local stresses at potential failure surface through the main member wall may limit the usable strength of the welded joint. The shear stress at which such failure occurs depends not only upon the strength of the main member steel, but also on the geometry of the: connection. Such connections shall be proportioned on the basis of either (1) punching shear, or (2) ultimate load calculations as given below. The punching shear is an allowable stress design (ASD) criterion and includes the safety factor. The ultimate load format may be used in load and resistance factor design (LRFD), with the resistance factor cI> to be included by the designer, see 2.20.5. +[ VpJ acting allow V p ~ 1.0 bending (2) LRFD Format (loads factored up to ultimate condition-see 2.20.5) Branch member loadings at which plastic chord wall failure in the main member occurs are given by: axial load: Pu sin 8 = t~ F yo [61t ~ Qq] Qf bending moment: Mu sin 8 = t~ Fyo [db /4][6 1t ~ Qq] Qf with the resistance factor cI> = 0.8. Qf should be computed with lJ2 redefmed as (Pe/AFyo )2 + (MclSFyo)2 where Pe and Me are factored chord load and moment, A is area, S is section modulus. 18 AWS D1.1/D1.1M:2008 PART 0 uniform, and local yielding can be expected before the connection reaches its design load. To prevent "unzipping" or progressive failure of the weld and ensure ductile behavior of the joint, the minimum welds provided in simple T-, Y-, or K-connections shall be capable of developing, at their ultimate breaking strength, the lesser of the brace member yield strength or local strength (punching shear) of the main member. The ultimate breaking strength of fillet welds and PIP groove welds shall be computed at 2.67 times the basic allowable stress for 60 ksi [415 MPa] or 70 ksi [485 MPa] tensile strength and at 2.2 times the basic allowable stress for higher strength levels. The ultimate punching shear shall be taken as 1.8 times the allowable V p of 2.24.1.1. These loadings are also subject to the chord material shear strength limits of: Pu sin e ~ 1t dbtc Fyol J3 M u sin e ~ d~ tc Fyol J3 with ep = 0.95 where tc = chord wall thickness db = branch member diameter and other terms are defined as 2.24.1.1(1). The limit state for combinations of axial load P and bending moment M is given by: (PlPu )1.75 + MlMu ~ 1.0 (2) This requirement may be presumed to be met by the prequalified joint details of Figure 3.8 (CJP) and 3.12.4 (PIP), when matching materials (Table 3.1) are used. 2.24.1.2 General Collapse. Strength and stability of a main member in a,tubular connection, with any reinforcement, shall be investigated using available technology in conformance with the applicable design code. General collapse is particularly severe in cross connections and connections subjected to crushing loads [see Figure 2.14(G) and (1)]. Such connections may be reinforced by increasing the main member thickness, or by use of diaphragms, rings, or collars. (3) Compatible strength of welds may also be presumed with the prequalified fillet weld details of Figure 3.2, when the following effective throat requirements are met: (a) E = 0.7 tb for elastic working stress design of mild steel circular steel tubes (Fy ~ 40 ksi [280 MPa] joined with overmatched welds (classified strength FExx = 70 ksi [485 MPa]) (1) For unreinforced circular cross connections, the allowable transverse chord load, due to compressive branch member axial load P, shall not exceed (b) E = 1.0 tb for ultimate strength design (LRFD) of circular or box tube connections of mild steel, F y ~ 40 ksi [280 MPa], with welds satisfying the matching strength requirements of Table 3.1. (2) For circular cross connections reinforced by a "joint can" having increased thickness to and length, L, the allowable branch axial load, P, may be employed as (c) E = lesser of tc or 1.07 tb for all other cases P = P(l) + [P(2) - P(l)]L/2.5D for L < 2.5/D P = P(2) for L ~ CLAUSE 2. DESIGN OF WELDED CONNECTIONS (4) Fillet welds smaller than those required in Figure 3.2 to match connection strength, but sized only to resist design loads, shall at least be sized for the following multiple of stresses calculated per 2.23.3, to account for nonuniform distribution of load: 2.5/D where P(l) is obtained by using the nominal main member thickness in the equation in (1); and P(2) is obtained by using the joint can thickness in the same equation. The ultimate limit state may be taken as 1.8 times the foregoing ASD allowable, with ep = 0.8. ASD LRFD E60XX and E70XX- 1.35 1.5 Higher strengths- 1.6 1.8 (3) For circular K-connections in which the main member thickness required to meet the local shear provisions of 2.24.1.1 extends at least D/4 beyond the connecting branch member welds, general collapse need not be checked. 2.24.1.4 Transitions. Flared connections and tube size transitions not excepted below shall be checked for local stresses caused by the change in direction at the transition (see Note Q to Table 2.J). Exception, for static loads: 2.24.1.3 Uneven Distribution of Load (Weld Sizing) (1) Due to differences in the relative flexibilities of the main member loaded normal to its surface, and the branch member carrying membrane stresses parallel to its surface, transfer of load across the weld is highly non- Circular tubes having D/t less than 30, and Transition slope less than 1:4. 19 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS 01.1/01.1 M:2008 PART 0 These terms are illustrated in Figure 2.18. 2.24.1.5 Other Configurations and Loads The ultimate limit state may be taken as 1.8 times the I foregoing ASD allowable, with <I> = 0.8. (1) The term "T-, Y-, and K-connections" is often used generically to describe tubular connections in which branch members are welded to a main member, or chord, at a structural node. Specific criteria are also given for cross (X-) connections (also referred to as double-tee) in 2.24.1.1 and 2.24.1.2. N-connections are a special case of K-connections in which one of the branches is perpendicular to the chord; the same criteria apply (see Commentary for multiplanar connections). (2) The allowable combined load component parallel to the main member axis shall not exceed V w tw :~:J 1> where :D 1 is the sum of the actual weld lengths for all braces in contact with the main member. (3) The overlap shall preferably be proportioned for at least 50% of the acting P1-. In no case shall the branch member wall thickness exceed the main member wall thickness. (2) Connection classifications as T-, Y-, K-, or cross should apply to individual branch members according to the load pattern for each load case. To be considered a Kconnection, the punching load in a branch member should be essentially balanced by loads on other braces in the same plane on the same side of the joint. In T- and Y -connections the punching load is reacted as beam shear in the chord. In cross connections the punching load is carried through the chord to braces on the opposite side. For branch members which carry part of their load as K-connections, and part as T-, Y-, or cross connections, interpolate based on the portion of each in total, or use computed alpha (see Commentary). (4) Where the branch members carry substantially different loads, or one branch member has a wall thickness greater than the other, or both, the thicker or more heavily loaded branch member shall preferably be the through member with its full circumference welded to the main member. (5) Net transverse load on the combined footprint shall satisfy 2.24.1.1 and 2.24.1.2. (6) Minimum weld size for fillet welds shall provide effective throat of 1.0 tb for F y < 40 ksi [280 MPa], 1.2 tb for F y > 40 ksi [280 MPa]. (3) For multiplanar connections, computed alpha as given in Annex T may be used to estimate the beneficial or deleterious effect of the various branch member loads on main member ovalizing. However, for similarly loaded connections in adjacent planes, e.g., paired TT and KK connections in delta trusses, no increase in capacity over that of the corresponding uniplanar connections shall be taken. 2.24.2 Box T-, Y, and K-Connections (see 2.26.1.1). Criteria given in this section are all in ultimate load format, with the safety factor removed. Resistance factors for LRFD are given throughout. For ASD, the allowable capacity shall be the ultimate capacity, divided by a safety factor of 1.44/<1>. The choice of loads and load factors shall be in conformance with the governing design specification; see 2.5.5 and 2.20.5. Connections shall be checked for each of the failure modes described below. 2.24.1.6 Overlapping Connections. Overlapping joints, in which part of the load is transferred directly from one branch member to another through their common weld, shall include the following checks: These criteria are for connections between box sections of uniform wall thickness, in planar trusses where the branch members loads are primarily axial. If compact sections, ductile material, and compatible strength welds are used, secondary branch member bending may be neglected. (Secondary bending is that due to joint deformation or rotation in fully triangulated trusses. Branch member bending due to applied loads, sidesway of unbraced frames, etc., cannot be neglected and shall be designed for (see 2.24.2.5). (1) The allowable individual member load component, P1- perpendicular to the main member axis shall be taken as P1- = (Vp tc 11) + (2V w tw 12 ) where V p is the allowable punching shear as defined in 2.24.1.1, and tc = the main member thickness 11 = actual weld length for that portion of the branch member which contacts the main member V p = allowable punching shear for the main member as K-connection(a = 1.0) V w = allowable shear-stress for the weld between branch members (Table 2.§) t~ = the lesser of the weld size (effective throat) or the thickness t b of the thinner branch member 12 = the projected chord length (one side) of the overlapping weld, measured perpendicular to the main member. Criteria in this section are subject to the limitations shown in Figure 2.19. 2.24.2.1 Local Failure. Branch member axial load Pu at which plastic chord wall failure in the main member occurs is given by: . P u sm 20 e -- F yo t 2c [ -211 -A I- p + 4 ,J(l-~) ] Qf AWS 01.1/01.1 M:2008 PARTD for cross, T-, and Y-connections with 0.25 ~ ~ < 0.85 and ep = 1.0. Also, Pu sin e = F yo t~ [9.8 ~eff and ep = 0.8 for compression. and JY] Qf 47ee Pu sin e = H _ 4 t JEFyo(Qf) with ep = 0.9 c with ep = 0.8 for cross connections, end post reactions, etc., in compression, and E = modulus of elasticity for gap K- and N-connections with least ~eff~ 0.1 + fcJ and g/D = S~ 0.5 (1-~) or Pu sin e = 1.5 t~ [1 + 3axlH] JEFyo (Qf) where F yo is specified minimum yield strength of the main member, te is chord wall thickness, "I is D/2te (D = chord face width); ~, 11, e, and Sare connection topology parameters as defined in Figure 2.14(M) and Figure C-2.26; (~eff is equivalent ~ defined below); and Qf = 1.3-O.4U!WQf ~ 1.0); use Qf = 1.0 (for chord in tension) with U being the chord utilization ratio. with ep = 0.75 for all other compression branch loads (2) For gap K- and N-connections, beam shear adequacy of the main member to carry transverse loads across the gap region shall be checked including interaction with axial chord forces. This check is not required for IT ~ 0.44 in stepped box connections having ~ + 11 ~ H/D (H is height of main member in plane of truss). 2.24.2.3 Uneven Distribution of Load (Effective Width). Due to differences in the relative flexibilities of the main member loaded normal to its surface and the branch member carrying membrane stresses parallel to its surface, transfer of load across the weld is highly nonuniform, and local yielding can be expected before the connection reaches its design load. To prevent progressive failure and ensure ductile behavior of the joint, both the branch members and the weld shall be checked, as follows: ~eff =(beompression + acompression + btension + atension)/4D branch branch branch branch These loadings are also subject to the chord material shear strength limits of Pu sin e = (Fy.J J3) teD [211 + 2 ~eop] Ifor cross, T-, or Y-connections with ~ > 0.85, using ep = 0.95, and Pu sin e = (FyJ J3) teD [211 + ~eop + ~gap] (1) Branch Member Check. The effective width axial capacity Pu of the branch member shall be checked for all gap K- and N-connections, and other connections having ~ > 0.85. (Note that this check is unnecessary if branch members are square and equal width.) for gap K- and N-connections with ~ ~ 0.1 + "1150, using ep = 0.95 (this check is unnecessary if branch members are square and equal width), where ~gap = ~ for K- and N-connections with S~ 1.5 (1-~) ~gap = ~eop for all other connections ~eop (effective outside punching) = 5~/y Pu = F ytb[2a + b gap + b eoi - 4tb] but not more than ~ with ep = 0.95 where 2.24.2.2 General Collapse. Strength and stability of a main member in a tubular connection, with any reinforcement, shall be investigated using available technology in conformance with the applicable design code. Fy = tb = a, b = bgap = b gap = (1) General collapse is particularly severe in cross connections and connections subjected to crushing loads. Such connections may be reinforced by increasing the main member thickness or by use of diaphragms, gussets, or collars. b . eOl specified minimum yield strength of branch branch wall thickness branch dimensions [see Figure 2.14(B)] b for K- and N-connections with S~ 1.5(1-~) b eoi for all other connections =(5b\~ y~) F y <b - NOTE: 't ~ 1.0 and Fy ~ Fyo are presumed. For unreinforced matched box connections, the ultimate load normal to the main member (chord) due to branch axial load P shall be limited to: ~ CLAUSE 2. DESIGN OF WELDED CONNECTIONS (2) Weld Checks. The minimum welds provided in simple T-, Y-, or K-connections shall be capable of developing at their ultimate breaking strength, the lesser of the branch member yield strength or local strength of the main member. Pu sin e = 2te Fyo(ax + 5 te) with ep = 1.0 for tension loads, 21 CLAUSE 2. DESIGN OF WELDED CONNECTIONS 'Yt = b/(2tb) of the through brace This requirement may be presumed to be met by the prequalified joint details of Figure 3.6 (CJP and PIP), when matching materials (Table 3.1) are used, 'tt = toverlapltthrough and other terms are as previously defined. (3) Fillet welds shall be checked as described in 2.23.5. (2) Net transverse load on the combined footprint, treated as a T- or Y -connection. 2.24.2.4 Overlapping Connections. Lap joints reduce the design problems in the main member by transferring most of the transverse load directly from one branch member to the other (see Figure 2.20). (3) For more than 100% overlap, longitudinal shearing shall be checked, considering only the sidewalls of the thru branch footprint to be effective. The criteria of this section are applicable to statically loaded connections meeting the following limitations: 2.24.2.5 Bending. Primary bending moment, M, due to applied load, cantilever beams, sidesway of unbraced frames, etc., shall be considered in design as an additional axial load, P: (1) The larger, thicker branch is the thru member. (2) ~~ 0.25. (3) The overlapping branch member is 0.75 'to 1.0 times the size of the through member with at least 25% of its side faces overlapping the through member. P= (5) All branch and chord members are compact box tubes with width/thickness ~ 35 for branches, and ~ 40 for chord. (1) Axial capacity Pu of the overlapping tube, using Pu = Fy tb [QOL (2a - 4tb) + beo + bet] e 2.24.2.6 Other Configurations. Cross T-, Y-, gap K-, and gap N-connections with compact circular branch tubes framing into a box section main member may bel designed using 78.5% of the capacity given in 2.24.2.1 and 2.24.2.2, by replacing the box dimension "a" and "b" in each equation by branch diameter, db (limited to compact sections with 0.4 ~ ~ ~ 0.8). The following checks shall be made: = 0.95 with M JD sin In lieu of more rational analysis (see Commentary), JD may be taken as Tl D/4 for in-plane bending, and as ~D/4 for out-of-plane bending. The effects of axial load, inplane bending and out-of-plane bending shall be considered as additive. Moments are to be taken at the branch member footprint. (4) Both branch members have the same yield strength. ep AWS 01.1/01.1 M:2008 PART 0 for 25% to 50% overlap, with Q _ % overlap OL- 50% 2.25 Thickness Transition Pu = Fy tb [(2a - 4tb) + beo + bet] Tension butt joints in cyclically loaded axially aligned primary members of different material thicknesses or size shall be made in such a manner that the slope through the transition zone does not exceed 1 in 2-112. The transition shall be accomplished by chamfering the thicker part, sloping the weld metal, or by any combination of these methods (see Figure 2.21). for 50% to 80% overlap. Pu = Fy tb [(2a - 4tb) + b + bet] for 80% to 100% overlap. Pu = Fytb [(2a - 4tb) + 2bet] for more than 100% overlap where beo is effective width for the face welded to the chord, 2.26 Material Limitations Tubular connections are subject to local stress concentrations which may lead to local yielding and plastic strains at the design load. During the service life, cyclic loading may initiate fatigue cracks, making additional demands on the ductility of the steel, particularly under dynamic loads. These demands are particularly severe in heavywall joint-cans designed for punching shear (see Commentary C-2.26.2.2). and bet is effective width for the face welded to the through brace. 22 AWS 01.1/01.1 M:2008 PART 0 CLAUSE 2. DESIGN OF WELDED CONNECTIONS (1) Base-metal thickness of 2 in [50 mm] or greater with a specified minimum yield strength of 40 ksi [280 MPa] or greater. 2.26.1 Limitations 2.26.1.1 Yield Strength. The design provisions of 2.24 for welded tubular connections are not intended for use with circular tubes having a specified minimum yield, F y , over 60 ksi [415 MPa] or for box sections over 52 ksi [360 MPa]. CVN testing shall be in conformance with ASTM A 673 (Frequency H, heat lot). For the purposes of this subclause, a tension member is defined as one having more than 10 ksi [70 MPa] tensile stress due to design loads. 2.26.1.2 Rednced Effective Yield. Reduced effective yield shall be used as Fyo in the design of tubular connections with limits ofFyo as follows: 2.26.2.2 LAST Requirements. Tubulars used as the main member in structural nodes, whose design is governed by cyclic or fatigue loading (e.g., the joint can in T-, Y-, and K-connections) shall be required to demonstrate CVN test absorbed energy of 20 ft·lb [27 J] at the Lowest Anticipated Service Temperature (LAST) for the following conditions: (1) 2/3 of specified minimum tensile strength for circular sections (see Notes in Table 2.10). (2) 4/5 of specified minimum tensile strength for rectangular sections (see Figure 2.19). (1) Base-metal thickness of2 in [50 mm] or greater. 2.26.1.3 Box T·, Y·, and K-Connections. The designer should consider~special demands which are placed on the steel used in box T-, Y-, and K-connections. (2) Base-metal thickness of 1 in [25 mm] or greater with a specified yield strength of 50 ksi [345 MPa] or greater. 2.26.1.4 ASTM A 500 Precaution. Products manufactured to this specification may not be suitable for those applications such as dynamically loaded elements in welded structures, etc., where low-temperature notch toughness properties may be important. Special investigation or heat treatment may be required if this product is applied to tubular T-,Y-, and K-connections. When the LAST is not specified, or the structure is not governed by cyclic or fatigue loading, testing shall be at a temperature not greater than 40°F [4°C]. CVN testing shall normally represent the as-furnished tubulars, and be tested in conformance with ASTM A 673 Frequency H (heat lot). 2.26.2.3 Alternative Notch Toughness. Alternative notch toughness requirements shall apply when specified in contract documents. The Commentary gives additional guidance for designers. Toughness should be considered in relation to redundancy versus criticality of structure at an early stage in planning and design. 2.26.2 Tubular Base-Metal Notch Toughness 2.26.2.1 CVN Test Requirements. Welded tubular members in tension shall be required to demonstrate CVN test absorbed energy of 20 ft·lb at 70°F [27 J at 20°C] for the following conditions: 23 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS 01.1/01.1 M:2008 Table 2.1 Effective Size of Flare-Groove Welds Filled Flush (see 2.3.1.4) Welding Process SMAWand FCAW-S GMAW· and FCAW-G SAW Flare-Bevel-Groove Flare-V-Groove 5/16 R 5/8R 5/16 R 5/8R 3/4R 1/2R • Except GMAW-8 Note: R = radius of outside surface. Table 2.2 Z Loss Dimension (Nontubular) (see 2.3.3.3) Position of Welding-V or OR Dihedral Angle 'P Position of Welding-R or F Process Z (in) Z(mm) Process Z (in) Z(mm) 60° > 'P ~45° SMAW FCAW-S FCAW-G GMAW 1/8 1/8 1/8 N/A 3 3 3 N/A SMAW FCAW-S FCAW-G GMAW 1/8 0 0 0 3 0 0 0 45° > 'P ~ 30° SMAW FCAW-S FCAW-G GMAW 1/4 1/4 3/8 N/A 6 6 10 N/A SMAW FCAW-S FCAW-G GMAW 1/4 1/8 1/4 1/4 6 3 6 6 24 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1M:2008 Table 2.3 Allowable Stresses (see 2.5.4 and 2.15.1) Allowable Stress Type of Applied Stress Required Filler Metal Strength Level CJP Groove Welds Tension normal to the effective area" Same as base metal Matching filler metal shall be used b Compression normal to effective area Same as base metal Filler metal with a strength level equal to or one classification (10 ksi [70 MFa]) less than matching filler metal may be used. Tension or compression parallel to axis of the weldc Not a welded joint design consideration Shear on effective area 0.30 x classification tensile strength of filler metal except shear on the base metal shall not exceed 0.40 x yield strength of the base metal / Filler metal with a strength level equal to or less than matching filler metal may be used PJP Groove Welds Tension normal to the effective area 0.30 x classification tensile strength offiller metal Compression normal to effective area of weld in joints designed to bear 0.90 x classification tensile strength of filler metal, but not more than 0.90 x yield strength of the connected base metal Compression normal to effective area of weld in joints not designed to bear 0.75 x classification tensile strength of filler metal Tension or compression parallel to axis of the weld C Not a welded joint design consideration Shear parallel to axis of effective area 0.30 x classification tensile strength of filler metal except shear on the base metal shall not exceed 0.40 x yield strength of the base metal Filler metal with a strength level equal to or less than matching filler metal may be used Fillet Welds Shear on effective area or weld Tension or compression parallel to axis of the weldc 0.30 x classification tensile strength of filler metal except that the base metal net section shear area stress shall not exceed 0.40 x yield strength of the base metal d. e Filler metal with a strength level equal to or less than matching filler metal may be used Not a welded joint design consideration Plug and Slot Welds Shear parallel to the faying surface on the effective areaf 0.30 x classification tensile strength of filler metal Filler metal with a strength level equal to or less than matching filler metal may be used For definitions of effective areas, see 2.3. bFor matching filler metal to base metal strength for code approved steels, see Table 3.1 and Table 4.9. C Fillet welds and groove welds joining components of built-up members are allowed to be designed without regard to the tension and compression stresses in the connected components parallel to the weld axis although the area of the weld normal to the weld axis may be included in the crosssectional area of the member. d The limitation on stress in the base metal to 0.40 x yield point of base metal does not apply to stress on the diagrammatic weld leg; however, a check shall be made to assure that the strength of the connection is not limited by the thickness of the base metal on the net area around the connection, particularly in the case of a pair of fillet welds on opposite sides of a plate element. e Alternatively, see 2.5.4.2, 2.5.4.3, and 2.5.4.~. Note d (above) applies. f The strength of the connection shall also be limited by the tear-out load capacity of the thinner base metal on the perimeter area around the connection. a 25 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1M:2008 Table 2.4 Equivalent Strength Coefficients for Obliquely Loaded Fillet Welds (see 2.5.4.4) Load Angle for the Element Being Analyzed Load Angle for Weld Element with Lowest Deformation Capability E> C (90) C (75) C (60) C (45) C (30) C (15) 0 0.825 0.849 0.876 0.909 0.948 0.994 15 1.02 1.04 1.05 1.07 1.06 0.883 30 1.16 1.17 1.18 1.17 1.10 45 1.29 1.30 1.29 1.26 60 1.40 1.40 1.39 75 1.48 1.47 90 1.50 C (0) Note: The weld element with the lowest deformation capability will be the element with the greatest load angle. Linear interpolation between adjacent load angles is permitted. 26 ~ B C 1.4 Weld access holes made to the requirements of2.16.5 and 5.17.1. B 1.2 Non-coated weathering steel base metal with rolled or cleaned surface and with rolled or flame-cut edges with ANSI smoothness of 1000 or less. 1.3 Flame-cut reentrant comers, except weld access holes, meeting the requirements of 2.16.5 with ANSI smoothness of 1000 or less. A 1.1 Base metal, except non-coated weathering steel, with rolled or cleaned surface and rolled or flame-cut edges with ANSI smoothness of 1000 or less, but without reentrant comers. Description 10 [69] From irregularities in surface of reentrant comer of weld access hole comer From irregularities in I surface of reentrant Away from all welds or structural connections Away from all welds or structural connections (A) (B) (Continued) (B) (0) ) 1.4 (A) (B) ~ tJfj U ~ 1.3 (A) (C) Illustrative Examples -~- 1.1/1.2 Section 2-Connected Material in Mechanically Fastened Joints-Not Used" 10 8 1 120 x 10 81 16 [110] l20x10 8 1 16 [110] 250x10 8 1 24 [166] 44 x Potential Crack Initiation Point Section I-Plain Material Away from Any Welding Threshold Stress Constant FTH ksi [MPa] Category Cf Table 2.~ Fatigue Stress Design Parameters (see 2.13.1) ~ z en (5 Q m o o o z z m o r ::iE m m o en G5 z o "Tl m !'J en o g o i\) s: :.... ~ ..... ~ ~ en 3.4 Base metal at ends of longitudinal intermittent fillet weld segments. Description E Potential Crack Initiation Point 11 x 10 8 \ 4.5 [31] (Continued) In connected material at start and stop locations of any weld deposit (A) (B) (B) (B) , (B) (C) (C) ~ Illustrative Examples @Sr ~s 3.4 (A) (A) ~ (A) Section 3-Welded Joints Joining Components of Built-Up Members FTH Stress Constant ksi [MPa] Category Cr Threshold Table 2.~ (Continued) Fatigue Stress Design Parameters (see 2.13.1) (Xl o ~ ..... s: ro o ..... g ~ CJ) 5 z CJ) ~ m Z G5 z o "T1 ::E m r o m o () o z CJ) m o ~ m CJ) ~ () N \0 E' E' Flange thickness> 0.8 in [20 rom] 3.6 Base metal at ends of partial length welded coverplates wider than the flange without welds across the ends. B 3.9 x 10 8 E' t> 0.8 in [20 rom] I 3.6 I 3.5 I (A) Initiating from end of any weld termination extending into the base metal 4.1 ~ 120 x 10 8 16 [110] (Continued) From internal discontinuities in weld metal or along fusion boundary 5.1 (A) ~ CJP - FINISH ~ (B) Illustrative Examples ~ (A) (A) Section 5-Welded Joints Transverse to Direction of Stress 2.6 [18] 11 x 1081 4.5 [31] 5.1 Base metal and weld metal in or adjacent to CJP groove welded splices in rolled or welded cross section with welds ground essentially parallel to the direction of stress. In edge of flange at end of coverplate weld In flange at toe of end weld or in flange at termination of longitudinal weld or in edge of flange with wide coverplates Potential Crack Initiation Point Section 4-Longitndinal FiDet Welded Connections 2.6 [18] E 3.9 x 10 8 11 x 10 8 4.5 [31] 3.9 x 10 8 2.6 [18] t ::; 0.8 in [20 rom] 4.1 Base metal at junction of axially loaded members with longitudinally welded end connections. Welds lengths shall be proportioned on each side of axis to balance weld stresses. E Flange thickness::; 0.8 in [20 rom] 3.5 Base metal at ends of partial length welded cover plates narrower than the flange having square or tapered ends, with or without welds across the ends or coverplates wider than the flange with welds across the ends. Description Threshold Stress Constant F TH ksi [MPa] Category Cf Table 2.§ (Continued) Fatigue Stress Design Parameters (see 2.13.1) (B) tl'1 (B) (B) (C) ~ ~ oz (J) m () o o z z :::E m r o m o "T1 z Gi (J) m o m !" (J) ~ () <Xl s: ~ o .... ~ .... ~ ~ (J) Vol o B C B' 5.4 Base metal and filler metal in or adjacent to the toe of CJP. T- or comer joints with backing removed or splices, with or without transitions in thickness having slopes no greater than 1 to 2-112 when weld reinforcement is not removed. 90 ksi [620 MPa] B ~ 5.3 Base metal with Fy equal to or greater than 90 ksi [620 MPa] and filler metal in or adjacent to CJP groove welded splices with welds ground essentially parallel to the direction of stress at transitions in width made on a radius of not less than 2 ft [600 mm] with the point of tangency at the end of the groove weld. Fy Fy < 90 ksi [620 MPa] 5.2 Base metal and filler metal in or adjacent to CJP groove welded splices with welds ground essentially parallel to the direction of stress at transitions in thickness or width made on a slope no greater than 1 to 2-112. Description 44 x 10 8 1 10 [69] 120 x 10 81 16 [110] 120 x 108116 [110] 61 x 10 8 12 [83] Threshold FTH Stress Constant ksi [MPa] Cf Category I (Continued) From surface discontinuity at toe of weld extending into base metal or along fusion boundary From internal discontinuities in filler metal or discontinuities along the fusion boundary From internal discontinuities in weld metal or along fusion boundary or at start of transition when Fy ~ 90 ksi [620 MPa] Potential Crack Initiation Point 5.4 5.3 5.2 (A) (A) Table 2.§ (Continued) Fatigue Stress Design Parameters (see 2.13.1) f (0) tt (B) (C) ~'iE (C) va } Illustrative Examples g N o s: ..... ~ :.... g ~ en en oz ~ m m o o () o z z r "m~ m o en G5 z o m !" en ~ () w ..... C n C Crack initiating from weld toe Crack initiating from weld root 5.6 Base metal and weld metal at transverse end connections of tensionloaded plate elements using a pair of fillet welds on opposite sides of the plate. F SR shall be the smaller of the toe crack or root crack stress range. C C' Crack initiating from weld root E D Crack initiating from weld toe 5.5 Base metal and filler metal at transverse end connections of tensionloaded plate elements using PJP butt, T-, or comer joints, with reinforcing or contouring fillets. F SR shall be the smaller of the toe crack or root crack stress range. Tack welds outside the groove and not closer than II2 in [12 rom] to edge of base metal Tack welds inside groove 5.4.1 Base metal and filler metal in or adjacent to CJP groove welded butt splices with backing left in place. Description X 10 8 Formula (5) 44 X 10 8 (4) None provided 10 [69] None provided 10 [69] 4.5 [31] 10 8 X 7 [48] Formula 44 11 22 X 10 8 FTH Stress Constant ksi [MPa] Category Cf Threshold (Continued) Initiating from discontinuity at weld toe extending into base metal or initiating from root due to tension extending up and then out through the weld Initiating from discontinuity at weld toe extending into base metal or initiating from root due to tension extending up and then out through the weld From the toe of the groove weld or the toe of the weld attaching backing Potential Crack Initiation Point (A) 5.6 (A) (C) (B) (0) 2a (C) ~ ~ (E) ~ ~ o z en m z z o () m o o r m ~ m o en G5 z o ." m !':l en ~ ~.;'~'.. 2a ex> .• m~."D'N~.·",~i=tt (B) (E) N o o () (A) (C) ~ '----' ~~ Illustrative Examples ~ ..... s:: ..... ~ ~ en oTENTIAL CRACKING DUE I]$ 5.5 5.4.1 Table 2.§ (Continued) Fatigue Stress Design Parameters (see 2.13.1) N W D E 6 in [150 mm] > R > 2 in [50 mm] 2 in [50 mm] > R C 6 in [150 mm] 24 in [600 mm] > R ~ B ~ C 24 in [600 mm] R 6.1 Base metal at details attached by CJP groove welds subject to longitudinal loading only when the detail embodies a transition radius, R, with the weld termination ground smooth. 5.7 Base metal of tension loaded plate elements at toe of transverse fillet welds, and, base metal at toe of welds on girders and rolled beam webs or flanges adjacent to welded transverse stiffeners. Description I 10 [69] From geometric discontinuity at toe of fillet extending into base metal Potential Crack Initiation Point 5.7 (A) 16 [110] 11 22 X 108 X 108 4.5 [31] 7 [48] 44 x 108 10 [69] 120 x 108 (Continued) Near point of tangency of radius at edge of member (A) R (B) (B) Illustrative Examples . =C (C) (C) ~ t IMMATERIAL ~~c:Q6=-@) 6.1 Section 6-Base Metal at Welded Transverse Member Connections 44 X 10 8 Threshold FTH Stress Constant ksi [MPa] Category Cf Table 2.~ (Continued) Fatigue Stress Design Parameters (see 2.13.1) ~ OJ N o o :s:: ..... ~ ..... g (J) ~ 5 z (J) m z o "'Tl ::E m r o m o o o z z o m (J) G5 m !" (J) ~ o w w 7 [48] Any radius When weld reinforcement not removed: R::;;2in[50mm] R> 2 in [50 mm] When weld reinforcement is removed: 11 x 108 4.5 [31] 4.5[31] 11 x E E 7 [48] 108 22 x X D 11 108 2 in [50 mm] > R 4.5 [31] 6 in [600 mm] > R > 2 in [50 mm] 44 X 108 108 C 24 in [150 mm] > R :2: 6 in [150 mm] E X 22 x 108 C R :2: 24 in [600 mm] 6.3 Base metal at details of unequal thickness attached by CJP groove welds subject to transverse loading with or without longitudinal loading when the detail embodies a transition radius, R, with the weld termination ground smooth. 4.5 [31] 108 11 D E 2 in [50 mm] > R 7 [48] 22 x 108 44 x 10 [69] 10 [69] D 6 in [150 mm] > R > 2 in [50 mm] 16 [110] 10 [69] I 108 120 x 108 I 44 x 108 C 24 in [600 mm] > R :2: 6 in [150 mm] When weld reinforcement not removed: B R :2: 24 in [600 mm] When weld reinforcement is removed: 6.2 Base metal at details of equal thickness attached by CJP groove welds subject to transverse loading with or without longitudinal loading when the detail embodies a transition radius, R, with the weld termination ground smooth. Description Threshold Stress Constant FTH ICategory Cf ksi [MPa] I (Continued) At toe of weld along edge of thinner material At toe of the weld either along edge of member or the attachment Near points of tangency of radius or in the weld or at fusion boundary or member or attachment Potential Crack Initiation Point 6.3 G R R (C) - (C) (A) -~- G (B) - ---..... (0) (B) (E) ---..... (0) ~~ rAW (A) .. \ , ~. ~ ' ,, Illustrative Examples .... ---... ~ __ 6.2 Table 2.~ (Continued) Fatigue Stress Design Parameters (see 2.13.1) ~ zC/) <5 -i () m z z 0 () 0 m r 0 "m~ 0 G5 z C/) m 0 I\J C/) m ~ () ex> 0 0 i\J s: --9.......... 9 C/) .j::.. w R 11 3.9 E E' a> 12b or 4 in [100 mm] when b is :;; 1 in [25 mm] a> 12b or 4 in [100 mm] when b is > 1 in [25 mm] , D X X 4.5 [31] 2.6 [18] 108 7 [48] 10 [69] 108 44 X 108 22 X 108 (Continued) In the member at the end of the weld (C) ~ (C) (A) ~- THICKNESS OF ATTACHMENT PLATE r-a (A) b=BA~ 7.1 Section 7-Base Metal at Short Attachmentsb 4.5 [31] X 108 11 7 [48] 22 X 108 2 in [50 mm] :;; a :;; 12b or 4 in [100 mm] a < 2 in [50 mm] C E R:;; 2 in [50 mm] 7.1 Base metal subject to longitudinal loading at details attached by fillet welds parallel or transverse to direction of stress where the detail embodies no transition radius, and with detail length in direction of stress, a, and attachment height normal to the surface of the memberb: D In weld termination or from the toe of the weld extending into member R (0) (B) b = BASE METAL THICKNESS OF ATTACHMENT PLATE b=AVERAGE BASE METAL THICKNESS OF CHANNEL .... n---- FLANGE (B) -c:Q€J:'" ~~ 6.4 Illustrative Examples s:: ~ g ..... ~ ..... ~ ~ en en oz ~ m :E m r o m o () o z z o"'T1 z Potential Crack Initiation Point Stress Constant FTH Category ksi [MPa] Cf o en G5 m R> 2 in [50 mm] 6.4 Base metal subject to longitudinal stress at transverse members, with or without transverse stress, attached by fillet or PJP groove welds parallel to direction of stress when the detail embodies a transition radius, R, with weld termination ground smooth. Description ~ en m !'l Threshold Table 2.~ (Continued) Fatigue Stress Design Parameters (see 2.13.1) () Ul ~ I I E F 8.2 Shear on throat of continuous or intermittent longitudinal or transverse fillet welds including fillet welds in holes or slots 8.3 Base metal at plug or slot welds. C E R :::; 2 in [50 mm] 8.1 Base metal at stud-type shear connectors attached by fillet or electric stud welding. D I 108 I 8 [55] 10 [69] I In throat of weld At toe of weld in base metal metal (Continued) (A) (B) (B) d:J d:J (A) - 8.3 (A) (A) (B) (C) - - bSS==== (B) ~~~~{L; 8.2 8.1 7.2 Illustrative Examples I ~~~ I Section 8-MisceUaneous extending into member I In weld termination Potential Crack Initiation Point I 11 X 108 I 4.5 [31] I At end of weld in base Formula (3) 150x 1010 44x 108 X 22 x 108 11 ,~ Table 2.~ (Continued) Fatigue Stress Design Parameters (see 2.13.1) Threshold Stress Constant FTH Cf ksi [MPa] Category R> 2 in [50 mm] 7.2 Base metal subject to longitudinal stress at details attached by fillet or PJP groove welds, with or without transverse load on detail, when the detail embodies a transition radius, R, with weld termination ground smooth. Description - (5 ~ zf/) m z z 0 () 0 r 0 m :E m "T1 0 G5 z f/) m 0 m !" f/) ~ () co 0 0 i0 ...s: ~ :.... ~ ~ f/) 0'1 VJ F (Fonnula 3) 150x 1010 8 [55] At faying surface Potential Crack Initiation Point 8.4 (A) --Llf: ~::: Illustrative Examples .-. L.diiiIIoo. ..... D1.l/D1.lM:2008 deals only with welded details. To maintain consistency and to facilitate cross referencing with other governing specifications, Section 2-Connected Material in Mechanically Fastened Joints, and Description 8.5 are not used in this table. b "Attachment," as used herein, is defined as any steel detail welded to a member which, by its mere presence and independent of its loading, causes a discontinuity in the stress flow in the member and thus reduces the fatigue resistance. a AWS 8.5 Description 8.5 deals only with mechanically fastened detail not pertinent to D1.1. 8.4 Shear on plug or slot welds. Description Threshold FTH Stress Constant ksi [MPa] Category Cf Table 2.§ (Continued) Fatigue Stress Design Parameters (see 2.13.1) ro 8Ol s: ..... ~ ..... ~ ~ rn rn z <5 Q m m o o o o z z r m :if o'"11 m o rn G5 z m !" ~rn o -...,J VJ Fillet Weld CJPGroove Weld Type of Weld Joints in structural T-, Y-, or K-connections in circular lap joints and joints of attachments to tubes Longitudinal joints of builtup tubular members Weld joints in structural T-, Y-, or K-connections in structures designed for critical loading such as fatigue, which would normally call for CJP welds Circumferential butt joints (girth seams) Longitudinal butt joints (longitudinal seams) Tubular Application 0040 Fy 0.3 FEXX (Continued) 0.30 F EXX or as limited by connection geometry (see 2.24) 0.75 0.30FEXXe Shear on effective area 0.6FEXX 0.6 FEXX Fy or as limited by connection geometry (see 2.24 for provision for LRFD) 0.75 0.9 Shear on effective throat regardless of direction of loading (see 2.23 and 2.24.1.3) Fy 0.6Fy 0.6FEXX Fy 0.6Fy 0.6FEXX 0.6Fy Nominal Strength Same as for base metal or as limited by connection geometry (see 2.24 provisions for LRFD) 0.9 Base metal 0.9 Weld metal 0.8 0.9 0.9 0.8 0.9 Resistance Factor , <I> Same as for base metal Same as for base metal or as limited by connection geometry (see 2.24 provisions for ASD) Same as for base metal Base metal Filler metal Same as for base metalC Allowable Stress Load and Resistance Factor Design (LRFD) Tension or compression parallel to axis of the weld Tension, compression, or shear on effective area of groove welds, made from both sides or with backing Tension, compression or shear on base metal adjoining weld conforming to detail of Figures 3.6 and 3.8-3.10 (tubular weld made from outside only without backing) Tension normal to the effective area Shear on effective area Compression normal to the effective areab Beam or torsional shear Tension or compression parallel to axis of the weldb Kind of Stress Allowable Stress Design (ASD) Table 2.§ Allowable Stresses in Tubular Connection Welds (see 2.20.3) Filler metal with a strength level equal to or less than matching filler metal may be used d Filler metal with a strength level equal to or less than matching filler metal may be used Matching filler metal shall be used Matching filler metal shall be used Filler metal with strength equal to or less than matching filler metal may be used Required Filler Metal Strength Level a ~ ~ oz en m m o o () o z z r "~m o m en G5 z o rv m en ~ () o0) N o :s: ..... ~ ..... ~ en VJ 00 Kind of Stress Structural T-, Y-, or K-connection in ordinary structures Circumferential and longitudinal joints that transfer loads Longitudinal seam of tubular members Joint designed to bear Load transfer across the weld as stress on the effective throat (see 2.23 and 2.24.1.3) Tension on effective area Shear on effective area Compression normal to the effective area Joint not designed to bear Tension or compression parallel to axis of the weldb Shear parallel to faying surfaces (on effective area) Tubular Application 0.40 Fy 0.3 FEXX 0.30 FEXX or as limited by connection geometry (see 2.24), except that stress on an adjoining base metal shall not exceed 0.50 Fy for tension and compression, nor 0.40 Fy for shear 0.30 FEXX, except that stress on adjoining base metal shall not exceed 0.50 Fy for tension, or 0.40 Fy for shear Same as for base metal 0.50 FEXX, except that stress on adjoining base metal shall not exceed 0.60 Fy Same as for base metalC Base metal Filler metal Allowable Stress or as limited by connection geometry (see 2.24 provisions for LRFD) Fy 0.6FEXX Fy 0.6FEXX Base metal 0.9 Filler metal 0.8 Base metal 0.9 Filler metal 0.8 0.6FEXX Fy 0.75 0.9 Fy Nominal Strength Not Applicable 0.9 «I> Resistance Factor Load and Resistance Factor ~\ Design (LRFD) Matching filler metal shall be used Filler metal with a strength level equal to or less than matching filler metal may be used Filler metal with a strength level equal to or less than matching filler metal may be used Filler metal with a strength level equal to or less than matching filler metal may be used Filler metal with a strength level equal to or less than matching filler metal may be used Required Filler Metal Strength Level a b a - ,.- -- For matching filler metal see Table 3.1. Beam or torsional shear up to 0.30 minimum specified tensile strength of filler metal is allowed, except that shear on adjoining base metal shall not exceed 0.40 F y (LRFD; see shear). C Groove and fillet welds parallel to the longitudinal axis of tension or compression members, except in connection areas, shall not be considered as transferring stress and hence may take the same stress as that in the base metal, regardless of electrode (filler metal) classification. Where the provisions of 2.24.1 are applied, seams in the main member within the connection area shall be CJP groove welds with matching filler metal, as defined in Table 3.1. d See 2.24.1.3. e Alternatively, see 2.5.4.2 and 2.5.4.3. PJPGroove Weld Plug and Slot Welds Type of Weld Allowable Stress Design (ASD) Table 2.6 Allowable Stresses in Tubular Connection Welds (see 2.20.3) co a a ro ..... s::: ~ ..... ~ en ~ en (5 ~ z m " Gi z o :mE r o m o () o z z m en o !" m en ~ () CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS 01.1/01.1 M:2008 Table 2.7 Stress Categories for Type and Location of Material for Circular Sections (see 2.20.6.2) Stress Category Kinds of Stress a Situation A Plain unwelded pipe TCBR B Pipe with longitudinal seam TCBR B Butt splices, CJP groove welds, ground flush and inspected by RT or UT (Class R) TCBR B Members with continuously welded longitudinal stiffeners TCBR Butt splices, CJP groove welds, as welded TCBR Members with transverse (ring) stiffeners TCBR D Members with miscellaneous attachments such as clips, brackets, etc. TCBR D Cruciform and T-joints with CJP welds (except at tubular connections) TCBR DT Connections designed as a simple T-, Y-, or Kconnections with CJP groove welds conforming to Figures 3.8-3.10 (including overlapping connections in which the main member at each intersection meets punching shear requirements) (see Note b) (Note: Main member must be checked separately per category K 1 or Kz ) E Balanced cruciform and T-joints with PJP groove welds or fillet welds (except at tubular connections) TCBR in member; weld must also be checked per category F E Members where doubler wrap, cover plates, longitudinal stiffeners, gusset plates, etc., terminate (except at tubular connections) TCBR in member; weld must also be checked per category F ET Simple T-, Y-, and K-connections with PJP groove welds or fillet welds; also, complex tubular connections in which the punching shear capacity of the main member cannot carry the entire load and load transfer is accomplished by overlap (negative eccentricity), gusset plates, ring stiffeners, etc. (see Note b) TCBR in branch member TCBR in branch member (Note: Main member in simple T-, Y-, or K-connections must be checked separately per category K 1 or Kz ; weld must also be checked per category FT and 2.24.1) F End weld of cover plate or doubler wrap; welds on gusset plates, stiffeners, etc. Shear in weld F Cruciform and T-joints, loaded in tension or bending, having fillet or PJP groove welds (except at tubular connections) Shear in weld (regardless of direction of loading) (see 2.23) FT Simple T-, Y-, or K-connections loaded in tension or bending, having fillet or PJP groove welds Shear in weld (regardless of direction of loading) Intersecting members at simple T-, Y-, and Kconnections; any connection whose adequacy is determined by testing an accurately scaled model or by theoretical analysis (e.g., fmite element) Greatest total range of hot spot stress or strain on the outside surface of intersecting members at the toe of the weld joining them-measured after shakedown in model or prototype connection or calculated with best available theory (Continued) 39 AWS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS Table2·Z Stress Categories for Type and Location of Material for Circular Sections (see 2.20.6.2) Kinds of Stress a Situation Stress Category As for x 2 , profile improved per 2.20.6.6 and 2.20.6.7 As forX 2 Unreinforced cone-cylinder intersection Hot-spot stress at angle change; calculate per Noted Simple T-, Y-, and K-connections in which the gamma ratio Rltc of main member does not exceed 24 (see Note c). Punching shear for main members; calculate per Notee As for K2 , profile improved per 2.20.6.6 and 2.20.6.7 aT =tension, C =compression, B =bending, R =reversal-Le., total range of nominal axial and bending stress. curves (Figure 2.13) based on "typical" connection geometries; if actual stress concentration factors or hot spot strains are known, use of curve XI or X z is preferred. ' e Empirical curves (Figure 2.13) based on tests with gamma (Rite) of 18 to 24; curves on safe side for very heavy chord members (low Rite); for chord members (Rite greater than 24) reduce allowable stress in proportion to b Empirical Allowable fatigue stress = (24_10.7 Stress from curve K Rltl Where actual stress concentration factors or hot-spot strains are known, use of curve X I or X z is preferred. 1 dStress concentration factor - SCF = -----= + 1.17 tan '¥ fib Cos '¥ where '¥ = angle change at transition 'Yb = radius to thickness ratio of tube at transition e Cyclic range of punching shear is given by where 't and e are defined in Figure 2.14, and la = cyclic range of nominal branch member stress for axial load. Iby = cyclic range of in-plane bending stress. I bz = cyclic range of out-of-plane bending stress. a. is as defined in Table 2.10. 40 4 AWS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS Table 2.8 Fatigue Category Limitations on Weld Size or Thickness and Weld Profile (Tubular Connections) (see 2.20.6.7) Level I Level II Limiting Branch Member Thickness for Categories Xl' K l , DT in [mm] Limiting Branch Member Thickness for Categories X 2 , K 2 in [mm] 0.375 [10] 0.625 [16] 0.625 [16] 1.50 [38] qualified for unlimited thickness for static compression loading Concave profile, as welded, Figure 3.10 with disk test per 2.20.6.6(1) 1.00 [25] unlimited Concave smooth profile Figure 3.10 fully ground per 2.20.6.6(2) unlimited Weld Profile Standard flat weld profile Figure 3.8 Profile with toe fillet Figure 3.9 41 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1M:2008 Table 2.10 Terms for Strength of Connections (Circular Sections) (see 2.24.1.1) Qq Branch member Geometry and load modifier Qq _ (1.7 0.18) Qo.7(a-I) -a+T ~ - Q q -_ Q~ Q~ (needed for Qq) Q a chord For axial loads (see Note d) (2.1 0.6)Q1.2(a-o.67) -a+lf ~ For bending = 1.0 For 13::;; 0.6 0.3 ~ = 13(1 - 0.83313) For 13 > 0.6 = 1.0 + 0.7 gldb For axial load in gap K-connections having all members in same plane and loads transverse to main member essentially balanced (see Note a) 1.0::;; a < 1.7 ovalizing a = 1.7 parameter a (needed for Qq) Main member stress interaction term Qf (See Notes b and c) a = 2.4 For axial load in T- and Y-connections For axial load in cross connections a = 0.67 a = 1.5 For in-plane bending (see Note c) For out-of-plane bending (see Note c) Of = 1.0-A.'Y lP 11.= 0.030 11.= 0.044 For axial load in branch member For in-plane bending in branch member For out-of-plane bending in branch member A. = O.oI8 a Gap g is defined in Figures 2.14(E), (F), and (H); db is branch diameter. b U is the utilization ratio (ratio of actual to allowable) for longitudinal compression (axial, bending) in the main member at the connection under consideration. _ (f a )2 ( fb )2 TJ2 O.6F + O.6F = C d yo yo For combinations of the in-plane bending and out-of-plane bending, use interpolated values of a and A.. For general collapse (transverse compression) also see 2.24.1.2. Notes: 1. y, f3 are geometry parameters defined by Figure 2.14(M). 2. F yo = the specified minimum yield strength of the main member, but not more than 2/3 the tensile strength. 42 AWS D1.1/D1.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS BASE METAL 1/4 in [6 mm] OR MORE IN THICKNESS BASE METAL LESS THAN 1/4 in [6 mm] THICK (A) (B) MAXIMUM DETAILED SIZE OF FILLET WELD ALONG EDGES Figure 2.1-Maximum Fillet Weld Size Along Edges in Lap Joints (see 2.3.2.9) 43 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1 M:2008 1~ 1L:::::: 2.5 (A) TRANSITION BY SLOPING WELD SURFACE 1~ REMOVE AFTER WELDING REMOVE AFTER WELDING REMOVE AFTER WELDING (B) TRANSITION BY SLOPING WELD SURFACE AND CHAMFERING ·1~ 1~ CHAMFER BEFORE WELDING CHAMFER BEFORE WELDING CHAMFER BEFORE WELDING (C) TRANSITION BY CHAMFERING THICKER PART CENTERLINE ALIGNMENT (PARTICULARLY APPLICABLE TO WEB PLATES) OFFSET ALIGNMENT (PARTICULARLY APPLICABLE TO FLANGE PLATES) Figure 2.2-Transition of Butt Joints in Parts of Unequal Thickness (Cyclically Loaded Nontubular) (see 2.16.1.1) 44 \WS D1.1/D1.1M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS SMOOTH TRANSITION, AVOID NOTCHES (A) TRANSITION WITHOUT CONTOURING FILLET WELDS (B) TRANSITION WITH CONTOURING FILLET WELDS Figure 2.3-Transition of Thicknesses (Statically Loaded Nontubular) (see 2.6.5 and 2.7.1) --i ~-~?~ 1. 51, MIN-.J (NOT LESS THAN 1 in [25 mm]) Note: t = thicker member, t j = thinner member. Figure 2.4-Transversely Loaded Fillet Welds (see 2.8.1.2) 45 L, CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1M:2008 Figure 2.5-'Minimum Length of Longitudinal Fillet Welds at End of Plate or Flat Bar Members (see 2.8.2) HOLDBACK NOT LESS THAN WELD SIZE Figure 2.6-Termination of Welds Near Edges Subject to Tension (see 2.8.3.2) 46 AWS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS Note: W = nominal size of the weld. Figure 2.7-End Return at Flexible Connections (see 2.8.3.3) Figure 2.8-Fillet Welds on Opposite Sides of a Common Plane (see 2.8.3.5) 47 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1 M:2008 2 TRANSVERSE WELDS MAY BE USED ALONG THESE ENDS Note: The effective area of weld 2 shall equal that of weld 1, but its size shall be its effective size plus the thickness of the filler plate T. Figure 2.9-Thin Filler Plates in Splice Joint (see 2.10.1) 3 -rt- ofT/--; x- hr-l~-;;~-;;B:iii~x~~~~-l TRANSVERSE WELDS MAY BE USED ALONG THESE EDGES Note: The effective areas of welds 1, 2, and 3 shall be adequate to transmit the design force, and the length of welds 1 and 2 shall be adequate to avoid overstress of filler plate in shear along planes x-x. Figure 2.10-Thick Filler Plates in Splice Joint (see 2.10.2) 48 AWS D1.1/D1.1M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS RANGE MAY BE TRUNCATED DEPENDENT UPON BASE MATERIAL F AND WHETHER RANGE IS TENSION TO TENSION OR COMPRESSION TO TENSION. (MAXIMUM TENSILE STRESS MAY NOT BE GREATER THAN STRESS ALLOWED BY TABLE 2.3) \ 100 ......... .............: ............. -- """ ....... ~~ r--....... ............ '" ~ !a: .......... 1-- ..... i""ooo. ............ """ ............ i " r-- -- ui ...... ..... ~ ............ ~ :-- ............... ...... r-- ~ ""- LE ............. ~ I""" 1-... :::~~ CATEGORY C 1"00 :.:::::::: ~ I-... ~ :::: r-r-....... ....... ............ ~ -I-.... ..... ............ r-- 1"001-. ~ ~ ~ r.=. 1"001-. ~~ hi: ~ 10 « c::: --r--r-- .. .. r--....... .... - 100. w c::: 100,000 I II r--...... fl' I CATEGORYB~ \ CATEGORY B' ---. 1 -- - .... ~ 1 10,000 CiTTGORY ............ ........... CATEGORY F---:J (j) (j) I\- ........ .......... -. 1,000,000 LCATEGORY D ~ r---. - L CATEGORY E l6AT~GIOky E' I "II" 10,000,000 100,000,000 LIFE, N (CYCLES) (A) U.S. CUSTOMARY UNITS RANGE MAY BE TRUNCATED DEPENDENT UPON BASE MATERIAL F AND WHETHER RANGE IS TENSION TO TENSION OR COMPRESSiON TO TENSION. (MAXIMUM TENSILE STRESS MAY NOT BE GREATER THAN STRESS ALLOWED BY TABLE 2.3) \ 1000 100. -. ""::-......... ........... --- ~~ 8!. r-- e.a: ui ~ 100 « c::: ~ ............ i"""'o r-... .... 1"001-. ~ r...... ............ r-_ r...... LE r-... .... ....... r-.... ~ .... ""-~ ~ .......... -- \ .... - ~ .....1-.1"00 r-::: .... 1'::1:-0 ......... r-- r-- ....... ~ j"-...... r-..... ..... I"-- s::: .... "1"00 "1"00 ~ ~ II w CATEGORY c::: F~ ~ ~ 10 10,000 ; \ '" .......... .........:- ..... ""- CATEGORY A-:I CATEGORY C ---. ----- -.........-==--'" I'-.. 1"'00. (j) (j) ............. f:::: ~ t: . ~ :::-......... j"-...... r-..... ..... ................ I""" .......... r..... I + CATEGORY B -:l CATEGORY B' ..... ..::::: ....... ..... I .. ~i'" - ·L - -:-1- I- C~TEGPRY ~ ............. t. CA~EGp~YlEI lbIATI~~O~~ E' "I I1II 100,000 1,000,000 10,000,000 100,000,000 LIFE, N (CYCLES) (B) METRIC UNITS Figure 2.11-Allowable Stress Range for Cyclically Applied Load (Fatigue) in Nontubular Connections (Graphical Plot of Table 2.~ 49 AWS D1.1/D1.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS WIDTH OF NARROWER PLATE BUTT JOINT WIDTH OF NARROWER PLATE t L......l. ,\ a .--.._--r...._---'--l =-it-----af r = 2 ft [0.6 m] a PLAN VIEW 3/32 in [2.5mm] \ Note: Mandatory for steels with a yield strength greater than or equal to 90 ksi [620 MPa]. Optional for all other steels. I I 6 in [150 mm] 4 in 2 in [100 mm] [50mm] I DETAIL OF CUT 0 ~ BUTT JOINTJ Figure 2.12-Transition of Width (Cyclically Loaded Nontubular) (see 2.16.1.2) ~ 100 500 ._ 50 en 200 100 til a. :2 50 '"'" ui 30 ~ <!:l ~ en en ~ Ien a: 20 10 0 ::J 5 0 20 >0 ...J ~ 10 .-. 12 ---... -- -- r--=::. r-::::.. r-- 1"-00_ r""-... II- I-o ... ~ - r--...: C""- "'- I'--... ... ~ ~ 3 --....:::::::- r---.. !"""- ....1--0 -- '""::::: r- r- 2 ~~ r--:: ~ i'- ""'" :::1--0""" .......... .... ,.... .... CATEGORY A-=] -. --...; 1-1--0 - - - ----..:::- f':::. ~ 2000 I" -- ....... ~ i""' ... I'-..... I'--- 10 4 2 2 2 z « a: ,2.2 A~ Xv-£. z 200 '-FT .....1--... r- 500 <!:l Cl AND Xl-:Y I-.. ......... --... ... ....---. ui B-:J -- - -- ..... 1000.§ c:: '5. - ....10........10- I- ~~ en ...J 100 DT--=:;::E -/, i'-- K 1\ r--..~ ~ET 2 4 1- 50 6 8 10 8 CYCLES OF LOAD N Figure 2.13-Allowable Fatigue Stress and Strain Ranges for Stress Categories (see Table 2.7), Redundant Tubular Structures for Atmospheric Service (see 2.20.6.3) 50 «a: ~ ~ c: Iw \WS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS SIDE SIDE CORNER CORNER TOE MAIN MEMBER (A) CIRCULAR SECTIONS (B) BOX SECTIONS MAXIMUM LIMIT OF T-CONNECTIONS TOE ZONE gOaT I 't' ,, ,, .. , (0) Y-CONNECTION (C) T-CONNECTION / / / / g CD (E) K-CONNECTION ® K(T-K) K(T-Y) (F) K-COMBINATION CONNECTIONS GAP g MEASURED ALONG THE SURFACE OFTHE CHORD BETWEEN PROJECTIONS OF THE BRANCH MEMBER OUTSIDE SURFACE AT THE NEAREST APPROACH a Relevant gap is between braces whose loads are essentially balanced. Type (2) may also be referred to as an N-connection. Figure 2.14-Parts of a Tubular Connection (see 2.21) 51 AWS D1.1/D1.1M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS - -_..1 [) _ _-..... -+/-1.... (G) CROSS CONNECTIONS lGAP9 OFFSET-l (H) DEVIATIONS FROM CONCENTRIC CONNECTIONS OUTSIDE STIFFENING RING INTERIOR DIAPHRAGM JOINT CAN CRUSHING LOAD (I) SIMPLE TUBULAR CONNECTION (J) EXAMPLES OF COMPLEX REINFORCED CONNECTIONS TRANSITION TRANSITION (K) FLARED CONNECTIONS AND TRANSITIONS Figure 2.14 (Continued)-Parts of a Tubular Connection (see 2.21) 52 AWS D1.1/D1.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS ..II tb_ ':'- I DETAIL(N)~ I I I I I I I I I I tc DD MATCHED, - -, I I I I I I I + f- R STEPPED (L) CONNECTION TYPES FOR BOX SECTIONS (M) GEOMETRIC PARAMETERS PARAMETER (N) CORNER DIMENSION OR RADIUS MEASUREMENT BOX SECTIONS P rblR OR db/D biD 11 - ax/D 'Y Rite D/2t e 1: tb/te tb/te r RADIUS AS MEASURED BY RADIUS GAGE CIRCULAR SECTIONS e ANGLE BETWEEN MEMBER CENTERLINES 'P LOCAL DIHEDRAL ANGLE AT A GIVEN POINT ON WELDED JOINT C CORNER DIMENSION AS MEASURED TO THE POINT OF TANGENCY OR CONTACT WITH A 90° SQUARE PLACED ON THE CORNER Figure 2.14 (Continued)-Parts of a Tubular Connection (see 2.21) 53 AWS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS 5 t 1 MIN (NOT LESS THAN 1 in [25 mm]) ~ -I++-""*""- - - - - ----+- t1 = THICKNESS OF THE THINNER TUBULAR SECTION Note: L = size as required. Figure 2.15-Fillet Welded Lap Joint (Tubular) (see 2.23.1.3) Cf. OF EFFECTIVE THROAT Figure 2.16-Tubular T·, Y·, and K·Connection Fillet Weld Footprint Radius (see 2.23.3) 54 AWS 01.1/01.1 M:2008 CLAUSE 2. DESIGN OF WELDED CONNECTIONS ACTIN:G~V.~p=:Of£~H~~ .r..-tC",,\ ----r---\~ e R --'1_/_ _--'-) -/--'- Figure 2.17-Punching Shear Stress (see 2.24.1.1) A ~ Ltc .------- iT ~ - - - - - vp - J 2 SECTION A-A Figure 2.18-Detail of Overlapping Joint (see 2.24.1.6) 55 CLAUSE 2. DESIGN OF WELDED CONNECTIONS AWS D1.1/D1.1M:2008 Notes: 1. -0.55H ~ e ~ 0.25H 2. a;:: 30 0 3. H/tc and D/tc ~ 35 (40 for overlap K- and N-connections) 4. a/tb and b/tb ~ 35 5. Fyo ~ 52 ksi [360 MPa] 6. 0.5 ~ HID ~ 2.0 7. FyJFult ~ 0.8 Figure 2.19-Limitations for Box T-, Y-, and K-Connections (see 2.24.2) OVERLAPPING MEMBER THROUGH MEMBER OVERLAP =~ x 100 % P Figure 2.20-0verlapping K-Connections (see 2.24.2.4) 56 VI -J _m REMOVE AFTER WELDING 'CHAMFER BEFORE WELDING CHAMFER BEFORE WELDING 2:5~ 1~ [ t ~ ---J t.= ~ ~ 2.5 (E) TRANSITION BY STRAIGHT AND TAPER BORE AT THICKER TUBE MACHINE BEFORE WELDING - - - ' 1/2 in [12 mm] OD OF TUBE (B) Figure 2.2l-Transition of Thickness of Butt Joints in Parts of Unequal Thickness (Tubular) (see 2.25) Notes: 1. Groove may be of any allowed or qualified type and detail. 2. Transition slopes shown are the maximum allowed. 3. In (B), (D), and (E) groove may be any allowed or qualified type and detail. Transition slopes. shown are maximum allowed. (F) TRANSITION BY TAPER OD OF THICKER TUBE (D) TRANSITION BY TAPER BORE OF THICKER TUBE MACHINE, GRIND, OR THERMAL 1 ~ CUT SMOOTH BEFORE WELDING 2.5 r- (C) TRANSITION BY TAPER WELD 2.5 ~ OD OF TUBE ~~ + S T ? U B E_ _.., ." [ 1/8 in [3 mm] MAXIMUM DIFFERENCE IN RADII BEFORE TAPER WELD IS REQUIRED REBEVEL AFTER WELD BUILDUP cd( (A) • .L_ { WELDED FROM ONE SIDE CONSTANT ID PREFERRED .. CHAMFER BEFORE WELDING (C) TRANSITION BY CHAMFERING THICKER PART r-=::: ~ .5 ~ '~~ 1 REMOVE AFTER WELDING • .'25~ 1~ (B) TRANSITION BY SLOPING WELD SURFACE AND CHAMFERING ~~ 1Y REMOVE AFTER WELDING (A) TRANSITION BY SLOPING WELD SURFACE 2:5~ 1~ 1 .5 r:::::: ~ G '~~ CENTERLINE ALIGNMENT - WELDED FROM TWO SIDES ~ Ul ~ 6 z m m o o o o z z r m ::E o"'T1 G5 z Ul m o m !" Ul o <Xl o ~ s: ..... § ~ ..... ~ Ul AWS D1.1/D1.1 M:2008 This page is intentionally blank. 58 AWS D1.1/D1.1M:2008 3. Prequalification of WPSs 3.1 Scope provided the WPSs are qualified by applicable tests as described in Clause 4. Prequalification of WPSs (Welding Procedure Specifications) shall be defined, as exempt from the WPS qualification testing requiied in Clause 4. All prequalified WPSs shall be written. In order for a WPS to be prequalified, conformance with all of the applicable requirements of Clause 3 shall be required. WPSs that do not conform to the requirements of Clause 3 may be qualified by tests in conformance with Clause 4. For convenience, Annex Q lists provisions to be included in a prequalified WPS, and which should be addressed in the fabricator's or Contractor's welding program. 3.2.4 FCAWand GMAW Power Sources. FCAW and GMAW that is done with prequalified WPSs shall be performed using constant voltage (CV) power supplies. 3.3 Base Metal/Filler Metal Combinations Only base metals and filler metals listed in Table 3.1 may be used in prequalified WPSs. (For the qualification of listed base metals and filler metals, and for base metals and filler metals not listed in Table 3.1, see 4.1.1.) Welders, welding operators and tack welders that use prequalified WPSs shall be qualified in conformance with Clause 4, Part C. The base metal/filler metal strength relationships below shall be used in conjunction with Table 3.1 to determine whether matching or undermatching filler metals are required. 3.2 Welding Processes 3.2.1 Prequalified Processes. SMAW, SAW, GMAW (except GMAW-S), and FCAW WPSs which conform to all of the provisions of Clause 3 shall be deemed as prequalified and are therefore approved for use without performing WPS qualification tests for the process. For WPS prequalification, conformance with all of the applicable provisions of Clause 3 shall be required (see 3.1). Relationship Matching 3.2.2 Code Approved Processes. ESW, EGW, GTAW, and GMAW-S welding may be used, provided the WPSs are qualified in conformance with the requirements of Clause 4. Note that the essential variable limitations in Table 4.5 for GMAW shall also apply to GMAW-S. Undermatching 3.2.3 Other Welding Processes. Other welding processes not covered by 3.2.1 and 3.2.2 may be used, Base Metal(s) Filler Metal Strength Relationship Required Any steel to itself or any steel to another in the same group Any filler metal listed in the same group Any steel in one group to any steel in another Any filler metal listed for a lower strength group. [SMAW electrodes shall be the low-hydrogen classification] Any steel to any steel in any group Any filler metal listed for a lower strength group. [SMAW electrodes shall be the low-hydrogen classification] Note: See Table 2.3 or 2.£ to determine the filler metal strength requirements to match or undermatch base metal strength. 59 CLAUSE 3. PREQUALIFICATION OF WPSS AWS 01.1/01.1 M:2008 involved in a joint of each 50 ft [15 m] of groove welds ~ or pair of fillet welds. 3.4 Engineer's Approval for Auxiliary Attachments (b) These hardness determinations may be discontinued after the procedure has been established and the discontinuation is approved by the Engineer. Unlisted materials for auxiliary attachments which fall within the chemical composition range of a steel listed in Table 3.1 may be used in a prequalified WPS when approved by the Engineer. The filler metal and minimum preheat shall be in conformance with 3.5, based upon the similar material strength and chemical composition. 3.6 Limitation of WPS Variables All prequalified WPSs to be used shall be prepared by the manufacturer, fabricator, or Contractor as written prequalified WPSs, and shall be available to those authorized to use or examine them. The written WPS may follow any convenient format (see Annex N for examples). The welding parameters set forth in (1) through (4) of this subclause shall be specified on the written WPSs within the limitation of variables described in Table 4.5 for each applicable process. Changes in these parameters, beyond those specified on the written WPS, shall be considered essential changes and shall require a new or revised prequalified written WPS: 3.5 Minimum Preheat and Interpass Temperature Requirements The preheat and interpass temperature shall be sufficient to prevent cracking. Table 3.2 shall be used to deterrp.ine the minimum preheat and interpass temperatures for steels listed in the code. 3.5.1 Base MetaVThickness Combination. The minimum preheat or interpass temperature applied to a joint composed of base metals with different minimum preheats from Table 3.2 (based on Category and thickness) shall be the highest of these minimum preheats. (1) Amperage (wire feed speed) 3.5.2 Alternate SAW Preheat and Interpass Temper- (2) Voltage atures. Preheat and interpass temperatures for parallel or multiple electrode SAW shall be selected in conformance with Table 3.2. For single-pass groove or fillet welds, for combinations of metals being welded and the heat input involved, and with the approval of the Engineer, preheat and interpass temperatures may be established which are sufficient to reduce the hardness in the HAZs of the base metal to less than 225 Vickers hardness number for steel having a minimum specified tensile strength not exceeding 60 ksi [415 MPa], and 280 Vickers hardness number for steel having a minimum specified tensile strength greater than 60 ksi [415 MPa], but not exceeding 70 ksi [485 MPa]. (3) Travel Speed (4) Shielding Gas Flow Rate 4 3.6.1 Combination of WPSs. A combination of qualified and prequalified WPSs may be used without qualification of the combination, provided the limitation of essential variables applicable to each process is observed. 3.7 General WPS Requirements All the requirements of Table 3.7 shall be met for prequalified WPSs. NOTE: The Vickers hardness number shall be determined in' conformance with ASTM E 92. If another method of hardness is to be used, the equivalent hardness number shall be determinedfrom ASTM E 140, and testing shall be peiformed according to the applicable ASTM specification. 3.7.1 Vertical-Up Welding Requirements. The progression for all passes in vertical position welding shall be upward, with the following exceptions: (1) Undercut may be repaired vertically downwards when preheat is in conformance with Table 3.2, but not lower than 70°F [20°e]. 3.5.2.1 Hardness Requirements. Hardness determination of the HAZ shall be made on the following: (2) When tubular products are welded, the progression of vertical welding may be upwards or downwards, but only in the direction(s) for which the welder is qualified. (1) Initial macroetch cross sections of a sample test specimen. (2) The surface of the member during the progress of the work. The surface shall be ground prior to hardness testing: 3.7.2 WidthlDepth Pass Limitation. Neither the depth nor the maximum width in the cross section of weld .. metal deposited in each weld pass shall exceed the width ~ at the surface of the weld pass (see Figure 3.1). (a) The frequency of such HAZ testing shall be at least one test area per weldment of the thicker metal 60 AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSS 3.7.3 Weathering Steel Requirements. For exposed, bare, unpainted applications of ASTM A 588 steel requiring weld metal with atmospheric corrosion resistance and coloring characteristics similar to that of the base metal, the electrode or electrode-flux combination shall conform to Table 3.3. 3.9.1 Details (Nontubular). See Figures 2.1 and 2.4 for the limitations for prequalified fillet welds. The exceptions to this requirement are as follows: (1) Prequalified WPSs. Fillet welded tubular connections made by SMAW, GMAW, or FCAW processes that may be used without performing WPS qualification tests are detailed in Figure 3.2 (see 2.23.1.2 for limitations). These details may also be used for GMAW-S qualified in conformance with 4.12.4.3. 3.9.2 Details (Tubular). For prequalified status, fillet welded tubular connections shall conform to the following provisions: 3.7.3.1 Single-Pass Groove Welds. Groove welds made with a single pass or a single pass each side may be made using any of the filler metals for Group II base metals in Table 3.1. (2) Prequalified fillet weld details in lap joints are shown in Figure 2.15. 3.7.3.2 Single-Pass Fillet Welds. Single-pass fillet welds up to the following sizes may be made using any of the filler metals for Group II base metals listed in Table 3.1: SMAW SAW GMAW/FCAW 3.9.3 Skewed T-Joints. Skewed T-joints shall be in conformance with Figure 3.11. 1/4 in [6 mm] 5/16 in [8 mm] 5/16 in [8 mm] 3.9.3.1 Dihedral Angle Limitations. The obtuse side of skewed T-joints with dihedral angles greater than 100° shall be prepared as shown in Figure 3.11, Detail C, to allow placement of a weld of the required size. The amount of machining or grinding, etc., of Figure 3.11, Detail C, should not be more than that required to achieve the required weld size (W). 3.7.4 Shielding Gas. Shielding gases for GMAW and FCAW-G shall conform to AWS A5. 32/A5.32M, and one of the following: (1) The shielding gas used for electrode classification per the applicable AWS A5 specification. (2) A shielding gas recommended for use with the specific electrode by the electrode manufacturer. Such recommendations shall be supported by tests which demonstrate that the electrode/shielding gas combination is capable of meeting all the mechanical and chemical property requirements for the electrode classification when tested in accordance with the applicable AWS A5 specification. Documentation of such testing shall be supplied when requested by the Engineer or Inspector. 3.9.3.2 Minimum Weld Size for Skewed T-Joints. For skewed T-joints, the minimum weld size for Details A, B, and C in Figure 3.11 shall be in conformance with Table 5.8. 3.10 Plug and Slot Weld Requirements The details of plug and slot welds made by the SMAW, GMAW (except GMAW-S), or FCAW processes are described in 2.3.5.1, 2.3.5.2, 2.3.5.4, and 2.9.4, and they may be used without performing the WPS qualification described in Clause 4, provided the technique provisions of 5.25 are met. 3.8 Common Requirements for Parallel Electrode and Multiple Electrode SAW 3.11 Common Requirements of PJP and CJP Groove Welds 3.8.1 GMAW Root Pass. Welds may also be made in the root of groove or fillet welds using GMAW, followed by parallel or multiple electrode submerged arcs, provided. that the GMAW conforms to the requirements of this section, and providing the spacing between the GMAW arc and the following SAW arc does not exceed 15 in [380 mm]. 3.11.1 FCAW/GMAW in SMAW Joints. Groove preparations detailed for prequalified SMAW joints may be used for prequalified GMAW or FCAW. 3.11.2 Corner Joint Preparation. For comer joints, the outside groove preparation may be in either or both members, provided the basic groove configuration is not changed and adequate edge distance is maintained to support the welding operations without excessive melting. 3.9 Fillet Weld Requirements See Table 5.8 for minimum fillet weld sizes. 61 CLAUSE 3. PREQUALIFICATION OF WPSS AWS D1.1/D1.1 M:2008 3.11.3 Root Openings. Joint root openings may vary as noted in 3.12.3 and 3.13.1. However, for automatic or machine welding using FCAW, GMAW, and SAW processes, the maximum root opening variation (minimum to maximum opening as fit-up) may not exceed 1/8 in [3 mm]. Variations greater than 1/8 in [3 mm] shall be locally corrected prior to automatic or machine welding. (3) J- and U-grooves may be prepared before or after assembly. 4 3.12.4 Details (Tubular). Details for PJP tubular groove welds that are accorded prequalified status shall conform to the following provisions: (1) PJP tubular groove welds, other than T-, Y-, and K-connections, may be used without performing the WPS qualification tests, when these may be applied and shall meet all of the joint dimension limitations as described in Figure 3.3. 3.12 PJP Requirements PJP groove welds shall be made using the joint details described in Figure 3.3. The joint dimensional limitations described in 3.12.3 shall apply. (2) PJP T-, Y-, and K-tubular connections, welded only by the SMAW, GMAW, or FCAW process, may be used without performing the WPS qualification tests, when they may be applied and shall meet all of the joint dimension limitations as described in Figure 3.5. These details may also be used for GMAW-S qualified in con~ formance with 4.12.4.3. 3.12.1 Definition. Except as provided in 3.13.4 and Figure 3.4 (B-Ll-S), groove welds without steel backing, welded from one side, and groove welds welded from both sides, but without backgouging, are considered PJP groove welds. 3.12.2 Weld Size. The weld size (E) of a prequalified PJP groove shall be as shown in Figure 3.3 for the particular welding process, joint designation, groove angle, and welding position proposed for use in welding fabrication. 3.12.4.1 Matched Box Connections. Details for PJP groove welds in these connections, the comer dimensions and the radii of the main tube are shown in Figure 3.5. Fillet welds may be used in toe and heel zones (see Figure 3.2). If the comer dimension or the radius of the main tube, or both, are less than as shown if Figure 3.5, a sample joint of the side detail shall be made and sectioned to verify the weld size. The test weld shall be made in the horizontal position. This requirement may be waived if the branch tube is beveled as shown for CJP groove welds in Figure 3.6. 3.12.2.1 Prequalified Weld Sizes (1) The minimum weld size ofPJP single- or doubleV, bevel-, J-, and U-groove welds, types 2 through 9, shall be as shown in Table 3.4. The base metal thickness shall be sufficient to incorporate the requirements of the joint details selected, conforming to the variances outlined in 3.12.3 and the requirements of Table 3.4. (2) The maximum base metal thickness shall not be limited. 4 3.13 CJP Groove Weld Requirements (3) The PJP square groove weld B-P1 and flare-bevel groove weld~ BTC-PlO and B-Pll minimum weld sizes shall be calculated from Figure 3.3. CJP groove welds which may be used without performing the WPS qualification test described in Clause 4 shall be as detailed in Figure 3.4 and are subject to the limitations described in 3.13.1. (4) Shop or working drawings shall specify the design grooves depths "S" applicable for the weld size "(E)" required per 3.12.2. (Note that this requirement shall not apply to the B-Pl, BTC-PlO, and B-Pll details.) 3.13.1 Joint Dimensions. Dimensions of groove welds specified in 3.13 may vary on design or detail drawings within the limits or tolerances shown in the "As Detailed" column in Figure 3.4. Fit up tolerance of Figure 3.4 may be applied to the dimension shown on the detail drawing. 3.12.3 Joint Dimensions (1) Dimensions of groove welds specified in 3.12 may vary on design or detail drawings within the limits of tolerances shown in the ':As Detailed" column in Figure 3.3. 3.13.2 Double-Sided Groove Preparation. J- and U-grooves and the other side of partially welded double-V and double-bevel grooves may be prepared before or after assembly. After backgouging, the other side of partially welded double-V or double-bevel joints .. should resemble a prequalified U- or J-joint configura- ~ tion at the joint root. (2) Fit-up tolerances of Figure 3.3 may be applied to the dimensions shown on the detail drawing. However, the use of fit-up tolerances does not exempt the user from meeting the minimum weld size requirements of 3.12.2.1. 62 CLAUSE 3. PREQUALIFICATION OF WPSS r:..WS 01.1/01.1 M:2008 NOTE: See the Commentary for engineering guidance in the selection ofa suitable profile. 3.13.3 Tubular Butt Joints. For tubular groove welds to be given prequalified status, the following conditions shall apply: The joint dimensions and groove angles shall not vary from the ranges detailed in Table 3.6 and shown in Figure 3.6 and Figures 3.8 through 3.10. The root face of joints shall be zero unless dimensioned otherwise. It may be detailed to exceed zero or the specified dimension by not more than 1116 in [2 mm]. It may not be detailed less than the specified dimensions. (1) Prequalified WPSs. Where welding from both sides or welding from one side with backing is possible, any WPS and groove detail that is appropriately prequalified in conformance with Clause 3 may be used, except that SAW is only prequalified for diameters greater than or equal to 24 in [600 mm]. Welded joint details shall be in conformance with Clause 3. 3.13.4.1 Joint Details. Details for CJP groove welds in tubular T-, Y-, and K-connections are described in 3.13.4. These details are prequalified for SMAW and FCAW. These details may also be used for GMAW-S qualified in conformance with 4.12.4.3. (2) Nonprequalified Joint Detail. There are no prequalified joint details for CJP groove welds in butt joints made from one side without backing (see 4.12.2). 3.13.4 Tubular T-, Y·, and K-Connections. Details for CJP groove welds welded from one side without backing in tubular T-, Y-, and ~"connections used in circular tubes are described in this section. The applicable circumferential range of Details A, B, C, and D are described in Figures 3.6 and 3.7, and the ranges of local dihedral angles, ['P], corresponding to these are described in Table 3.5. 3.14 Postweld Heat Treatment Postweld heat treatment (PWHT) shall be prequalified provided that it shall be approved by the Engineer and the following conditions shall be met. Joint dimensions including groove angles are described in Table 3.6 and Figure 3.8. When selecting a profile (compatible with fatigue category used in design) as a function of thickness, the guidelines of 2.20.6.7 shall be lobserved. Alternative weld profiles that may be required for thicker sections are described in Figure 3.9. In the absence of special fatigue requirements, these profiles shall be applicable to branch thicknesses exceeding 5/8 in [16mm]. (1) The specified minimum yield strength of the base metal shall not exceed 50 ksi [345 MPa]. (2) The base metal shall not be manufactured by quenching and tempering (Q&T), quenching and selftempering (Q&ST), thermo-mechanical controlled processing (TMCP) or where cold working is used to achieve higher mechanical properties (e.g., certain grades of ASTM A 500 tubing). Improved weld profiles meeting the requirements of 2.20.6.6 and 2.20.6.7 are described in Figure 3.10. In the absence of special fatigue requirements, these profiles shall be applicable to branch thicknesses exceeding 1-112 in [38 mm] (not required for static compression loading). (3) There shall be no requirements for notch toughness testing of the base metal, HAZ, or weld metal. (4) There shall be data available demonstrating that the weld metal shall have adequate strength and ductility in the PWHT condition (e.g., as can be found in the relevant AWS A5.X filler metal specification and classification or from the filler metal manufacturer). Prequalified details for CJP groove welds in tubular T-, Y-, and K-connections, utilizing box sections, are further described in Figure 3.6. The foregoing details are subject to the limitation of 3.13.3. (5) PWHT shall be conducted in conformance with 5.8. 63 ~ I u p 0 ABS API5L ASTM A 1011 SS ASTMA 709 ASTM A 1008 SS ASTMA573 ASTMA524 ASTMA501 ASTMA516 ASTMA36 ASTMA53 ASTMA 106 ASTMA 131 ASTMA 139 ASTMA381 ASTM A 500 ~ G r Grade 55 Grade 60 Gradel Grade II Grade 65 Grade 58 Grade 36 (::;;3/4 in [20 mm]) Grade 30 Grade 33 Type 1 Grade 40 Type 1 Grade 30 Grade 33 Grade 36 Type 1 Grade 40 Grade 45 GradeB GradeX42 GradesA,B,D,CS,DS GradeEb GradeB GradeB GradesA,B,CS,D,DS,E GradeB Grade Y35 Grade A GradeB GradeC (::;;3/4 in [20 mm]) Steel Specification 36 35 35 34 35 35 33 42 46 36 30 32 35 30 35 32 36 30 33 40 30 33 36 40 45 35 42 ksi 250 240 240 235 241 240 228 290 317 250 205 220 240 205 240 220 250 205 230 275 205 230 250 275 310 240 290 MPa Minimum Yield Point/Strength Steel Specification Requirements ~ (Continued) 58-80 60 min. 60 min. 58-71 60 min. 60 min. 45 min. 58 min. 62 min. 58 min. 55-75 60-80 60-85 55-80 65-77 58-71 58-80 45 min. 48 min. 52 min. 49 min. 52 min. 53 min. 55 min. 60 min. 60 60 58-71 58-71 ksi 400-550 415 min. 415 min. 4()()...490 414 min. 415 min. 310 min. 400 min. 427 min. 400 min. 380-515 415-550 415-586 380-550 450-530 400-490 400-550 330 min. 330 min. 360 min. 340 min. 360 min. 365 min. 380 min. 410 min. 415 415 4()()...490 400-490 MPa Tensile Range FCAW GMAW SAW SMAW Process E6XTX-X, E6XTX-XC, E6XT-XM, E7XTX-X, E7XTX-XC, E7XTX-XM A5.29c ~ E7XT-X, E7XT-XC, E7XT-XM (Electrodes with the -2~, -2M, -3, -10, -13, -14, and -GS suffix shall be excluded and electrodes with the -11 suffix shall be excluded for thicknesses greater than 1/2 in [12 mm]) ER70S-XXX, E7OC-XXX A5.28 c A5.20 ER70S-X, E70C-XC, E7OC-XM (Electrodes with the -GS suffix shall be excluded) F7XX-EXXX-XX, F7XX-ECXXX-XX A5.23 c A5.18 F6XX-EXXX, F6XX-ECXXX, F7XX-EXXX, F7XX-ECXXX E70XX-X AS.5c A5.17 E60XX, E70XX Electrode Classification A5.1 AWS Electrode Specification Filler Metal Requirements Table 3.1 Prequalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3) jg g s:: ~.... ~ ~ en :E '1l en CIJ o"11 5z ~ (5 ~ j; r =n :II ~ '1l m ~en o 0\ Ut II u p 0 G r -- Grade 65 Grade 70 Grade 50 Grade 55 Class 1 Grade 42 Grade 50 Grade 55 (4 in [100 mm] and under) Grade A Grades B and C Grades AH32, DH32, EH32 Grades AH36, DH36, EH36 (>3/4 in [20 mm]) Steel Specification MPa ksi MPa Tensile Range 58-80 400-550 250 345 65 min. 450 min. 70 min. 485 min. 345 345-450 65 min. 450 min. 65 min. 450 min. 380 290 60 min. 415 min. 65 min. 450 min. 345 345-450 65 min. 450 min. 60 min. 410 min. 310 55 min. 380 min. 310 65 min. 450 min. 340 340 60 min. 410 min. 70 min. 480 min. 380 65 min. 450 min. 380 340 60 min. 410 min. (Continued) 36 58-80 400-550 250 45 315 68-85 470-585 71-90 490-620 51 350 40-50 275-345 60-70 415-485 35 240 65-85 450-585 70-90 485-620 38 260 50 345 70-100 485-690 70-100 485-690 55 380 45-50 310-345 65-90 450-620 42 60 min. 415 min. 290 65 min. 450 min. 50 345 55 380 70 min. 485 min. 50 345 70 min. 485 min. 55 380 65 min. 450 min. 60 415 70 min. 480 min. 45-50 310-340 65 min. 450 min. 46-50 315-345 65 min. 450 min. 42 63-83 430-570 290 70-90 485-620 50 345 ksi Minimum Yield Point/Strength Steel Specification Requirements FCAW GMAW SAW SMAW Process E7XT-X, E7XT-XC, E7XT-XM (Electrodes with the -2g, -2M, -3, -10, -13, -14, and -GS suffix shall be excluded and electrodes with the -11 suffix shall be excluded for thicknesses greater than 1/2 in [12 mm]) E7XTX-X, E7XTX-XC, E7XTX-XM A5.29c ER70S-XXX, E70C-XXX A5.28c A5.20 ER70S-X, E70C-XC, E70C-XM (Electrodes with the -GS suffix shall be excluded) F7XX-EXXX-XX, F7XX-ECXXX-XX A5.23 c A5.18 F7XX-EXXX, F7XX-ECXXX E7015-X, E7016-X, E7018-X A5.5 c A5.17 E7015,E7016,E7018,E7028 Electrode Classification - A5.1 AWS Electrode Specification Filler Metal Requirements Table 3.1 (Continued) Prequalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3) Grades Ib, II, III Grade A Grades C, D (2-1/2 in [65 mm] and under) ASTMA 709 Grade 36 (>3/4 in [20 mm]) 36 50 Grade 50 50 Grade50W Grade 50S 50-65 Grade A, Class 2 > 2 in [50 mm] ASTMA 710 55 (2-112 in [65 mm] and under) 42 ASTMA808 ASTMA913 Grade 50 50 ASTMA992 50-65 45 ASTM A 1008 HSLAS Grade 45 Class 1 Grade 45 Class 2 45 Grade 50 Class 1 50 Grade 50 Class 2 50 Grade 55 Class 1 55 Grade 55 Class 2 55 ASTM A 1008 HSLAS-F Grade 50 50 ASTMA606b ASTMA618 ASTMA633 ASTMA595 ASTMA588 b ASTMA537 ASTMA572 ASTMA529 ASTMA441 ASTMA516 ASTMA36 ASTMA 131 ~ CIJ (J) "U " o ::E oz 2:l o ;; r §; o m ::Il ~ "U m (J) ~ (') g i0 o s:: ..... § ..... ~ ~ (J) 0'1 0'1 ASTM A 1018 HSLAS ASTM A 1011 HSLAS-F ASTM A 1011 SS ASTM A 1011 HSLAS API5L ABS API2Y API2MTl API2W API2H Grade 42 Grade 50 Grade50T Grade 42 Grade 50 Grade50T GradeX52 Grades AH32, DH32, EH32 Grades AH36, DH36, EH36b Grade 45 Class 1 Grade 45 Class 2 Grade 50 Class 1 Grade 50 Class 2 Grade 55 Class 1 Grade 55 Class 2 Grade 50 Grade 50 Grade 55 Grade 45 Class 1 Grade 45 Class 2 Grade 50 Class 1 Grade 50 Class 2 Grade 55 Class 1 Grade 55 Class 2 Grade 50 Grade 30 Grade 33 Grade 36 Grade 40 Grade 42 Grade 50 45 45 50 50 55 55 50 50 55 45 45 50 50 55 55 50 30 33 36 40 42 50 50 42-67 50--75 50--80 42-67 50--75 50--80 52 45.5 51 ksi MPa 60 min. 410 min. ksi Tensile Range 55 min. 380 min. 310 340 65 min. 450 min. 340 60 min. 410 min. 380 70 min. 480 min. 380 65 min. 450 min. 340 60 min. 410 min. 65 min. 450 min. 340 380 70 min. 480 min. 60 min. 410 min. 310 55 min. 380 min. 310 340 65 min. 450 min. 60 min. 410 min. 340 380 70 min. 480 min. 65 min. 450 min. 380 340 60 min. 410 min. 205 49 min. 340 min. 230 52 min. 360 min. 250 53 min. 365 min. 275 55 min. 380 min. 62-80 430--550 290 345 70 min. 485 min. 345 65-90 450--620 290--462 62 min. 427 min. 345-517 65 min. 448 min. 345-552 70 min. 483 min. 290--462 62 min. 427 min. 345-517 65 min. 448 min. 345-552 70 min. 483 min. 360 66--72 455-495 315 71-90 490--620 350 71-90 490--620 (Continued) 310 MPa Minimum Yield Point/Strength Steel Specification Requir~ments Steel Specification II· ASTM A 1018 HSLAS-F ASTM A 1018 SS u p 0 G r FCAW GMAW SAW SMAW Process E7XT-X, E7XT-XC, E7XT-XM (Electrodes with the -2Q, -2M, -3, -10, -13, -14, and -GS suffix shall be excluded and electrodes with the -II suffix shall be excluded for thicknesses greater than 112 in [12 mmJ) E7XTX-X, E7XTX-XC, E7XTX-XM AS.29c ER70S-XXX, E70C-XXX A5.28c A5.20 ER70S-X, E70C-XC, E70C-XM (Electrodes with the -GS suffix shall be excluded) F7XX-EXXX-XX, F7XX-ECXXX-XX A5.18 A5.23 c F7XX-EXXX, F7XX-ECXXX E7015-X, E7016-X, E7018-X A5.5O A5.17 E7015,E7016,E7018,E7028 Electrode Classification A5.1 AWS Electrode Specification Filler Metal Requirements Table 3.1 (Continued) Prequalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3) CD o ~ ~ .... s: .... ~ ~ en :E "'tl en C/l o." oz ~ (5 ." C ~ o m :D "'tl m p ~en () 0\ -.l !iJ The heat input limitations of 5.7 shall not apply to ASTM A 913 Grade 60 or 65. b Special welding materials and WPS (e.g., E80XX-X low-alloy electrodes) may be required to match the notch toughness of base metal (for applications involving impact loading or low temperature), or for atmospheric corrosion and weathering characteristics (see 3.7.3). C Filler metals of alloy group B3, B3L, B4, B4L, B5, B5L, B6, B6L, B7, B7L, B8, B8L, B9, E90l5-C5L, E90l5-DI, E9018-Dl, E90l8-D3, or any BXH grade in AWS A5.5, A5.23, A5.28, or A5.29 are not prequalified for use in the as-welded condition. Notes: 1. Injoints involving base metals of different groups, either of the following filler metals may be used: (1) that which matches the higher strength base metal, or (2) that which matches the lower strength base metal and produces a low-hydrogen deposit. Preheating shall be in conformance with the requirements applicable to the higher strength group. 2. Match API standard 2B (fabricated tubes) according to steel used. 3. When welds are to be stress-relieved, the deposited weld metal shall not exceed 0.05% vanadium. 4. See Tables 2.3 and 2.6 for allowable stress requirements for matching filler metal. 5. Filler metal propertieS-have been moved to nonmandatory Annex V. 6. AWS A5M (SI Units) electrodes of the same classification may be used in lieu of the AWS A5 (U.S. Customary Units) electrode classification. 7. Any of the electrode classifications for a particular Group (located on the right) may be used to weld any of the base metals in that Group (located on the left). W o 'Tl :E "1J oz ;:; (5 'Tl C o ~ m JJ "1J m ~ en 90-110 620-760 90-110 620-760 E9XTX-X, E9XTX-XC, E9XTX-XM 485 485 A5.29c 70 70 FCAW Grade HPS70W ER90S-XXX, E90C-XXX ASTMA 709 ASTMA852 A5.28 c () (Xl ro 8 GMAW E8XTX-X, E8XTX-XC, E8XTX-XM A5.29c FCAW F8XX-EXXX-XX, F8XX-ECXXX-XX E8015-X, E8016-X, E8018-X ER80S-XXX, E80C-XXX A5.23 c A5.5 c Electrode Classification A5.28c , GMAW SAW SMAW Process F9XX-EXXX-XX, F9XX-ECXXX-XX 517 min. 517 min. 515 min. 550 min. 550-690 515-690 495 min. 485 min. 520 min. 550 min. 480 min. 550 min. 480 min. 550 min. MPa A5.23 c 75 min. 75 min. 75 min. 80 min. 80-100 75-100 72 min. 70 min. 75 min. 80 min. 70 min. 80 min. 70 min. 80 min. ksi ~ s: SAW 414-621 414-621 415 450 315-415 380-415 415-450 415-450 415 450 415 480 415 480 MPa AWS Electrode Specification ~ ~ ~ ~ en E9015-X, E9016-X, E9018-X, E9018-M 60-90 60-90 60 65 46-60 55-60 60-65 60-65 60 65 60 70 60 70 ksi Tensile Range Filler Metal Requirements ~ A5.5 c a Grade 60 Grade 60 Grade 60 Grade 65 Class 2b GradeEb Grade A, Class 2 ::; 2 in [50 mm] Grade A, Class 3 > 2 in [50 mm] Grade 60 Grade 65 Grade 60 Class 2 ASTM A 1018 HSLAS Grade 70 Class 2 ASTM A 1018 HSLAS-F Grade 60 Class 2 Grade 70 Class 2 ASTMA537 ASTMA633 ASTMA 710 ASTMA 710 ASTMA 913 a API2W API2Y ASTM A 572 Steel Specification Minimum Yield Point/Strength Steel Specification Requirements Table 3.1 (Continued) Prequalified Base Metal-Filler Metal Combinations for Matching Strength (see 3.3) ,., SMAW IV III u p 0 G r ., CLAUSE 3. PREQUALIFICATION OF WPSs AWS 01.1/01.1 M:2008 Table 3.2 Prequalified Minimum Preheat and Interpass Temperature (see 3.5) Thickness of Thickest Part at Point of Welding C a t e g 0 r y ASTMA36 ASTMA53 ASTMA 106 ASTMA 131 ASTMA 139 ASTMA381 ASTMA500 A ASTMA501 ASTMA516 ASTMA524 ASTMA573 ASTMA 709 ASTM A 1008 SS ASTM A 1011 SS API5L ABS ASTMA36 ASTMA53 ASTMA 106 ASTMA 131 B Welding Process Steel Specification ASTMA 139 ASTMA381 ASTMA441 ASTMA500 ASTMA501 ASTMA516 ASTMA524 ASTMA529 ASTMA537 ASTM A 572 GradeB GradeB Grades A, B, CS, D, DS, E GradeB Grade Y35 Grade A GradeB GradeC Grades I & II Grade 65 Grade 36 Grade 30 Grade 33 Type 1 Grade 40 Type 1 Grade 30 Grade 33 Grade 36 Type 1 Grade 40 Grade 45 Grade 50 Grade 55 GradeB GradeX42 Grades A, B, D, CS, DS GradeE GradeB GradeB Grades A, B, CS,D,DS,E AH32& 36 DH32& 36 EH 32&36 GradeB Grade Y35 Grade A GradeB Grade C SMAW with other than lowhydrogen electrodes SMAW with lowhydrogen electrodes, SAW, GMAW, FCAW Grades 55 & 60 65&70 Grades I & II Grades 50 & 55 Classes 1 & 2 Grades 42, 50, 55 (Continued) 68 in rom Minimum Preheat and Interpass Temperature OF 32a °C oa 1/8 to 3/4 incl. 3 to 20 incl. Over 3/4 thru 1-1/2 incl. thru 38 Over 1-1/2 thru 2-1/2 incl. thru 65 Over 2-1/2 Over 65 1/8 to 3/4 incl. 3 to 20 incl. Over 3/4 thru 1-1/2 Over 20 thru 38 incl. 50 10 150 65 225 110 incl. Over 20 150 65 225 110 300 150 incl. Over 38 incl. Over 1-1/2 Over 38 thru 2-1/2 thru 65 incl. incl. Over 2-1/2 Over 65 32a oa AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs Table 3.2 (Continued) Prequalified Minimum Preheat and Interpass Temperature (see 3.5) C a t e g Thickness of Thickest Part at Point of Welding 0 r y Welding Process Steel Specification ASTMA573 ASTMA588 ASTMA595 ASTM A 606 ASTMA618 ASTMA633 ASTMA 709 ASTMA 710 , ASTMA808 ASTMA 913 b ASTMA992 ASTM A 1008 HSLAS ASTM A 1008 HSLAS-F ASTM A 1011 HSLAS B (Cont'd) ASTM A 1011 HSLAS-F ASTM A 1018 HSLAS ASTM A 1018 HSLAS-F ASTM A 1018 SS API5L API Spec. 2H API2MTl API2W API2Y ABS ABS in mm Minimum Preheat and Interpass Temperature OF °C Grade 65 Grades A, B, C Grades Ib, II, III Grades A, B Grades C, D Grades 36, 50, 50S, 50W Grade A, Class 2 (>2 in [50 mm]) Grade 50 Grade 45 Class 1 Grade 45 Class 2 Grade 50 Class 1 Grade 50 Class 2 Grade 55 Class 1 Grade 55 Class 2 Grade 50 Grade 45 Class 1 Grade 45 Class 2 Grade 50 Class 1 Grade 50 Class 2 Grade 55 Class 1 Grade 55 Class 2 Grade 50 Grade 45 Class 1 Grade 45 Class 2 Grade 50 Class 1 Grade 50 Class 2 Grade 55 Class 1 Grade 55 Class 2 Grade 50 Grade 30 Grade 33 Grade 36 Grade 40 GradeB Grade X42 Grades 42, 50 SMAW with lowhydrogen electrodes, SAW, GMAW, FCAW Grades 42, 50, 50T Grades 42, 50, 50T Grades AH 32 & 36 DH32& 36 EH 32 & 36 Grades A, B, D, CS,DS GradeE (Contmued) 69 118 to 3/4 inc!. 3 to 20 inc!. 32" Over 3/4 thru 1-1/2 incl. Over 20 thru 38 inc!. 50 10 Over 1-112 thru 2-1/2 inc!. Over 38 thru 65 inc!. 150 65 Over 2-112 Over 65 225 110 0" AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs Table 3.2 (Continued) Prequalified Minimum Preheat and Interpass Temperature (see 3.5) Thickness of Thickest Part at Point of Welding C a t e g Minimum Preheat and Interpass Temperature 0 r y Steel Specification ASTM A 572 ASTMA633 ASTMA913 b ASTMA 710 ASTMA 710 C D ASTMA 709 0 ASTMA 852 0 ASTMA 1018 HSLAS ASTMA 1018 HSLAS-F API2W API2Y API5L ASTMA 710 ASTMA 913b Grades 60, 65 GradeE Grades 60, 65 Grade A, Class 2 (::;2 in [50 mm]) Grade A, Class 3 (>2 in [50 mm]) Grade HPS70W Grade 60 Class 2 Grade 70 Class 2 Grade 60 Class 2 Grade 70 Class 2 Grade 60 Grade 60 GradeX52 Grade A (All classes) Grades 50, 60, 65 mm of °C 1/8 to 3/4 incl. 3 to 20 incl. 50 10 Over 3/4 thru 1-1/2 incl. Over 20 thru 38 incl. 150 65 Over 1-1/2 thru 2-1/2 incl. Over 38 thru 65 incl. 225 110 Over 2-112 Over 65 300 150 in Welding Process SMAWwith low-hydrogen electrodes, SAW, GMAW, FCAW SMAW, SAW, GMAW, and FCAW with electrodes or electrode-flux combinations capable of depositing weld metal with a maximum diffusible hydrogen content of 8 m1I100 g (H8), when tested according to AWS A4.3. All thicknesses 1/8 in [3 mm] ~ 32a oa When the base metal temperature is below 32°F [O°C], the base metal shall be preheated to a minimum of 70°F [20°C] and the minimum interpass temperature shall be maintained during welding. bThe heat input limitations of 5.7 shall not apply to ASTM A 913. C For ASTM A 709 Grade HPS70W and ASTM A 852, the maximum preheat and interpass temperatures shall not exceed 400°F [200°C] for thicknesses up to 1-112 in [40 mm], inclusive, and 450°F [230°C] for greater thicknesses. a Notes: 1. For modification of preheat requirements for SAW with parallel or multiple electrodes, see 3.5.~. 2. See 5.12.2 and 5.6 for ambient and base-metal temperature requirements. 3. ASTM A 570 and ASTM A 607 have been deleted. 70 AWS D1.1·/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs Table 3.4 Minimum Prequalified PJP Weld Size (E) (see 3.12.2.1) • Table 3.3 (see 3.7.3) ., Filler Metal Requirements for Exposed Bare Applications of Weathering Steels Process AWS Filler Metal Specification Base Metal Thickness (T)a Approved Electrodes a SMAW A5.5 All electrodes that deposit weld metal meeting a B2L, CI, CIL, C2, C2L, C3, or WX analysis per A5.5. SAW A5.23 All electrode-flux combinations that deposit weld metal with a Nil, Ni2, Ni3, Ni4, or WX analysis per A5.23. FCAW A5.29 All electrodes that deposit weld metal with a B2L, K2, Nil, Ni2, Ni3, Ni4, or WX analysis per A5.29. A5.28 All electrodes that meet filler metal composition requirements of B2L, Ga, Nil, Ni2, Ni3, analysis per A5.28. GMAW in [mm] in mm 1/8 [3] to 3/16 [5] incl. Over 3/16 [5] to 1/4 [6] incl. Over 1/4 [6] to 1/2 [12] incl. Over 1/2 [12] to 3/4 [20] incl. Over 3/4 [20] to 1-1/2 [38] incl. Over 1-1/2 [38] to 2-1/4 [57] incl. Over 2-1/4 [57] to 6 [150] incl. Over 6 [150] 1/16 1/8 3/16 1/4 5/16 3/8 1/2 5/8 2 3 5 6 8 10 12 16 a For nonlow-hydrogen processes without preheat calculated in conformance with 4.7.4, T equals the thickness of the thicker part joined; single pass welds shall be used. For low-hydrogen processes and nonlow-hydrogen processes established to prevent cracking in conformance with 4.7.4, T equals thickness of the thinner part; single pass requirement does not apply. b Except that the weld size need not exceed the thickness of the thinner part joined. a Deposited weld metal shall have a chemical composition the same as that for anyone of the weld metals in this table. t Minimum Weld Sizeb Notes: 1. Filler metals shall meet requirements of Table 3.1 in addition to the compositional requirements listed above. The use of the same type of filler metal having next higher tensile strength as listed in AWS filler metal specification may be used. 2. Composite (metal cored) electrodes are designated as follows: SAW: Insert letter "C" between the letters "E" and "X," e.g., E7AXECXXX-Ni1. GMAW: Replace the letter "S" with the letter "C," and omit the letter "R," e.g., E80C-Ni1. 3. This table shall apply to ASTM A 588 and A 709 Grade SOW. Table 3.5 Joint Detail Applications for Prequalified CJP T-, Y-, and K-Tubular Connections (see 3.13.4 and Figure 3.7) Detail A B C D Applicable Range of Local Dihedral Angle, 'P 180° to 150° to 75° to 40° to 135° 50° 30° } 15° Not prequalified for groove angles under 30° Notes: 1. The applicable joint detail (A, B, C, or D) for a particular part of the connection shall be determined by the local dihedral angle, '1', which changes continuously in progressing around the branch member. 2. The angle and dimensional ranges given in Detail A, B, C, or D include maximum allowable tolerances. 3. See Annex K for definition of local dihedral angle. 71 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 Table 3.6 Prequalified Joint Dimensions and Groove Angles for CJP Groove Welds in Tubular T-, V-, and K-Connections Made by SMAW, GMAW-S, and FCAW (see 3.13.4) Detail B '¥ = 150° - 50° Detail A '¥ = 180° - 135° End preparation «())) max. 10° or 45° for'¥ > 105° GMAW-S FCAW-Ge FCAW-S SMAWd FCAW-S SMAWd 3/16 in [5mm] 3/16 in [5mm] 1/16 in [2mm] No min. for <1»90° 1/16 in [2mm] No min. for <I> > 120° Joint included angle <I> max. 90° min. 45° Completed weld tw L ;::: tb ;::: tb /sin '¥ but need not exceed 1.75 tb Otherwise as needed to obtain required $. Not prequalified for groove angles ($) under 30 0 • e Initial passes of back-up weld discounted until width of groove provided by back-up weld. d These root details apply to SMAWand FCAW-S. eThese root details apply to GMAW-S and FCAW-G. 114 in [6mm] 1116 in [2mm] (Note c) Wmax. GMAW-S FCAW-Ge 114 in [6 mm] for <I> > 45° min. Detail D '¥ =40° - 15 0b (Note a) min. Fit-up or root opening (R) max. Detail C '¥ =75° - 300b FCAW-S SMAW {1I8 in [3 mm] (1) 3/16 in [5 mm] 5/16 in [8mm] for <I> ~45° 1/16 in [2mm] GMAW-S { 118 in [3 mm] 1I4in [6mm] FCAW-G (2) 3/8 in [10 mm] 112 in [12 mm] 30°-40° 25°-30° 20°-25° 15°-20° 40°; if more use Detail B 37-112°; ifless use Detail C ;::: tb for '¥ > 90° ;::: tbIsin '¥ for '¥ < 90° 1I2'¥ ;::: tb /sin '¥ but need not exceed 1.75 tb Weld may be built up to meet this a b CW) is sufficient to assure sound welding; the necessary width of weld groove CW) Notes: I. For GMAW-S see 4.12.4.3. These details are not intended for GMAW (spray transfer). 2. See Figure 3.8 for minimum standard profile (limited thickness). 3. See Figure 3.9 for alternate toe-fillet profile. 4. See Figure 3.10 for improved profile (see 2.20.6.6 and 2.20.6.7). 72 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 Table 3.7 Prequalified WPS Requirements f (see 3.7) SAWd Variable Position Weld Type Fillet" Flat Maximum Electrode Diameter Horizontal Vertical Overhead All , Maximum Current All Single SMAW 1/4 in [6.4 mm] Root pass Fillet 3/16 in [4.8 mm] Groove 3/16 in [4.8 mm] 3/16 in [4.8 mm]b 3/16 in [4.8 mm]b Groove weld root pass with opening Groove weld root pass without opening Groove weld fill passes Flat Maximum Fill Pass Thickness Horizontal Vertical Overhead All All All 1/4 in [6.4 mm] 1/8 in [3.2 mm] 1/4 in [6.4 mm] Requires WPS Qualification Test 1/8 in [3.2 mm] ...•...• 'i 'i i·c· 1000 A Maximum Single Pass Layer Width Horizontal Fillet Vertical Overhead All (for GMAWI FCAW) F&H (for SAW) 900A l200A Within the range of recommended operation by the filler metal manufacturer Unlimited 3/8 in [10 mm] 5/16 in [8 mm] 1/2 in [12 mm] 3/16 in [5 mm] 1/4 in [6mm] ii/""/i Unlimited 5/16 in [8 mm] 1/2 in [12 mm] " Root opening IXi.•/ii/··iC.·i > 1/2 in [12mm], or ·i '~~~i(l~ iii./,»/ i 5116 in • [8 mm] /c [12 mm] c. 'c, Laterally displaced Split layers electrodes or split layer Split layers Split layers with tandem ifw > 5/8 in electrodes [16 mm] ifw > 5/8 in [16mm] ll/2 in [12 mm] 5/16 in [8 mm] 1/4 in [6 mm] 1/2 in [12 mm] Unlimited 5/16 in [8mm] a Except 5/16 in [8 mm] iii'<;Yj/;i2;;~';':;,i<i>ii>'C iC.·.L Ic Ii 3/8 in [10 mm] Unlimited 5/16 in [8 mm] 318 in [lOmm] . 1/2 in [12 mm] 5/16 in [8 mm] Split layers Split layers Ifw>lin [25 mm], split layers (Note e) root passes. in [4.0 mm] for EXX14 and low-hydrogen electrodes. c See 3.7.3 for requirements for welding unpainted and exposed ASTM A 588. d See 3.7.2 for width-to-depth limitations. e In the F, R, or OR positions for nontubulars, split layers when the layer width w > 5/8 in [16 mm]. In the vertical position for nontubulars or the flat, horizontal, vertical, and overhead positions for tubulars, split layers when the width w > 1 in [25 mm]. f Shaded area indicates nonapplicability. g GMAW-S shall not be prequalified. b 5132 t 3/32 in [2.4 mm] 5/64 in [2.0 mm] l200A Unlimited 600A 'c1l6in[8~ Any layer of width w i, iii cii i, i j .c 700A Within the range of recommended operation by the filler metal manufacturer 3/8 in [10 mm] Flat Maximum Single Pass Fillet Weld Sizec GMAWI FCAWg 1/4 in [6.4 mm] Groove weld cap pass Maximum Root Pass Thickness d Multiple 5/16 in [8.0 mm] Groove" All All Fillet Parallel 73 AWS 01.1/01.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs Figure 3.t-Weld Bead in which Depth and Width Exceed the Width of the Weld Face (see 3.7.2) TOE ZONE FOR 'I' > 120° EDGE SHALL BE CUT BACK TO FACILITATE THROAT THICKNESS L L J__"-.-: L SIDE (CIRCULAR) TOE SIDE (BOX) MIN L FOR HEEL < 60° E = 0.7t E=t E = 1.07t 1.5t 1.5t LARGER OF 1.5t OR 1.4t + Z t 1.4t 1.5t SIDE 100-110° 1.1 t 1.6t 1.75t SIDE 110-120° 1.2t 1.8t 2.0t t BEVEL 1.4t BEVEL FULL BEVEL 60-90° GROOVE SIDE:5 100° TOE> 120° Notes: 1. t = thickness of thinner part. 2. L = minimum size (see 2.24.1.3 which may require increased weld size for combinations other than 36 ksi [250 MPa] base metal and 70 ksi [485 MPa] electrodes). 3. Root opening 0 in to 3/16 in [5 mm] (see 5.22). 4. Not prequalified for <jJ < 30°. For <jJ < 60°, the Z loss dimensions in Table 2.9 apply. See Table 4.10 for welder qualification position requirements. 5. See 2.23.1.2 for limitations on ~ = diD. 6. 'I' = dihedral angle. Figure 3.2-Fillet Welded Prequalified Tubular Joints Made by SMAW, GMAW, and FCAW (see 3.9.2) 74 AWS D1.1/D1.1M:2008 .. CLAUSE 3. PREQUALIFICATION OF WPSs Legend for Figures 3.3 and 3.4 1'---------Symbols for joint types B - butt joint C - corner joint T - T-joint BC - butt or corner joint TC - T- or corner joint BTC - butt, T-, or corner joint Welding processes SMAW - shielded metal arc welding GMAW - gas metal arc welding FCAW - flux cored metal arc welding SAW - submerged arc welding Welding positions F - flat H - horizontal V - vertical OH - overhead Symbols for base metal thickness and penetration P-PJP L - limited thickness-CJP V - unlimited thickness-CJP t Symbol for weld types 1 - square-groove 2 - single-V-groove 3 - double-V-groove 4 - single-bevel-groove 5 - double-bevel-groove 6 - single-V-groove 7 - double-V-groove 8 - single-J-groove 9 - double-J-groove 10 - flare-bevel-groove 11 -. flare-V-groove Dimensions R= ex, ~ = f= r= S, Sl ' S2 = E, E 1 ' Symbols for welding processes if not SMAW S-SAW G-GMAW F-FCAW Root Opening Groove Angles Root Face J- or V-groove Radius PJP Groove Weld Depth of Groove E 2 = PJP Groove Weld Sizes corresponding to S, Sl , S2' respectively Joint Designation The lower case letters, e.g., a, b, c, etc., are used to differentiate between joints that would otherwise have the same joint designation. Notes for Figures 3.3 and 3.4 a Not prequalified for GMAW-S nor GTAW. shall be welded from one side only. C Cyclic load application limits these joints to the horizontal welding position (see 2.17.2). d Backgouge root to sound metal before welding second side. e SMAW detailed joints may be used for prequalified GMAW (except GMAW-S) and FCAW. f Minimum weld size (E) as shown in Table 3.4. S as specified on drawings. 9 If fillet welds are used in statically loaded structures to reinforce groove welds in corner and T-joints, these shall be equal to T 1 /4, but need not exceed 3/8 in [10 mm]. Groove welds in corner and T-joints of cyclically loaded structures shall be reinforced with fillet welds equal to T 1 /4, but need not exceed 3/8 in [10 mm]. h Double-groove welds may have grooves of unequal depth, but the depth of the shallower groove shall be no less than one-fourth of the thickness of the thinner part joined. i Double-groove welds may have grooves of unequal depth, provided these conform to the limitations of Note 1. Also the weld size (E) applies individually to each groove. 0 0 0 0 0 0 j The orientation of the two members in the joints may vary from 135 to 180 for butt joints, or 45 to 135 for corner joints, or 45 to 90 for T-joints. k For corner joints, the outside groove preparation may be in either or both members, prOVided the basic groove configuration is not changed and adequate edge distance is maintained to support the welding operations without excessive edge melting. I Weld size (E) shall be based on joints welded flush. mFor f1are-V-groove welds and flare-bevel-groove welds to rectangular tubular sections, r shall be as two times the wall thickness. n For flare-V-groove welds to surfaces with different radii r, the smaller r shall be used. b Joint • • 75 AWS D1.1/D1.1M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Square-groove weld (1) Butt joint (B) / ti:::::3 ' (E)[Rl T1~ T~"'---~~ REINFORCEMENT 1/32 TO 1/8 --J ~R Groove Preparation Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 B-P1a SMAW 1/8 B-P1c 1/4 max. T2 NO TOLERANCE Tolerances As Detailed (see 3.12.3) Root Opening - R=Oto1/16 - T1 . R= - min. .2 +1/16, -0 +1/16, -0 As Fit-Up (see 3.12.3) ±1/16 ±1/16 Allowed Welding Positions Weld Size (E) Notes All T 1 -1/32 b,e T1 b,e All 2 Square-groove weld (1) Butt joint (B) E1 + E2 MUST NOT EXCEED -i 3T Groove Preparation Base Metal Thickness 1 - - - - - - - - r - - - - - - - - - - - - 1 (U = unlimited) Tolerances Welding Process Joint Designation T1 SMAW B-P1b 1/4 max. T2 Root Opening T1 R= 2 As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) Allowed Welding Positions +1/16, -0 ±1/16 All Figure 3.3-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 76 Total Weld Size (E 1 + E2) 3T 1 4 Notes e AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-V-groove weld (2) Butt joint (B) Corner joint (C) I I I I \a Z mtT t -J-~~ I Base Metal Thickness (U = unlimited) Welding Process SMAW Joint Designation BC-P2 T1 T2 1/4 min. U 1/4 min. U 7/16 min. U ? GMAW FCAW BC-P2-GF SAW BC-P2-S S(E)/R'" a '\- R Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) R=O f = 1/32 min. a= 60° R=O f = 1/8 min. a= 60° R=O f = 1/4 min. a= 60° +1/16, -0 +U,-o +10°, -00 +1/16, -0 +U,-o +10°, -00 ±O +U,-o +10°, -00 +1/8,-1/16 ±1/16 +10°, _5° +1/8,-1/16 ±1/16 +10°, _5° +1/16, -0 ±1/16 +10°, _5° Double-V-groove weld (3) Butt joint (B) \aV ~ S2(E2) Allowed Welding Positions Weld Size (E) Notes All S b, e, f, j All S a, b, f, j F S b, f, j Allowed Welding Positions Total Weld Size (E 1 + E2) Notes All Sl +S2 e, f, i, j All S1 +S2 a, f, i, j F Sl +S2 f, i, j "'.'i S1(E1) / R ' " a [Sl I <?> + t ,:::-r f T1 --=rt=--t ~ S2 a Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW B-P3 1/2 min. - GMAW FCAW B-P3-GF 1/2 min. - SAW B-P3-S 3/4 min. - Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) R=O f = 1/8 min. a= 60° R=O f = 1/8 min. a= 60° R=O f = 1/4 min. a= 60° +1/16, -0 +U,-o +10°, -00 +1/16, -0 +U,-o +10°, -00 ±O +U,-o +10°, -00 +1/8, -1/16 ±1/16 +10°, _5° +1/8,-1/16 ±1/16 +10°, _5° +1/16, -0 ±1/16 +10°, _5° Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 77 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 See Notes on Page 75 Single-bevel-groove weld (4) Butt joint (B) T-joint (T) Corner joint (C) ai? r·","~-"\~7 I +1 r Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW BTC-P4 U U GMAW FCAW BTC-P4-GF 1/4 min. U SAW TC-P4-S 7/16 min. U 'a ~-7 1/ v t " '~~~l ~ S(E) l ~ 1 t J t OJ 1• S R Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) R=O t = 1/8 min. a= 45° R=O t= 1/8 min. a= 45° R=O t = 1/4 min. a= 60° +1/16, -0 +U-O +10°, -00 +1/16, -0 +u-o +10°, -00 ±O +U,-o +10°, -00 +1/8, -1/16 ±1/16 +10°, _5° +1/8, -1/16 ±1/16 +10°, _5° +1/16, -0 ±1/16 +10°, _5° Double-bevel-groove weld (5) Butt joint (B) T-joint (T) Corner joint (C) Allowed Welding Positions Weld Size (E) All S-1/8 F, H S V,OH S-1/8 F S Notes b, e, t, g,j, k a, b, t, g,j, k b, t, g, j, k ~, ~-~ I al? r-"'''~-ltY +1 S1 ~ t , t J I ;b. Ll~ S2 1/ Sl(E1) ~ 'a~-7 1/ ,~ ".,.. ~~}t~R I f S2(E2) V T1 a::...t. OJ ~ Base Metal Thickness (U = unlimited) Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) Welding Process Joint Designation T1 T2 SMAW BTC-P5 5/16 min. U R=O t = 1/8 min. a=45° +1/16, -0 +U-O +10°, -00 +1/8, -1/16 ±1/16 +10°, _5° GMAW FCAW BTC-P5-GF 1/2 min. U R=O t = 1/8 min. a=45° +1/16, -0 +U-o +10°, -00 +1/8, -1/16 ±1/16 +10°, _5° SAW TC-P5-S 3/4 min. U R=O t = 1/4 min. a=60° ±O +U,-o +10°, -00 +1/16, -0 ±1/16 +10°, _5° Allowed Welding Positions Total Weld Size (E1 + E2) Notes All S1 + S2 -1/4 e, t, g, i, j, k F, H S1 +S2 V,OH S1 + S2 -1/4 F S1 + S2 Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 78 a, t, g, i, j, k t, g, i, j, k AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-U-groove weld (6) Butt joint (B) Corner joint (C) S(E)~ ,r-~1 ~ a ~Ij' '\ ~~:~ tJ , Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 R Groove Preparation Root Opening Root Face Bevel Radius Groove Angle R=O SMAW BC-P6 1/4 min. U GMAW FCAW BC-P6-GF 1/4 min. U SAW BC-P6-S 7/16 min. U t = 1/32 min. r = 1/4 a=45° R=O t = 1/8 min. r = 1/4 a= 20° R=O t = 1/4 min. r = 1/4 a=20° Tolerances As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +1/16, -0 +U,-o +1/4, -0 +10°, -00 +1/16, -0 +U,-o +1/4, -0 +10°, _0° ±O +U,-o +1/4, -0 +10°, _0° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +1/16, -0 ±1/16 ±1/16 +10°, _5° Double-U-groove weld (7) Butt joint (B) S2(E2) 'Y S1(E1) ~ \~1 ~+----l ~ @ Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW B-P7 1/2 min. - GMAW FCAW B-P7-GF 1/2 min. - SAW B-P7-S 3/4 min. - .. t t Allowed Welding Positions Weld Size (E) All S b, e, t, j All S a, b, t, j F S b, Allowed Welding Positions Total Weld Size (E 1 + E2) All Sl +S2 e, t, i, j All Sl +S2 a, t, F Sl +S2 Notes t, j a T1 -:ItT S2 Groove Preparation Root Opening Root Face Bevel Radius Groove Angle Tolerances As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) R=O t = 1/8 min. r = 1/4 a=45° R=O t = 1/8 min. r = 1/4 a=20° R=O t = 1/4 min. r = 1/4 a=20° +1/16, -0 +U,-o +1/4, -0 +10°, _0° +1/16, -0 +U,-o +1/4, -0 +10°, -00 ±O +U,-O +1/4, -0 +10°, -00 +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +1/16, -0 ±1/16 ±1/16 +10°, _5° Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 79 Notes i, j t, i, j CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 See Notes on Page 75 Single-J-groove weld (8) Butt joint (B) T-joint (T) Corner joint (C) S(E) at r~-h +! ~ t 1 J ~ la ~-7 V 1 'l T2_r~·,A~1 Base Metal Thickness (U = unlimited) Welding Process Joint Designation B-P8 T1 1/4 min. T2 - SMAW TC-P8 1/4 min. U t R 1/4 min. - GMAW FCAW TC-P8-GF 1/4 min. U 7/16 min. - SAW TC-P8-S 7/16 min. U ~~ Tolerances Root Opening Root Face Bevel Radius Groove Angle R=O t = 1/8 min. r= 3/8 a=30° R=O t = 1/8 min. r = 3/8 a oe = 30°* aie = 45°** t = 1/8 min. r = 3/8 a=30° R=O t = 1/8 min. r = 3/8 a oe = 30°* aie = 45°** R=O B-P8-S INSIDE CORNER Groove Preparation R=O B-P8-GF OUTSIDE CORNER 1/ t = 1/4 min. r = 1/2 a= 20° R=O t = 1/4 min. r = 1/2 a oe = 20°* aie = 45°** Allowed Welding Positions Weld Size (E) +1/8, -1/16 ±1/16 ±1/16 +10°, _5° All S e, t, Q;j, k +1/16, -0 +U,-o +1/4, -0 +10°, -00 +10°, _0° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +10°, _5° All S e, t, g, j, k +1/16, -0 +U,-o +1/4, -0 +10°, -00 +1/8, -1/16 ±1/16 ±1/16 +10°, _5° All S +1/16, -0 +U,-o +1/4, -0 +10°, _0° +10°, _0° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +10°, _5° All S ±O +U,-O +1/4, -0 +10°, -00 +1/16, -0 ±1/16 ±1/16 +10°, _5° F S t, g, j, k ±O +U,-o +1/4, -0 +10°, _0° +10°, _0° +1/16, -0 ±1/16 ±1/16 +10°, _5° +10°, _5° F S t, g, j, k As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +1/16, -0 +U,-o +1/4, -0 +10°, -00 *aoe = Outside corner groove angle. **aie = Inside corner groove angle. Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 80 Notes : a, t, g,j, k a, t, g, j, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS 01.1/01.1 M:2008 See Notes on Page 75 • , Double-J-groove weld (9) Butt joint (B) T-joint (T) Corner joint (C) OUTSIDE CORNER elL C ORNER Welding Process Groove Preparation Base Metal Thickness f - - - - - - , - - - - - - - - - - - - - - - i (U = unlimited) Root Opening Tolerances f------,-------i Root Face 1 - - - - - , - - - - - - - 1 Allowed Bevel Radius As Detailed As Fit-Up Welding Joint (see 3.12.3) (see 3.12.3) Positions Designation Groove Angle B-P9 1/2 min. SMAW R=O f = 1/8 min. r = 3/8 (X = 30° +1/16, -0 +U,-O +1/4, -0 +10°, _0° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° All R=O +1/16, -0 +U,-O +1/4, -0 +10°, _0° +10°, _0° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° +10°, _5° All +1/16, -0 +U,-o +1/4, -0 +10°, _0° +1/8, -1/16 ±1/16 ±1/16 +10°, _5° All ±O +U,-o +1/4, -0 +10°, _0° +10°, -00 +1/16, -0 ±1/16 ±1/16 +10°, _5° +10°, _5° All ±O +U,-o +1/4, -0 +10°, -00 +1/16, -0 ±1/16 ±1/16 +10°, _5° F ±O +U,-o +1/4, -0 +10°, -00 +10°, -00 +1/16, -0 ±1/16 ±1/16 +10°, _5° +10°, _5° F t = 1/8 min. TC-P9 1/2 min. U r = 3/8 (Xoe = 30°' (Xie = 45°** R=O B-P9-GF f = 1/8 min. 1/2 min. r= 3/8 (X = 30° GMAW FCAW R=O t = 1/8 min. TC-P9-GF 1/2 min. B-P9-S 3/4 min. U r= 3/8 (Xoe = 30°* (Xie = 45°** R=O t = 1/4 min. r = 1/2 (X = 20° SAW R=O TC-P9-S 3/4 min. U f = 1/4 min. r = 1/2 (Xoe = 20°* (Xie = 45°** Total Weld Size (E 1 + E2) '(Xoe = Outside corner groove angle. **(Xie = Inside corner groove angle. Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 81 Notes e, t, g, i, j,k e, t, g, i, j,k a, t, g, i, j, k a, t, g, i, j, k f, g, i, j, k f, g, i, j, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS 01.1/01.1 M:2008 See Notes on Page 75 Flare-bevel-groove weld (10) Butt joint (B) T-joint (T) Corner joint (C) -i ~ ' _ ~_____ J'"------ _. - ~ Co" Ts (E) 1'~-7 ..-i ? l v 1/ ~ f F Lt.y.-i :;. -l Base Metal Thickness (U = unlimited) Welding Process Joint Designation SMAW FCAW-S BTC-P10 GMAW FCAW-G SAW BTC-P10-GF B-P10-S T1 3/16 min. 3/16 min. 1/2 min. ~R I-T2 Groove Preparation T2 Ts U T1 min. R=O f = 3/16 min. 3T 1 . r= 2 min. T1 min. R=O f = 3/16 min. 3T 1 . r= 2 min. 1/2 min. R=O f = 1/2 min. 3T 1 . r= 2 min. U N/A Tolerances Root Opening Root Face Bend Radius As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) Allowed Welding Positions Weld Size (E) Notes +1/16, -0 +U,-o +1/8, -1/16 +U, -1/16 All 5/16 r e, g,j, I +U,-O +U,-O +1/16, -0 +U,-o +1/8, -1/16 +U, -1/16 All 5/8 r +U,-O +U,-O a,g,j,l, m ±O +U,-o +1/16, -0 +U, -1/16 F 5/16 r g,j,l,m +U,-O +U,-O Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 82 AWS 01.1/01.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Flare-V-groove weld (11) Butt joint (B) ...L <, T2T ~<'~ i-IT (E)...! ' - tTl f ~~:Base Metal Thickness (U = unlimited) Welding Process SMAW FCAW-S GMAW FCAW-G SAW Joint Designation B-P11 B-P11-GF B-P11-S T1 3/16 min. 3/16 min. 1/2 min. Groove Preparation Tolerances Root Opening Root Face Bend Radius As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) T l min. R=Q f = 3/16 min. 3T l . r= 2 min. +1/16, -0 +U,-o +U,-o T 1 min. R=O f = 3/16 min. 3T l . r= 2 min. T1 min. R=O f = 1/2 min. 3T 1 . r= 2 min. T2 F Allowed Welding Positions Weld Size (E) +1/8, -1/16 +U, -1/16 +U,-o All 5/8 r e,j,I,m, n +1/16, -0 +U,-o +U,-O +1/8, -1/16 +U, -1/16 +U,-O All 3/4 r a,j,l,m, n ±O +U,-o +U,-O +1/16, -0 +U, -1/16 +U,-O F 1/2 r j,l,m,n Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Inches) 83 Notes CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1 /D1.1 M:200B See Notes on Page 75 Square-groove weld (1) Butt joint (B) . / W:::::3 T1~ (E)fRl + T~""--""'~~ REINFORCEMENT 1 TO 3 --J ALL DIMENSIONS IN mm Joint Designation T1 B-P1a SMAW 3 6 max. B-P1c NO TOLERANCE Groove Preparation Base Metal Thickness (U = unlimited) Welding Process ~R Tolerances Root Opening As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) Allowed Welding Positions Weld Size (E) Notes - R=Oto2 +2,-0 ±2 All T 1 -1 b, e - T1 All T1 2 b, e Allowed Welding Positions Total Weld Size (E 1 + E2 ) T2 R= 2" . +2,-0 min. ±2 Square-groove weld (1) Butt joint (B) E1 + E2 MUST NOT EXCEED 3T -i- ALL DIMENSIONS IN mm Groove Preparation Base Metal Thickness f - - - - - - . . , . - - - - - - - - - - - - - - 1 (U = unlimited) Tolerances Welding Process SMAW Joint Designation B-P1b T2 As Detailed (see 3.12.3) Root Opening 6 max. +2,-0 As Fit-Up (see 3.12.3) ±2 All 3T 1 4 Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 84 Notes e CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 See Notes on Page 75 Single-V-groove weld (2) Butt joint (B) Corner joint (C) '\"Z I I I I ~ S(E)/~" ffis ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) R Groove Preparation Tolerances Root Opening Root Face Groove Angle Welding Process Joint Designation T1 T2 SMAW BC-P2 6 min. U t = 1 min. a= 60° R=O ? t '~ -J-~~ I T1 R=O GMAW FCAW BC-P2-GF 6 min. U t = 3 min. a = 60° SAW BC-P2-S 11 min. U t = 6 min. a = 60° R=O As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U,-o +10°, -00 +2,-0 +U,-O +10°, _0° ±O +U,-O +10°, _0° +3,-2 ±2 +10°, _5° +3,-2 ±2 +10°, _5° +2,-0 ±2 +10°, _5° Double-V-groove weld (3) Butt joint (B) S2(E2) Allowed Welding Positions Weld Size (E) All S b, e, t, j All S a, b, t, j F S b, Allowed Welding Positions Total Weld Size (E 1 + E2) All S1 +S2 e, t, All 8 1 +S2 a, t, i, j F S1 +S2 t, Notes t, j "'-Y S1 (E1) /R"'- \ay _t.' ~ ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) ~ a I '::-T + t t T1 --:rt::i @ S2 Groove Preparation Tolerances Root Opening Root Face Groove Angle Welding Process Joint Designation T1 SMAW B-P3 12 min. - t = 3 min. a = 60° GMAW FCAW B-P3-GF 12 min. - t = 3 min. a = 60° SAW B-P3-S 20 min. - t= 6 min. a= 60° T2 [S1 R=O R=O R=O As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U,-O +10°, -00 +2,-0 +U,-o +10°, -00 ±O +U,-o +10°, -00 +3,-2 ±2 +10°, _5° +3,-2 ±2 +10°, _5° +2,-0 ±2 +10°, _5° Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 85 Notes i, j i, j CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 See Notes on Page 75 Single-bevel-groove weld (4) Butt joint (B) T-joint (T) Corner joint (C) al? r-",,"--"1~> I +1 , Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW BTC-P4 U U GMAW FCAW BTC-P4-GF 6 min. U SAW TC-P4-S 11 min. U ~-7 1/ r ~ 1• S CP 1 1 '~ v t " ~~~ ALL DIMENSIONS IN mm ~ la S(E) f J R Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U-o +10°, -00 +3,-2 ±2 +10°, _5° +3,-2 ±2 +10°, _5° +2,-0 ±2 +10°, _5° R=O f= 3 min. a=45° R=O f = 3 min. a= 45° R=O f = 6 min. a= 60° +2,-0 +U-O +10°, -00 ±O +U,-o +10°, -00 Double-bevel-groove weld (5) Butt joint (B) T-joint (T) Corner joint (C) All S-3 F,H S V,OH S-3 F S Allowed Welding Positions Total Weld Size (E 1 + E2) Notes b, e, f, 9,j, k a, b, f, g,T. k ~,f, g,j, k ~-~ S1(E1) ai? :-"""--11J ,..- +! :!b. < i/' ~ la~-7 1/ [S1 L."J'__ }j ~ V '::-1"" t t f T1 l::..i I S2] ~T2-r~R ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) [JJ Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) Welding Process Joint Designation T1 T2 SMAW BTC-P5 8min. U R=O f = 3 min. a=45° +2,-0 +U-o +10°, -00 +3,-2 ±2 +10°, _5° GMAW FCAW BTC-P5-GF 12 min. U R=O f = 3 min. a= 45° +2,-0 +U-o +10°, -00 +3,-2 ±2 +10°, _5° U R=O f = 6 min. a=60° ±O +U,-o +10°, -00 +2,-0 ±2 +10°, _5° TC-P5-S Weld Size (E) ~, S2(E2) SAW Allowed Welding Positions 20 min. All F, H V,OH F S1 +S2 -6 S1 +S2 S1 +S2 -6 S1 +S2 Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 86 Notes e, f, g, i, j, k a, f, g, i, j, k f, g, i, j, k AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-U-groove weld (6) Butt joint (B) Corner joint (C) ~ : '"I~~:~ ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW BC-P6 6 min. U GMAW FCAW BC-P6·GF 6 min. U SAW BC-P6-S 11 min. U a 1 1 1 t t S(E)~ J R Groove Preparation Root Opening Root Face Bevel Radius Groove Angle R=O t = 1 min. r= 6 a=45° R=O t = 3 min. r=6 a= 20° R=O t =6 min. r=6 a= 20° Tolerances As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U,-O +6,-0 +10°, -00 +3,-2 ±2 ±2 +10°, _5° +3,-2 ±2 ±2 +10°, _5° +2,-0 ±2 ±2 +10°, _5° +2,-0 +U,-O +6,-0 +10°, _0° ±O +U,-o +6,-0 +10°, -00 Double-U-groove weld (7) Butt joint (B) S2(E2) Allowed Welding Positions Weld Size (E) Notes All S b, e, t, j All S a, b, t, j F S b, t, j Allowed Welding Positions Total Weld Size (E 1 + E2) Notes All S1 +S2 e, t, i, j All S1 +S2 a, t, i, j F S1 + S2 t, i, j 'l-J S1(E1)~ \~1 ~t----l ..> •• t ~~ ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW B-P7 12 min. - GMAW FCAW B-P7-GF 12 min. - SAW B-P7-S 20 min. - a T1 -:ItT S2 Groove Preparation Root Opening Root Face Bevel Radius Groove Angle Tolerances R=O t= 3 min. r=6 a= 45° R=O t = 3 min. r= 6 a=20° R=O t= 6 min. r=6 a= 20° As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U,-o +6,-0 +10°, -00 +3,-2 ±2 ±2 +10°, _5° +3,-2 ±2 ±2 +10°, _5° +2,-0 ±2 ±2 +10°, _5° +2,-0 +U,-o +6,-0 +10°, -00 ±O +U,-O +6,-0 +10°, _0° Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 87 AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-J-groove weld (8) Butt joint (B) T-joint (T) Corner joint (C) S(E) at r~+. I I, S I ~ t ! 'l T2~L~.,A~1 ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 B-P8 6 min. T2 t SMAW TC-P8 6 min. U B-P8-GF 6 min. - TC-P8-GF B-P8-S 6 min. 11 min. U - SAW U 1 ~ JtJ Tolerances Root Opening Root Face Bevel Radius Groove Angle t = 3 min. r = 10 a= 30° R=O t=3min. r=10 a oe = 30°* aie = 45°** t = 3 min. r = 10 a= 30° R=O t= 3 min. r=10 a oe = 30°* a ie = 45°** Allowed Welding Positions Weld Size (E) +3,-2 ±2 ±2 +10°, _5° All S e, t, g,j, k +2,-0 +U,-o +6,-0 +10°, -00 +10°, -00 +3,-2 ±2 ±2 +10°, _5° +10°, _5° All S e, t, g, j, k +2,-0 +U,-o +6,-0 +10°, -00 +3,-2 ±2 ±2 +10°, _5° All S +2,-0 +U,-o +6,-0 +10°, -00 +10°, -00 +3,-2 ±2 ±2 +10°, _5° +10°, _5° All S a, t, g, j, k +2,-0 ±2 ±2 +10°, _5° F S t, g, j, k +2,-0 ±2 ±2 +10°, _5° +10°, _5° F S t, g, j, k As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U,-o +6,-0 +10°, -00 ±O +U,-o +6,-0 +10°, _0° R=O t = 6 min. r = 12 a=20° R=O 11 min. 1 INSIDE CORNER Groove Preparation ±O +U,-o +6,-0 +10°, -00 +10°, -00 t = 6 min. TC-P8-S v J R=O GMAW FCAW OUTSIDE CORNER 1/ R R=O - ~ 'a ~-7 r=12 a oe = 20°* aie = 45°** *aoc = Outside corner groove angle. **aie = Inside corner groove angle. Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 88 Notes a, t, g,j, k AWS D1.1/D1.1M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Double-J-groove weld (9) Butt joint (B) T-joint (T) Corner joint (C) ~ S2(E2) r !X~ -~, ." ---- I . ... r ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) , Welding Process Joint Designation B-P9 T1 12 min. T2 - SMAW TC-P9 12 min. B-P9-GF 6 min. U I ,-:.r~. I s,T GMAW FCAW TC-P9-GF 6min. U 20 min. - SAW TC-P9-S 20 min. U ~!X -7 1/ V T1 t--.1. ruDE CORNER Groove Preparation Tolerances Root Opening Root Face Bevel Radius Groove Angle R=O t=3 min. r = 10 !X= 30° R=O t=3 min. r=10 !Xoe = 30°* !Xie = 45°** t = 3 min. r = 10 !X = 30° R=O t=3 min. r = 10 !Xoe = 30°* !Xie = 45°** R=O B-P9-S OUTSIDE CORNER R R=O - ~ IR =-.- <!>. t t - ~T2 S1(E 1) _,_ IDii'J I ... _--- ~ c:; t = 6 min. r=12 !X= 20° R=O t = 6 min. r = 12 !Xoe = 20°* !Xie = 45°** Allowed Welding Positions Total Weld Size (E 1 + E2) +3,-2 ±2 ±2 +10°, _5° All S1 +S2 e, t, g, i, j, k +2,-0 +U,-o +6,-0 +10°, -00 +3,-2 ±2 ±2 +10°, _5° +10°, _5° All S1 +S2 e, t, g, i, j, k +2,-0 +U,-o +6,-0 +10°, _0° +3,-2 ±2 ±2 +10°, _5° All S1 +S2 a, t, g, i, j, k +2,-0 +U,-O +6,-0 +10°, -00 +3,-2 ±2 ±2 +10°, _5° +10°, _5° All S1 +S2 a, t, g, i, j, k ±O +U,-o +6,-0 +10°, -00 +2,-0 ±2 ±2 +10°, _5° F S1 +S2 ±O +U,-o +6,-0 +10°, -00 +2,-0 ±2 ±2 +10°, _5° +10°, _5° F S1 +S2 As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) +2,-0 +U,-O +6,-0 +10°, -00 *!Xoe = Outside corner groove angle. **!Xie = Inside corner groove angle. Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 89 Notes t, g, i, j, k t, g, i, j, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS 01.1/01.1 M:2008 See Notes on Page 75 Flare-bevel-groove weld (10) Butt joint (B) T-joint (T) Corner joint (C) --i .. _____ ~ _ TJ.. ----- - c,' ' '-h -i ~ 1'- (E) ~-7 V 1"- lT1 F f ..tv-±- ~ ~R -l ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process SMAW FCAW-S GMAW FCAW-G SAW Joint Designation BTC-P10 BTC-P10-GF B-P10-S T1 5 min. 5 min. 12 min. T2 U U 12 min. Ts ~T2 Groove Preparation Root Opening Root Face Bend Radius T1 min. R=O f = 5 min. 3T 1 . r= 2' min. T1 min. R=O f = 5 min. 3T1 . r= 2' min. N/A R=O f=12min. 3T 1 . r= 2' min. Tolerances As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) Allowed Welding Positions Weld Size (E) Notes +2,-0 +U,-O +3,-2 +U,-2 All 5/16 r e, g, j, I +U,-o +U,-o +2,-0 +U,-o +3,-2 +U,-2 All 5/8 r +U,-o +U,-o a,g,j, I, m ±O +U,-o +2,-0 +U,-2 F 5/16 r g,j, I, m +U,-o +U,-o Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 90 CLAUSE 3. PREQUALIFICATION OF WPSs AWS 01.1/01.1 M:2008 See Notes on Page 75 Flare-V-groove weld (11) Butt joint (B) L ~<,---.t <, T2T i-IT (E)./ ' - tTl F f ~~~ Base Metal Thickness (U = unlimited) Welding Process SMAW FCAW-S GMAW FCAW-G SAW Joint Designation B-P11 B-P11-GF B-P11-S Tl 5 min. 5 min. 12 min. Groove Preparation Tolerances Root Opening Root Face Bend Radius As Detailed (see 3.12.3) As Fit-Up (see 3.12.3) T l min. R=O f= 5 min. 3T l . r=""""2 min. +2,-0 +U,-o +U,-o Tl min. R=O f = 5 min. 3T l . r=""""2 min. Tl min. R=O f = 12 min. 3T l . r=""""2 min. T2 Allowed Welding Positions Weld Size (E) +3,-2 +U,-2 +U,-o All 5/8 r e,j,l,m, n +2,-0 +U,-o +U,-o +3,-2 +U,-2 +U,-O All 3/4 r a,j,l,m, n ±O +U,-o +U,-O +2,-0 +U,-2 +U,-o F 1/2 r j, I, m, n Figure 3.3 (Continued)-Prequalified PJP Groove Welded Joint Details (see 3.12) (Dimensions in Millimeters) 91 Notes AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Square-groove weld (1) Butt joint (B) Corner joint (C) C-L1a B·L1a Groove Preparation Base Metal Thickness (U = unlimited) Welding Process SMAW FCAW GMAW Joint Designation T1 B-L1a 1/4 max. C-L1a 1/4 max. B-L1a-GF 3/8 max. T2 U Tolerances Root Opening As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) Allowed Welding Positions R=T1 +1/16, -0 +1/4, -1/16 All e,j R=T1 +1/16, -0 +1/4, -1/16 All e,j R=T1 +1/16, -0 +1/4, -1/16 All Gas Shielding for FCAW Not required Notes a,j Square-groove weld (1) Butt joint (B) BACKGOUGE (EXCEPT B-L1-S) ~ ~11 ~~R Groove Preparation Base Metal Thickness (U = unlimited) Welding Process SMAW GMAW FCAW SAW SAW Joint Designation T1 Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) Allowed Welding Positions T2 Root Opening +1/16, -0 +1/16, -1/8 All Gas Shielding for FCAW Notes ~ B-L1b 1/4 max. - T R=-1 2 B-L1b-GF 3/8 max. - R = 0 to 1/8 +1/16, -0 +1/16, -1/8 All B-L1-S B-L1a-S 3/8 max. 5/8 max. - - R=O R=O ±O ±O +1/16, -0 +1/16, -0 F F Figure 3.4-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 92 Not required - - d, e,j a, d,j j d,j AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Square-groove weld (1) T-joint (T) Corner joint (C) "I' ~-~ BACKGOUGE .. -'"" : ,.-, v ~-7 h 1/ T V T1 ---.L J T,-t~ Groove Preparation Base Metal Thickness (U = unlimited) Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) Allowed Welding Positions Gas Shielding for FCAW Notes T R=-1 2 +1/16, -0 +1/16, -1/8 All - d,e, g R = 0 to 1/8 +1/16, -0 +1/16, -1/8 All Not required a,d,g Welding Process Joint Designation T1 T2 Root Opening SMAW TC-L1b 1/4 max. U TC-L1-GF 3/8 max. U GMAW FCAW SAW TC-L1-S 3/8 max. U ±O R=O Single-V-grooye weld (2) Butt joint (B) 6 +1 SMAW B-U2a d,g /"'- As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +1/16,-0 IX = +10°,-0° +1/4, -1/16 +10°, _5° 1 ... Joint Designation F Tolerances I ~ Welding Process +1/16, -0 - Base Metal Thickness (U = unlimited) T1 T2 U - GMAW FCAW B-U2a-GF U - SAW SAW B-L2a-S B-U2-S 2 max. U - --R Groove Preparation Root Opening Groove Angle R = 1/4 R= 3/8 R = 1/2 R = 3/16 R = 3/8 R = 1/4 R = 1/4 R = 5/8 IX = 45° IX= 30° IX= 20° IX= 30° IX= 30° IX = 45° IX= 30° IX= 20° Allowed Welding Positions All F, V, OH F,V,OH F,V,OH F, V,OH F, V,OH F F Gas Shielding for FCAW Required Not req. Not req. - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 93 Notes e, j e, j e,j a,j a,j a,j j j AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-V-groove weld (2) Corner joint (C) Tolerances I I /""-. tal T As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +1/16,-0 a = +10°, _0° +1/4, -1/16 +10°, _5° T1 .-L ~ Welding Process Joint Designation T+" Base Metal Thickness (U = unlimited) T1 T2 SMAW C-U2a U U GMAW FCAW C-U2a-GF U U SAW SAW C-L2a-S C-U2-S 2 max. U U U Groove Preparation Root Opening Groove Angle a=45° a=30° a=20° a= 30° a= 30° a=45° a= 30° a= 20° R = 1/4 R =3/8 R = 1/2 R = 3/16 R=3/8 R = 1/4 R = 1/4 R =5/8 Single-V-groove weld (2) Butt joint (B) ~ 'Ca~ Welding Process Joint Designation T1 T2 SMAW B-U2 U - GMAW FCAW B-U2-GF U - SAW B-L2c-S Over 1/2 to 1 - Over 1 to 1-1/2 - Over 1-1/2 to 2 - Gas Shielding for FCAW - All F, V,OH F, V, OH Required Not req. Not req. F, V,OH F, V, OH F, V,OH F F - Notes e, j e, j e,j a a,j a,j j j BACKGOUGE ~t "'l RJ Base Metal Thickness (U = unlimited) ~ /""-. Allowed Welding Positions L f TI T1 Groove Preparation Tolerances Root Opening Root Face Groove Angle R = 0 to 1/8 f=Oto1/8 a= 60° R = 0 to 1/8 f=Oto 1/8 a= 60° R=O f = 1/4 max. a= 60° R=O f = 1/2 max. a= 60° R=O f = 5/8 max. a= 60° As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) +1/16,-0 +1/16,-0 +10°, _0° +1/16,-0 +1/16,-0 +10°, _0° +1/16, -1/8 Not limited +10°, _5° +1/16, -1/8 Not limited +10°, _5° R=±O f = +O,-f a=+10°,-o° +1/16, -0 ±1/16 +10°, _5° Allowed Welding Positions All All F Gas Shielding for FCAW " - Not required - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 94 Notes d, e, j a, d,j d, j AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-V-groove weld (2) Corner joint (C) ""~-~ A /"". a 'C 2 ~ BACKGOUGE ~~-hT' Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW C-U2 U U GMAW FCAW C-U2-GF U U SAW C-U2b-S U U Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = 0 to 1/8 f=Oto1/8 a= 60° R = 0 to 1/8 f = 0 to 1/8 a= 60° R=Oto1/8 f = 1/4 max. a= 60° +1/16, -0 +1/16, -0 +10°, _0° +1/16, -0 +1/16, -0 +10°, -00 ±O +0, -1/4 +10°, -00 +1/16,-1/8 Not limited +10°, _5° +1/16, -1/8 Not limited +10°,-5° +1/16, -0 ±1/16 +10°,-5° Allowed Welding Positions All - Not required a, d, g, j F - d, g, j \a-v ~+ ~:~ Joint Designation T1 As Detailed (see 3.13.1) BACKGOUGE Spacer Base Metal Thickness (U = unlimited) Welding Process d, e, g,j Tolerances J fJ r - Notes All Double-V-groove weld (3) Butt joint (B) t Gas Shielding for FCAW T2 Groove Preparation R=±O f= ±O a=+10°,-o° SAW ±O SMAW ±O As Fit-Up (see 3.13.1) +1/4, -0 +1/16, -0 +10°, _5° +1/16, -0 +1/8, -0 Allowed Welding Positions Gas Shielding for FCAW Root Opening Root Face Groove Angle f=Oto1/8 f = 0 to 1/8 f = 0 to 1/8 a=45° a= 30° a=20° All F, V,OH F, V,OH - d, e, h, j f = 0 to 1/4 a=20° F - d, h,j SMAW B·U3a U Spacer = 1/8 x R - R = 1/4 R = 3/8 R = 1/2 SAW B-U3a-S U Spacer = 1/4 x R - R = 5/8 Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 95 Notes CLAUSE 3. PREQUALlFICATION OF WPSs AWS D1.1/D1.1 M:2008 See Notes on Page 75 Double-V-groove weld (3) Butt joint (B) ""'-/ /""'- t -1r U + For B-U3c-S only S1 L T1 I 1 , I ~R~ lS2 BACKGOUGE T f lf Welding Process Joint Designation SMAW GMAW FCAW B-U3b SAW T1 B-U3-GF B-U3c-S T2 U - U - Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) +1/16, -0 +1/16, -0 +10°, -00 +1/16, -1/8 Not limited +10°, _5° R = 0 to 1/8 f=Oto1/8 u= ~ = 60° R=O f = 1/4 min. +1/16, -0 +1/16, -0 +1/4, -0 +1/4, -0 +10°, _0° +10°, _5° u=~=60° To find S1 see table above: S2 = T 1- (S1 + f) R - J Gas Shielding for FCAW All - d, e, h,j All Not required a, d, h,j - F Notes· d, h, j 1 As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +1/16,-0 u = +10°,-0° +1/4, -1/16 +10°, _5° I -J SMAW Allowed Welding Positions Tolerances ~u Joint Designation 1-3/8 1-3/4 2-1/8 2-3/8 2-3/4 3-1/4 3-3/4 Groove Preparation Single-bevel-groove weld (4) Butt joint (B) Welding Process S1 to 2-1/2 3 3-5/8 4 4-3/4 5-1/2 6-1/4 ForT1 > 6-1/4 orT1 ::;; 2 S1 = 2/3 (T1 - 1/4) ~ Base Metal Thickness (U = unlimited) T1 Over 2 2-1/2 3 3-5/8 4 4-3/4 5-1/2 T1 Base Metal Thickness (U = unlimited) T1 T2 B-U4a U - GMAW FCAW B-U4a-GF U - SAW B-U4a-S U - ~ """Groove Preparation Root Opening Groove Angle R = 1/4 R =3/8 R = 3/16 R = 1/4 R = 3/8 R = 3/8 R = 1/4 u=45° u=30° u=30° u=45° u=30° u=30° u=45° Allowed Welding Positions Gas Shielding for FCAW All All All All F, H .Required Not req. Not req. e,j e,j a, c,j a, c,j a, c,j F - c,j Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 96 Notes C, C, AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALlFICATION OF WPSs See Notes on Page 75 • • Single-bevel-groove weld (4) T-joint (T) Corner joint (C) Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +1/16,-0 0. = +10°,-0° +1/4, -1/16 +10°, _5° R Welding Process Joint Designation SMAW TC-U4a Base Metal Thickness (U = unlimited) T1 T2 U U GMAW FCAW TC-U4a-GF U U SAW TC-U4a-S U U Single-bevel-groove weld (4) Butt joint (B) . Groove Preparation Root Opening Groove Angle = = 0. = 0. = 0. = 0. = 0. = R = 1/4 R =3/8 R = 3/16 R = 3/8 R = 1/4 R=3/8 R = 1/4 0. 0. 45° 30° 30° 30° 45° 30° 45° Allowed Welding Positions All F, V,OH All F All Gas Shielding for FCAW Required Not req. Not req. Notes e, e, a, a, a, g, j, g, j, g,j, g,j, g,j, k k k k k g,j, k F 1 I--f /\ 0. L U RJ ~ Base Metal Thickness (U = unlimited) r.- f""'\ Groove Preparation Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) U - R = 0 to 1/8 f=Ot01/8 0. = 45° +1/16, -0 +1/16, -0 +10°, -00 +1/16, -1/8 Not limited 10°, _5° U - R=O f = 1/4 max. 0. = 60° ±O +0, -1/8 +10°, -00 +1/4, -0 ±1/16 10°, _5° Joint Designation T1 T2 SMAW GMAW FCAW B-U4b U B-U4b-GF B-U4b-S BACKGOUGE I" Root Opening Root Face Groove Angle Welding Process SAW T1 Allowed Welding Positions All All F Gas Shielding for FCAW Not required - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 97 Notes c, d, e,j a, c, d,j c, d,j CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 See Notes on Page 75 Single-bevel-groove weld (4) T-joint (T) Corner joint (C) Base Metal Thickness (U = unlimited) Welding Process Joint Designation T2 T1 Groove Preparation Tolerances Root Opening Root Face Groove Angle SMAW TC-U4b U U GMAW FCAW R=Oto1/8 f = 0 to 1/8 TC-U4b-GF U U SAW TC-U4b-S U U As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) ex=45° +1/16, -0 +1/16, -0 +10°, -00 +1/16, -1/8 Not limited 10°, _5° R=O f = 1/4 max. ex= 60° ±O +0, -1/8 +10°, _0° +1/4, -0 ±1/16 10°,_5° Allowed Welding Positions Gas Shielding for FCAW Notes Not required d, e, g, j,k a, d, g, j, k All All F Double-bevel-groove weld (5) Butt joint (B) T-joint (T) Corner joint (C) d, g, j, k 1- To _l-,er_a_nc_e_s_ _----j As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = ±O f=+1/16,-o +1/4,-0 ±1/16 +1/16, -0 +1/8,-0 Spacer f Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 B-U5b U Spacer = 1/8 x R TC-U5a U Spacer = 1/4x R SMAW T2 Groove Preparation Allowed Welding Positions Root Opening Root Face Groove Angle R = 1/4 f = 0 to 1/8 ex= 45° All R = 1/4 f = 0 to 1/8 ex= 45° All Gas Shielding for FCAW U f = 0 to 1/8 R = 3/8 ex= 30° F,OH Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 98 Notes c, d, e, h,j d, e, g, h,j, k d, e, g, h,j, k " '4 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 See Notes on Page 75 ~ Double-bevel-groove weld (5) , Butt joint (B) Welding Process SMAW GMAW FCAW Groove Preparation Base Metal Thickness 1 - - - - - - - , - - - - - - - - - - - - 1 (U = unlimited) Tolerances f - - - - - - , . - - - - 1 Root Opening I - - - - - . . . . . . . - , , - - - - - - - l Allowed As Fit-Up Joint As Detailed Welding Root Face Designation (see 3.13.1) (see 3.13.1) Positions Groove Angle B-U5a U B-U5-GF +1/16, -0 +1/16, -0 R = 0 to 1/8 f=Oto 1/8 a=45° U +1/16, -1/8 Not limited p = 0° to 15° R = 0 to 1/8 f = 0 to 1/8 +1/16, -0 +1/16, -0 +1/16, -1/8 Not limited a=45° a+p= +10°, -00 a+p= a+ Notes c, d, e, All p+28: a+ P+2g: p = 0° to 15° Gas Shielding for FCAW h,j All Not required Allowed Welding Positions Gas Shielding for FCAW a, c, d, h, j +10°, _5° Double-bevel-groove weld (5) T-joint (T) Corner joint (C) BACKGOUGE Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 Groove Preparation Tolerances Root Opening Root Face Groove Angle SMAW TC-U5b U U GMAW FCAW R=Oto 1/8 f = 0 to 1/8 TC-U5-GF U U a=45° SAW TC-U5-S U U R=O f = 1/4 max. As Detailed (see 3.13.1) a= 60° As Fit-Up (see 3.13.1) +1/16, -0 +1/16, -0 +10°, -00 +1/16, -1/8 Not limited +10°, _5° ±O +0, -3/16 +10°, -00 +1/16, -0 ±1/16 +10°, _5° All All Not required F Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 99 Notes d, e, h,j, a, d, h,j, g, k g, k d, g, h, j, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS 01.1/01.1 M:2008 See Notes on Page 75 Single-U-groove weld (6) Butt joint (B) Corner joint (C) ""~-~ r----.. a~ r a_ r -L t ~ BACKGOUGE A 7 ~ 'I fTT T+" ~ Base Metal Thickness (U = unlimited) Joint Designation T1 Root Opening R = 0 to 1/8 R = 0 to 1/8 R=Oto1/8 R=Oto1/8 R=Oto1/8 R=Oto1/8 a= 45° a = 20° a=45° a= 20° a= 20° a=20° - C-U6 U U B-U6-GF C-U6-GF U U U Double-U-groove weld (7) Butt joint (B) r f r y r:"? -.- -.£T1 A Root Face f= f= f= f= f= f= 1/8 1/8 1/8 1/8 1/8 1/8 Bevel Radius r= r= r= r= r= r= 1/4 1/4 1/4 1/4 1/4 1/4 :2:"~ + f-l BACKGOUGE t T1 T2 Allowed Welding Positions Gas Shielding for FCAW - All F,OH All F,OH All All Not req. Not req. As Detailed (see 3.13.1) Notes d, e,j d, e, j d, e, g, j d, e, g, j a, d, j a, d, g, j As Fit-Up (see 3.13.1) f = +0, -1/4 r = +1/4,-0 ±1/16 ±1/16 , Base Metal Thickness (U = unlimited) Joint Designation +1/16, -1/8 +10°, _5° Not Limited +1/8, -0 For B-U7 and B-U7-GF R = +1/16,-0 +1/16, -1/8 a = +10°, _0° +10°, _5° f = +1/16,-0 Not Limited ±1/16 r= +1/4,-0 For B-U7-S R=+O +1/16,-0 +10°, _5° a= +10°,-0° a Welding Process R = +1/16,-0 a = +10°,-0° f=±1/16 r = +1/8,-0 Tolerances ."..-> J As Fit-Up (see 3.13.1) fTT T2 U As Detailed (see 3.13.1) T1 Groove Preparation SMAW GMAW FCAW t Groove Angle B-U6 BACKGOUGE A j T1 -4-R Welding Process Tolerances Groove Preparation Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions a=45° a=20° f = 1/8 f = 1/8 r = 1/4 r = 1/4 All F,OH SMAW B-U7 U - R=Oto1/8 R=Oto1/8 GMAW FCAW B-U7-GF U - R=Oto 1/8 a=20° f = 1/8 r = 1/4 All SAW B-U7-S U - R=O a=20° f = 1/4 max. r = 1/4 F Gas Shielding for FCAW Not required - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 100 Notes d, e, h, j d, e, h, j a, d, j, h d, h, j AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-J-groove weld (8) Butt joint (B) I Tolerances ~I' As Detailed (see 3.13.1) ~ a 1_ r--... L Base Metal Thickness (U = unlimited) Joint Designation T1 T2 SMAW GMAW FCAW B-U8 U B-U8-GF U - B-U8-S U - SAW Groove Preparation Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions Gas Shielding for FCAW Notes R = 0 to 1/8 a=45° f = 1/8 r = 3/8 All - c, d, e,j R = 0 to 1/8 a=30° f = 1/8 r = 3/8 All Not req. a, c, d,j R=O a=45° f = 1/4 max. r= 3/8 F Single-J-groove weld (8) T-joint (T) Corner joint (C) ~ •• J. : : r-, v " : \. ~ ;; r ---.i J T~~L ~-7 v l!J1 If t Base Metal Thickness (U = unlimited) SMAW TC-U8a T1 U T2 BACKGOUGE 1/ T1 Joint Designation As Detailed (see 3.13.1) ~_.:l. j----a Groove Preparation Root Opening Groove Angle - c, d,j Tolerances ., " .. Welding Process R BACKGOUGE h Welding Process B-U8 and B-U8-GF R = +1/16,-0 +1/16, -1/8 a = +10°,-0° +10°,-5° f = +1/8,-0 Not Limited ±1/16 r = +1/4,-0 B-U8-S R=±O +1/4, -0 a = +10°, _0° +10°, _5° f = +0, -1/8 ±1/16 r = +1/4,-0 ±1/16 ~ r As Fit-Up (see 3.13.1) Root Face Bevel Radius As Fit-Up (see 3.13.1) TC-U8a and TC-U8a-GF +1/16, -1/8 R = +1/16,-0 +10°, _5° a = +10°, _0° Not Limited f = +1/16,-0 r = +1/4,-0 ±1/16 TC-U8a-S R=±O +1/4, -0 +10°, _5° a = +10°,-0° ±1/16 f = +0, -1/8 ±1/16 r = +1/4,-0 Allowed Welding Positions Gas Shielding for FCAW R = 0 to 1/8 a = 45° f = 1/8 r = 3/8 All - R = 0 to 1/8 a = 30° f = 1/8 r = 3/8 F,OH - U GMAW FCAW TC-U8a-GF U U R = 0 to 1/8 a=30° f = 1/8 r = 3/8 All SAW TC-U8a-S U U R=O a=45° f = 1/4 max. r= 3/8 F Not required - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 101 Notes d, e, g, j, k d, e, g, j,k a, d, g, j,k d, g, j, k AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Double-J-groove weld (9) Butt joint (B) 8'1 ~~ --t ft- ex~ L - f- Base Metal Thickness (U = unlimited) Welding Process SMAW GMAW FCAW Joint Designation B-U9 B-U9-GF T1 U U T2 - S2 ~ex ~ r ~ Tolerances R = 0 to 1/8 R=Oto1/8 Double-J-groove weld (9) T-joint (T) Corner joint (C) As Fit-Up (see 3.13.1) R = +1/16,-0 ex = +10°, _0° f = +1/16,-0 r = +1/8,-0 +1/16, -1/8 +10°, _5° Not Limited ±1/16 r BACKGOUGE Groove Preparation Root Opening As Detailed (see 3.13.1) Groove Angle ex = 45° ex = 30° Root Face f = 1/8 f = 1/8 Bevel Radius r = 3/8 r = 3/8 Allowed Welding Positions Gas Shielding for FCAW All - All Not required Notes c, d, e, h,j a, c, d, h,j Tolerances ""~-~ As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +1/16,-0 +1/16, -1/8 ex = +10°, _0° f = +1/16,-0 r= 1/8,-0 Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW TC-U9a U U GMAW FCAW TC-U9a-GF U U Groove Preparation Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions R = 0 to 1/8 ex = 45° f = 1/8 r= 3/8 All R=Oto1/8 ex = 30° f = 1/8 r= 3/8 F,OH R = 0 to 1/8 ex = 30° f = 1/8 r= 3/8 All Gas Shielding for FCAW Notes Not required d, e, g, h, j, k d, e, g, h,k a, d, g, h, j, k Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Inches) 102 Not Limited ±1/16 AWS 01.1/01.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 • Square-groove weld (1) . , Butt joint (B) Corner joint (C) B-L1a ALL DIMENSIONS IN mm C-L1a Groove Preparation Base Metal Thickness (U == unlimited) Welding Process SMAW FCAW GMAW Joint Designation T1 B-L1a 6 max. C-L1a 6 max. B-L1a-GF T2 U Tolerances Root Opening As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) Allowed Welding Positions R=T1 +2,-0 +6,-2 All R=T1 +2,-0 +6,-2 All R=T1 10 max. +2,-0 +6,-2 All Gas Shielding for FCAW Notes e,j e,j Not required a,j Square-groove weld (1) Butt joint (B) BACKGOUGE (EXCEPT B-L1-S) ~ ALL DIMENSIONS IN mm ~{1 ~~R Groove Preparation Base Metal Thickness (U = unlimited) Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) Allowed Welding Positions Gas Shielding for FCAW Notes R= T 1 2 +2,-0 +2,-3 All - d, e,j R=Oto3 +2,-0 +2,-3 All R=O R=O ±O ±O +2,-0 +2,-0 F F Welding Process Joint Designation T1 T2 Root Opening SMAW B-L1b 6 max. - B-L1b-GF 10 max. B-L1-S B-L1a-S 10 max. 16 max. - GMAW FCAW SAW SAW Not required - - Figure 3.4 (Continued)-Prequalitied C.n: Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 103 a, d,j j d,j CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 See Notes on Page 75 Square-groove weld (1) T-joint (T) Corner joint (C) "~-~ "' BACKGOUGE r- "vr-1~ J ~-7 1/ T V T1 -.L J T,-t~ ALL DIMENSIONS IN mm Groove Preparation Base Metal Thickness (U = unlimited) Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) Allowed Welding Positions T R=-1 2 +2,-0 +2,-3 All U R=Oto3 +2,-0 +2,-3 All U R=O ±O +2,-0 F Welding Process Joint Designation T1 T2 Root Opening SMAW TC-L1b 6 max. U TC-L1-GF 10 max. TC-L1-S 10 max. GMAW FCAW SAW Single-V-groove weld (2) Butt joint (B) I II:};f1 d,e,g Not required - a,d,g d,g Base Metal Thickness (U = unlimited) T1 ~ As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R =+2,-0 a = +10°,-0° +6,-2 +10°, _5° 1 ... ALL DIMENSIONS IN mm Joint Designation - Notes Tolerances ~ Welding Process Gas Shielding for FCAW T2 SMAW B-U2a U - GMAW FCAW B-U2a-GF U - SAW SAW B-L2a-S B-U2-S 50 max. U - - I--R Root Opening Groove Angle Allowed Welding Positions R=6 R = 10 R = 12 R=5 R = 10 R=6 R=6 R = 16 a= 45° a=30° a=20° a= 30° a= 30° a=45° a= 30° a=20° All F, V,OH F, V,OH F, V,OH F,V,OH F, V,OH F F Groove Preparation Gas Shielding for FCAW Required Not req. Not req. - Figure 3.4 (Continued)-.Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 104 Notes e,j e,j e,j a,j a,j a,j j 1 AWS D1.1/D1.1M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-V-groove weld (2) Corner joint (C) Tolerances I I /"'" tal T As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +2,-0 a = +10°,-0° +6,-2 +10°, _5° Tl ---.L ALL DIMENSIONS IN mm Welding Process Joint Designation ~ T+ R Base Metal Thickness (U = unlimited) T1 T2 SMAW C-U2c; U U GMAW FCAW C-U2a-GF U U SAW SAW C-L2a-S C-U2-S 50 max. U U U Root Opening Groove Angle Allowed Welding Positions R=6 R = 10 R = 12 R=5 R = 10 R=6 R=6 R = 16 a= 45° a=30° a= 20° a= 30° a=30° a=45° a= 30° a= 20° All F, V,OH F, V,OH F, V, OH F,V,OH F, V,OH F F Groove Preparation Single-V-groove weld (2) Butt joint (B) r--.. /"'" 'Ca~ ~t <? RJ ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 SMAW B-U2 U - GMAW FCAW B-U2-GF U - Over 12 to 25 - Over 25 to 38 - Over 38 to 50 - SAW B-L2c-S "'l L Gas Shielding for FCAW Required Not req. Not req. - Notes e,j e,j e,j 1 a,j a,j j j BACKGOUGE f TI T1 Groove Preparation Tolerances Root Opening Root Face Groove Angle R=Ot03 f = 0 to 3 a=60° R=Ot03 f = 0 to 3 a= 60° R=O f= 6 max. a= 60° R=O f=12max. a= 60° R=O f = 16 max. a= 60° As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) +2,-0 +2,-0 +10°, -00 +2,-0 +2,-0 +10°, -00 +2,-3 Not limited +10°, _5° +2,-3 Not limited +10°, _5° R=±O f = +O,-f a = +10°,-0° +2,-0 ±2 +10°, _5° Allowed Welding Positions Gas Shielding for FCAW All - d, e,j All Not required a, d, j F - d,j Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 105 Notes CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 See Notes on Page 75 Single-V-groove weld (2) Corner joint (C) l\ "~-~ ~ /'" a 'C 2 ~-f 'l -TIT, ~ ALL DIMENSIONS IN mm T211 Base Metal Thickness (U = unlimited) Welding Process Joint Designation T2 T1 SMAW C-U2 U U GMAW FCAW C-U2-GF U U SAW C-U2b-S U U Double-V-groove weld (3) Butt joint (B) - R Groove Preparation Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R=Oto3 f = 0 to 3 a= 60° R=Oto3 f = 0 to 3 a= 60° R=Oto3 f = 6 max. a= 60° +2,-0 +2,-0 +10°, _0° +2,-0 +2,-0 +10°, _0° ±O +0,-6 +10°, -00 +2,-3 Not limited +10°, _5° +2,-3 Not limited +10°, _5° +2,-0 ±2 +10°, _5° Allowed Welding Positions Gas Shielding for FCAW - All Notes d, e, g,j All Not required a, d, g, j F - d, g, j Tolerances ~BACKGOUGE As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R=±O f= ±O +6,-0 +2,-0 +10°, _5° +2,-0 +3,-0 tav ~11 i- J fJ BACKGOUGE r l!:~ a=+10°,-o° Spacer SAW SMAW ±O ±O ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation 1 T T2 Groove Preparation Groove Angle Root Opening Root Face f = 0 to 3 f = 0 to 3 f = 0 to 3 a= 30° f = 0 to 6 SMAW B-U3a U Spacer = 1/8 x R - R=6 R = 10 R = 12 SAW B-U3a-S U Spacer = 1/4 x R - R,. 16 a=45° Allowed Welding Positions Gas Shielding for FCAW a=20° - d, e, h, j a= 20° F - d, h, j Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 106 Notes All F, V,OH F, V,OH CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 See Notes on Page 75 Double-V-groove weld (3) Butt joint (B) For B-U3c-S only ""-./ t -7r / a ~ SMAW GMAW FCAW B-U3t:> SAW L T1 , ........ I ~R~ lS2 t T If T2 T1 B-U3-GF B-U3c-S Tolerances Root Opening Root Face Groove Angle As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) +2,-0 +2,-0 +10°, -0° +2,-3 Not limited +10°, _5° U - U - +2,-0 +2, -0 +6,-0 +6,-0 +10°, _0° +10°, _5° a=~=60° To find S1 see table above: S2 = T1 - (S1 + f) R=O f= 6 min. ....r t ;"\ - 1 RJ ~ ALL DIMENSIONS IN mm Welding Process Joint Designation SMAW T1 Base Metal Thickness (U = unlimited) T1 T2 B-U4a U - GMAW FCAW B-U4a-GF U - SAW B-U4a-S U - 35 45 55 60 70 80 95 Allowed Welding Positions Gas Shielding for FCAW Notes All - d, e, h, j All Not required a, d, h, j F - d, h, j Tolerances a I S1 to 60 80 90 100 120 140 160 Groove Preparation R=Ot03 f = 0 to 3 a= ~ = 60° Single-bevel-groove weld (4) Butt joint (B) T1 Over 50 60 80 90 100 120 140 ForT1 > 1600rT1 :550 S1 = 2/3 (T1 - 6) ~ Base Metal Thickness (U = unlimited) Joint Designation S1 I ALL DIMENSIONS IN mm Welding Process BACKGOUGE ~ ~ As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +2,-0 a = +10°,-0° +6,-2 +10°, -5° I Groove Preparation Root Opening Groove Angle R=6 R = 10 R=5 R=6 R = 10 R = 10 R=6 a=45° a= 30° a= 30° a=45° a=30° a= 30° a= 45° Allowed Welding Positions Gas Shielding for FCAW All All All All F, H - F Required Not req. Not req. - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 107 Notes c, c, a, a, a, e, j e, j c, j c,j c,j c, j AWS D1.1/D1.1M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-bevel-groove weld (4) T-joint (T) Corner joint (C) A Tolerances 1--------.---1 ~ As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R=+2,-0 ex = +10°, _0° +6,-2 +10°, _5° R ALL DIMENSIONS IN mm Welding Process Joint Designation Base Metal Thickness (U = unlimited) T1 Groove Preparation T2 SMAW TC-U4a U U GMAW FCAW TC-U4a-GF U U SAW TC-U4a-S U U Single-bevel-groove weld (4) Butt joint (B) 1 Root Opening Groove Angle R=6 R = 10 R=5 R = 10 R=6 R = 10 R=6 ex = 45° ex=30° ex= 30° ex=30° ex = 45° ex= 30° ex=45° Allowed Welding Positions All F, V, OH All F All Gas Shielding for FCAW Required Not req. Not req. F Notes e, e, a, a, a, g, j, g, j, g,j, g, j, g,j, k k k k k g,j, k --f /\ex U L Rr ~ ALL DIMENSIONS IN mm T1 SMAW GMAW FCAW SAW Joint Designation T1 T2 ~ BACKGOUGE Groove Preparation Base Metal Thickness (U = unlimited) Welding Process f'\ l.- Tolerances Root Opening As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) B-U4b U B-U4b-GF U - R=Oto3 f = 0 to 3 ex = 45° +2,-0 +2,-0 +10°, -00 +2,-3 Not limited 10°, _5° B-U4b-S U - R=O f = 6 max. ex= 60° ±O +0,-3 +10°, -00 +6,-0 ±2 10°, _5° Allowed Welding Positions Gas Shielding for FCAW Notes All - c, d, e, j All Not required a, c, d, j F - c, d, j Figure 3.4 (Continued)-Prequalified eJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 108 AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 Single-bevel-groove weld (4) T-joint (T) Corner joint (C) .", ~-~ BACKGOUGE ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 SMAW TC-U4b U U GMAW FCAW TC-U4b-GF U U SAW TC-U4b-S U U Groove Preparation Root Opening Root Face Groove Angle Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R=Oto3 f = 0 to 3 a=45° +2,-0 +2,-0 +10°, _0° +2,-3 Not limited 10°, _5° R=O f=6 max. a= 60° ±O +0,-3 +10°, -00 +6,-0 ±2 10°, _5° Allowed Welding Positions Gas Shielding for FCAW Notes Not required d, e, g, j, k a, d, g, j, k All All d, g, j, k F Double-bevel-groove weld (5) Butt joint (B) T-joint (T) Corner joint (C) Tolerances ~ As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R=±O f=+2,-o +6,-0 ±2 +2,-0 +3,-0 Spacer a 1.-.. ,.~ ~ \-=1 f T, ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 B-U5b U Spacer = 1/8 x R TC-U5a U Spacer = 1/4 x R SMAW T2 Groove Preparation Root Opening Root Face Groove Angle Allowed Welding Positions R=6 f= 0 to 3 a=45° All R=6 f = 0 to 3 a=45° All R = 10 f = 0 to 3 a= 30° F,OH Gas Shielding for FCAW U Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 109 Notes c, d, e, h,j d, e, g, h, j, k d, e, g, h,j, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 See Notes on Page 75 Double-bevel-groove weld (5) Butt joint (B) ALL DIMENSIONS IN mm Welding Process SMAW Groove Preparation Base Metal Thickness 1 - - - - - - - , - - - - - - - - - - - - 1 (U = unlimited) Tolerances 1 - - - - - - , . . . - - - - 1 Root Opening I - - - - - - - - - , r - - - - - - - i Allowed As Detailed As Fit-Up Joint Root Face Welding Designation Groove Angle (see 3.13.1) (see 3.13.1) Positions B-U5a U R=Oto3 f = 0 to 3 +2,-0 +2,-0 +2,-3 Not limited a= 45° a+~= a+~= +10°, _0° +2,-0 +2,-0 +10°, _5° +2,-3 Not limited a+~= a+~= +10°, _0° +10°, _5° ~=00to15° GMAW FCAW B-U5-GF R=Oto3 f = 0 to 3 a=45° ~ = 0° to 15° U Double-bevel-groove weld (5) T-joint (T) Corner joint (C) Gas Shielding for FCAW Notes c, d, e, All h, j All Not required Allowed Welding Positions Gas Shielding for FCAW a, c, d, h,j "~-~ " BACKGOUGE ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation T1 T2 Groove Preparation Root Opening Root Face Groove Angle SMAW TC-U5b U U GMAW FCAW R=Oto3 f = 0 to 3 TC-U5-GF U U a= 45° SAW TC-U5-S U U R=O f=6 max. Tolerances As Detailed (see 3.13.1) a= 60° As Fit-Up (see 3.13.1) +2,-0 +2,-0 +10°, -00 +2,-3 Not limited +10°, _5° ±O +0,-5 +10°, _0° +2,-0 ±2 +10°, _5° All All Not required F Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 110 Notes d, e, h, j, a, d, h,j, g, k g, k d, g, h, j, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 See Notes on Page 75 Single-U-groove weld (6) Butt joint (B) Corner joint (C) ~-~ ~ o:~ r ~ BACKGOUGE A 7 Tolerances ., " 7 r ~ + T1 "'l fTT BACKGOUGE A 0: ___ ~ + T1 As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +2,-0 0:=+10°,-0° f=±2 r=+3,-0 +2,-3 +10°, _5° Not Limited +3,-0 fTT R ~ T:+ --n.-R ALL DIMENSIONS IN mm , Welding Process Base Metal Thickness (U = unlimited) Joint Designation T1 Groove Preparation T2 Root Opening Groove Angle R=Oto3 R=Oto3 R=Oto3 R=Oto3 R=Oto3 R=Oto3 0: = 45° 0: = 20° 0: = 45° 0: = 20° 0: = 20° 0: = 20° B-U6 U - C-U6 U U B-U6-GF C-U6-GF U U - SMAW GMAW FCAW U Double-U-groove weld (7) Butt joint (B) r '5\"] r .-L -.'• ..- ? l:R:\ T1 f.J y A Root Face Bevel Radius Allowed Welding Positions Gas Shielding for FCAW f=3 f=3 f=3 f=3 f=3 f=3 r=6 r= 6 r=6 r=6 r= 6 r= 6 All F,OH All F,OH All All - BACKGOUGE As Fit-Up (see 3.13.1) As Detailed (see 3.13.1) For B-U7 and B-U7-GF +2,-3 R = +2,-0 +10°, _5° 0: = +10°,-0° Not Limited f = ±2,-o ±2 r = +6,-0 For B-U7-S R=+O +2,-0 0: ALL DIMENSIONS IN mm Groove Preparation 0: = +10°,-0° +10°, _5° f = +0,-6 r = +6,-0 ±2 ±2 Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions Gas Shielding for FCAW Notes - R=Oto3 R=Oto3 0: = 45° 0: = 20° f=3 f=3 r=6 r=6 All F, OH - d, e, h, j d, e, h,j - R=Oto3 . 0: = 20° f=3 r=6 All Not required a, d, h,j f=6 max. r=6 F - d, h,j Welding Process Joint Designation T1 T2 SMAW B-U7 U B-U7-GF U B-U7-S U GMAW FCAW SAW d, e,j d, e, j d, e, g, j d, e, g,j a, d,j a, d, g,j Tolerances t Base Metal Thickness (U = unlimited) Not req. Not req. Notes R=O 0: = 20° Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 111 AWS 01.1/01.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 F l /"; Single-J-groove weld (8) Butt joint (B) Tolerances As Detailed (see 3.13.1) T1 -- f a 1_ --*- r r---.. Base Metal Thickness (U = unlimited) Groove Preparation T2 Groove Angle Root Face Bevel Radius Allowed Welding Positions - R=Oto3 a= 45° f=3 r = 10 All U - R=Oto3 a= 30° f= 3 r=10 All U - R=O a=45° f=6 max. r = 10 F Joint Designation T1 SMAW GMAW FCAW B-U8 U B-U8-GF B-U8-S Single-J-groove weld (8) T-joint (T) Corner joint (C) ..: " ....v , j--a !-. : ';; r :'io ~ h --l v T1 T;L j Welding Process Joint Designation T1 T2 SMAW TC-U8a U U BACKGOUGE ~. If t Base Metal Thickness (U = unlimited) - Groove Preparation - a, c, d, j c, d, j As Fit-Up (see 3.13.1) TC-U8a and TC-U8a-GF R = +2,-0 +2,-3 +10°, _5° a=+10°,-0° f = +2,-0 Not Limited r = +6,-0 ±1/16 TC-U8a-S R=±O +6,-0 a = +10°, _0° +10°, _5° f = +0,-3 ±2 r = +6,-0 ±2 Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions Gas Shielding for FCAW R=Oto3 a=45° f=3 r=10 All - R=Oto3 a=45° f=3 r = 10 F,OH - GMAW FCAW TC-U8a-GF U U R=Oto3 a =45° f= 3 r = 10 • All SAW TC-U8a-S U U R=O a=45° f=6 max. r = 10 F Not required - Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 112 Notes c, d, e, j Not req. As Detailed (see 3.13.1) ~-7 1/ Gas Shielding for FCAW Tolerances "I' ~-~ " ALL DIMENSIONS IN mm B-U8 and B-U8-GF +2,-3 R = +2,-0 +10°, _5° a = +10°, _0° f = +3,-0 Not Limited r = +6,-0 ±1/16 B-U8-S R=±O +3,-0 a = +10°, _0° +10°, _5° f = +0, -1/8 ±2 r = +6,-0 ±2 Root Opening Welding Process SAW BACKGOUGE h ALL DIMENSIONS IN mm lR As Fit-Up (see 3.13.1) Notes d, e, g, j, k d, e, g, j, k a, d, g, j, k d, g,j, k AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs See Notes on Page 75 • II' Double-J-groove weld (9) Butt joint (B) Tolerances As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R = +2,-0 a= +10°, _0° f = +2,-0 r = +3,-0 +2,-3 Not Limited ±2 BACKGOUGE ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process Joint Designation SMAW B-U9 GMAW FCAW B-U9-GF Groove Preparation Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions Gas Shielding for FCAW U R=Ot03 a = 45° f= 3 r = 10 All - U R = 0 to 3 a= 30° f=3 r=10 All Not required Double-J-groove weld (9) T-joint (T) Corner joint (C) Notes c, d, e, h, j a, c, d, h, j Tolerances ., '" ~-~ As Detailed (see 3.13.1) As Fit-Up (see 3.13.1) R =+2,-0 +2,-3 f = +2,-0 r = 3,-0 Not Limited ±2 ALL DIMENSIONS IN mm Base Metal Thickness (U = unlimited) Welding Process SMAW GMAW FCAW Joint Designation TC-U9a TC-U9a-GF T1 U U T2 Groove Preparation Root Opening Groove Angle Root Face Bevel Radius Allowed Welding Positions R=Ot03 a=45° f= 3 r = 10 All R=Ot03 a=30° f= 3 r=10 F,OH R=Ot03 a=30° f=3 r = 10 All Gas Shielding for FCAW U U Not required Figure 3.4 (Continued)-Prequalified CJP Groove Welded Joint Details (see 3.13) (Dimensions in Millimeters) 113 Notes d, e, h, j, d, e, h, j, a, d, h, j, g, k g, k g, k CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 HEEL ZONE TOE ZONE TRANSITION ZONE (A) CIRCULAR CONNECTION MITER CUT FOR '¥ < 60 0 TOE OF WELD BEVEL CORNER TRANSITION PLAN SECTION (B) STEPPED BOX CONNECTION TOE ZONE HEEL ZONE CORNER TRANSITION CORNER TRANSITION <t -,--TOE OF WELD MITER CUT BRANCH END ADDITIONAL BEVEL (C) MATCHED BOX CONNECTION Figure 3.5-Prequalified Joint Details for PJP T·, Y·, and K-Tubular Connections (see 3.12.4) 114 G AWS 01.1/01.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs 1.5t MIN. THIS LINE TANGENT ATW.P. THIS LINE TANGENT ATW.P. 1.5t MIN. TRANSITION B TRANSITION A THIS LINE TANGENT AT w.P. TRANSITION OR HEEL SKETCH FOR ANGULAR DEFINITION 150° 2': 'P 2': 30° 90° > cjl2': 30° HEEL Figure 3.5 (Continued)-Prequalified Joint Details for PJP T·, Y·, and K·Tubular Connections (see 3.12.4) 115 AWS D1.1/D1.1 M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs 'I' = 150°-1 05° 'I' = 105°-90° 'I' = 90°-75° TOE TOE OR HEEL SIDE OR HEEL CORNER DIMENSION C ~ t b + 1/8 in [3 mm] AND r ~ 2tb OR ROOT OPENING ~ 1/16 in [2 mm] OR SEE 3.12.4.1 r = RADIUS 1.5 tb MIN. OR AS REQUIRED TO FLUSH OUT (WHICHEVER IS LESS) THIS LINE TANGENT ATWP. TOE CORNER SIDE MATCHED Notes: 1. t = thickness of thinner section. 2. Bevel to feather edge except in transition and heel zones. 3. Root opening: 0 in to 3/16 in [5 mm]. 4. Not prequalified for under 30°. 5. Weld size (effective throat) tw ~ t; Z Loss Dimensions shown in Table 2.g. 6. Calculations per 2.24.1.3 shall be done for leg length less than 1.5t, as shown. 7. For Box Section, joint preparation for corner transitions shall provide a smooth transition from one detail to another. Welding shall be carried continuously around corners, with corners fully built up and all weld starts and stops within flat faces. 8. See Annex K for definition of local dihedral angle, '1'. 9. WP. = work point. Figure 3.5 (Continued)-Prequalified Joint Details for PJP T-, Y-, and K-Tubular Connections (see 3.12.4) 116 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 HEEL DETAIL B, C, OR D FIGURE 3.8 DEPENDING ON '¥ (SEE TABLE 3.5) TOE DETAIL A OR B FIGURE 3.8 CORNER TRANSITION CORNER TRANSITION SIDE DETAIL B FIGURE 3.8 STEPPED BOX CONNECTION ROOT FACE -I I- 0 TO 0.10 in [2.5 mm] HEEL DETAIL B, C, OR D FIGURE 3.8 DEPENDING ON '¥ (SEE TABLE 3.5) TOE DETAILAOR B FIGURE 3.8 CORNER TRANSITION CORNER TRANSITION SIDE DETAIL B FIGURE 3.8 (SEE ALTERNATE DETAIL B FOR MATCHED BOX CONNECTIONS) POINT OF TANGENCY IN LINE WITH INSIDE OF BRANCH TUBE ALTERNATE DETAIL B (FOR MATCHED BOX SECTIONS) MATCHED BOX CONNECTION Notes: 1. Details A, B, C, D as shown in Figure 3.8 and all notes from Table 3.6 apply. 2. Joint preparation for corner welds shall provide a smooth transition from one detail to another. Welding shall be carried continuously around corners, with corners fully built up and all arc starts and stops within flat faces. 3. References to Figure 3.8 include Figures 3.9 and 3.10 as appropriate to thickness (see 2.20.6.7). Figure 3.6-Prequalified Joint Details for CJP T-, Y-, and K-Tubular Connections (see 3.13.4) 117 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 AREA FOR DETAIL C ORD MAIN MEMBER Figure 3.7-Definitions and Detailed Selections for Prequalified CJP T-, Y-, and K- Tubular Connections (see 3.13.4 and Table 3.5) 118 CLAUSE 3. PREOUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 ROOT FACE 0-1/16 in [2 mm] BUILD UP AS REOUIREDTO MAINTAIN t w F VARIES FROM OTO tb/2 AS '¥ VARIES FROM 135° TO 90° F '¥ = 150°-90° DETAIL B DETAIL A BACK UPWELD F = tb/2 BACK UP WELD BACK UP WELD F = tb/2 F = tb/2 TRANSITION FROM CTO 0 DETAIL 0 '¥ = 75°-30° DETAILC Notes: 1. See Table 3.6 for dimensions t w' L, R, W, 0>, $. 2. Minimum standard flat weld profile shall be as shown by solid line. 3. A concave profile, as shown by dashed lines, shall also be applicable. 4. Convexity, overlap, etc. shall be subject to the limitations of 5.24. 5. Branch member thickness, t b , shall be subject to limitations of 2.20.6.7. Figure 3.8-Prequalified Joint Details for CJP Groove Welds in Tubular T-, Y-, and K-Connections-Standard Flat Profiles for Limited Thickness (see 3.13.4) 119 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1M:2008 ROOT FACE 0-1/16 in. [2 mm] BUILD UP AS REQUIRED TO MAINTAIN tw t R DETAIL A DETAIL B BACK UP WELD INSIDE BEVEL OPTIONAL F t T tw F BACK UP WELD T tw t _ F w 'P = 75°-30° 'P= 45°-30° 'P = 40°-15° DETAIL C TRANSITION FROM CTO D DETAIL D F Notes: 1. Sketches illustrate alternate standard profiles with toe fillet. 2. See 2.20.6.7 for applicable range of thickness tb . 3. Minimum fillet weld size, F = tJ2, shall also be subject to limits of Table 5.8. 4. See Table 3.6 for dimensions t w ' L, R, W, 0), <\>. 5. Convexity and overlap shall be subject to the limitations of 5.24. 6. Concave profiles, as shown by dashed lines shall also be acceptable. Figure 3.9-Prequalified Joint Details for CJP Groove Welds in Tubular T-, Y-, and K-Connections-Profile with Toe Fillet for Intermediate Thickness (see 3.13.4) 120 CLAUSE 3. PREQUALIFICATION OF WPSs AWS D1.1/D1.1 M:2008 MIN RADIUS tb/2 BUILD UP AS REQUIRED TO MAINTAIN tW7 ~ 0):Jf <I> tb MIN RADIUS tb/2 'P ROOT FACE 0-1/16 in [2 mm] ~--~~ t T R DETAIL B DETAIL A INSIDE BEVEL OPTIONAL FOR 'P < 45° • • MIN. RADIUS tb/2 BACK UP WELD MADE FROM OUTSIDE BACK UP WELD MADE FROM OUTSIDE BACK UP WELD MADE FROM OUTSIDE MIN. RADIUS \2 tb/ / I ~ <I> AND 'P ~-+ tw tw tw THEORETICAL WELD THEORETICAL WELD. THEORETICAL WELD 'P = 75°-30° 'P = 45°-30° 'P = 40°-15° DETAIL C TRANSITION FROM CTO D DETAIL D Notes: 1. Illustrating improved weld profiles for 2.20.6.6(1) as welded and 2.20.6.6(2) fully ground. 2. For heavy sections or fatigue critical applications as indicated in 2.20.6.7. 3. See Table 3.6 for dimensions tb, L, R, W, ro, <1>. Figure 3.10-Prequalified Joint Details for CJP Groove Welds in Tubular T-, Y-, and K-Connections-Concave Improved Profile for Heavy Sections or Fatigue (see 3.13.4) 121 AWS D1.1/D1.1M:2008 CLAUSE 3. PREQUALIFICATION OF WPSs (B) (A) (0) (See Note b) a Detail (D). Apply Z loss dimension of Table 2.2 to determine effective throat. b Detail (D) shall not be prequalified for under 30°. For welder qualifications, see Table 4.10. Notes: 1. (En)' (E'n) = Effective throats dependent on magnitude of root opening (R n) (see 5.22.1). (n) represents 1 through 5. 2. t = thickness of thinner part 3. Not prequalified for GMAW-S or GTAW. Figure 3.11-Prequalified Skewed T-Joint Details (Nontubular) (see 3.9.3) 122 AWS D1.1/D1.1M:2008 4. Qualification 4.0 Scope this code to qualify the WPS. Properly documented WPSs qualified under the provisions of this code by a company that later has a name change due to voluntary action or consolidation with a parent company may utilize the new name on its WPS documents while maintaining the supporting PQR qualification records with the old company name. The requirements for qualification testing of welding procedure specifications (WPSs) and welding personnel are described as follows: Part A-General Requirements. This part covers general requirements of both WPS and welding personnel performance requirements. 4.1.1.2 WPS Qualification to Other Standards. The acceptability of qualification to other standards is the Engineer's responsibility, to be exercised based upon the specific structure, or service conditions, or both. AWS B2.1-X-XXX Series on Standard Welding Procedure Specifications may, in this manner, be accepted for use in this code. Part B-Welding Procedure Specification (WPS). This part covers the qualification of a WPS that is not classified as prequalified in conformance with Clause 3. ~ Part C-Performance Qualification. This part covers , the performance qualification tests required by the code to determine a welder's, welding operator's, or tack welder's ability to produce sound welds. 4.1.1.3 CVN Test Requirements. When required by contract documents, CVN tests shall be included in the WPS qualification. The CVN tests, requirements, and procedure shall be in conformance with the provisions of Part D of this section, or as specified in the contract documents. Part D-Requirements for CVN Testing. This part covers general requirements and procedures for CVN testing when specified by the contract document. 4.1.2 Performance Qualification of Welding Personnel. Welders, welding operators and tack welders to be employed under this code, and using the shielded arc welding SMAW, SAW, GMAW, GTAW, FCAW, ESW, or EGW processes, shall have been qualified by the applicable tests as described in Part C of this section (see Commentary). Part A General Requirements 4.1 General The requirements for qualification testing of WPSs and welding personnel (defined as welders, welding operators, and tack welders) are described in this section. 4.1.2.1 Previous Performance Qualification. Previous performance qualification tests of welders, welding operators, and tack welders that are properly documented are acceptable with the approval of the Engineer. The acceptability of performance qualification to other standards is the Engineer's responsibility, to be exercised based upon the specific structure, or service conditions, or both. 4.1.1 Welding Procedure Specification (WPS). Except for prequalified WPSs in conformance with Clause 3, a WPS'for use in production welding shall be qualified in conformance with Clause 4, Part B. Properly documented evidence of previous WPS qualification may be ~ used. , 4.1.2.2 Qualification Responsibility. Each manufacturer or Contractor shall be responsible for the qualification of welders, welding operators and tack welders, 4.1.1.1 Qualification Responsibility. Each manufacturer or Contractor shall conduct the tests required by 123 CLAUSE 4. QUALIFICATION PARTSA&B AWS 01.1/01.1 M:2008 PartB Welding Procedure Specification (WPS)4 whether the qualification is conducted by the manufacturer, Contractor, or an independent testing agency. 4.1.3 Period of Effectiveness 4.1.3.1 Welders and Welding Operators. The welder's or welding operator's qualification as specified in this code shall be considered as remaining in effect indefinitely unless (1) the welder is not engaged in a given process of welding for which the welder or welding operator is qualified for a period exceeding six months or unless (2) there is some specific reason to question a welder's or welding operator's ability (see 4.32.1). 4.3 Production Welding Positions Qualified 4.1.3.2 Tack Welders. A tack welder who passes the test described in Part C or those tests required for welder qualification shall be considered eligible to perform tack welding indefinitely in the positions and with the process for which the tack welder is qualified unless there is some specific reason to question the tack welder's ability (see 4.32.2). The type and number of qualification tests required to qualify a WPS for a given thickness, diameter, or both, shall conform to Table 4.2 (CJP), Table 4.3 (PJP) or Table 4.4 (fillet). Details on the individual NDT and mechanical test requirements are found in the following subclauses: The production welding positions qualified by a WPS shall conform to the requirements of Table 4.1. 4.4 Type of Qualification Tests (1) Visual Inspection (see 4.8.1) (2) NDT (see 4.8.2) 4.2 Common Requirements for WPS and Welding Personnel Performance Qualification (3) Face, root and side bend (see 4.8.3.1) (4) Reduced Section Tension (see 4.8.3.4) (5) All-Weld-Metal Tension (see 4.8.3.6) 4.2.1 Qualification to Earlier Editions. Qualifications which were performed to and met the requirements of earlier editions of AWS D1.1 or AWS D 1.0 or AWS D2.0 while those editions were in effect are valid and may be used. The use of earlier editions shall be prohibited for new qualifications in lieu of the current editions, unless the specific early edition is specified in the contract documents. (6) Macroetch (see 4.8.4) 4.5 Weld Types for WPS Qualification For the purpose of WPS qualification, weld types shall be classified as follows: (1) CJP groove welds for Nontubular Connections (see 4.9) 4.2.2 Aging. When allowed by the filler metal specification applicable to weld metal being tested, fully welded qualification test specimens may be aged at 200°F to 220°F [95°C to 105°C] for 48 ± 2 hours. (2) PJP groove welds for Nontubular Connections (see 4.10) 4.2.3 Records. Records of the test results shall be kept by the manufacturer or Contractor and shall be made available to those authorized to examine them. (3) Fillet Welds for Tubular and Nontubular Connections (see 4.11) (4) CJP groove welds for Tubular Connections (see 4.12) 4.2.4 Positions of Welds. All welds shall be classified as flat (F), horizontal (H), vertical (V), and overhead (OH), in conformance with the definitions shown in Figures 4.1 and 4.2. (5) PJP groove welds for Tubular T-, Y-, and Kconnections and Butt Joints (see 4.13) (6) Plug and Slot welds for Tubular and Nontubular Connections (see 4.14) Test assembly positions are shown in: (1) Figure 4.3 (groove welds in plate) (2) Figure 4.4 (groove welds in pipe or tubing) 4.6 Preparation of WPS (3) Figure 4.5 (fillet welds in plate) 6nr The manufacturer or Contractor shall prepare a written.,i WPS that specifies all of the applicable essential vari- (4) Figure 4.6 (fillet welds in pipe or tubing) 124 AWS D1.1/D1.1M:2008 • II' PARTB abIes referenced in 4.7. The specific values for these WPS variables shall be obtained,~ from the procedure qualification record (PQR), which shall serve as written confirmation of a successful WPS qualification. 4.8 Methods of Testing and Acceptance Criteria for WPS Qualification 4.7 Essential Variables The welded test assemblies conforming to 4.8.2 shall have test specimens prepared by cutting the test plate, pipe, or tubing as shown in Figures 4.7 through 4.11, whichever is applicable. The test specimens shall be prepared for testing in conformance with Figures 4.12, 4.13, 4.14, and 4.18, as applicable. 4.7.1 SMAW, SAW, GMAW, GTAW, and FCAW. Changes beyond the limitations of PQR essential variables for the SMAW, SAW, GMAW, GTAW, and FCAW processes shown in Table 4.5 and Table 4.6 (when CVN testing is specified) shall require requalification of the WPS (see 4.1.1.3). 4.8.1 Visual Inspection of Welds. The visual acceptable qualification for qualification of groove and fillet welds (excluding weld tabs) shall conform to the following requirements, as applicable: 4.7.2 ESW and EGW. See Table 4.7 for the PQR essential variable changes requiring WPS requalification for the EGW and ESW processes. 4.8.1.1 Visual Inspection of Groove Welds. Groove welds shall meet the following requirements: (1) Any crack shall be unacceptable, regardless of size. 4.7.3 Base-Metal Qualification. WPSs requiring qualification that use base metals listed in Table 3.1 shall qualify other base metal groups in conformance with Table 4.8. WPSs for base metals not listed in Table 3.1 or Table 4.9 shall be qualified in conformance with Clause 4. The use of unlisted base metals shall be approved by the Engineer. (2) All craters shall be filled to the full cross section of the weld. (3) Weld reinforcement shall not exceed 1/8 in [3 mm]. The weld profile shall conform to Figure 5.4 and shall have complete fusion. ~ WPSs with steels listed in Table 4.9 shall also qualify (4) Undercut shall not exceed 1/32 in [1 mm]. Table 3.1 or Table 4.9 steels in conformance with Table 4.8. Table 4.9 contains recommendations for matching strength filler metal and minimum preheat and interpass temperatures for ASTM A 514, A 517, A 709 Grades 100 and 100W, ASTM A 710 Grade A (Class 1 and 3) steels, and ASTM A 871 Grades 60 and 65. (5) The weld root for CJP grooves shall be inspected, and shall not have any cracks, incomplete fusion, or inadequate joint penetration. (6) For CJP grooves welded from one side without backing, root concavity or melt through shall conform to the following: 4.7.4 Preheat and Interpass Temperature. The minimum preheat and interpass temperature should be established on the basis of steel composition as shown in Table 3.1. Alternatively, recognized methods of prediction or guidelines such as those provided in Annex I, or other methods may be used. Preheat and interpass temperatures lower than required per Table 3.2 or calculated per Annex I may be used provided they are approved by the Engineer and qualified by WPS testing. • • CLAUSE 4. QUALIFICATION (a) The maximum root concavity shall be 1/16 in [2 mm], provided the total weld thickness is equal to or greater than that of the base metal. (b) The maximum melt-through shall be 1/8 in [3 mm] except for tubular T-, Y-, and K-connections, where melt through is not limited. 4.8.1.2 Visual Inspection of Fillet Welds. Fillet welds shall meet the following requirements: The methods of Annex I are based on laboratory cracking tests and may predict preheat temperatures higher than the minimum temperature shown in Table 3.2. Annex I may be of value in identifying situations where the risk of cracking is increased due to composition, restraint, hydrogen level or lower welding heat input where higher preheat may be warranted. Alternatively, Annex I may assist in defining conditions under which hydrogen cracking is unlikely and where the minimum requirements of Table 3.2 may be safely relaxed. (1) Any crack shall be unacceptable, regardless of size. (2) All craters shall be filled to the full cross section of the weld. (3) The fillet weld leg sizes shall not be less than the required leg sizes. (4) The weld profile shall meet the requirements of Figure 5.4. 125 CLAUSE 4. QUALIFICATION PARTB (5) Base metal undercut shall not exceed 1/32 in AWS 01.1/01.1 M:2008 is applicable. The test specimens for the longitudinal bend • test shall be prepared for testing as shown in Figure 4.12. . . [1 mm]. 4.8.3.3 Acceptance Criteria for Bend Tests. The convex surface of the bend test specimen shall be visually examined for surface discontinuities. For acceptance, the surface shall contain no discontinuities exceeding the following dimensions: 4.8.2 NDT. Before preparing mechanical test specimens, the qualification test plate, pipe, or tubing shall be nondestructively tested for soundness as follows: 4.8.2.1 RT or UT. Either RT or UT shall be used. The entire length of the weld in test plates, except the discard lengths at each end, shall be examined in conformance with Clause 6, Part E or F. For tubulars, the full circumference of the completed weld shall be examined in conformance with Clause 6, Part C. (1) 1/8 in [3 mm] measured in any direction on the surface (2) 3/8 in [10 mm]-the sum of the greatest dimensions of all discontinuities exceeding 1/32 in [l mm], but less than or equal to 1/8 in [3 mm] 4.8.2.2 RT or UT Acceptance Criteria. For acceptable qualification, the weld, as revealed by RT or UT, shall conform to the requirements of Clause 6, Part C. (3) 1/4 in [6 mm]-the maximum comer crack, except when that comer crack results from visible slag inclusion or other fusion type discontinuity, then the 1/8 in [3 mm] maximum shall apply 4.8.3 Mechanical Testing. Mechanical testing shall be as follows: Specimens with comer cracks exceeding 1/4 in [6 mm] with no evidence of slag inclusions or other fusion type discontinuity shall be disregarded, and a replacement test specimen from the original weldment shall be tested. 4.8.3.1 Root, Face, and Side Bend Specimens (see Figure 4.12 for root and face bends, Figure 4.13 for side bends). Each specimen shall be bent in a bend test jig that meets the requirements shown in Figures 4.15 through 4.17 or is substantially in conformance with those figures, provided the maximum bend radius is not exceeded. Any convenient means may be used to move the plunger member with relation to the die member. 4.8.3.4 Reduced-Section Tension Specimens (see Figure 4.14). Before testing, the least width and corresponding thickness of the reduced section shall be measured. The specimen shall be ruptured under tensile load, ~.• and the maximum load shall be determined. The cross- • sectional area shall be obtained by multiplying the width by the thickness. The tensile strength shall be obtained by dividing the maximum load by the cross-sectional area. The specimen shall be placed on the die member of the jig with the weld at midspan. Face bend specimens shall be placed with the face of the weld directed toward the gap. Root bend and fillet weld soundness specimens shall be placed with the root of the weld directed toward the gap. Side bend specimens shall be placed with that side showing the greater discontinuity, if any, directed toward the gap. 4.8.3.5 Acceptance Criteria for Reduced-Section Tension Test. The tensile strength shall be no less than the minimum of the specified tensile range of the base metal used. The plunger shall force the specimen into the die until the specimen becomes U-shaped. The weld and HAZs shall be centered and completely within the bent portion of the specimen after testing. When using the wraparound jig, the specimen shall be firmly clamped on one end so that there is no sliding of the specimen during the bending operation. The weld and HAZs shall be completely in the bent portion of the specimen after testing. Test specimens shall be removed from the jig when the outer roll has been moved 180 0 from the starting point. 4.8.3.6 All-Weld-Metal Tension Specimen (see Figure 4.18). The test specimen shall be tested in conformance with ASTM A 370, Mechanical Testing of Steel Products. .. 4.8.4 Macroetch Test. The weld test specimens shall be prepared with a finish suitable for macroetch examination. A suitable solution shall be used for etching to give a clear definition of the weld. 4.8.4.1 Acceptance Criteria for Macroetch Test. For acceptable qualification, the test specimen, when inspected visually, shall conform to the following requirements: 4.8.3.2 Longitudinal Bend Specimens. When material combinations differ markedly in mechanical bending properties, as between two base materials or between the weld metal and the base metal, longitudinal bend tests (face and root) may be used in lieu of the transverse face and root bend tests. The welded test assemblies conforming to 4.8.2 shall have test specimens prepared by cutting the test plate as shown in Figure 4.10 or 4.11, whichever (1) PIP groove welds; the actual weld size shall be equal to ~r greater than the specifi~d weld size, (E). ~] (2) FIllet welds shall have fusIOn to the root of the • joint, but not necessarily beyond. 126 PARTB AWS D1.1/D1.1M:2008 4.10.2 Weld Size Verification by Macroetch. For WPSs which conform in all respects to Clause 4, three macroetch cross section specimens shall be prepared to demonstrate that the designated weld size (obtained from the requirements of the WPS) are met. .. (3) Minimum leg size shall meet the specified fillet , weld size. (4) The PIP groove welds and the following: fill~t welds shall have (a) no cracks 4.10.3 Verification of CJP Groove WPS by Macroetch. When a WPS has been qualified for a CJP groove weld and is applied to the welding conditions of a PIP groove weld, three macroetch cross section tests specimens shall be required to demonstrate that the specified weld size shall be equalled or exceeded. (b) thorough fusion between adjacent layers of weld metal and between weld metal and base metal (c) weld profiles conforming to specified detail, but with none of the variations prohibited in 5.24 4.10.4 Other WPS Verifications by Macroetch. If a WPS is not covered by either 4.10.2 or 4.10.3, or if the welding conditions do not meet a prequalified status, or if these have not been used and tested for a CIP weld in a butt joint, then a sample joint shall be prepared and the first operation shall be to make a macroetch test specimen to determine the weld size of the joint. Then, the excess material shall be machined off on the bottom side of the joint to the thickness of the weld size. Tension and bend test specimens shall be prepared and tests performed, as required for CJP groove welds (see 4.9). (d) no undercut exceeding 1/32 in [1 mm] 4.8.5 Retest. If anyone specimen of all those tested fails to meet the test requirements, two retests for that particular type of test specimen may be performed with specimens cut from the same WPS qualification material. The results of both test specimens shall meet the test requirements. For material over 1-1/2 in [38 mm] thick, failure of a specimen shall require testing of all specimens of the same type from two additional locations in the test material. 4.10.5 Flare-Groove Welds. The effective weld sizes for qualified flare-groove welds shall be determined by the following: 4.9 CJP Groove Welds for Nontubular Connections - CLAUSE 4. QUALIFICATION (1) Test sections shall be used to verify that the effective weld size is consistently obtained. See Table 4.2(1) for the requirements for qualifying a WPS of a CJP weld on nontubular connections. See Figures 4.9-4.11 for the appropriate test plate. (2) For a given set of WPS conditions, if the Contractor has demonstrated consistent production of larger effective weld sizes than those shown in Table 2.1, the Contractor may establish such larger effective weld sizes by qualification. 4.9.1.1 Corner or T-Joints. Test specimens for groove welds in comer or T-joints shall be butt joints having the same groove configuration as the comer or T-joint to be used on construction, except the depth of groove need not exceed 1 in [25 mm]. (3) Qualification required by (2) shall consist of sectioning the radiused member, normal to its axis, at midlength and ends of the weld. Such sectioning shall be made on a number of combinations of material sizes representative of the range used by the Contractor in construction. 4.10 PJP Groove Welds for Nontubular Connections 4.10.1 Type and Number of Specimens to be Tested. The type and number of specimens that shall be tested to qualify a WPS are shown in Table 4.3. A sample weld shall be made using the type of groove design and WPS to be used in construction, except the depth of groove need not exceed 1 in [25 mm]. For the macroetch test required below, any steel of Groups I, II, and III of Table 3.1 may be used to qualify the weld size on any steels or combination of steels in those groups. If the PJP groove weld is to be used for comer or T-joints, the butt joint shall have a ~ temporary restrictive plate in the plane of the square face , to simulate the T-joint configuration. The sample welds shall be tested as follows: 4.11 Fillet Welds for Tubular and Nontubular Connections 4.11.1 Type and Number of Specimens. Except as allowed elsewhere in Clause 4, the type and number of specimens that shall be tested to qualify a single-pass fillet weld and/or multiple-pass fillet weld WPS are shown in Table 4.4. Qualification testing may be for either a single-pass fillet weld or multiple-pass fillet weld or both. 4.11.2 Fillet Weld Test. A fillet welded T-joint, as shown in Figure 4.19 for plate or Figure 4.20 for pipe 127 CLAUSE 4. QUALIFICATION PARTB (Detail A or Detail B), shall be made for each WPS and position to be used in construction. Testing is required for the maximum size single-pass fillet weld and the minimum size multiple-pass fillet weld used in construction. These two fillet weld tests may be combined in a single test weldment or assembly or individually qualified as stand alone qualifications. Each weldment shall be cut perpendicular to the direction of welding at locations shown in Figure 4.19 or Figure 4.20 as applicable. Specimens representing one face of each cut shall constitute a macroetch test specimen and shall be tested in conformance with 4.8.4. AWS D1.1/D1.1 M:2008 conform to the requirements of Table 2.3 or the base •. metal strength level being welded. ,. 4.12 CJP Groove Welds for Tubular Connections CJP groove welds shall be classified as follows: (1) CJP butt joints with backing or backgouging (see 4.12.1). (2) CJP butt joints without backing welded from one side only (see 4.12.2). 4.11.3 Consumables Verification Test. If both the proposed welding consumable and the proposed WPS for welding the fillet weld test plate or test pipe described in 4.11.2 are neither prequalified nor otherwise qualified by Clause 4, that is: (3) T-, Y-, K-connections with backing or backgouging (see 4.12.3). (4) T-, Y-, K-connections without backing welded from one side only (see 4.12.4). (1) If the welding consumables used do not conform to the prequalified provisions of Clause 3, and also 4.12.1 CJP Butt Joints with Backing or Backgouging. A WPS with backing or backgouging shall be qualified using the detail shown in Figure 4.25(A) (with backgouging) or Figure 4.25(B) (with backing). (2) If the WPS using the proposed consumable has not been established by the Contractor in conformance with either 4.9 or 4.10, then a CJP groove weld test plate shall be welded to qualify the proposed combination. 4.12.2 CJP Butt Joints without Backing Welded from One Side Only. A WPS without backing welded from one side only shall be qualified using the joint detail "'. shown in Figure 4.25(A). • The test plate shall be welded as follows: (1) The test plate shall have the groove configuration shown in Figure 4.21 (Figure 4.22 for SAW), with steel backing. (2) The plate shall be welded in the IG (flat) position. 4.12.3 T-, Y-, or K-Connections with Backing or Backgouging. A WPS for tubular T-, Y-, or K-connections with backing or backgouging shall be qualified using: (3) The plate length shall be adequate to provide the test specimens required and oriented as shown in Figure 4.23. (1) the appropriate nominal pipe OD selected from Table 4.2(2), and (2) the joint detail of Figure 4.25(B), or (4) The welding test conditions of current, voltage, travel speed, and gas flow shall approximate those to be used in making production fillet welds as closely as practical. (3) for nominal pipe ODs equal to or greater than 24 in [600 mm], a plate qualification in conformance with 4.9 using the joint d'etail of Figure 4.25(B). These conditions establish the WPS from which, when production fillet welds are made, changes in essential variables will be measured in conformance with 4.7. 4.12.4 T-, yo, or K-Connections without Backing Welded from One Side Only. When qualification is required, a WPS for T-, Y-, or K-connections without backing welded from one side only shall require the following: The test plate shall be tested as follows: 4.12.4.1 WPSs without Prequalified Status. For a WPS whose essential vrn;iables are outside the prequalified range, qualification for CJP tubular groove welds shall require the following: (1) Two side bend (Figure 4.13) specimens and one all-weld-metal tension (Figure 4.18) test specimen shall be removed from the test plate, as shown in Figure 4.23. (2) The bend test specimens shall be tested in conformance with 4.8.3.1. Those test results shall conform to the requirements of 4.8.3.3. (1) Qualification in conformance with Figure 4.27 for pipes with outside diameters greater than or equal to 4 in [lOQ mm] or Figure 4.27 and Figure 4.29 for box tubes. Qualification in conformance with Figure 4.28 for pipes with outside diameters less than 4 in [100 mm] or Figure 4.28 and Figure 4.29 for box tubes. (3) The tension test specimen shall be tested in conformance with 4.8.3.6. The test result shall determine the strength level for the welding consumable, which shall 128 AWS D1.1/D1.1M:2008 PARTB bevel groove, offset root and restriction ring as shown in Figure 4.27. (2) A Sample Joint or Tubular Mock-up. The sample • joint or tubular mock-up shall provide at least one macro• etch test section for each of the following conditions: 4.12.4.4 Weldments Requiring CVN Toughness. WPSs for butt joints (longitudinal or circumferential seams) within 0.5D of attached branch members, in tubular connection joint cans requiring CVN testing under 2.26.2.2, shall be required to demonstrate weld metal CVN absorbed energy of 20 ft·lb [27 J] at the LAST, (Lowest Anticipated Service Temperature), or at O°F [-18°C], whichever is lower. If AWS specifications for the welding materials to be used do not encompass this requirement, or if production welding is outside the range covered by prior testing, e.g., tests per AWS filler metal specifications, then weld metal CVN tests shall be made during WPS qualification, as described in Part D of this clause. (a) The groove combining the greatest groove depth with the smallest groove angle, or combination of grooves to be used: test with welding position vertical. (b) The narrowest root opening to be used with a 37.5° groove angle: one test welded in the flat position and one test welded in the overhead position. (c) The widest root opening to be used with a 37.5° groove angle: one test to be welded in the flat position and one test to be welded in the overhead position. (d) for matched box connections only, the minimum groove angle, comer dimension and comer radius to be used in combination: one test in horizontal position. (3) The macroetch test specimens required in (1) and (2) above shall be examined for discontinuities and shall have: 4.13 PJP Tubular T-, Y-, or K-Connections and Butt Joints (a) No cracks When PIP groove welds are specified, in T-, Y-, or K-connections or butt welds, qualification shall be in conformance with Table 4.3. (b) Thorough fusion between adjacent layers of weld metal and between weld metal and base metal • • (c) Weld details conforming to the specified detail but with none of the variations prohibited in 5.24. 4.14 Plug and Slot Welds for Tubular and Nontubular Connections (d) No undercut exceeding the values allowed in 6.9. When plug and slot groove welds are specified, WPS qualification shall be in conformance with 4.29. (e) For porosity 1/32 in [l mm] or larger, accumulated porosity shall not exceed 1/4 in [6 mm] (f) No accumulated slag, the sum of the greatest dimension of which shall not exceed 1/4 in [6 mm] 4.15 Welding Processes Requiring Qualification Those specimens not conforming to (a) through (f) shall be considered unacceptable; (b) through (f) not applicable to backup weld. 4.15.1 ESW, EGW, GTAW, and GMAW-S. ESW, EGW, GTAW, and GMAW-S may be used, provided the WPSs are qualified in conformance with the requirements of Clause 4. Note that the essential variable limitations in Table 4.5 for GMAW shall also apply to GMAW-S. 4.12.4.2 CJP Groove Welds in a T-, yo, or KConnection WPS with Dihedral Angles Less than 30°. The sample joint described in 4.12.4.1(2)(a) shall be required. Three macroetch test sections shall be cut from the test specimens, shall conform to the requirements of 4.12.4.1(3), and shall show the required theoretical weld (with due allowance for backup welds to be discounted, as shown in Details C and D of Figures 3.8-3.10) (see Figure 4.26 for test joint details). • • CLAUSE 4. QUALIFICATION 4.15.2 Other Welding Processes~ Other welding processes not listed in 3.2.1 or 4.15.1 may be used, provided the WPSs are qualified by testing. The limitation of essential variables applicable to each welding process shall be established by the Contractor developing the WPS and approved by the Engineer. Essential variable ranges shall be based on documented evidence of experience with the process, or a series of tests shall be conducted to establish essential variable limits. Any change in essential variables outside the range so established shall require requalification. 4.12.4.3 CJP Groove Welds in a T-, yo, or KConnection WPS Using GMAW-S. For T-, Y-, and Kconnections, where GMAW-S is used, qualification in conformance with Clause 4 shall be required prior to welding the standard joint configurations detailed in 3.13.4. The joint tested shall incorporate a 37.5° single 129 CLAUSE 4. QUALIFICATION PARTSB& C AWS D1.1 /D1.1 M:2008 welding operators shall be in conformance with Table 4 .10._ 4.16 WPS Requirement (GTAW) Prior to use, the Contractor shall prepare a WPS(s) and qualify each WPS in conformance with to the requirements of Clause 4. 4.18.1.2 Tack Welders. A tack welder shall be qualified by one test plate in each position in which the tack welding is to be performed. 4.18.2 Production Thicknesses and Diameters Qualified 4.17 WPS Requirements (ESWIEGW) 4.18.2.1 Welders or Welding Operators. The range of qualified production welding thicknesses and diameters for which a welder or welding operator is qualified for shall be in conformance with Table 4.11. Prior to use, the Contractor shall prepare and qualify each ESW or EGW WPS to be used according to the requirements in Clause 4. The WPS shall include the joint details, filler metal type and diameter, amperage, voltage (type and polarity), speed of vertical travel if not an automatic function of arc length or deposition rate, oscillation (traverse speed, length, and dwell time), type of shielding including flow rate and dew point of gas or type of flux, type of molding shoe, PWHT if used, and other pertinent information. 4.18.2.2 Tack Welders. Tack welder qualification shall qualify for thicknesses greater than or equal to 1/8 in [3 mm], and all tubular diameters. 4.18.3 Welder and Welding Operator Qualification Through WPS Qualification. A welder or welding operator may also be qualified by welding a satisfactory WPS qualification test plate, pipe or tubing that meets the requirements of 4.8. The welder or welding operator is thereby qualified in conformance with 4.18.1 and 4.18.2. 4.17.1 Previous Qualification. WPSs that have been previously qualified may be used, providing there is proper documentation, and the WPS is approved by the Engineer. 4.17.2 All-Weld-Metal Tension Test Requirements. Prior to use, the Contractor shall demonstrate by the test described in Clause 4, that each combination of shielding and filler metal will produce weld metal having the mechanical properties specified in the latest edition of AWS A5.25, Specification for Carbon and Low Alloy Steel Electrodes and Fluxesfor Electroslag Welding, or the latest edition of AWS A5.26, Specification for Carbon and Low Alloy Steel Electrodesfor Electrogas Welding, as applicable, when welded in conformance with the WPS. 4.19 Type of Qualification Tests Required 4 4.19.1 Welders and Welding Operators. The type and number of qualification tests required for welders or welding operators shall conform to Table 4.11. Details on the individual NDT and mechanical test requirements are found in the following subclauses: (1) Visual Inspection (see 4.8.1) (use WPS requirements) (2) Face, root, and side bend (see 4.8.3.1) (use WPS requirements) Parte Performance Qualification (3) Macroetch (see 4.30.2) (4) Fillet Weld Break (see 4.30.4) 4.19.1.1 Substitution of RT for Guided Bend Tests. Except for joints welded by GMAW-S, radiographic examination of a welder or welding operator qualification test plate or test pipe may be made in lieu of bend tests described in 4.19.1(2) (see 4.30.3 for RT requirements). 4.18 General The performance qualification tests required by this code are specifically devised tests to determine a welder's, welding operator's, or tack welder's ability to produce sound welds. The qualification tests are not intended to be used as guides for welding or tack welding during actual construction. The latter shall be performed in conformance with a WPS. 4.18.1 Production Welding Positions Qualified In lieu of mechanical testing or RT of the qualification test assemblies, a welding operator may be qualified by RT of the initial 15 in [380 mm] of a production groove weld. The material thickness range qualified shall be that shown in Table 4.11. ,. 4.18.1.1 Welders and Welding Operators. The qualified production welding positions for welders and 4.19.1.2 Guided Bend Tests. Mechanical test specimens shall be prepared by cutting the test plate, pipe, or 130 .JJ AWS D1.1/D1.1 M:2008 • • tubing as shown in Figures 4.21, 4.30, 4.31, 4.32, 4.33, and 4.34 for welder qualification or Figure 4.22, 4.33, or 4.36 for welding operator qualification, whichever is applicable. These specimens shall be approximately rectangular in cross section, and be prepared for testing in conformance with Figure 4.12, 4.13, 4.14, or 4.18: whichever is applicable. performance essential variables of 4.22. The Welding Performance Qualification Record (WPQR) shall serve as written verification and shall list all of the applicable essential variables of Table 4.12. Suggested forms are found in Annex N. 4.19.2 Tack Welders. The tack welder shall make a 114 in [6 mm] maximum size tack weld approximately 2 in [50 mm] long on the fillet-weld-break specimen as shown in Figure 4.39. 4.22 Essential Variables Changes beyond the limitation of essential variables for welders, welding operators, or tack welders shown in Table 4.12 shall require requalification. 4.19.2.1 Extent of Qualification. A tack welder who passes the fillet weld break test shall be qualified to tack weld all types of joints (except CJP groove welds, welded from one side without backing; e.g., butt joints and T-, Y-, and K-connections) for the process and in the position in which the tack welder is qualified. Tack welds in the foregoing exception shall be performed by welders fully qualified for the process and in the position in which the welding is to be done. 4.23 CJP Groove Welds for Nontubular Connections See Table 4.10 for the position requirements for welder or welding operator qualification on nontubular connections. Note that qualification on joints with backing qualifies for welding production joints that are backgouged and welded from the second side. 4.20 Weld Types for Welder and Welding Operator Performance t 4.23.1 Welder Qualification Plates. The following figure numbers apply to the position and thickness requirements for welders. ~~~;::::~ (1) Figure 4.21-All Positions-Unlimited Thickness Fo, the and weldmg opemw, qulli;flcation, weld types shall be classified as follows: (2) Figure 4.3O-Horizontal Position-Unlimited Thickness (1) CIP Groove Welds for Nontubular Connections (see 4.23) (3) Figure 4.31-All Positions-Limited Thickness (2) PIP Groove Welds for Nontubular Connections (see 4.24) (4) Figure Thickness (3) Fillet Welds for Nontubular Connections (see 4.25) 4.32-Horizontal Position-Limited 4.23.2 Welding Operator Qualification Test Plates (4) CIP Groove Welds for Tubular Connections (see 4.26) 4.23.2.1 For Other than EGW, ESW, and Plug Welds. The qualification test plate for a welding operator not using EGW or ESW or plug welding shall conform to Figure 4.22. This shall qualify a welding operator for groove and fillet welding in material of unlimited thickness for the process and position tested. (5) PIP Groove Welds for Tubular Connections (see 4.27) (6) Fillet Welds for Tubular Connections (see 4.28) (7) Plug and Slot Welds for Tubular and Nontubular Connections (see 4.29) 4.23.2.2 For ESW and EGW. The qualification test plate for an ESW or EGW welding operator shall consist of welding a joint of the maximum thickness of material to be used in construction, but the thickness of the material of the test weld need not exceed 1-112 in [38 rom] (see Figure 4.35). If a 1-112 in [38 mm] thick test weld is made, no test need be made for a lesser thickness. The test shall qualify the welding operator for groove and fillet welds in material of unlimited thickness for this process and test position. 4.21 Preparation of Performance Qualification Forms • • CLAUSE 4. QUALIFICATION PARTe The welding personnel shall follow a WPS applicable to the qualification test required. All of the WPS essential variable limitations of 4.7 shall apply, in addition to the 131 CLAUSE 4. QUALIFICATION PARTe AWS D1.1/D1.1 M:2008 4.12.4.2 shall be performed by each welder in addition to the 6GR tests (see Figure 4.28 or 4.29). The test position ~ shall be vertical. ,. 4.24 PJP Groove Welds for Nontubular Connections Qualification for CIP groove welds shall qualify for all PJP groove welds. 4.27 PJP Groove Welds for Tubular Connections 4.25 Fillet Welds for Nontubular Connections Qualification for CIP groove welds on tubular connections shall qualify for all PIP groove welds. Qualification of CIP groove welds shall qualify for fillet welds. However, where only fillet weld qualification is required, see Table 4.11. 4.28 Fillet Welds for Tubular Connections See Table 4.11 for fillet weld qualification requirements. 4.26 CJP Groove Welds for Tubular Connections Welder or welding operator qualification tests shall use the following details: 4.29 Plug and Slot Welds for Tubular and Nontubular Connections (1) CIP groove butt joints with backing or backgouging in pipe. Use Figure 4.24(B). Qualification for CIP groove welds on tubular or nontubular connections shall qualify for all plug and slot welds. ~ (2) CIP groove butt joints without backing or backgouging. Use Figure 4.24(A). See Table 4.10 for plug and slot weld qualification only. The joint shall consist of a 3/4 in [20 mm] diameter hole in a 3/8 in [10 mm] thick plate with a 3/8 in [10 mm] minimum thickness backing plate (see Figure 4.38). (3) CIP groove butt joints or T-, Y-, and Kconnections with backing in box tubing. Use Figure 4.24(B) in pipe (any diameter), plate or box tubing. (4) CIP groove T-, Y-, and K-Connections welded from one side with backing in pipe. Use Figure 4.24(B) in pipe of the appropriate diameter. (5) CIP groove T-, Y-, and K-connections welded from one side without backing in pipe. Use Figure 4.27 for nominal pipe diameter of;;::;6 in [150 mm] or Figure 4.28 for nominal pipe::;;4 in [l00 mm]. 4.30 Methods of Testing and Acceptance Criteria for Welder and Welding Operator Qualification (6) CIP groove T-, Y-, and K-connection welded from one side without backing or backgouging in box tubing. The options are the following: 4.30.1 Visual Inspection. See 4.8.1 for acceptance criteria. 4.30.2 Macroetch Test. The test specimens shall be prepared with a finish suitable for macroetch examination. A suitable solution shall be used for etching to give a clear definition of the weld. (a) Figure 4.27 in pipe (any diameter) or box tubing plus Figure 4.29 in box tubing. (b) Figure 4.27 in box tubing with macroetch specimens removed from the locations shown in Figure 4.29. 4.30.2.1 Plug and Fillet Weld Macroetch Tests. The face of the macroetch shall be smooth for etching. See Table 4.11 for the production ranges of diameter and thickness qualified by the test assembly diameters and thicknesses. (1) The plug weld macroetch tests shall be cut from the test joints per: 4.26.1 Other Joint Details or WPSs. For joint details, WPSs, or assumed depth of sound welds that are more difficult than those described herein, a test described in (a) Welder Qualification-Figure 4.38 (b) Welding Operator Qualification-Figure 4.38 132 4 AWS D1.1/D1.1M:2008 PARTC (2) The fillet weld macroetch tests shall be cut from the test joints per: CLAUSE 4. QUALIFICATION regularities or juncture with the base metal would cause objectionable weld discontinuities to be obscured in the radiograph. If the backing is removed for RT, the root shall be ground flush (see 5.24.4.1) with the base metal. (a) Welder Qualification-Fi&ure 4.37 (b) Welding Operator Qualification-Figure 4.37 4.30.3.1 RT Test Procedure and Technique. The RT procedure and technique shall be in conformance with the requirements of Part E, Clause 6. For welder qualification, exclude 1-1/4 in [32 mm] at each end of the weld from evaluation in the plate test; for welding operator qualification exclude 3 in [75 mm] at each end of the test plate length. Welded test pipe or tubing 4 in [100 mm] in diameter or larger shall be examined for a minimum of one-half of the weld perimeter selected to include a sample of all positions welded. (For example, a test pipe or tube welded in the 5G, 6G, or 6GR position shall be radiographed from the top centerline to the bottom centerline on either side.) Welded test pipe or tubing less than 4 in [100 mm] in diameter shall require 100% RT. 4.30.2.2 Macroetch Test for T-, yo, and KConnections. The comer macroetch test joint for T-, Y-, and K-connections on box tubing in Figure 4.29 shall have four macroetch test specimens cut from the weld comers at the locations shown in Figure 4.29. One face from each comer specimen shall be smooth for etching. If the welder tested on a 6GR coupon (Figure 4.28) using box tubing, the four required comer macroetch test specimens may be cut from the comers of the 6GR coupon in a manner similar to Figure 4.29. One face from each comer specimen shall be smooth for etching. 4.30.2.3 Macroetch Test Acceptance Criteria. For acceptable qualification, the test specimen, when inspected visually, shall conform to the following requirements: 4.30.3.2 RT Acceptance Criteria. For acceptable qualification, the weld, as revealed by the radiograph, shall conform to the requirements of 6.12.2, except that 6.12.2.2 shall not apply. (1) Fillet welds shall have fusion to the root of the joint but not necessarily beyond. (2) Minimum leg size shall meet the specified fillet weld size. 4.30.4 Fillet Weld Break Test. The entire length of the fillet weld shall be examined visually, and then a 6 in [150 mm] long specimen (see Figure 4.37) or a quartersection of the pipe fillet weld assembly shall be loaded in such a way that the root of the weld is in tension. At least one welding start and stop shall be located within the test specimen. The load shall be increased or repeated until the specimen fractures or bends flat upon itself. (3) Fillet welds and the comer macroetch test joint for T-, Y-, and K-connections on box tubing, Figure 4.29, shall have: (a) No cracks (b) Thorough fusion between adjacent layers of weld metals and between weld metal and base metal 4.30.4.1 Acceptance Criteria for Fillet Weld Break Test. To pass the visual examination prior to the break test, the weld shall present a reasonably uniform appearance and shall be free of overlap, cracks, and undercut in excess of the requirements of 6.9. There shall be no porosity visible on the weld surface. (c) Weld profiles conforming to intended detail, but with none of the variations prohibited in 5.24 (d) No undercut exceeding 1/32 in [1 mm] (e) For porosity 1/32 in [1 mm] or larger, accumulated porosity not exceeding 1/4 in [6 mm] The broken specimen shall pass if: (f) No accumulated slag, the sum of the greatest dimensions of which shall not exceed 1/4 in [4 mm] (1) The specimen bends flat upon itself, or (4) Plug welds shall have: (2) The fillet weld, if fractured, has a fracture surface showing complete fusion to the root of the joint with no inclusion or porosity larger than 3/32 in [2.5 mm] in greatest dimension, and (a) No cracks (b) Thorough fusion to backing and to sides of the hole (3) The sum of the greatest dimensions of all inclusions and porosity shall not exceed 3/8 in [10 mm] in the 6 in [150 mm] long specimen. (c) No visible slag in excess of 1/4 in [6 mm] total accumulated length 4.30.3 RT. If RT is used in lieu of the prescribed bend tests, the weld reinforcement need not to be ground or otherwise smoothed for inspection unless its surface ir- 4.30.5 Root, Face, and Side Bend Specimens. See 4.8.3.3 for acceptance criteria. 133 PARTSC& 0 CLAUSE 4. QUALIFICATION 4.32.2 Tack Welder Retest Requirements 4.31 Method of Testing and Acceptance Criteria for Tack Welder Qualification 4.32.2.1 Retest without Additional Training. In case of failure to pass the test requirements, the tack welder may make one retest without additional training. A force shall be applied to the specimen as shown in Figure 4.35 until rupture occurs. The force may be applied by any convenient means. The surface of the weld and of the fracture shall be examined visually for defects. PartD Requirements for CVN Testing 4.31.2 Destructive Testing Acceptance Criteria. The fractured surface of the tack weld shall show fusion to the root, but not necessarily beyond, and shall exhibit no incomplete fusion to the base metals or any inclusion or porosity larger than 3/32 in [2.5 mm] in greatest dimension. 4.33 General 4.33.1 The CVN test requirements and test procedures in this section shall apply only when specified in the contract documents in conformance with 5.26.5(3)[d] and 4.1.1.3, and Table 3.1 of this code. While the requirements of this section do not address CVN testing of base metals, it is assumed that the base metals are suitable for applications where CVN testing of theWPS is required. 4.32 Retest When a welder, welding operator or tack welder either fails a qualification test, or if there is specific reason to question their welding abilities or period of effectiveness has lapsed, the following shall apply: and Welding Operator 4 4.32.2.2 Retest After Further Training or Practice. A retest may be made, provided the tack welder has had further training or practice. A complete retest shall be required. 4.31.1 Visual Acceptance Criteria. The tack weld shall present a reasonably uniform appearance and shall be free of overlap, cracks, and undercut exceeding 1/32 in [1 mm]. There shall be no porosity visible on the surface of the tack weld. 4.32.1 Welder Requirements AWS D1.1/D1.1 M:2008 4.33.2 The CVN test specimens shall be machined and tested in conformance with ASTM E 23, Standard Methods for Notched Bar Impact Testing of Metallic Materials, for Type A Charpy (simple beam) Impact Specimen, ASTM A 370, Standard Test Method and Definitionsfor Mechanical Testing of Steel Products, or A WS B4.0, Standard Methods for Mechanical Testing of Welds. Retest 4.32.1.1 Immediate Retest. An immediate retest may be made consisting of two welds of each type and position that the welder or welding operator failed. All retest specimens shall meet all of the specified requirements. 4.32.1.2 Retest After Further Training or Practice. A retest may be made, provided there is evidence that the welder or welding operator has had further training or practice. A complete retest of the types and positions failed or in question shall be made. 4.34 Test LocatiQns 4.34.1 The test location for individual CVN test specimens, unless otherwise specified on contract documents, shall be as shown in Figure 4.40 and Table 4.14. 4.32.1.3 Retest After Lapse of Qualification Period of Effectiveness. When a welder's or welding operator's qualification period of effectiveness has lapsed, a requalification test shall be required. Welders have the option of using a test thickness of 3[8 in [10 mm] to qualify any production welding thickness greater than or equal to 1/8 in [3 mm]. 4.34.2 The positioning of the notch for all CVN test specimens shall be done" by first machining the specimens from the test weld at the appropriate depth as shown in Figure 4.40. The specimens should be made slightly overlength to allow for exact positioning of the notch. Next, the bars should be etched with a mild etchant such as 5% nital, to reveal the location of the weld fusion zone and HAZs. The centerline of the notch shall then be located in the specimens, as shown in Figure 4.40. 4.32.1.4 Exception-Failure of a Requalification Retest. No immediate retest shall be allowed after failure of a requalification retest. A retest shall be allowed only after further training and practice per 4.32.1.2. 134 ." • .\.'.1 AWS D1.1/D1.1M:2008 t 4.35 CVN Tests 4.36 Test Requirements 4.35.1 There are two options for the number of CVN test specimens to be taken from a single test location: 4.36.1 Test requirements for welds between base metals with specified minimum yield strengths of 50 ksi [345 MPa] or less shall not be less than the minimum requirements in Table 4.14, unless otherwise specified. Test requirements for welds between base metals with a specified minimum yield strength greater than 50 ksi [345 MPa] shall be specified in the contract documents. These requirements may include, but are not limited to, absorbed energy, percent ductile fracture appearance, and lateral expansion values. Option A-3 specimens Option B-5 specimens 4.35.2 CVN test specimens shall be machined from the same welded test assembly made to determine other weld joint properties (see Figure 4.7, 4.8, 4.10, or 4.11). Where the size of the welded test assemblies is not sufficient to satisfy all the mechanical testing specimen requirements, an additional welded test assembly shall be performed. The CVN test specimens shall be machined from the welded test assembly in which the tensile test specimens are machined. • • 4.36.2 The acceptance criteria for each test shall be specified in contract drawings or specifications, and shall consist of the following: (1) Minimum individual value-the value of which no one specimen may be below, and (2) Minimum average value-the value of which the arithmetic mean of three specimens shall equal or exceed. 4.35.3 When CVN testing is a requirement and a qualified WPS exists which satisfies all requirements except for CVN testing, it shall be necessary only to prepare an additional test weldment with sufficient material to provide the required CVN test specimens. The test plate shall be welded using that WPS, which conforms to the limits of Tables 4.1, 4.2, and 4.5, plus those supplementary essential variables applicable only to CVN testing (Table 4.6). A new or revised PQR shall be prepared and a new or revised WPS written to accommodate the qualification variables for CVN testing. Unless specified otherwise, in contract drawings or specifications, the acceptance values for the CVN test requirements described in 4.36.1 for welds between base metals with a specified minimum yield strength of 50 ksi [345 MPa] or less, are shown in Table 4.14. 4.36.3 If Option B (see 4.35.1) is chosen, the specimens with the highest and lowest values shall be discarded, leaving 3 specimens for evaluation. For both Option A and the 3 remaining specimens of Option B, 2 of the 3 values for the specimens shall equal or exceed the specified minimum average value. One of the three may be lower than the specified minimum average value, but not lower than the specified minimum individual value, and the average of the three shall not be less than the minimum specified average value. 4.35.4 The longitudinal centerline of the specimens shall be transverse to the weld axis and the base notch shall be perpendicular (normal) to the surface unless otherwise specified in the contract documents. 4.35.5 The standard 10 x 10 mm specimen shall be used where the test material thickness is 7/16 in [11 mm] or greater. Sub-sized specimens shall be used where the test material thickness is less than 7/16 in [11 mm], or where the extraction of full-sized specimens is not possible due to the shape of the weldment. When sub-sized specimens are required, they shall be made to one of the dimensions shown in Table 4.15. (Note: the largest possible specimens shall be machined from the qualification test piece.) 4.37 Retest 4.37.1 When the requirements in 4.36.2 and 4.36.3 are not met, one retest may be performed. Each individual value of the remaining three specimens shall equal or exceed the minimum specified average value. Retest specimens shall be removed from the original test weldment(s). If specimens cannot be provided from these weldments, a new test weldment shall be performed and all mechanical tests required by this code shall be performed. 4.35.6 The CVN test temperature shall be specified in the contract documents. • • CLAUSE 4. QUALIFICATION PART 0 4.35.7 When sub-sized specimens are required, and the width of the specimen across the notch is less than 80% of the base metal thickness, the test temperature shall be reduced in conformance with Table 4.15, unless otherwise specified in the contract documents. 4.38 Reporting 4.38.1 All CVN test measured values required by this code, contract documents, or specifications shall be reported on the PQR. 135 W 0\ ...... Fillet CJP Groove Plug/ Slot Fillet" lG Rotated 2G 5G (2G+ 5G) 6G 6GR IF Rotated 2F 2FRotated 4F 5F lG 2G 3G 4G IF 2F 3F 4F Positions F,H V OH F Groove PJP Fh (F, H)b Vb OHb Fh (F, H)b Vb OHb F F,H V OH F F,H V OH All All Alld All All All , PJP F F,H V OH F F,H V OH Filleti F F,H V OH CJP Allg Allg All All All All • All Aile Aile All All All All F F,H F,H F,H,OH Allc AUC Alld F F,H V OH PJP Butt Joint Allc Allc Alld All All All Allf Allf CJP F F,H V OH F F,H V OH Filleti Allg,h Allg,h All .. All F F,H F,H F,H,OH All All All F F F,H F,H F, V, OH F, V, OH PJP T-, Y-, KConnections Production Box Tube Welding Qualified pc F F F F,H (F, H)C F,H F,H F, V, OH F, V, OH (F, V, OH)C F, V, OH F F,H F,H F,H,OH All All All CJP T-, Y-, KConnections Qualifies Plug/Slot Welding for Only the Positions Tested PJP CJP Filleti pc F F F F F,H F,H F,H (F, H)C F,H F,V,OH F, V, OH F, V, OH (F, V, OH)C F,V,OH F F,H V OH Groove CJP Butt Joint Production Pipe Welding Qualified - • Qualifies for a welding axis with an essentially straight line, including welding along a line parallel to the axis of circular pipe. b Qualifies for circumferential welds in pipes equal to or greater than 24 in [600 mm] nominal outer diaIMter. C Production butt joint details without backing or backgouging require qualification testing of the joint detail shown in Figure 4.25(A). d Limited to prequalifiedjoint details (see 3.12 or 3.13). e For production joints ofCJP T-, Y-, and K-connections that conform to either Figure 3.8,3.9, or 3.10 and Table 3.6, use Figure 4.27 detail for testing. For other production joints, see 4.12.4.1. f For production j oints ofCJP T-, Y-, and K-connections that conform to Figure 3.6, and Table 3.6, use Figures 4.27 and 4.29 detail for testing, or, alternatively, test the Figure 4.27 joint and cut macroetch specimens from the corner locations shown in Figure 4.29. For other production joints, see 4.12.4.1. g For production joints ofPJP T-, Y-, and K-connections that conform to Figure 3.5, use either the Figure 4.25(A) or Figure 4.25(B) detail for testing. h For matched box connections with corner radii less than twice the chord member thickness, see 3.12.4.1. i Fillet welds in production T-, Y-, or K-connections shall conform to Figure 3.2. WPS qualification shall conform to 4.11. CJP-Complete Joint Penetration PJP-Partiai Joint Penetration R A T U B U L T E A P L CJP Groove" Weld Type Qualification Test Production Plate Welding Qualified Table 4.1 WPS Qualification-Production Welding Positions Qualified by Plate, Pipe, and Box Tube Tests (see 4.3) m Ol o o i\) s: ...... ~ ...... ~ ~ C/) 6 z "(2:j5 o ~ c: lJ :IJ f'> m C/) ~ () AWS D1.1/D1.1M:2008 CLAUSE 4. PREQUALIFICATION Table 4.2 WPS Qualification-CJP Groove Welds: Number and Type of Test Specimens and Range of Thickness ~nd Diameter Qualified (see 4.4) (Dimensions in Inches) 1. Tests on Platea, b - Nominal Plate, Pipe or Tube Thicknessc,d Qualified, in Number of Specimens Reduced Nominal Plate Section Thickness (T) Tension (see Tested, in Fig. 4.14) lI8 ~ T ~ 3/8 3/8 < T < 1 1 and over 2 2 2 Root Bend (see Fig. 4.12) Face Bend (see Fig. 4.12) Side Bend (see Fig, 4.13) Min. Max. 2 (Note i) 4 4 lI8 lI8 lI8 2T 2T Unlimited 2 - - - - 2. Tests on Pipe or Tubinga,g Number of Specimens Reduced Nominal Nominal Wall Section Root Bend Pipe Size or Thickness, Tension (see (see Fig. T,in Fig. 4.14) 4.12) Diam., in lI8 ~ T <24 4 2 2 T~3/4 Standard Test Pipes 2 inSch. 80 or 3 in Sch. 40 6 in Sch. 120 or 8 in Sch. 80 - - - - 2 2 2 2 - - 2T T/2 3/8 2T Unlimited Unlimited - 3/8 <T < 3/4 lI8 3/16 - 2 Unlimited 4 and over 2 2 3/8 4 T~3/4 2 2T 3/4 4 3/8 T/2 lI8 - ~ 2T 3/4 through 4 - T lI8 - 2 ~ Max, 4 4 3/8 < T < 3/4 2 Min. Test diam. and over Test diam. and over Testdiam. and over Test diam. and over 24 andover 24 andover 2 lI8 2 Side Bend (see Fig. 4.13) 3/8 Job Size Test Pipes ~24 ~ Face Bend (see Fig. 4.12) Nominal Diameter" of Pipe or Tube Size Qualified, in Nominal Plate, Pipe or Tube Wall Thicknessc,d Qualified, in (Note i) (Note i) 3. Tests on ESW and EGwa,h Nominal Plate Thickness Qualified Number of Specimens AII-WeldReduced Nominal Plate Section Metal Side Bend Thickness Tension (see Tension (see (see Fig. 4,13) Fig. 4.18) Tested Fig.4.14) T 2 1 4 CVN Tests Min. Max. (Note f) O.5T I.IT All test plate, pipe or tube welds shall be visually Inspected (see 4.8.1) and subject to NDT (see 4.8.2). One test plate, pipe or tube shall be reqUIred for each qualified position. b See Figures 4.10 and 4.11 for test plate requirements. c For square groove welds that are qualified without backgouging, the maximum thickness qualified shall be limited to the test plate thickness. d CJP groove weld qualification on any thickness or diameter shall qualify any size of fillet or PJP groove weld for any thickness or diameter ~ 4.10.3). e Qualification with any pipe diameter shall qualify all box section widths and depths. f When specified, CVN tests shall conform to Clause 4, Part D. g See Table 4.1 for the groove details required for qualification of tubular butt and T-, Y-, K-connection joints. h See Figure 4.9 for plate requirements. i For 3/8 in plate or wall thickness, a side-bend test may be substituted for each of the required face- and root-bend tests. a 137 CLAUSE 4. PREQUALIFICATION AWS D1.1/D1.1M:2008 Table 4.2 WPS Qualification-CJP Groove Welds: Number and Type of Test Specimens and Range of Thickness and Diameter Qualified (see 4.4) (Dimensions in Millimeters) 1. Tests on Platea, b Nominal Plate, Pipe or Tube Thickness c, d Qualified, mm Number of Specimens Reduced Nominal Plate Section Thickness (T) Tension (see Fig. 4.14) Tested, mm 3:::::T::::: 10 IO<T<25 25 and over 2. Tests on Pipe or 2 2 2 Root Bend (see Fig. 4.12) Face Bend (see Fig. 4.12) Side Bend (see Fig. 4.13) Min. Max. 2 (Note i) 4 4 3 3 3 2T 2T Unlimited 2 - - - - Tubing a•g Number of Specimens Nominal Pipe Size or Diam.,mm Reduced Section Root Bend Nominal Wall Thickness, Tension (see (see Fig. 4.12) T,mm Fig. 4.14) 3 :::::T::::: 10 <600 2 (Note i) 2 - - 4 T~20 2 - - 4 3 :::::T::::: 10 2 IO<T<20 2 2 T~20 Standard Test Pipes 2 2 Nominal Diameter" Side Bend of Pipe or (see Fig. Tube Size 4.13) Qualified, rom 10 < T < 20 Job Size Test Pipes ~600 Face Bend (see Fig. 4.12) 50 mm OD x 6 mm WT or 75 mm OD x 6 mm WT 150mmODx 14mmWT or 200 rom OD x 12 rom WT 2 2 2 2 - - - - 2 - (Note i) 4 4 2 - Nominal Plate, Pipe or Tube Wall Thicknessc, d Qualified, rom - 4 Testdiam. and over Test diam. and over Testdiam. and over Test diam. and over 600 and over 600 and over 20 through 100 100 and over Min. Max. 3 2T T/2 2T 10 Unlimited 3 2T J T/2 10 • •. i.·.· 2T Unlimited 3 20 5 Unlimited 3. Tests on ESW and EGwa, h Nominal Plate Thickness Qualified Number of Specimens Reduced All-WeldNominal Plate Section Metal Side Bend Thickness Tension (see Tension (see (see Fig. Fig. 4.14) Tested Fig. 4.18) 4.13) T 2 1 4 CVN Tests Min. Max. (Note f) 0.5T l.1T All test plate, pipe or tube welds shall be visually mspected (see 4.8.1) and subject to NDT (see 4.8.2). One test plate, pipe or tube shall be reqUired for each qualified position. b See Figures 4.10 and 4.11 for test plate requirements. c For square groove welds that are qualified without backgouging, the maximum thickness qualified shall be limited to the test plate thickness. d CJP groove weld qualification on any thickness or diameter shall qualify any size of fillet or PJP groove weld for any thickness or diameter (see 4.10.3). e Qualification with any pipe diameter shall qualify all box section widths and depths. f When specified, CVN tests shall conform to Clause 4, Part D. g See Table 4.1 for the groove details required for qualification of tubular butt and T-, Y-, K-connection joints. IIJ.'.i.' h See Figure 4.9 for plate requirements. ., i For 10 mm plate or wall thickness, a side-bend test may be substituted for each of the required face- and root-bend tests. a 138 AWS D1.1/D1.1M:2008 CLAUSE 4. PREQUALIFICATION Table 4.3 Number and Type of Test Specimens and Range of Thickness QualifiedWPS Qualification; PJP Groove Welds (see 4.10) , Qualification Ranges C,d Number of Specimens" b Nominal Plate, Pipe or Tubing Plate Thickness, in [mm] Macroetch for Weld Size (E) 4.10.2 4.10.3 4.10.4 ReducedSection Tension (see Fig. 4.14) Root Bend (see Fig. 4.12) Face Bend (see Fig. 4.12) 1/8 ~ T ~ 3/8 [3 ~ T ~ 10] 3 2 2 2 3/8 < T ~ 1 [10 < T ~25] 3 2 Test Groove Depth, T in [mm] - - Side Bend (see Fig. 4.13) - 4 Groove Depth Min. Max. T 1/8 [3] 2T T 1/8 [3] Unlimited BASIC REQUIREMENTS One test plate, pipe, or tubing per position shall be required (see Figure 4.10 or 4.11 for test plate). Use the production PJP groove detail for qualification. All plates, pipes, or tubing shall be visually inspected (see 4.8.1). b If a PIP bevel- or I-groove weld is to be used for T-joints or double-bevel- or double-I-groove weld is to be used for comer joints, the butt joint shall have a temporary restrictive plate in the plane of the square face to simulate a T-joint configuration. C See the pipe diameter qualification requirements of Table 4.2. d Any PIP qualification shall also qualify any fillet weld size on any thickness. a Table 4.4 Number and Type of Test Specimens and Range of Thickness QualifiedWPS Qualification; Fillet Welds (see 4.11.1) Test Specimens Requiredb Test Specimen Fillet Size Single pass, max. size to be used Plate T-test in construction (Figure 4.19) Multiple pass, min. size to be used in construction Single pass, max. size to be used in construction Pipe T-testC (Figure 4.20) Multiple pass, min. size to be used in construction Groove testd (Figure 4.23) Sizes Qualified Number of Welds perWPS Macroetch 4.11.1 4.8.4 All-Weld-Metal Side Bend Tension (see (see Figure 4.13) Figure 4.18) 1 in each position to be used 3 faces Unlimited Max. tested single pass and smaller 1 in each position to be used 3 faces Unlimited Min. tested multiple pass and larger 1 in each position to be used (see Table 4.1) 3 faces (except for4F&5F, 4 faces req'd) Unlimited Max. tested single pass and smaller 1 in each position to be used (see Table 4.1) 3 faces (except for4F & 5F, 4 faces req'd) Unlimited Min. tested multiple pass and larger 2 1 in IG position PlatelPipe Thickness' Fillet Size Qualifies welding consumables to be used in T-test above • The minimum thickness qualified shall be 1/8 in [3 mm]. All welded test pipes and plates shall be visually inspected per 4.8.1. C See Table 4.2(2) for pipe diameter qualification. d When the welding consumables used do not conform to the prequalified provisions of Clause 3, and a WPS using the proposed welding consumables has not been established by the Contractor in conformance with either 4.9 or4.10.1, a CJP groove weld test plate shall be welded in conformance with 4.9. b 139 AWS D1.1 /D1.1 M:2008 CLAUSE 4. PREQUALIFICATION Table 4.5 PQR Essential Variable Changes Requiring WPS Requalification for SMAW, SAW, GMAW, FCAW, and GTAW (see 4.7.1) Process Essential Variable Changes to PQR Requiring Requalification SMAW SAW GMAW FCAW X X GTAW Filler Metal I) Increase in filler metal classification strength X 2) Change from low-hydrogen to nonlowhydrogen SMAW electrode X 3) Change from one electrode or flux-electrode classification to any other electrode or flux-electrode classification" 4) Change to an electrode or flux-electrode classificatione not covered in: X AWS A5.! or A5.5 X X AWS AWS AWS AWS A5.17 or A5.23 A5.18 or A5.28 A5.20 or A5.29 A5.18 or A5.28 5) Addition or deletion of filler metal X 6) Change from cold wire feed to hot wire feed or vice versa X 7) Addition or deletion of supplemental powdered or granular filler metal or cut wire X 8) Increase in the amount of supplemental powdered or granular filler metal or wire X 9) If the alloy content of the weld metal is largely dependent on supplemental powdered filler metal, any WPS change that results in a weld deposit with the important alloying elements not meeting the WPS chemical composition requirements X Any increase b Any increase or decrease Any increase > 1/16 in [1.6 mm] increase or decrease 4 X X -X > 1/32 in 10) Change in nominal filler metal diameter by: [0.8mm] increase 11) Change in number of electrodes Process Parameters 12) A change in the amperage for each diameter used by: 13) A change in type of current (ac or dc) or polarity (electrode positive or negative for dc current) To a value not > 10% increase > 10% increase > 10% increase > 25% increase recommended or decrease or decrease or decrease or decrease by manufacturer X X X X 14) A change in the mode of transfer X 15) A change from CV to CC output X X > 7% increase > 7% increase > 7% increase or decrease or decrease or decrease 16) A change in the voltage for each diameter used by: 17) An increase or decrease in the wire feed speed for each electrode diameter (if not amperage controlled) by: X , ." > 10% (Continued) 140 > 10% > 10% AWS D1.1/D1.1M:2008 CLAUSE 4. PREQUALIFICATION Table 4.5 (Continued) PQR EssentiafVariable Changes Requiring WPS Requalification for SMAW, ~,AW, GMAW, FCAW, and GTAW (see 4.7.1) Process Essential Variable Changes to PQR Requiring Requalification SAW SMAW GMAW FCAW GTAW Process Parameters (Cont'd) > 15% increase> 25% increase> 25% increase> 50% increase or decrease or decrease or decrease or decrease 18) A change in the travel speedc by: Shielding Gas 19) A change in shielding gas from a single gas to any other single gas or mixture of gas, or in the specified nominal percentage composition of a gas mixture, or to no gas x x x 20) A change in total gas flow rate by: Increase> 50% Increase> 50% Increase> 50% Decrease> 20% Decrease> 20% Decrease> 20% 21) A change to a shielding gas not covered in: AWS AWS A5.18 or A5.28 A5.20 or A5.29 SAW Parameters • • 22) A change of> 10%, or 1/8 in [3 mm], whichever is greater, in the longitudinal spacing of the arcs x 23) A change of> 10%, or 1/8 in [3 mm], whichever is greater, in the lateral spacing of the arcs x 24) An increase or decrease of more than 10° in the angular orientation of any parallel electrode x 25) For machine or automatic SAW; an increase or decrease of more than 3° in the angle of the electrode x 26) For machine or automatic SAW, an increase or decrease of more than 5° normal to the direction of travel x General 27) A change in position not qualified by Table 4.1 X X X X X 28) A change in diameter, or thickness, or both, not qualified by Table 4.2 X X X X X 29) A change in base metal or combination of base metals not listed on the PQR or qualified by Table 4.8 X X X X X 30) Vertical Welding: For any pass from uphill to downhill or vice versa X X X X (Continued) 141 AWS D1.1 /D1.1 M:2008 CLAUSE 4. PREQUALIFICATION _ _ _ _ _ _ _ _ _ _ _ _,.-Ta_b_le_4_"s_<_c_o_n_ti_nu_e_d_> •.• Process Essential Variable Changes to PQR Requiring Requalification • SMAW SAW GMAW FCAW GTAW 31) A change in groove type (e.g., single-V to double-V), except qualification of any CJP groove weld qualifies for any groove detail contonning with the requirements of 3.12 or 3.13 X X X X X 32) A change in the type of groove to a square groove and vice versa X X X X X 33) A change exceeding the tolerances of 3.12, 3.13,3.13.4,5.22.4.1, or 5.22.4.2 involving: a) A decrease in the groove angle b) A decrease in the root opening c) An increase in the root face X X X X X 34) The omission, but not inclusion, of backing or backgouging X X X X X > 25°F > 25°F > 25°F > 25°F > lOO°F [15°C] [15°C] [15°C] [15°C] [55°C] > 25°F > 25°F > 25°F > 25°F > lOO°F [15°C] [15°C] [15°C] [15°C] [55°C] X X X General (Cont'd) 35) Decrease from preheat temperatured by: 32) Decrease from interpass temperatured by: 31) Addition or deletion of PWHT XI X a The filler metal strength may be decreased without WPS requalification. WPSs using alloy flux, any increase or decrease in the electrode diameter shall require WPS requalification. C Travel speed ranges for all sizes of fillet welds may be determined by the largest single pass fillet weld and the smallest multiple-pass fillet weld qualification tests. d The production welding preheat or interpass temperature may be less than the PQR preheat or interpass temperature provided that the provisions of 5.6 are met, and the base metal temperature shall not be less than the WPS temperature at the time of subsequent welding. e AWS A5M (SI Units) electrodes of the same classification may be used in lieu of the AWS A5 (U.S. Customary Units) electrode classification. b For Note: An "x" indicates applicability for the process; a shaded block indicates nonapplicability. 142 AWS D1.1/D1.1M:2008 CLAUSE 4. PREQUALIFICATION Table 4.6 PQR SupplementartEssential Variable Changes for CVN Testing Applications Requiring WPS Requ,~lification for SMAW, SAW, GMAW, FCAW, and GTAW I Variable SMAW I SAW I I GMAW FCAW I GTAW Base Metal 1) A change in Group Number X X X X X 2) Minimum thickness qualified is T or S/8 in [16 mm] whichever is less, except if T is less than 1/4 in [6 mm], then the minimum thickness qualified is 1/8 in [3mm] X X X X X X X X X X X X Filler Metal 3) A change in the AWS AS.X Classification, or to a weld metal or filler metal classification not covered by ASX specifications 4) A change in the FluxIWire classification, or a change in either the. electrode or flux trade name when not classified by an AWS specification, or to a crushed slag S) A change in the manufacturer or the manufacturer's brand name or type of electrode Position 6) A change in position to vertical up. A 3G vertical up test qualifies for all positions and vertical down X ;1 r X 1 Preheat/lnterpass Temperature 7) An increase of more than lOO°F [S6°C] in the maximum preheat or interpass temperature qualified X X X X X X X X X X X X X X X 10) In the vertical position, a change from stringer to weave X X X X X lD A change from multipass per side to single pass per side X X X X X X X X X Post Weld Heat Treatment 8) A change in the PWHT temperature and/or time ranges. The PQR test shall be subject to 80% of the aggregate times at temperature(s). The PWHT total time(s) at temperature(s) may be applied in one heating cycle Electrical Characteristics 9) An increase in heat input or volume of weld metal deposited per unit length of weld, over that qualified, except when a grain refining austenitizing heat treatment is applied after welding. The increase may be measured by either of the following: a) Heat Input (J/in.) = Trave VOl;s; ~~~ ~ 6? ) pee m. mm b) Weld Metal Volume-An increase in bead size, or a decrease in the length of weld bead per unit length of electrode Other Variables 12) A change exceeding ±20% in the oscillation variables for mechanized or automatic welding 143 CLAUSE 4. PREQUALIFICATION AWS D1.1 /D1.1 M:2008 Table 4.7 • PQR Essential Variable Changes Requiring WPS Requalification for ESW or EGW (see 4.7.2) ,. Requalification by RT or UTa Requalification byWPS Test Essential Variable Changes to PQR Requiring Requalification Filler Metal x 1) A "significant" change in filler metal or consumable guide metal composition Molding Shoes (fixed or movable) 2) A change from metallic to nonmetallic or vice versa , X , X 3) A change from fusing to nonfusing or vice versa 4) A reduction in any cross-sectional dimension or area of a solid nonfusing shoe> 25% X , I. X 5) A change in design from nonfusing solid to water cooled or vice versa ' " " Filler Metal Oscillation 6) A change in oscillation traverse speed> 10 ipm (4 mm/s) . 7) A change in oscillation traverse dwell time> 2 seconds (except as necessary to compensate for joint opening variations) , ' X , X I 8) A change in oscillation traverse length which affects by more than 1/8 in [3 mm], the proximity of filler metal to the molding shoes X Filler Metal Supplements 9) A change in consumable guide metal core cross-sectional area> 30% 10) A change in the flux system, i.e., cored, magnetic electrode, external, etc. 11) A change in flux composition including consumable guide coating 12) A change in flux burden> 30% Electrode/Filler Metal Diameter X 13) Increase or decrease in electrode diameter> 1/32 in [1 mm] 14) A change in the number of electrodes used X '. , ' Electrode Amperage X 15) An increase or decrease in the amperage> 20% 16) A change in type of current (ac or dc) or polarity X Electrode Arc Voltage 17) An increase or decrease in the voltage> 10% X Process Characteristics 18) A change to a combination with any other welding process X 19) A change from single pass to mUlti-pass and vice versa X 20) A change from constant current to constant voltage and vice versa ...... ' . if i • )' • f'.'X Wire Feed Speed X 21) An increase or decrease in the wire feed speed> 40% ",.'" Travel Speed 22) An increase or decrease in the travel speed (if not an automatic function of arc length or deposition rate) > 20% (except as necessary to compensate for variation in joint opening) (Continued) 144 X .,".', AWS D1.1/D1.1M:2008 CLAUSE 4. PREQUALIFICATION Table 4.7 (Continued) PQR Essential Variable Ctlanges Requiring WPS Requalification for ESW or EGW (see 4.7.2) Requalification byWPSTest Essential Variable Changes to PQR Requiring Requalification Requalification by RTorUT' Electrode Shielding (EGW only) 23) A change in shielding gas composition of anyone constituent> 5% of total flow 24) An increase or decrease in the total shielding flow rate> 25% Welding Position 25) A change in vertical position by > 10° Groove Type 26) An increase in cross-sectional area (for nonsquare grooves) 27) A decrease in cross-sectional area (for nonsquare grooves) 28) A change in PQR joint thickness, T outside limits of O.5T-1.1 T 29) An increase or decrease> 1/4 in [6 mm] in square groove root opening Postweld Heat Treatment x 30) A change in PWHT • Testing shall be performed in conformance with Clause 6, Parts E or F, as applicable. Note: An "x" indicates applicability for the requalification method; a shaded block indicates nonapplicability. Table 4.8 Table 3.1, Table 4.9, and Unlisted Steels Qualified by PQR (see 4.7.3) WPS Base Metal Group Combinations Allowed by PQR PQR Base Metal Any Group I Steel to Any Group I Steel Any Group I Steel to Any Group I Steel Any Group II Steel to Any Group II Steel Any Group I Steel to Any Group I Steel Any Group II Steel to Any Group I Steel Any Group II Steel to Any Group II Steel Any Specific Group III or Table 4.9 Steel to Any Group I Steel The Specific PQR Group III or Table 4.9 Steel Tested to Any Group I Steel Any Specific Group III or Table 4.9 Steel to Any Group II Steel The Specific PQR Group III or Table 4.9 Steel Tested to Any Group I or Group II Steel Any Group III Steel to the Same or Any Other Group III Steel or Any Group IV Steel to the Same or Any Other Group IV Steel Steels shall be of the same material specification, grade/type and minimum yield strength as the Steels listed in the PQR or Any Table 4.9 Steel to the Same or Any Other Table 4.9 Steel Any Combination of Group III, IV, and Table 4.9 Steels Only the Specific Combination of Steels listed in the PQR Any Unlisted Steel to Any Unlisted Steel or Any Steel Listed in Table 3.1 or Table 4.9 Only the Specific Combination of Steels listed in the PQR Notes: 1. Groups I through IV are found in Table 3.l. 2. When allowed by the steel specification, the yield strength may be reduced with increased metal thickness. 145 ..... ..,.. 0\ A5.28 A5.29 GMAW FCAW A5.29 FCAW Over 20 thru 38 Up to 20 mm Over 2-112 Over 65 Over 1-1/2 Over 38 thru 2-112 thru 65 Over 3/4 thru 1-112 Up to 3/4 in Base Metal Thickness, T 225 175 125 50 of 110 80 50 10 °C Minimum Preheat and Interpass Temperature -. Notes. 1. When welds are to be stress relieved, the deposited weld metal shall not exceed 0.05% vanadium (see 5.8). 2. When required by contract or job specifications, deposited weld metal shall have a minimum CVN energy of 20 ft·lbs. [27.1 J] at OaF [20°C] as determined using CVN testing in conformance with Clause 4, Part D. 3. For ASTM A 514, A 517, and A 709, Grades 100 and 100W, the maximum preheat and interpass temperature shall not exceed 400°F [200°C] for thicknesses up to 1-1/2 [38 mm] inclusive, and 450°F [230°C] for greater thickness. 4. Filler metal properties have been moved to informative Annex V. 5. AWS A5M (SI Units) electrodes of the same classification may be used in lieu of the AWS A5 (U.S. Customary Units) electrode classification. EIIXTX-X~, EIIXTX-XM ER110S-XXX, E110C-XXX ElOXTX-XM A5.28 ElOXTX-X~, FIIXX-EXXX-XX, FIIXX-ECXXX-XX A5.29 585 min. FCAW ER100S-XXX, E100C-XXX FlOXX-EXXX-XX, FlOXX-ECXXX-XX A5.23 A5.28 A5.23 620 min. GMAW SAW BlOOI5-X, E10016-X, BlOOI8-X, ElO018M E8XTX-X, E8XTX-XC, E8XTX-XM ER80S-XXX, E80C-XXX F8XX-EXXX-XX, F8XX-ECXXX-XX E8015-X, E8016-X, E8018-X EI1015-X, EI1016-X, EI1018-X, EI1018-M 85 min. 90 min. 100-130 690-895 A5.5 A5.23 SAW 100-130 690-895 SMAW 550 min. A5.5 Electrode Classification A5.5 515 75 Process 520 min. SMAW MPa AWS Electrode Specification Matching Strength Filler Metal 110-130 760-895 SMAW ASTM A 514 (2-112 in 100 690 [65 mm] and under) ASTMA517 90-100 620-690 105-135 725-930 SAW ASTM A 709 Grades 100, 110-130 760-895 100 690 100W (2-112 in [65 mm] and under) GMAW 550 620 620 80 90 90 80 min. 450 65 ASTM A 514 (Over 2-112 in [65 mm]) ASTM A 709 Grades 100, 100W (Over 2-112 in to 4 in [65 to 100 mm]) ASTM A 710 Grade A. Class 1 ::; 3/4 in [20 mm] ASTM A 710 Grade A. Class 3 ::;2 in [50 mm] 70 min. 415 60 ksi ASTM A 871 Grades 60, 65 MPa ksi Tensile Range Specification Minimum Yield Point/Strength Base Metal Table 4.9 Code-Approved Base Metals and Filler Metals Requiring Qualification per Clause 4 <Xl o N o ~ ~ ~ ~ ~ ~ en 5 z ~ o "Tl C o §;; m :c 1J ~ en m ~ () 5 " • " P Pipe Fillet Groove" (Pipe or Box) Plug Fillet F F,H F,H,V F,OH All Positions" IG 2G 3G 4G 3G+4G . All 6GR (Fig. 4.27 &4.29) , All 6GR (Fig, 4,27) IF Rotated 2F 2FRotated 4F 5F F F,H F, V, OH All All IG Rotated i 2Gi 5Gi 6G i (2G +5G)i IF 2F 3F 4F 3F+4F Groove CJP All All . F F,H F,V,OH All All F F,H F,H,V F,OH All Groove PJP . , ' ' CJP (F, H)h (F, H)h (F, H, V)h (F, H, OH)h Allh pc.e (F, H)c.e (F, H, v)c.e (F,OH)c.e Allc.e Fh (F, H)h (F, H, V)h (F, H, OH)h Allh Fillet PJP T-, Y-,K-Connections Fd (F, H)d (F, H, V)d (F,OH)d Alld CJP Fh (F, H)h (F, H)h (F, H, OH)h Allh Allh Allh Alld.f Alld,f . Allf AUf , , :':' Alle,f Alle,f Alle,f AUC,f Fh (F, H)h (F, H)h (F,H,OH)h Allh Allh Allh Alld Alld All All F F,H F,V,OH All All F F,H F,H,V F,OH All PJP : : Alle,g CJP !(F, H)h (F, H, V)h (F, H, OH)h All h (F, H)h (F, H)h (F, H, V)h (F, H, OH)h Allh Fh .# Fillet AUC AUC . Fh (F, H)h (F, H)h (F, H, OH)h Allh Allh Allh pc (F, H)h (F, H)e (F, H)h (F, V, OH)e (F, V, OH)h Aile Allh Aile Allh pc (F, H)e (F, H, v)e (F,OH)e Aile PJP T-, Y-,K-Connections Production Box Tube Welding Qualified Butt Joint Qualifies Plug and Slot Welding for Only the Positions Tested pc,f pf pf (F, H)h (F, H)h F (F, H)e.f (F,H)f (F, H)h (F, H)h (F, H)f F,H (F, V, OH)h (F, V, OH)f (F, V, OH)f (F, V, OH)e.f (F, V, OH)h F, V, OH Alle,f Allh Allh Allf All AUf h Alle.f Allf All All AUf Allh , pc (F, H)C (F, H, V)C (F,OH)C AUC pc (F, H)C (F, H, V)C (F,OH)C Allc (F, H)h (F, H)h (F, H, V)h (F, H, OH)h Allh Fh (F, H)h (F,H, V) (F,H,OH)h Allh PJP CJP Butt Joint Production Pipe Welding Qualified Fillet Production Plate Welding Qualified Notes: 1. Not applicable for welding operator qualification (see Table 4.12). 2. Footnotes shown at the bottom of a column box apply to all entries): CJP-Complete Joint Penetration; PJP-Partiai Joint Penetration " See Figures 4.3, 4.4, 4.5, and 4.6. b Groove weld qualification shall also qualify plug and slot welds for the test positions indicated. c Only qualified for pipe equal to or greater than 24 in [600 mm] in diameter with backing, backgouging, or both. d 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 30° (see 4.12.4.2). f Qualification using box tubing (Figure 4.27) also qualifies welding pipe over 24 in [600 mm] in diameter. g Pipe or box tubing is required for the 6GR qualification (Figure 4.27).lfbox tubing is used per Figure 4.27, the macroetch test may be performed on the comers of the test specimen (similar to Figure 4.29). h See 4.25 and 4.28 for dihedral angle restrictions for plate joints and tubular T-, Y-, K-connections. i Qualification for welding production joints without backing or backgouging shall require using the Figure 4.24(A) joint detail. For welding production joints with backing or backgouging, either the Figure 4.24(A) or Figure 4.24(B) joint detail may be used for qualification. j The qualification of welding operators for electroslag welding (ESW) or electrogas welding (EGW) shall only apply for the position tested. A R L T U B U E A T L Grooveb Weld Type Qualification Test Table 4.10 Welder and Welding Operator Qualification-Production Welding Positions Qualified by Plate, Pipe, and Box Tube Tests {see 4.18.1)i ~" ~ 5z ~ (5 "Tl C §;i o m ::D ~ "tJ m (J) o o o co i\) s: ..... ~ ..... ~ ~(J) CLAUSE 4. PREQUALIFICATION AWS D1.1/D1.1 M:2008 Table 4.11 Welder and Welding Operator Qualification-Number and Type of Specimens and Range of Thickness and Diameter Qualified (Dimensions in Inches) (see 4.18.2.1) (l) Test on Plate Number of Specimens' Qualified Dimensions Nominal Plate, Pipe or Tube Thickness Qualified, in Production Groove or Plug Welds Type of Test Weld (Applicable Figures) Nominal Thickness of Test Plate (T) in Groove (Fig. 4.31 or 4.32) 3/8 Face Root Side Bendb Bendb Bendb (Fig. (Fig. (Fig. Macro4.12) 4.12) 4.13) etch 1 1 Min. Max. (Note c) - 118 3/4 max d Groove (Fig. 4.21, 4.22, or 4.30) 3/8<T< 1 - - 2 - 118 2Tmaxd Groove (Fig. 4.21, 4.22, or 4.30) 1 or over - - 2 - 118 Unlimitedd 3/8 - - 118 Unlimited Plug (Fig. 4.38) Production Fillet Welds (T-joint and Skewed) Type of Test Weld (Applicable Figures) ~ 2 - Number of Specimens' Qualified Dimensions Nominal Plate Thickness Qualified, in Nominal Test Plate Fillet Thickness, Weld Macro- Side Root Face T, in Break etch Bendb Bendb Bendb I Dihedral Angles Qualifiedh Min. Max. Min. Max. 118 Unlimited 30° Unlimited - - (Note c) Groove (Fig. 4.31 or 4.32) 3/8<T< 1 - - 2 - - 118 Unlimited 30° Unlimited Groove (Fig. 4.21, 4.22, or 4.30) ;::1 - - 2 - - 118 Unlimited 30° Unlimited Fillet Option 1 (Fig. 4.37) 112 - - 118 Unlimited 60° 135° Fillet Option 2 (Fig. 4.33) 3/8 - - 118 Unlimited 60° 135° Fillet Option 3 (Fig. 4.20) [Any diam. pipe] > 118 - - 118 Unlimited 30° Unlimited Groove (Fig. 4.31 or 4.32) 3/8 1 1 - 2 - 1 (2) Tests on Pipe or Tubingf - 1 - - 1 Number of Specimens' 5G, 6G and 6GR Positions Only 1G and 2G Positions Only Production CJP Groove Butt Joints Nominal Nominal Test Type of Size of Test Thickness, Face Root Side Face Root Side Test Weld Pipe, in in Bendb Bendb Bendb Bendb Bendb Bendb Nominal Plate, Pipe or Tube Wall Nominal Pipe or Tube Thickness d Size Qualified, in Qualified, in Min. Max. Min. Max. Groove :5:4 Unlimited 1 1 (Note c) 2 2 (Note c) 3/4 4 118 3/4 Groove >4 :5: 3/8 1 1 (Note c) 2 2 (Note c) (Note e) Unlimited 118 3/4 Groove >4 > 3/8 4 (Note e) Unlimited 3/16 Unlimited - - 2 - (Continued) 148 - AWS D1.1/D1.1 M:2008 CLAUSE 4. PREQUALIFICATION Table 4.11 (Continued) Welder and Welding Operator Qualification-Number and Type of Specimens and Range of Thickness and Diameter Qualified (Dimensions in Inches) (see 4.18.2.1) " (2) Test on Pipe or Tubing f (Cont'd) Qualified Dimensions ~ Number of Specimens' Production T-, Y-, or K-Connection CJP Groove Welds Type of Test Weld Nominal Nominal Test Size of Test Thickness, Pipe, in in Side Bendb Nominal Pipe or Tube Size Qualified, in Macroetch Nominal Wall or Plate Thickness c Qualified, in Dihedral Angles Qualifiedg Min. Max. 30° Unlimited Min. Max. Min. Max. Pipe Groove (Fig. 4.27) ;::60.D. ;::1/2 4 - 4 Unlimited 3/16 Unlimited Pipe Groove (Fig. 4.28) <40.D. ;::0.203 Notei - 3/4 <4 1/8 Unlimited 30° Unlimited Box Groove (Fig. 4.29) Unlimited ;::1/2 4 3/16 Unlimited 30° Unlimited Production T-, Y-, or K-Connection Fillet Welds Unlimited Unlimited (Box only) (Box only) 4 Nominal Wall or Plate Thickness Qualified Dihedral Angles Qualifiedg Min. Min. Max. Unlimited 2 2 1/8 (Note e) Unlimited (Note c) (Note c) (Noted) (Noted) 30° Unlimited Nominal Nominal Test Fillet Size of Type of Test Pipe, Thickness, Weld Macro- Root Test Weld D in Break etch Bendb 5G position Unlimited (Groove) ;:: 1/8 Option 1Fillet (Fig. 4.37)g - ;:: 1/2 Option 2Fillet (Fig. 4.33)g - 3/8 - ;:: 1/8 - Option 3Fillet (Fig. 4.20) Unlimited Qualified Dimensions Number of Specimens • - - 1 1 - 2 - 1 - Face Bendb Nominal Pipe or Tube Size Qualified, in Min. Max. Max. - 24 Unlimited 1/8 Unlimited 60° Unlimited - 24 Unlimited 1/8 Unlimited 60° Unlimited - D Unlimited 1/8 Unlimited 30° Unlimited (3) Tests on Electroslag and Electrogas Welding Production Plate Groove Welds Type of Test Weld Groove (Fig. 4.36) Number of Specimens' Side Bendb (see Fig. 4.13) Min. Max. < 1-1/2 2 1/8 T 1-1/2 2 1/8 Unlimited Nominal Plate Thickness Tested, T, in a All 1·.··.·- 1.·. . . :'::"' ... Nominal Plate Thickness Qualified, in welds shall be visually inspected (see 4.30.1). One test pipe, plate or tubing shall be required for each position tested, unless otherwise noted. b Radiographic examination of the test plate, pipe or tubing may be made in lieu of the bend tests (see 4.19.1.1). c For 3/8 in plate or wall thickness, a side-bend test may be substituted for each of the required face- and root-bend tests. d Also qualifies for welding any fillet or PJP weld size on any thickness of plate, pipe or tubing. e The minimum pipe size qualified shall be 112 the test diameter or 4 in, whichever is greater. f See Table 4.10 for appropriate groove details. g Two plates required, each subject to the test specimen requirements described. One plate shall be welded in the 3F position and the other in the 4F position. h For dihedral angles < 30°, see 4.26.1. i Two root and two face bends. 149 AWS D1.1 /D1.1 M:2008 CLAUSE 4. PREQUALIFICATION Table 4.11 (Continued) Welder and Welding Operator Qualification-Number and Type of Specimens and Range of Thickness and Diameter Qualified (Dimensions in Millimeters) (see 4.18.2.1) (l) Test on Plate Number of Specimens' Qualified Dimensions Nominal Plate, Pipe or Tube Thickness Qualified, mm Production Groove or Plug Welds Type of Test Weld (Applicable Figures) Face Root Side Nominal Thickness of Bendb Bendb Bendb Test Plate, T, (Fig. (Fig. (Fig. Macro4.12) 4.12) 4.13) etch mm Groove (Fig. 4.31 or 4.32) 1 10 1 Min. Max. (Note c) - 3 20maxd Groove (Fig. 4.21, 4.22, or IO<T<25 4.30) - - 2 - 3 2Tmaxd Groove (Fig. 4.21, 4.22, or 4.30) 25 or over - - 2 - 3 Unlimitedd 10 - - 3 Unlimited Plug (Fig. 4.38) Production Fillet Welds (T-joint and Skewed) Type of Test Weld (Applicable Figures) 2 - Number of Specimens' Qualified Dimensions Nominal Test Fillet Plate Thickness, T, Weld Macro- Side Root Face Break etch Bendb Bendb Bendb mm Nominal Plate Thickness Qualified, mm Dihedral Angles Qualifiedh Min. Max. Min. Max. 3 Unlimited 30° Unlimited - - (Note 3) Groove (Fig. 4.31 or 4.32) 10< T< 25 - - 2 - - 3 Unlimited 30° Unlimited Groove (Fig. 4.21, 4.22, or 4.30) ::::: 25 - - 2 - - 3 Unlimited 30° Unlimited Fillet Option I (Fig. 4.37) 12 - - 3 Unlimited 60° 135° Fillet Option 2 (Fig. 4.33) 10 - - 3 Unlimited 60° 135° Fillet Option 3 (Fig. 4.20) [Any diam. pipe] >3 - - 3 Unlimited 30° Unlimited Groove (Fig. 4.31 or 4.32) 10 1 1 1 (2) Tests on Pipe or Tubinge - 2 - - I 1 - - Number of Specimens' 5G, 6G and 6GR Positions Only IG and 2G Positions Only Production CJP Groove Butt Joints Nominal Nominal Test Face Root Side Face Root Side Type of Size of Test Thickness, Test Weld Pipe,mm mm Bendb Bendb Bendb Bendb Bendb Bendb Nominal Plate, Pipe or Tube Wall Nominal Pipe or Tube Thickness d Size Qualified, mm Qualified, mm Min. Max. Min. Max. Groove :::; 100 Unlimited I 1 (Note c) 2 2 (Note c) 20 100 3 20 Groove > 100 :::;10 I 1 (Note c) 2 2 (Note c) (Note e) Unlimited 3 20 Groove > 100 >10 4 (Note e) Unlimited 5 Unlimited - - 2 - (Continued) 150 - ~ ~ AWS D1.1/D1.1 M:2008 • CLAUSE 4. PREQUALIFICATION Table 4.11 (Continued) Welder and Welding Operator Qualification-Number and Type of Specimens and Range of Thickness and Diameter Qualified (Dimensions in Millimeters) (see 4.18.2.1) (2) Test on Pipe or Tubingf (Cont'd) Qualified Dimensions Number of Specimens' Production T-, Y-, or K-Connection CJP Groove Welds Type of Test Weld Nominal Nominal Test Size of Test Thickness, Pipe,mm mm Pipe Groove (Fig. 4.27) ~ Pipe Groove (Fig. 4.28) < 100O.D. Box Groove (Fig. 4.29) Unlimited ~ 1500.D. 12 ~5 ~ 12 :.• ,•. .;. • 0. •. \'c Macroetch Option 1Fillet (Fig. 4.37)g - Option 2Fillet (Fig. 4.33)g - Option 3Fillet (Fig. 4.20) Unlimited ~3 ~ ~3 - 30° Unlimited Min. Max. Unlimited 5 Unlimited Note i - 20 < 100 3 Unlimited 30° Unlimited 5 Unlimited 30° Unlimited Unlimited Unlimited (Box only) (Box only) 4 Qualified Dimensions Face Bendb Nominal Pipe or Tube Size Qualified, mm Min. Max. Nominal Wall or Plate Thickness Qualified, mm Dihedral Angles Qualifiedh Min. Min. Max. 30° Unlimited Max. Unlimited 2 2 3 (Note e) Unlimited (Noted) (Noted) (Note c) (Note c) - I - Max. Max. 100 - 10 Min. Min. Number of Specimens' 12 Dihedral Angles Qualifiedh - Nominal Nominal Test Fillet Size of Type of Test Pipe, Thickness, Weld Macro- Root Break: etch Bendb Test Weld D mm 5Gposition Unlimited (Groove) Nominal Wall or Plate Thicknessd Qualified, mm 4 4 Production T-, Y-, or K-Connection Fillet Welds (:: Side Bendb Nominal Pipe or Tube Size Qualified, mm I - 2 - 1 - - 600 Unlimited 3 Unlimited 60° Unlimited - 600 Unlimited 3 Unlimited 60° Unlimited - D Unlimited 3 Unlimited 30° Unlimited (3) Tests on Electroslag and Electrogas Welding Production Plate Groove Welds Type of Test Weld Groove (Fig. 4.36) Number of Specimens' Nominal Plate Thickness Qualified, mm Side Bendb (see Fig. 4.13) Min. Max. <38 2 3 T 38 2 3 Unlimited Nominal Plate Thickness Tested, T, mm • All welds shall be visually inspected (see 4.30.1). One test pipe, plate or tubing shall be required for each position tested, unless otherwise noted. b Radiographic examination of the test plate, pipe or tubing may be made in lieu of the bend tests (see 4.19.1.1). c Forl0 mm plate or wall thickness, a side-bend test may be substituted for each of the required face- and root-bend tests. d Also qualifies for welding any fillet or PJP weld size on any thickness of plate, pipe or tubing. e The minimum pipe size qualified shall be 1/2 the test diameter or 100 mm, whichever is greater. f See Table 4.10 for appropriate groove details. g Two plates required, each subject to the test specimen requirements described. One plate shall be welded in the 3F position and the other in the 4F position. h For dihedral angles < 30°, see 4.26.1. i Two root and two face bends. 151 AWS D1.1/D1.1M:2008 CLAUSE 4. PREQUALIFICATION Table 4.12 Welding Personnel Performance Essential Variable Changes Requiring Requalification (see 4.22) Welding Personnel Essential Variable Changes to WPQR Requiring Requalification Welders b Welding Operatorsb,c Tack Welders x x X (I) To a process not qualified (GMAW-S is considered a separate process) (2) To an SMAW electrode with an F-number (see Table 4.13) higher than the WPQR electrode F-number (3) To a position not qualified (4) To a diameter or thickness not qualified (5) To a vertical welding progression not qualified (uphill or downhill) (6) The omission of backing (if used in the WPQR test) (7) To multiple electrodes (if a single electrode was used in the WPQR test) but not vice versa Not for ESW or EGW. Welders qualified for SAW, GMAW, FCAW or GTAW shall be considered as qualified welding operators in the same process(es) and subject to the welder essential variable limitations. C A groove weld qualifies a slot weld for the WPQR position and the thickness ranges as shown in Table 4.11. a b Notes: 1. An "x" indicates applicability for the welding for the welding personnel; a shaded area indicates nonapplicability. 2. WPQR Welding Performance Qualification Record. 3. See Table 4.10 for positions qualified by welder WPQR. 4. See Table 4.11 for ranges of diameters or thicknesses qualified. = Table 4.13 Electrode Classification Groups (see Table 4.12) Group Designation AWS Electrode Classification F4 EXXI5, EXXI6, EXXI8, EXX48, EXXI5-X, EXXI6-X, EXXI8-X F3 EXXlO, EXXll, EXXlO-X, EXXll-X F2 EXXI2, EXXI3, EXXI4, EXX13-X FI EXX20, EXX24, EXX27, EXX28, EXX20-X, EXX27-X Note: The letters "XX" used in t!.le classification designation in this table stand for the various strength levels (60 [415], 70 [485], 80 [550], 90 [620], 100 [690], 110 [760], and 120 [830]) of electrodes. 152 4 AWS 01.1/01.1 M:2008 CLAUSE 4. PREQUALIFICATION Table 4.14 CVN Test Requirements (see 4.35) ~. Minimum Individual Absorbed Energy; ft-lbf [J] Minimum Average Percent Shear Area, % Minimum Average Lateral Expansion, Mils/mm Welding Process' Test Location Number of Specimensb Test Temperature °F/oC Specimen Size,d mm Minimum Average Absorbed Energy; ft-lbf [J] SMAW GTAW GMAW SAW ESW EGW FCAW-S FCAW-G Weld Metal 3 (Note c) 1OxlO 20 [27] 15 [20] (Note t) (Note t) Fusion Line +lmm 3 (Note c) lOx 10 20 [27] 15 [20] (Note t) (Note t) Fusion Line +5mm 3 (Note c) lOx 10 20 [27] 15 [~O] (Note t) (Note t) A WPS which combines FCAW-S with another welding process shall be specifically tested to assure CVN test criteria are met at the interface between the weld deposits. b The alternate number of specimens allowed per test location is five. The highest and lowest values shall be discarded to minimize some of the scatter normally associated with CVN testing of welds and HAZs. C Test temperatures shall be specified in contract documents or specifications. When sub-sized specimens are required, and the width of the specimens across the notch is less than 80% of the base metal thickness, the test temperature shall be reduced in conformance with Table 4.15. d Full size specimens shall be used when test material is 7/16 in [11 mm] or thicker. Sub-sized specimens shall be used when test material thIckness is less than 7/16 in [11 mm], or when weldment geometry prohibits the removal of full sized samples. e Applicable in welds between base materials with a specified minimum yield strength (SMYS) of 50 ksi [345 MPa] or less. Acceptance criteria for welds between materials exceeding SYMS of 50 ksi [345 MPa] shall be specified in the contract documents or specifications. f Values for percent shear and lateral expansion shall be recorded when specified in the contract documents or specifications. a Table 4.15 CVN Test Temperature Reduction (see 4.35.5) For sub-sized CVN test specimens where the width across the notch is less than 80% of the base metal thickness. Test Temperature Reduction Below the Specified Test Temperature t Specimen Size mm of °C lOx 10 lOx9 lOx 8 10 x 7.5 lOx7 lOx 6.7 lOx6 lOx5 lOx4 10 x 3.3 10 x 3 lOx2.5 0 0 0 5 8 10 15 20 30 35 40 50 0 0 0 2.8 4.5 5.6 8.4 11.1 16.8 19.4 22.4 27.8 Example: If design drawings or specifications indicate that CVN tests shall be performed at 32°F used; the actual test temperature would be 12°F [-11 0q. [ooq and 10 mrn x 5 mm sub-sized specimens are Note: The reduction in the minimum acceptance energy values for sub-sized specimens shall be determined in conformance with ASTM A 370a-97, Table 9. 153 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION Tabulation of Positions of Groove Welds Diagram Reference Inclination of Axis Rotation of Face Flat A 0 0 to 150 1500 to 2100 Horizontal B 0 0 to 15 0 80 0 to 150 0 2100 to 2800 Overhead C 0 0 to 80 0 0 0 to 80 0 280 0 to 3600 Vertical 0 E 150 to 80 0 80 0 to 90 0 80 0 to 280 0 0 0 to 360 0 Position AXIS LIMITS FOR C -------- --AXIS LIMITS FORA&B ~ 360 0 - ... ~ _ , Oo~- -------- HORIZONTAL PLANE --- --- --- -- Notes: 1. The horizontal reference plane shall always be taken to lie below the weld under consideration. 2. The inclination of axis shall be measured from the horizontal reference plane toward the vertical reference plane. 3. The angle of rotation of the face shall be determined by a line perpendicular to the theoretical face of the weld which passes through the axis of the weld. The reference position (0 0 ) of rotation of the face invariably points in the direction opposite to that in which the axis angle increases. When looking at point P, the angle of rotation of the face of the weld shall be measured in a clockwise direction from the reference position (0 0 ). Figure 4.1-Positions of Groove Welds (see 4.2.4) 154 AWS D1.1 /D1.1 M:200B CLAUSE 4. QUALIFICATION Tabulation of Positions of Fillet Welds Position Diagram Reference Inclination of Axis Rotation of Face Flat A Horizontal B 125° to 150° 210° to 235° Overhead C 0° to 125° 235° to 360° Vertical D E 15° to BO° 80° to 90° 125° to 235° 0° to 360° 1' .... 1 I I I I : 80° .... 1 I AXIS ,~--~-L1MITS FORE AXIS LIMITS FOR C ~.'t· .· ."t· .·.· · \ \ VERTICAL PLANE --- --- --- --.... 0° AXIS LIMITS FOR A & B \ ~ ~ -- 00 <::--- __ __ - - - - 360° HORIZONTAL PLANE ---- --- --- ------- --- Figure 4.2-Positions of Fillet Welds (see 4.2.4) 155 1 I I I I I 1 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION PLATES HORIZONTAL PLATES VERTICAL; AXIS OFWELO HORIZONTAL (A) FLAT WELDING TEST POSITION 1G (B) HORIZONTAL WELDING TEST POSITION 2G PLATES VERTICAL; AXIS OF WELD VERTICAL PLATES HORIZONTAL (C) VERTICAL WELDING TEST POSITION 3G (D) OVERHEAD WELDING TEST POSITION 4G Figure 4.3-Positions of Test Plates for Groove Welds (see 4.2.4) 156 CLAUSE 4. QUALIFICATION AWS D1.1/D1.1 M:2008 • PIPE HORIZONTAL AND ROTATED. WELD FLAT (±15°). DEPOSIT FILLER METAL AT OR NEAR THE TOP. (A) FLAT WELDING TEST POSITION 1G ROTATED PIPE OR TUBE VERTICAL AND NOT ROTATED DURING WELDING. WELD HORIZONTAL (±15°). (B) HORIZONTAL WELDING TEST POSITION 2G • PIPE OR TUBE HORIZONTAL FIXED (±15°) AND NOT ROTATED DURING WELDING. WELD FLAT, VERTICAL, OVERHEAD. (C) MULTIPLE WELDING TEST POSITION 5G RESTRICTION RING PIPE INCLINATION FIXED (45° ±5°) AND NOT ROTATED DURING WELDING. (D) MULTIPLE WELDING TEST POSITION 6G (E) MULTIPLE WELDING TEST POSITION 6GR WITH RESTRICTION RING (T-, yo, OR K-CONNECTIONS) Figure 4.4-Positions of Test Pipe or Tubing for Groove Welds (see 4.2.4) 157 AWS D1.1/D1.1 M:2008 CLAUSE 4. QUALIFICATION AXIS OF WELD HORIZONTAL THROAT OF WELD VERTICAL AXIS OF WELD ..,. HORiZONTAL ........ Note: One plate must be horizontal. (A) FLAT WELDING TEST POSITION 1F (B) HORIZONTAL WELDING TEST POSITION 2F AXIS OF WELD VERTICAL I I I AXIS OFWELD HORIZONTAL Note: One plate must be horizontal. (D) OVERHEAD WELDING TEST POSITION 4F (C) VERTICAL WELDING TEST POSITION 3F Figure 4.5-Positions of Test Plate for Fillet Welds (see 4.2.4) 158 AWS D1.1 /D1.1 M:2008 CLAUSE 4. QUALIFICATION , ~ ... ..•.. . . • . . (A) FLAT WELDING TEST POSITION 1F (ROTATED) (B) HORIZONTAL WELDING TEST POSITION 2F (FIXED) (C) HORIZONTAL WELDING TEST POSITION 2F (ROTATED) i. (E) MULTIPLE WELDING TEST POSITION SF (FIXED) (D) OVERHEAD WELDING TEST POSITION 4F (FIXED) Figure 4.6-Positions of Test Pipes or Tubing for Fillet Welds (see 4.2.4) i I /i '.:'.••.c'..·.". \':~ 159 AWS D1.1/D1.1M:2008 CLAUSE 4. QUALIFICATION CVN TEST SPECIMENS, WHEN REQUIRED (TYPICAL) TOP OF PIPE FOR 5G, 6G AND 6GR POSITIONS TOP OF PIPE FOR 5G, 6G AND 6GR POSITIONS FACE BEND FACE BEND ROOT BEND BEND SPECIMENS TENSION AND CVN TEST SPECIMENS DETAIL A-2 in OR 3 in IN DIAMETER [50 mm OR 75 mm IN DIAMETER] TOP OF PIPE FOR 5G, 6G AND 6GR POSITIONS TENSION CVN TEST SPECIMENS, WHEN REQUIRED (TYPICAL) SIDE BEND SIDE BEND 90 0 CVNTEST SPECIMENS, WHEN REQUIRED (TYPICAL) HORIZONTAL REFERENCE LINE FOR THE 5G OR 6G POSITIONS 41 ~ SIDE BEND SIDE BEND DETAIL 8-6 in OR 8 in IN DIAMETER [150 mm OR 200 mm IN DIAMETER] DETAIL C-CVN TEST SPECIMEN LOCATION FOR JOB SIZE PIPE, IF REQUIRED Note: Duplicate test pipes or tubes or larger job size pipe may be required when CVN testing is specified on contract documents or specifications. Figure 4.7-Location of Test Specimens on Welded Test Pipe (see 4.8) 160 AWS D1.1/D1.1M:2008 CLAUSE 4. QUALIFICATION TOP OF TUBING 5G, 6G, AND 6GR POSITIONS FACE OR SIDE BEND TENSION CVNTEST SPECIMENS, WHEN REQUIRED (TYPICAL) ROOT OR SIDE BEND FACE OR SIDE BEND ROOT OR SIDE BEND TENSION Figure 4.8-Location of Test Specimens for Welded Box Tubing (see 4.8) ii' .•................. \~ 161 CLAUSE 4. QUALIFICATION AWS D1.1/D1.1 M:2008 /....----« CJP ...... 1 - - - - DIRECTION OF ROLLING (OPTIONAL)l------I.~ DISCARD THIS PIECE =====11IIII:===== ==========-========== =====11IIII:===== SIDE BEND SPECIMEN REDUCED SECTION TENSION SPECIMEN SIDE BEND SPECIMEN ------=1---- ~1 t..- IMPACT SPECIMENS WHEN REQUIRED) ____ r~- -, 3_· _ WELD METAL TENSION SPECIMEN SIDE BEND SPECIMEN =====-===== 24 in [600 mm] EXTENSIONS NEED NOT BE USED IF THE JOINT IS OF SUFFICIENT LENGTH TO PROVIDE 19 in [480 mm] OF SOUND WELD EXCLUSIVE OF RETESTS REDUCED SECTION TENSION SPECIMEN -----~---------------SIDE BEND SPECIMEN ------~----- -- - - - ---~ I-- DISCARD THIS PIECE 12 in [300 mm] -.J-I 12 in [300 mm] -I Notes: 1. The groove configuration shown is for illustration only. The groove shape tested shall conform to the production groove shape that is being qualified. 2. When CVN test specimens are required, see Clause 4, Part D for requirements. 3. All dimensions are minimum. Figure 4.9-Location of Test Specimens on Welded Test PlatesESW and EGW-WPS Qualification (see 4.8) 162 CLAUSE 4. QUALIFICATION AWS 01.1/01.1 M:2008 • jr----« CJP / . . . . - DIRECTION OF ROLLING (OPTIONAL)-----" ~ ---, -- --r ( CJP DIRECTION OF ROLLING (OPTIONAL) ..... DISCARD THIS PIECE T 6in [150 mm] l 2 in [50 mm] T 0 en a» :0 LONGITUDINAL FACE BEND SPECIMEN I I --:::::I --=I -- 0 !:::-- REDUCED SECTION TENSION SPECIMEN F--- 0 Cii 6in [150 mm] +-t- 30 in [750 mm] or 36 in [910 mm] 6 in WHEN [150 mm] CVNTEST SPECIMENS REQUIRED 6 in [150mm] l 2 in [50 mm] T 6in [150mm] l a » :0 0 L- --J I I CVN TEST SPECIMENS (IF REQUIRED) I . LONGITUDIN~L F= . 0 en a » :0 FACE BENp SPECIMEN --=I b-- 0 REDUCED SECTION TENSION SPECIMEN == -SIDE BE I I LONGITUDINAL ROOT BEND SPECIMEN ==~ ECIMEN = =#II,T = CVN TEST SPECIMENS (IF REQUIRED) ==W.l.= --11II-- - -- --11I-- -- - - 1 15in [380 mm] or 21 in [525 mm] WHEN CVNTEST SPECIMENS REQUIRED REDUCED SECTION TENSION SPECIMEN .. -- .---- DISCARD THIS PIECE SIDE BEND SPECIMEN t:: - - :::::I -- SIDE BEND SPECIMEN I =~ DISCARD THIS PIECE - --I I I---- SIDE BE ECIMEN ~== 0 en 0 » :0 \-- 7 in [180 mm] --I-- 7 in [180 mm]-l 0 DISCARD THIS PIECE ~ 7 in [180 mm] --I-- 7 in [180 mm] --l (2) TRANSVERSE BEND SPECIMENS (1) LONGITUDINAL BEND SPECIMENS Notes: 1. The groove configuration shown is for illustration only. The groove shape tested shall conform to the production groove shape that is being qualified. 2. When CVN tests are required, the specimens shall be removed from their locations, as shown in Figure 4.40. 3. All dimensions are minimum. Figure 4.10-Location of Test Specimens on Welded Test Plate Over 3/8 in [10 mm] Thick-WPS Qualification (see 4.8) Ii. " .•..... ,v: 163 AWS D1.1/D1.1 M:2008 CLAUSE 4. QUALIFICATION /r----« ..--DIRECTION OF ROLLING CJP I (OPTIONAL)~ ( CJP "-DIRECTION OF ROLLING (OPTIONAL).... ---, T6in [150 mm] -.L 2 in [50 mm] T6in r - - oen LONGITUDINAL FACE BEND SPECIMEN I I ===1 ===J ~ ---1 I I T 2 in [50 mm] T 6in [150 mm] -.L ~ = L- :D 20 in FACE BEND SPECIMEN en o rrIIhT = [510mm] or 26 in [660mm] WHEN CVNTEST SPECIMENS REQUIRED CVN TEST SPECIMENS (IF REQUIRED) I = lW..L = ROOT BEND SPECIMEN I ==j o ~ :D REDUCED SECTION TENSION SPECIMEN t::== :t:::==- Io REDUCED SECTION TENSION SPECIMEN I I LONGITUDINAL ROOT BEND SPECIMEN -==BI==-==.=====111=== FACE BEND SPECIMEN en LONGITUDIN~L FACE BE~D SPECIMEN ===' ===1 ==-J 1 ROOT BEND SPECIMEN CVN TEST SPECIMENS (IF REQUIRED) + NSION SPECIMEN o o REDUCED SECTION TENSION SPECIMEN T+ [11: REDUCED SECTI ==181== ==.== :1:::== F== :D [150 mm] 30 in [750m] or36in 6in [910 mm] [150 ] WHEN mm CVNTEST SPECIMENS REQUIRED 6 in PIECE DISCARD THIS PIECE 7 in [180 mm] -I-- 7 in [180 mm] -l DISCARD THIS PIECE I- 7 in [180 mm]---/- 7 in [180 mm] --l (1) LONGITUDINAL BEND SPECIMENS (2) TRANSVERSE BEND SPECIMENS Notes: 1. The groove configuration shown is for illustration only. The groove shape tested shall conform to the production groove shape that is being qualified. 2. When CVN tests are required, the specimens shall be removed from their locations, as shown in Figure 4.40. 3. All dimensions are minimum. 4. For 3/8 in [10 mm] plate, a side-bend test may be substituted for each of the required face- and root-bend tests. See Figure 4.10(2) for plate length and location of specimens. Figure 4.11-Location of Test Specimens on Welded Test Plate 3/8 in [10 mm] Thick and Under-WPS Qualification (see 4.8) 164 AWS D1.1/D1.1M:2008 • CLAUSE 4. QUALIFICATION rI1 r 1 r F-TI 3/8 in 3/8 i n i [~?~-;-~:. .-" .-\~-i.-Jfl-~. .:~-~o_:-.m. :.] ~ i ~r mm] to I..I I -I -I 6 in [150 mm] MIN. ! - FACE BEND 3/8 in [10 mm] TEST PLATE 3/8 in [10 mm] !-ROOT BEND TEST PLATE OVER 3/8 in [10 mm] THICK (1) LONGITUDINAL BEND SPECIMEN 1_ 6 in [150mm] MIN. (See Note a) ~ ...---.. . .-LI .- "o~ .. 1 -r lrjADIUS 1/8 in [3 mm] MAX. ~ '310· I1 ~ . t L MATERIAL TO BE REMOVED FOR CLEANUP [10mm] 3/8 in-.J [10 mm] FACE BEND SPECIMEN ..I 6 in [150 mm] MIN. (See Note a) - - - ~ ---r (PLATE) ~~~~~ml ~I~ Note b MATERIAL TO BE REMOVED L.!0_R C_LEAN_UP _ _ _ in~1-­ t-.l _ (PIPE) ~~~f~:ii --_-....I~ t ] w£ "me e I~ ~ p~o ~m~t~," b 1_ 01 1 3/8 [10 mm] /lTIf (PLATE) 1"'----N-ot-e-c-.j'.......l"iiS'B,..:V'------3..... (PIPE) [10 mm] ROOT BEND SPECIMEN (2) TRANSVERSE BEND SPECIMEN Dimensions Test Specimen Width, W in [mm] Test Weldment Plate Test pipe or tube :s; 4 in [100 mm] in diameter 1-1/2 [40] 1 [25] Test pipe or tube > 4 in [100 mm] in diameter 1-1/2 [40] a A longer specimen length may be necessary when using a wraparound type bending fixture or when testing steel with a yield strength of 90 ksi [620 MPa] or more. bThese edges may be thermal-cut and mayor may not be machined. "The weld reinforcement and backing, if any, shall be removed flush with the surface of the specimen (see 5.24.4.1 and 5.24.4.2). If a recessed backing is used, this surface may be machined to a depth not exceeding the depth of the recess to remove the backing; in such a case, the thickness of the finished specimen shall be that specified above. Cut surfaces shall be smooth and parallel. Notes: 1. T = plate or pipe thickness. ( . 2. When the thickness of the test plate is less than 3/8 in [10 mm], the nominal thickness shall be used for face and root bends. Figure 4.12-Face and Root Bend Specimens (see 4.8.3.1) 165 AWS D1.1/D1.1 M:2008 CLAUSE 4. QUALIFICATION 6 in [150 mm] (Note a) +------ r-----I--_-_---i~ ~~8~~] IF THERMAL-CUT, ALLOW NOT LESS THAN 1/8 in [3 mm] TO BE MACHINED FROM EDGES 3/8 in [10 mm] l 1 / 8 in [3 mm] 6GR SPECIMEN r------, ;".,.. ... "'",------., f -----,- tc T t MACHINE THE MINIMUM AMOUNT NEEDED TO OBTAIN PLANE PARALLEL FACES (OPTIONAL) WHEN t EXCEEDS 1-1/2 in [38 mm], CUT ALONG THIS LINE. EDGE MAY BE THERMAL CUT. T, in t, in 3/8 to 1-1/2 > 1-1/2 t t, mm 10 to 38 > 38 t (Note b) T, mm t (Note b) a A longer specimen length may be necessary when using a wraparound-type bending fixture or when testing steel with a yield strength of 90 ksi [620 MPa] or more. bFor plates over 1-1/2 in [38 mm] thick, the specimen shall be cut into approximately equal strips with T between 3/4 in [20 mm] and 1-1/2 in [38 mm] and test each strip. Ct =.plate or pipe thickness. Figure 4.13-Side Bend Specimens (see 4.8.3.1) 166 4 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION MACHINE WELD REINFORCEMENT FLUSH WITH BASE METAL THESE EDGES MAY PLATE BE THERMAL CUT ~A;l 1/4 in 1/4 in [6 mm] [6 mm] t I" =1 ---- ---- I ;HI~ SECTION I ~MACHINED~ EDGE OF WIDEST FACE OF WELD PREFERABLY BY MILLING ...- - - - - L - - - - -.. MACHINE THE MINIMUM AMOUNT NEEDED TO OBTAIN PLANE PARALLEL FACES OVER THE REDUCED SECTION 6GR SPECIMEN 1 Dimensions in inches [mm] Test Plate Nominal Thickness, Tp Ie Tp ~ 1 in [25mm] A-Length of reduced section 1 in [25 mm] < Tp < 1-1/2 in [38mm] Tp 2: 1-1/2 in [38mm] Test Pipe 2 in [50 mm] & 3in [75 mm] Diameter 6 in [150 mm] & 8 in [200mm] Diameter or Larger Job Size Pipe Widest face of weld + 1/2 in [12 mm], 2-1/4 in [60 mm] min. Widest face of weld + 1/2 in [12 mm], 2-1/4 in [60 mm] min. As required by testing equipment As required by testing equipment L-Overalilength, min a W-Width of reduced sectionb,c 3/4 in [20 mm] min. 3/4 in [20 mm] min. 3/4 in [20 mm] min. 1/2 ± 0.01 (12 ± 0.025) 3/4 in [20 mm] min. C-Width of grip sectionc,d W + 1/2 in [12 mm] min. W + 1/2 in [12 mm] min. W + 1/2 in [12 mm] min. W + 1/2 in [12 mm] min. W + 1/2 in [12 mm] min. Tp Tp Tp/n (Note !l 1/2 in [12 mm] 1/2 in [12 mm] 1/2 in [12 mm] t-Specimen thicknesse,f r-Radius of fillet, min. Maximum possible with plane parallel faces within length A 1 in [25 mm] 1 in [25 mm] a It is desirable, if possible, to make the length of the grip section large enough to allow the specimen to extend into the grips a distance equal to two-thirds or more of the length of the grips. bThe ends of the reduced section shall not differ in width by more than 0.004 in [0.102 mm]. Also, there may be a gradual decrease in width from the ends to the center, but the width of either end shall not be more than 0.015 in [0.381 mm] larger than the width at the center. c Narrower widths (Wand C) may be used when necessary. In such cases, the width of the reduced section should be as large as the width of the material being tested allows. If the width of the material is less than W, the sides may be parallel throughout the length of the specimen. dFor standard plate-type specimens, the ends of the specimen shall be symmetrical with the center line of the reduced section within 1/4 in [6 mm]. eThe dimension t is the thickness of the specimen as provided for in the applicable material specifications. The minimum nominal thickness of 1-1/2 in [38 mm] wide specimens shall be 3/16 in [5 mm] except as allowed by the product specification. f For plates over 1-1/2 in [38 mm] thick, specimens may be cut into approximately equal strips. Each strip shall be at least 3/4 in [20 mm] thick. The test results of each strip shall meet the minimum requirements. Note: Due to limited capacity of some tensile testing machines, alternate specimen dimensions for Table 4.9 steels may be used when approved by the Engineer. Figure 4.14-Reduced-Section Tension Specimens (see 4.8.3.4) 167 AWS D1.1/D1.1 M:2008 CLAUSE 4. QUALIFICATION TAPPED HOLE TO SUIT TESTING MACHINE AS REQUIRED l 1-1/8 in. [28.6 mm 1/4 6-3/4 in. [171.4 mm] ;0] [6.4 mm] HARDENED ROLLERS 1-1/2 in. [38.1 mm] IN DIAMETER MAY BE SUBSTITUTED FOR JIG SHOULDERS DIE MEMBER ------------4 Specified or Actual Base Metal Yield Strength 50 ksi [345 MPa] & under over 50 ksi [345 MPa] to 90 ksi [620 MPa] 90 ksi [620 MPa] & over A B C in [mm] in [mm] in [mm] D in [mm] 1-1/2 [38.1] 3/4 [19.0] 2-3/8 [60.3] 1-3/16 [30.2] 2 [50.8] 1 [25.4] 2-7/8 [73.0] 1-7/16 [36.6] 2-1/2 [63.5] 1-1/4 [31.8] 3-3/8 [85.7] 1-11/16 [42.9] Note: Plunger and interior die surfaces shall be machine-finished. Figure 4.15-Guided Bend Test Jig (see 4.8.3) 168 AWS D1.1/D1.1M:2008 CLAUSE 4. QUALIFICATION • ROLLER ANY DIAMETER Specified or Actual Base Metal Yield Strength, ksi [MPa] 50 [345] & under over 50 [345] to 90 [620] A in B in A B mm mm 1-1/2 3/4 38.1 19.0 50.8 25.4 63.5 31.8 2 90 [620] over 2-1/2 1-1/4 Figure 4.16-Alternative Wraparound Guided Bend Test Jig (see 4.8.3) '• <•... ''I;, B = A/2 ~C~ Specified or Actual Base Metal Yield Strength, ksi [MPa] 50 [345] & under over 50 [345] to 90 [620] 90 [620] & over ~RMIN. A in B in C in A B C mm mm mm 1-112 3/4 2-3/8 38.1 19.0 60.3 2 1 2-7/8 50.8 25.4 73.0 3-3/8 63.5 31.8 85.7 2-112 1-1/4 Figure 4.17-Alternative Roller-Equipped Guided Bend Test Jig for Bottom Ejection of Test Specimen (see 4.8.3) 169 AWS D1.1/D1.1 M:2008 CLAUSE 4. QUALIFICATION - ------ - - - --- 1----- G ---.-- -----<~ Dimensions in inches Small-Size Specimens Proportional to Standard Standard Specimen 0.500 in Round 0.350 in Round 0.250 in Round G-Gage length 2.000 ± 0.005 1.400 ± 0.005 1.000 ± 0.005 D-Diameter (Note a) 0.500 ± 0.010 0.350 ± 0.007 0.250 ± 0.005 r-Radius of fillet, min. 3/8 1/4 3/16 2-1/4 1-3/4 1-1/4 Nominal Diameter A-Length of reduced section (Note b), min. Dimensions (metric version per ASTM E 8M) Standard Specimen Small-Size Specimens Proportional to Standard 12.5 mm Round 9 mm Round 6 mm Round G-Gage length 62.5 ± 0.1 45.0 ± 0.1 30.0 ± 0.1 D-Diameter (Note a), mm 12.5 ± 0.2 9.0 ± 0.1 6.0 ± 0.1 r-Radius of fillet, mm, min. 10 8 6 A-Length of reduced section, mm (Note b), min. 75 54 36 Nominal Diameter a The reduced section may have a gradual taper from the ends toward the center, with the ends not more than 1% larger in diameter than the center (controlling dimension). b If desired, the length of the reduced section may be increased to accommodate an extensometer of any convenient gage length. Reference marks for the measurement of elongation should be spaced at the indicated gage length. Note: The gage length and fillets shall be as shown, but the ends may be of any form to fit the holders of the testing machine in such a way that the load shall be axial. If the ends are to be held in wedge grips, it is desirable, if possible, to make the length of the grip section great enough to allow the specimen to extend into the grips a distance equal to two-thirds or more of the length of the grips. Figure 4.18-All-Weld-Metal Tension Specimen (see 4.8.3.6) 170 AWS D1.1/D1.1M:2008 CLAUSE 4. QUALIFICATION • 6 in [150 mm] MIN. Y W1 = MAXIMUM SINGLE PASS FILLET WELD USED IN CONSTRUCTION W2 = MINIMUM MULTIPLE PASS FILLET WELD USED IN CONSTRUCTION MACROETCH TEST SPECIMEN • E INCHES MILLIMETERS Weld Size T1 min. T2min. Weld Size 1/8 1/4 3/16 3 6 5 3/16 1/2 3/16 5 12 5 1/4 3/4 1/4 6 20 6 T1 min. T2 min. 5/16 5/16 8 25 8 3/8 3/8 10 25 10 1/2 1/2 12 25 12 5/8 5/8 16 25 16 3/4 3/4 20 25 20 >20 25 25 > 3/4 1 Note: Where the maximum plate thickness used in production is less than the value shown above, the maximum thickness of the production pieces may be substituted for T1 and T2. Figure 4.19-Fillet Weld Soundness Tests for WPS Qualification (see 4.11.2) 171 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION l If-3in (n---r-r--< t = MAXIMUM FILLET SIZE 3in [75mm] J_ START AND STOP OF WELD DETAIL A-PIPE TO PIPE ASSEMBLY MACROETCH ONE FACE OF CUT-TYPICAL MACROETCH TEST SPECIMEN Notes: 1. See Table 4.1 for position requirements. 2. Pipe shall be of sufficient thickness to prevent melt-through. TOP 1F ROTATED, 2F, 2F ROTATED 4F AND 5F LOCATION OF TEST SPECIMENS ON WELDED PIPE - WPS QUALIFICATION (A---r-r--( t = MAXIMUM FILLET SIZE l 2 in LL,.m_]---------------f/"-. L TMAX . T = WALL THICKNESS START AND STOP OF WELD . DETAIL B-PIPE TO PLATE ASSEMBLY MACROETCH ONE FACE OF CUT-TYPICAL MACROETCH TEST SPECIMEN Notes: 1. See Table 4.1 for position requirements. 2. Pipe shall be of sufficient thickness to prevent melt-through. 3. All dimensions are minimums. Figure 4.2o-Pipe Fillet Weld Soundness Test-WPS Qualification (see 4.11.2) 172 AWS 01.1/01.1 M:2008 • CLAUSE 4. QUALIFICATION SIDE BEND SPECIMEN SIDE BEND SPECIMEN DIRECTION OF ROLLING OPTIONAL ~ 5 in [125 mmj MIN aThe backing thickness shall be 1/4 in [6 mmj min. to 3/8 in [10 mmj max.; backing width shall be 3 in [75 mmj min. when not removed for RT, otherwise 1 in [25 mmj min. Note: When RT is used, no tack welds shall be in test area. • Figure 4.21-Test Plate for Unlimited Thickness-Welder Qualification (see 4.23.1) aThe backing thickness shall be 3/8 in [10 mmj min. to 1/2 in [12 mmj max.; backing width shall be 3 in [75 mmj min. when not removed for RT, otherwise 1-1/2 in [40 mmj min. Notes: 1. When RT is used, no tack welds shall be in test area. 2. The joint configuration of a qualified WPS may be used in lieu of the groove configuration shown here. • Figure 4.22-Test Plate for Unlimited Thickness-Welding Operator Qualification (see 4.23.2) 173 CLAUSE 4. QUALIFICATION AWS 01.1/01.1 M:2008 .....--- DIRECTION OF ROLLING (OPTIONAL)--------.- SIDE BEND SPECIMEN WELD METAL TENSION SPECIMEN 10 in [250 mm] MIN. SIDE BEND SPECIMEN LI3'" I [75 mm] M I N . + J 3/8in [10 mm] MIN. Figure 4.23-Location of Test Specimen on Welded Test Plate 1 in [25 mm] ThickConsumables Verification for Fillet Weld WPS Qualification (see 4.11.3) 174 AWS D1.1/D1.1 M:2008 • CLAUSE 4. QUALIFICATION \00 0 7 _ {=j L.----~ -l I-- 1/8 in [3 mm] MAX. + ~ [3 mm] MAX. (A) WELDER QUALIFICATION WITHOUT BACKING (B) WELDER QUALIFICATION WITH BACKING Note: T = qualification pipe or box tube wall thickness Figure 4.24-Tubular Butt Joint-Welder Qualification with and without Backing (see 4.26) ex = PRODUCTION ii I ex = GROOVE ANGLE (60 0 RECOMMENDED) " ~ PRODUCTION GROOVE ANGLE (60 0 RECOMMENDED) ex { \ / j( -l I-- 1/8 in [3 mm] MAX. ~t ~3mm] { MAX. (A) WPS QUALIFICATION WITHOUT BACKING (B) WPS QUALIFICATION WITH BACKING Note: T = qualification pipe or box tube wall thickness. Figure 4.25-Tubular Butt Joint-WPS Qualification with and without Backing (see 4.12.1 and 4.12.2) ••..i.' •~i" 175 AWS D1.1/D1.1M:2008 CLAUSE 4. QUALIFICATION in 5/8 [16mm]MI~ _ _ _ --- -r~ Gin ~ BACKUP WELD AREA (GROOVE WIDTH IS LESS THAN D1MENSIONW [TABLE 3.6]) [25 mm] MIN. DETAIL A SOUND THEORETICAL WELD Figure 4.26-Acute Angle Heel Test (Restraints not Shown) (see 4.12.4.2) 176 AWS 01.1/01.1M:2008 CLAUSE 4. QUALIFICATION 6in [150 mm] MIN. RESTRICTION RING 6in [150 mm] MIN. NOMINAL------'-,.--~~~~~ MINIMUM TEST PIPE 0.0. = 6 in [150 mm]; """'NO LIMIT FOR BOX TUBES """'- v7 0-1/16in~m] [12mmi~~ • / / / SAME 0.0. AS TEST PIPE OR SAME SIZE AS TEST BOX TUBING // Figure 4.27-Test Joint for T-, Y-, and K-Connections without Backing on Pipe or Box Tubing (~6 in [150 mm] O.D.)-Welder and WPS Qualification (see 4.12.4.1 and 4.26) 177 CLAUSE 4. QUALIFICATION AWS 01.1/01.1 M:2008 6 in [150 mm] MIN. RESTRICTION RING 6 in [150 mm] MIN. ----'-:--~~~,~ / NOMINAL TEST PIPE 0.0. < 4 in [100 mm]; NO LIMIT FOR BOX TUBES "'"'- O-1/16in~[0-2mm]/ 0.203 in [5.16 mm] MIN. <X / SAME 0.0. AS TEST PIPE OR SAME SIZE AS TEST BOX TUBING / / / Figure 4.28-Test Joint for T-, Y-, and K-Connections without Backing on Pipe or Box Tubing «4 in [100 mm] O.D.)-Welder and WPS Qualification (see 4.12.4.1 and 4.26) 178 ~ , AWS D1.1/D1.1 M:2008 • CLAUSE 4. QUALIFICATION MACROETCH TEST SPECIMEN LOCATION.;;r-r___ ,--~r-, 3 in ~ [75 mm] MIN. ~ 37-1~~111~ ~ 6in [150mm]MIN.~ 3/8 in [10 mm] MIN. -< 0-1/16in~ [0-2mm] MACROETCH TEST SPECIMEN LOCATIONS x: ; 6 in [150 mm] MIN Figure 4.29-Corner Macroetch Test Joint for T., Y·, and K·Connections without Backing on Box Tubing for CJP Groove Welds-Welder and WPS Qualification (see 4.12.4.1 and 4.26) • 179 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION DIRECTION OF ROLLING OPTIONAL r 6in [150 mm) MIN. ..........-........--.:---''----{ (Note a) SIDE BEND SPECIMEN SIDE BEND SPECIMEN a When RT is used, no tack welds shall be in test area. bThe backing thickness shall be 1/4 in [6 mm) min. to 3/8 in [10 mm) max.; backing width shall be 3 in [75 mm) min. when not removed for RT, otherwise 1 in [25 mm) min. Figure 4.3O-0ptional Test Plate for Unlimited ThicknessHorizontal Position-Welder Qualification (see 4.23.1) 180 AWS D1.1/D~.1 M:2008 • CLAUSE 4. QUALIFICATION ROOT BEND SPECIMENQ (Note a) FACE BEND DIRECTION OF ROLLING OPTIONAL ~ 7 in [180 mm] MIN. a When RT is used, no tack welds shall be in test area. bThe backing thickness shall be 1/4 in [6 mm] min. to 3/8 in [10 mm] max.; backing width shall be 3 in [75 mm] min. when not removed for RT, otherwise 1 in [25 mm] min. e For 3/8 in [10 mm] plate, a side-bend test may be substituted for each of the required face- and root-bend tests. • Figure 4.31-Test Plate for Limited Thickness-All PositionsWelder Qualification (see 4.23.1) • 181 CLAUSE 4. QUALIFICATION AWS 01.1/01.1 M:2008 DIRECTION OF ROLLING OPTIONAL r 6in [150 mm] MIN. (Note a) ROOT BEND SPECIMENl< a When RT is used, no tack welds shall be in test area. bThe backing thickness shall be 1/4 in [6 mm] min. to 3/8 in [10 mm] max.; backing width shall be 3 in [75 mm] min. when not removed for RT, otherwise 1 in [25 mm] min. e For 3/8 in [10 mm] plate, a side-bend test may be substituted for each of the required face- and root-bend tests. Figure 4.32-0ptional Test Plate for Limited Thickness-Horizontal Position-Welder Qualification (see 4.23.1) 182 AWS 01.1/01.1 M:2008 • CLAUSE 4. QUALIFICATION DIRECTION OF ROLLING (OPTIONAL) ------1.~ ..... ..1 - - - - - ~1-1/2 in [40 mm] ~'1"125mml ROOT BEND SPECIMEN - - - - - ~--+t<t ~';"[25mml ROOT BEND SPECIMEN L 1-1/2 in [40 mm] THESE EDGES MAY BE THERMAL-CUT AND MAY OR MAY NOT BE MACHINED. t 1-112 in [40mm] * I ~3;"~ 15/16 in.[24 mm]-j ~ 3In~ [75 mm] MIN. [75 mm] MIN. THE PORTION BETWEEN FILLET WELDS MAY BE WELDED IN ANY POSITION. 13/8 in [10 mm] -f RADIUS 1/8 in [3mm] MAX. r-------- MAXIMUM SIZE SINGLE L.. PASS FILLET WELD 3/8 in [10 mm] - - - - ~ AT LEAST 3/8 x 2 in [10 x 50 mm]IF RT IS USED, THEN USE AT LEAST 3/8 x 3 in [10 x 75 mm] BACKING. THE BACKING SHALL BE IN INTIMATE CONTACT WITH THE BASE METAL THE WELD REINFORCEMENT AND THE BACKING SHALL BE REMOVED FLUSH WITH THE BASE METAL (SEE 5.24.4.1). THERMAL CUTTING MAY BE USED FOR THE REMOVAL OF THE MAJOR PART OF THE BACKING. PROVIDED AT LEAST 1/8 in [3 mm] OF ITS THICKNESS IS LEFT TO BE REMOVED BY MACHINING OR GRINDING. a L = 7 in [175 mm] min. (welder), L = 15 in [380 mm] min. (welding operator). Figure 4.33-Fillet Weld Root Bend Test Plate-Welder or Welding Operator Qualification-Option 2 (see 4.28 or 4.25) 183 CLAUSE 4. QUALIFICATION AWS D1.1 /D1.1 M:2008 FACE BEND SIDE BEND 4 ROOT OR SIDE BEND FACE OR SIDE BEND SIDE BEND ROOT BEND PIPE WALL 3/8 in [10 mm] AND UNDER (Note a) PIPE WALL OVER 3/8 in [10 mm] ALL WALL THICKNESSES SPECIMENS FOR 1G AND 2G POSITIONS r--- TOP OF PIPE FOR 5G, 6G, AND 6GR - - , POSITIONS TOP OF TUBING FOR 5G, 6G, AND 6GR POSITIONS FACE OR SIDE BEND FACE BEND SIDE BEND SIDE BEND FACE BEND PIPE WALL 3/8 in [10 mm] AND UNDER (Note a) ROOT BEND SIDE BEND PIPE WALL OVER 3/8 in [10 mm] ROOT OR SIDE BEND ALL WALL THICKNESSES SPECIMENS FOR 5G, 6G, AND 6GR POSITIONS a For 3/8 in [10 mm] wall thickness, a side-bend test may be substituted for each of the required face- and root-bend tests. Figure 4.34-Location of Test Specimens on Welded Test Pipe and Box Tubing-Welder Qualification (see 4.19.1.2) 184 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION • FORCE Figure 4.35-Method of Rupturing Specimen-Tack Welder Qualification (see 4.31) DIRECTION OF ROLLING (OPTIONAL) - - - - I.. ~ .......1 - - - - - '. ~. SIDE BEND SPECIMEN -f 4in --+ [4dJ [100 mm] :;;m] MIN. C 4 in [100 mm] SIDE BEND SPECIMEN -~ a Root opening "R" established by WPS. bT = maximum to be welded in construction but need not exceed 1-1/2 in [38 mm]. I.?··· C Extensions need not be used if joint is of sufficient length to provide 17 in [430 mm] of sound weld. \~ . Figure 4.36-Butt Joint for Welding Operator Qualification-ESW and EGW (see 4.23.2) 185 CLAUSE 4. QUALIFICATION r~ FILLET WELD BREAK SPECIMEN AWS D1.1/D1.1 M:2008 3 In [75 mm] MIN DISCARD 1/2 in N ['2mm 4 in [100 mm] MIN. & 1/2in~ [12mm] MIN. < 4' In [100 mm] MIN. L /V" ~ V \ ~ ""- MACROETCH SPECIMEN (ETCH INTERIOR FACE)b ~ La ~ STOP AND RESTART WELDING NEAR CENTER CUTLINE a L = 8 in [200 mm] min. welder, 15 in [380 mm] min. (welding operator). bEither end may be used for the required macroetch specimen, The other end may be discarded. Figure 4.37-Fillet Weld Break and Macroetch Test Plate-Welder or Welding Operator Qualification-Option 1 (see 4.28 or 4.25) 186 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION r - - - - - - - - - - , _ _L 3/8 in [10 mm] r MACROETCH TEST SPECIMEN l 3 / 8 in [10 mm] MIN. r----------- 1 I MACROETCH SPECIMEN (ETCH INTERIOR FACE) • -1 I I I I I I I I CUTLINE --~I ~ Ll (Note a) L2 (Note a) WELD l_ ----- t-----~-I I- Ll (Note a) L2 (Note a) ~I .1 PLUG WELD TEST PLATE (MACROETCH BOTH INTERIOR FACES) aLl = 2 in [50 mm] min. (welder), 3 in [75 mm] min. (welding operator); L2 = 3 in [75 mm] min. (welder), 5 in [125 mm] min. (welding operator). Figure 4.38-Plug Weld Macroetch Test Plate-Welder or Welding Operator Qualification (see 4.14) and WPS Qualification (see 4.29) 187 AWS 01.1/01.1 M:2008 CLAUSE 4. QUALIFICATION r-I 4in [100mm] 1/2 in [12 mm] 1/2 in [12 mm] ~ -j r- r-- LI 4 in 1 [1~O mm] h5~m-n I I 4in [10[.. . __,. . __ ---1 1/2in-J [12mm] ~ Figure 4.39-Fillet Weld Break Specimen-Tack Welder Qualification (see 4.19.2) 188 AWS D1.1/D1.1 M:2008 • <t CLAUSE 4. QUALIFICATION rr--;m;---~~T::;1/2in ------c:=---~=--~ t .L I ,, ~r-Hl-~-r-'-- ~ -:...1 SINGLE V-GROOVE: BUTT JOINT, CORNER JOINT (ALL TYPES) T/4 (MIN.) T> 1/2 in [12 mm] _ T/4 1 1.._-- [12mm] (MIN.) <t--+-- -'-\:----:__-+....:::C"-/.::D L ,,- - , ,---'-iHH--+--:,- - :--I I T/4 (MIN.) ANYT DOUBLE V-GROOVE: BUTT JOINT, CORNER JOINT (ALL TYPES) 1-1- - - T/4 (MIN.) • -+-----.---"'--r\--ttt--+-~---.-~~ 21 T::; 1/2 in [12mm] SINGLE BEVEL GROOVE: BUTT JOINT, T-JOINT, CORNER JOINT <t--t--'-<t T> 1/2 in [1/2 mm] DOUBLE BEVEL GROOVE: BUTT JOINT, T-JOINT, CORNER JOINT (ALL TYPES) --'-~r------'--L.I T> 1/2 in [1/2 mm] A = CENTERLINE OF WELD ON SPECIMEN CENTERLINE C = HAZ i+ 1 mm FROM FUSION LINE} D = HAZ i+5 mm FROM FUSION LINE} Figure 4.40-CVN Test Specimen Locations (see 4.34.1) 189 AWS D1.1/D1.1 M:2008 ... This page is intentionally blank. 190 .. AWS D1.1/D1.1 M:2008 5. Fabrication 5.3 Welding Consumables and Electrode Requirements 5.1 Scope All applicable provisions of this section shall be observed in the fabrication and erection of welded assemblies and structures produced by any process acceptable under this code (see 3.2 and 4.15). 5.3.1 General 5.3.1.1 Certification for Electrodes or ElectrodeFlux Combinations. When requested by the Engineer, the Contractor or fabricator shall furnish 'certification that the electrode or electrode-flux combination conforms to the requirements of the classification. 5.2 Base Metal 5.3.1.2 Suitability of Classification. The classification and size of electrode, arc length, voltage, and amperage shall be suited to the thickness of the material, type of groove, welding positions, and other circumstance's attending the work. Welding current shall be within the range recommended by the electrode manufacturer. 5.2.1 Specified Base Metal. The contract documents shall designate the specification and classification of base metal to be used. When welding is involved in the structure, approved base metals, listed in Table 3.1 or Table 4.9, should be used wherever possible. 5.2.2 Base Metal for Weld Tabs, Backing, and Spacers 5.2.2.1 Weld Tabs. Weld tabs used in welding shall conform to the following requirements: (1) When used in welding with an approved steel listed in Table 3.1 or Table 4.9, they may be any of the steels listed in Table 3.1 or Table 4.9. (2) When used in welding with a steel qualified in conformance with 4.7.3 they may be: - 5.3.1.3 Shielding Gas. A gas or gas mixture used for shielding shall conform to the requirements of AWS A5.32, Specification for 'YVelding Shielding Gases. When requested by the Engineer, the Contractor or fabricator shall furnish the gas manufacturer's certification that the gas or gas mixture conforms to the dew point requirements of AWS A5.32. When mixed at the welding site, suitable meters ~hall be used for proportioning the gases. Percentage of gases shall conform to the requirements of 'the WPS. 5.3.1.4 Storage. Welding con~umables that have been removed from the original package shall be protected and stored so that the welding properties are not affected. (a) The steel qualified, or (b) Any steel listed in Table 3.1 or Table 4.9 5.3.1.5 Condition. Electrodes shall be dry and in suitable condition for use. 5.2.2.2 Backing. Steel for backing shall conform to the requirements of 5.2.2.1 or ASTM A 109 T3 and T4, except that 100 ksi [690 MPa] minimum yield strength steel as backing shall be used only with 100 ksi [690 MPa] minimum yield strength steels. '..".- ....•. t .. 5.3.2 SMAW Electrodes. Electrodes for SMAW shall conform to the requirements of the latest edition of AWS A5.lIA5.1M, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding, or to the requirements of AWS A5.5/A5.5M, Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding. 5.2.2.3 Spacers. Spacers shall be of the same material as the base metal. . 191 AWS D1.1/D1.1 M:2008 CLAUSE 5. FABRICATION hour at temperatures between 700°F and 800°F [370°C and 430°C]. 5.3.2.1 Low-Hydrogen Electrode Storage Conditions. All electrodes having low-hydrogen coverings conforming to AWS A5.1 and AWS A5.5 shall be purchased in hermetically sealed containers or shall be baked by the user in conformance with 5.3.2.4 prior to use. Immediately after opening the hermetically sealed container, electrodes shall be stored in ovens held at a temperature of at least 250°F [120°C]. Electrodes shall be rebaked no more than once. Electrodes that have been wet shall not be used. All electrodes shall be placed in a suitable oven at a temperature not exceeding one half the final baking temperature for a minimum of one half hour prior to increasing the oven temperature to the final baking temperature. Final baking time shall start after the oven reaches final baking temperature. • 5.3.2.5 Electrode Restrictions for ASTM A 514 or A 517 Steels. When used for welding ASTM A 514 or A 517 steels, electrodes of any classification lower than E100XX-X, except for E7018M and E70XXH4R, shall be baked at least one hour at temperatures between 700°F and 800°F [370°C and 430°C] before being used, whether furnished in hermetically sealed containers or otherwise. 5.3.2.2 Approved Atmospheric Time Periods. Mter hermetically sealed containers are opened or after electrodes are removed from baking or storage ovens, the electrode exposure to the atmosphere shall not exceed the values shown in column A, Table 5.1, for the specific electrode classification with optional supplemental designators, where applicable. Electrodes exposed to the atmosphere for periods less than those allowed by column A, Table 5.1 may be returned to a holding oven maintained at 250°F [120°C] min.; after a minimum hold period of four hours at 250°F [120°C] min. the electrodes may be reissued. 5.3.3 SAW Electrodes and Fluxes. SAW may be performed with one or more single electrodes, one or more parallel electrodes, or combinations of single and parallel electrodes. The spacing between arcs shall be such that the slag cover over the weld metal produced by a leading arc does not cool sufficiently to prevent the proper weld deposit of a follo.,}Ving electrode. SAW with multiple electrodes may be used for any groove or fillet weld pass. 5.3.2.3 Alternative Atmospheric Exposure Time Periods Established by Tests. The alternative exposure time values shown in column B in Table 5.1 may be used provided testing establishes the maximum allowable time. The testing shall be performed in conformance with AWS A5.5, subclause 3.10, for each electrode classification and each electrode manufacturer. Such tests shall establish that the maximum moisture content values of AWS A5.5 (Table 9) are not exceeded. Additionally, E70XX or E70XX-X (AWS A5.1 or A5.5) low-hydrogen electrode coverings shall be limited to a maximum moisture content not exceeding 0.4% by weight. These electrodes shall not be used at relative humidity-temperature combinations that exceed either the relative humidity or moisture content in the air that prevailed during the testing program. 5.3.3.1 Electrode-Flux Combination Requirements. The bare electrodes and flux used in combination for SAW of steels shall conform to the requirements in the latest edition of AWS A5.17, Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc Welding, or to the requirements of the latest edition of AWS A5.23, Specification for Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding. • 5.3.3.2 Condition of Flux. Flux used for SAW shall be dry and free of contamination from dirt, mill scale, or other foreign material. All flux shall be purchased in packages that can be stored, under normal conditions, for at least six months without such storage affecting its welding characteristics or weld properties. Flux from damaged packages shall be discarded or shall be dried at a minimum temperature of 500°F [260°C] for one hour before use. Flux shall be placed in the dispensing system immediately upon opening a package, or if used from an opened package, the top one inch shall be discarded. Flux that has been wet shall not be used. For proper application of this subclause, see Annex F for the temperature-moisture content chart and its examples. The chart shown in Annex F, or any standard psychometric chart, shall be used in the determination of temperature-relative humidity limits. 5.3.2.4 Baking Electrodes. Electrodes exposed to the atmosphere for periods greater than those allowed in Table 5.1 shall be baked as follows: 5.3.3.3 Flux Reclamation. SAW flux that has not been melted during the welding operation may be reused after recovery by vacuuming, catch pans, sweeping, or other means. The welding fabricator shall have a system for collecting unmelted flux, adding new flux, and welding with the mixture of these two, such that the flux com- (1) All electrodes having low-hydrogen coverings conforming to AWS A5.1 shall be baked for at least two hours between 500°F and 800°F [260°C and 430°C], ot (2) All electrodes having low-hydrogen coverings conforming to AWS A5.5 shall be baked for at least one 192 I AWS D1.1/D1.1 M:2008 • CLAUSE 5. FABRICATION 5.4.2 Condition of Electrodes and Guide Tubes. Electrodes and consumable guide tubes shall be dry, clean, and in suitable condition for use. position and particle size distribution at the weld puddle are relatively constant. 5.3.3.4 Crushed Slag. Crushed slag may be used provided it has its own marking, using the crusher's name and trade designation. In addition, each dry batch or dry blend (lot) of flux, as defined in AWS A5.01, Filler Metal Procurement Guidelines, shall be tested in conformance with Schedule I of AWS A5.01 and classified by the Contractor or crusher per AWS A5.17 or A5.23, as applicable. 5.4.3 Condition of Flux. Flux used for ESW shall be dry and free of contamination from dirt, mill scale, or other foreign material. All flux shall be purchased in packages that can be stored, under normal conditions, for at least six months without such storage affecting its welding characteristics or weld properties. Flux from packages damaged in transit or in handling shall be discarded or shall be dried at a minimum temperature of 250°F [120°C] for one hour before use. Flux that has been wet shall not be used. 5.3.4 GMAW/FCAW Electrodes. The electrodes for GMAW or FCAW shall conform to the requirements of 5.3.4.1 or 5.3.4.2, as applicable. 5.4.4 Weld Starts and Stops. Welds shall be started in such a manner as to allow sufficient heat buildup for complete fusion of the weld metal to the groove faces of the joint. Welds which have been stopped at any point in the weld joint for a sufficient amount of time for the slag or weld pool to begin to solidify may be restarted and completed, provided the completed weld is examined by UT for a minimum of 6 in [150 mm] on either side of the restart and, unless prohibited by joint geometry, also confirmed by RT. All such restart locations shall be recorded and reported to the Engineer. 5.3.4.1 60 ksi [415 MPa] or Less Yield Strength Weld Metal. Electrodes for producing weld metal with minimum specified yield strength~ of 60 ksi [415 MPa] or less -- shall conform -to the latest edition of AWS A5.18/A5.18M, Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding, or AWS A5.20/A5.20M, Specification for Carbon Steel Electrodes for Flux Cored Arc Welding, as applicable. • 5.3.4.2 Greater Than 60 ksi [415 MPa] Yield Strength Weld Metal. Electrodes for producing weld metal with minimum specified yield strength~ greater than 60 ksi [415 MPa] shall conform to the latest edition of AWS A5.28/A5.28M, Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding, or AWS A5.29/A5.29M, Specificationfor Low Alloy Steel Electrodes for Flux Cored Arc Welding, as applicable. 5.4.5 Preheating. Because of the high-heat input characteristic of these processes, preheating is not normally required. However, no welding shall be performed when the temperature of the base metal at the point of welding is below 32°F [O°C]. 5.4.6 Repairs. Welds having discontinuities prohibited by Clause 6, Part C shall be repaired as allowed by 5.26 utilizing a qualified welding process, or the entire weld shall be removed and replaced. 5.3.5 GTAW 5.3.5.1 Tungsten Electrodes. Welding current shall be compatible with the diameter and type or classification of electrode. Tungsten electrodes shall be in conformance with AWS A5.12, Specification for Tungsten and Tungsten Alloy Electrodes for Arc Welding and Cutting. 5.4.7 Weathering Steel Requirements. For ESW and EGW of exposed, bare, unpainted applications of ASTM A 588 steel requiring weld metal with atmospheric corrosion resistance and coloring characteristics similar to that of the base metal, the electrode-flux combination shall be in conformance with 4.17.2, and the filler metal chemical composition shall conform to Table 3.3. 5.3.5.2 Filler Metal. The filler metal shall conform to all the requirements of the latest edition of AWS A5.18 or AWS A5.28 and AWS A5.30, Specification for Consumable Inserts, as applicable. 5.5 WPS Variables The welding variables shall be in conformance with a written WPS (see Annex N, Form N-l, as an example). Each pass will have complete fusion with the adjacent base metal, and such that there will be no depressions or undue undercutting at the toe of the weld. Excessive concavity of initial passes shall be avoided to prevent cracking in the roots of joints under restraint. All welders, 5.4 ESW and EGW Processes • 5.4.1 Process Limitations. The ESW and EGW processes shall be restricted to use of Table 3.1, Group I, II, and III steels, except that ESW and EGW of A 710 shall not be permitted. 193 CLAUSE 5. FABRICATION AWS D1.1/D1.1 M:2008 ... welding operators, and tack welders shall be informed in the proper use of the WPS, and the applicable WPS shall be followed during the performance of welding. (1) The temperature of the furnace shall not exceed 600°F [315°C] at the time the welded assembly is placed in it. (2) Above 600°F, the rate of heating shall not be more than 400°F per hour divided by the maximum metal thickness of the thicker part, in inches, but in no case more than 400°F per hour. Above 315°C, the rate of heating in °C/hr shall not exceed 5600 divided by the maximum metal thickness, in millimeters, but not more than 220°C/hr. During the heating period, variations in temperature throughout the portion of the part being heated shall be no greater than 250°F [140°C] within any 15 ft [5 m] interval of length. The rates of heating and cooling need not be less than 100°F [55°C] per hour. However, in all cases, consideration of closed chambers and complex structures may indicate reduced rates of heating and cooling to avoid structural damage due to excessive thermal gradients. 5.6 Preheat and Interpass Temperatures Base metal shall be preheated, if required, to a temperature not less than the minimum value listed on the WPS (see 3.5 for prequalified WPS limitations and Table 4.5 for qualified WPS essential variable limitations). For combinations of base metals, the minimum preheat shall be based on the highest minimum preheat. This preheat and all subsequent minimum interpass temperatures shall be maintained during the welding operation for a distance at least equal to the thickness of the thickest welded part (but not less than 3 in [75 mmD in all directions from the point of welding. (3) After a maximum temperature of I 100°F [600°C] is reached on quenched and tempered steels, or a mean temperature range between 1l00°F and 1200°F [600°C and 650°C] is reached on other steels, the temperature of the assembly shall be held within the specified limits for a time not less than specified in Table 5.2, based on weld thickness. When ti'le specified stress relief is for dimensional stability, the holding time shall be not less than specified in Table 5.2, based on the thickness of the thicker part. During the holding period there shall be no difference greater than 150°F [85°C] between the highest and lowest temperature throughout the portion of the assembly being heated. Minimum interpass temperature requirements shall be considered equal to the preheat requirements, unless otherwise indicated on the WPS. The preheat and interpass temperature shall be checked just prior to initiating the arc for each pass. 5.7 Heat Input Control for Quenched and Tempered Steels (4) Above 600°F [315°C], cooling shall be done in a closed furnace or cooling chamber at a rate no greater than 500°F [260°C] per hour divided by the maximum metal thickness of the thicker part in inches, but in no case more than 500°F [260°C] per hour. From 600°F [315°C], the assembly may be cooled in still air. When quenched and tempered steels are welded, the heat input shall be restricted in conjunction with the maximum preheat and interpass temperatures required. Such considerations shall include the additional heat input produced in simultaneous welding on the two sides of a common member. The preceding limitations shall be in conformance with the producer's recommendations. Oxygen gouging of quenched and tempered steel shall be prohibited. 5.8.2 Alternative PWHT. Alternatively, when it is impractical to PWHT to the temperature limitations stated in 5.8.1, welded assemblies may be stress-relieved at lower temperatures for longer periods of time, as given in Table 5.3. 5.8.3 Steels Not Recommended for PWHT. Stress relieving of weldments of ASTM A 514, ASTM A 517, ASTM A 709 Grades 100 (690) and 100W (690W), and ASTM A 710 steels is not generally recommended. Stress relieving may be necessary for those applications where weldments shall be required to retain dimensional stability during machining or where stress corrosion may be involved, neither condition being unique to weldments involving ASTM A 514, ASTM A 517, ASTM A 709 Grades 100 (690) and 100W (690W), and ASTM A 710 steels. However, the results of notch toughness 5.8 Stress-Relief Heat Treatment Where required by the contract documents, welded assemblies shall be stress relieved by heat treating. Final machining after stress relieving shall be considered when needed to maintain dimensional tolerances. 5.8.1 Requirements. The stress-relief treatment shall conform to the following requirements: 194 AWS D1.1/D1.1 M:2008 • CLAUSE 5. FABRICATION tests have shown that PWHT may actually impair weld metal and HAZ toughness, and intergranular cracking may sometimes occur in the grain-coarsened region of the weld HAZ. shall be removed, and the joints shall be ground or finished smooth. Steel backing of welds that are parallel to the direction of stress or are not subject to computed stress need not be removed, unless so specified by the Engineer. 5.10.4.1 Externally Attached Backing. Where the steel backing of longitudinal welds in cyclically loaded structures is externally attached to the base metal by welding, such welding shall be continuous for the length of the backing. 5.9 Backing, Backing Gas, or Inserts CJP groove welds may be made with or without the use of backing gas, backing or consumable inserts, or may have the root of the initial weld gouged, chipped, or otherwise removed to sound metal before welding is started on the second side. 5.10.5 Statically Loaded Connections. Steel backing for welds in statically loaded structures (tubular and nontubular) need not be welded full length and need not be removed unless specified by the Engineer. 5.10 Backing Roots of groove or fillet welds may be backed by copper, flux, glass tape, ceramic, iron powder, or similar materials to prevent melting through. They may also be sealed by means of root passes deposited with lowhydrogen electrodes if SMAW is used, or by other arc welding processes. Steel backing shall conform to the following requirements: 5.11 Welding and Cutting Equipment All welding and thermal-cutting equipment' shall be so designed and manufactured, and shall be in such condition, as to enable designated personnel to follow the procedures and attain the results described elsewhere in this code. 5.10.1 Fusion. Groove welds made with the use of steel ... • backing shall have the weld metal thoroughly fused with the backing. 5.12 Welding Environment 5.10.2 Full-Length Backing. Steel backing shall be 5.12.1 Maximum Wind Velocity. GMAW, GTAW, EGW, or FCAW-G shall not be done in a draft or wind unless the weld is 'protected by a shelter. Such shelter shall be of material and shape appropriate to reduce wind velocity in the vicinity of the weld to a maximum of five mUes per hour [eight kilometers per hour]. made continuous for the full length of the weld. All joints in the steel backing shall be CJP groove weld butt joints meeting all the requirements of Clause 5 of this code. 5.10.3 Backing Thickness. The recommended minimum nominal thickness of backing bars, provided that the backing shall be of sufficient thickness, to prevent melt-through, is shown in the following table: 5.12.2 Minimuni Ambient Temperature. Welding shall not be done Thickness, min. Process GTAW SMAW GMAW FCAW-S FCAW-G SAW in mm 1/8 3/16 1/4 1/4 3/8 3/8 3 (1) when the ambient temperature is lower than O°F [-20°C], or (2) when surfaces are wet or exposed to rain, snow, or 5 6 6 (3) high wind velocities, or 10 10 (4) when welding personnel are exposed to inclement conditions. NOTE: Commercially available steel backing for pipe and tubing is acceptable, provided there is no evidence ofmelting on exposed interior surfaces. NOTE: ZerooF does not mean the ambient environmental temperature, but the temperature in the immediate vicinity of the weld. The ambient environmental temperature may be below O°F [-20°C], but a heated structure or shelter around the area being welded may maintain the temperature adjacent to the weldment at O°F [-20°C] or higher. 5.10.4 Cyclically Loaded Nontubular Connections. •.... For cyclically loaded structures, steel backing of welds that are transverse to the direction of computed stress 195 AWS D1.1/D1.1 M:2008 CLAUSE 5. FABRICATION ... conformance with the procedure of ASTM A 435, Speci- • fication for Straight Beam Ultrasonic Examination o f . Steel Plates. 5.13 Conformance with Design The sizes and lengths of welds shall be no less than those specified by design requirements and detail drawings, except as allowed in Table 6.1. The location of welds shall not be changed without approval of the Engineer. (2) For acceptance of W, X, or Y discontinuities, the area of the discontinuity (or the aggregate area of multiple discontinuities) shall not exceed 4% of the cut material area (length times width) with the following exception: if the length of the discontinuity, or the aggregate width of discontinuities on any transverse section, as measured perpendicular to the cut material length, exceeds 20% of the cut material width, the 4% cut material area shall be reduced by the percentage amount of the width exceeding 20%. (For example, if a discontinuity is 30% of the cut material width, the area of discontinuity cannot exceed 3.6% of the cut material area.) The discontinuity on the cut surface of the cut material shall be removed to a depth of 1 in [25 mm] beyond its intersection with the surface by chipping, gouging, or grinding, and blocked off by welding with a low-hydrogen process in layers not exceeding 1/8 in [3 mm] in thickness for at least the first four layers. 5.14 Minimum Fillet Weld Sizes The minimum fillet weld size, except for fillet welds used to reinforce groove welds, shall be as shown in Table 5.8. The minimum fillet weld size shall apply in all cases, unless the design drawings specify welds of a larger size. 5.15 Preparation of Base Metal Surfaces on which weld metal is to be deposited shall be smooth, uniform, and free from fins, tears, cracks, and other discontinuities which would adversely affect the quality or strength of the weld. Surfaces to be welded, and surfaces adjacent to a weld, shall also be free from loose or thick scale, slag, rust, moisture, grease, and other foreign material that would prevent proper welding or produce objectionable fumes. Mill scale that can withstand vigorous wire brushing, a thin rust-inhibitive coating, or antispatter compound may remain with the following exception: for girders in cyclically loaded structures, all mill scale shall be removed from the surfaces on which flange-to-web welds are to be made. (3) Repair shall not be required if a discontinuity Z, not exceeding t1UiI allowable area in 5.15.1.1(2), is discovered after the joint has been completed and is determined to be 1 in [25 mm] or more away from the face of . , the weld, as measured on the cut base-metal surface. If • the discontinuity Z is less than 1 in [25 mm] away from the face of the weld, it shall be removed to a distance of 1 in [25 mm] from the fusion zone of the weld by chipping, gouging, or grinding. It shall then be blocked off by welding with a low- hydrogen process in layers not exceeding 1/8 in [3 mm] in thickness for at least the first four layers. 5.15.1 Mill-Induced Discontinuities. The limits of acceptability and the repair of visually observed cut surface discontinuities shall be in conformance with Table 5.4, in which the length of discontinuity is the visible long dimension on the cut surface of material and the depth is the distance that the discontinuity extends into the material from the cut surface. All welded repairs shall be in conformance with this code. Removal of the discontinuity may be done from either surface of the base metal. The aggregate length of welding shall not exceed 20% of the length of the plate surface being repaired except with approval of the Engineer. (4) If the area of the discontinuity W, X, Y, or Z exceeds the allowable in 5.15.1.1(2), the cut material or subcomponent shall be rejected and replaced, or repaired at the discretion of the Engineer. 5.15.1.2 Repair. In the repair and determination of limits of mill induced discontinuities visually observed on cut surfaces, the amount of metal removed shall be the minimum necessary to remove the discontinuity or to determine that the limits of Table 5.4 are not exceeded. However, if weld repair is required, sufficient base metal shall be removed to provide access for welding. Cut surfaces may exist at any angle with respect to the rolling direction. All welded repairs of discontinuities shall be made by: 5.15.1.1 Acceptance Criteria. For discontinuities greater than I in [25 mm] in length and depth discovered on cut surfaces, the following procedures shall be observed. (1) Where discontinuities such as W, X, or Y in Figure 5.1 are observed prior to completing the joint, the size and shape of the discontinuity shall be determined by UT. The area of the discontinuity shall be determined as the area of total loss of back reflection, when tested in (1) Suitably preparing the repair area (2) Welding with an approved low-hydrogen process and observing the applicable provisions of this code 196 , AWS D1,1/D1,1 M:2008 • CLAUSE 5. FABRICATION (3) Grinding the completed weld smooth and flush (see 524.4.1) with the adjacent surface to produce a workmanlike finish. greater than that defined by the American National Standards Institute surface roughness value of 1000 !lin (25/lID] for material up to 4 in [100 mm] thick and 2000 !lin [50 !lm] for material 4 in to 8 in [200 mm] thick, with the following exception: the ends of members not subject to calculated stress at the ends shall not exceed a surface roughness value of 2000 !lin [50 flllll ASME B46.1, Suiface Texture (Surface Roughness, Waviness, and Lay) is the reference standard. AWS C4.1, Criteria for Describing Oxygen-Cut Suifaces and Oxygen Cutting Suiface Roughness Gauge may be used as a guide for evaluating surface roughness of these edges. For materials up to and including 4 in [l00 mm] thick, Sample No. 3 shall be used, and for materials over 4 in up to 8 in [200 mm] thick, Sample No.2 shall be used. NOTE: The requirements of 5.15.1.2 may not be adequate in cases of tensile load applied through the thickness of the material. 5.15.2 Joint Preparation. Machining, thermal cutting, gouging (including plasma arc cutting and gouging), chipping, or grinding may be used for joint preparation, or the removal of unacceptable work or metal, except that oxygen gouging shall not be used on steels that are ordered as quenched and tempered or normalized. 5.15.3 Material Trimming. For cyclically loaded structures, material thicker than specified in the following list shall be trimmed if and as required to produce a satisfactory welding edge wherever a weld is to carry calculated stress: 5.15.4.4 Gouge or Notch Limitations. Roughness exceeding these values and notches or gouges not more than 3/16 in [5 mm] deep on other wise satisfactory surfaces shall be removed by machining or grinding. Notches or gouges exceeding 3/16 in [5 mm] deep may be repaired by grinding if the nominal cross-sectional area is not reduced by more than 2%. Ground or machined surfaces shall be fared to the original surface with a slope not exceeding one in ten. Cut surfaces and adjacent edges shall be left free of slag. In thermal-cut surfaces, occasional notches or gouges may, with approval of the Engineer, be repaired by welding, (1) Sheared material thicker than 1/2 in [12 mm] (2) Rolled edges of plates (other than universal mill plates) thicker than 3/8 in [10 mm] • (3) Toes of angles or rolled shapes (other than wide flange sections) thicker than 5/8 in [16 mm] (4) Universal mill plates or edges of flanges of wide flange sections thicker than 1 in [25 mm] (5) The preparation for butt joints shall conform to the requirements of the detail drawings 5.16 Reentrant Corners 5.15.4 Thermal Cntting Processes. Electric arc cutting and gouging processes (including plasma arc cutting and gouging) and oxyfuel gas cutting processes are recognized under this code for use in preparing, cutting, or trimming materials. The use of these processes shall conform to the applicable requirements of Clause 5. Reentrant comers of cut material shall be formed to provide a gradual transition with a radius of not less than 1 in [25 mm]. Adjacent surfaces shall meet without offset or cutting past the point of tangency. The reentrant corners may be formed by thermal cutting, followed by grinding, if necessary, in conformance with the surface requirements of 5.15.4.3. 5.15.4.1 Other Processes. Other thermal cutting and gouging processes may be used under this code, provided the Contractor demonstrates to the Engineer an ability to successfully use the process. • 5.17 Beam Copes and Weld Access Holes 5.15.4.2 Profile Accnracy. Steel 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. Radii of beam copes and weld access holes shall provide a smooth transition free of notches or cutting past the points of tangency between adjacent surfaces and shall meet the surface requirements of 5.15.4.3. 5.15.4.3 Ronghness Requirements. In thermal cutting, the equipment shall be so adjusted and manipulated as to avoid cutting beyond (inside) the prescribed lines. The roughness of all thermal cut surfaces shall be no 5.17.1 Weld Access Hole Dimensions. All weld access holes required to facilitate welding operations shall have a length (Q) from the toe of the weld preparation not less than 1-1/2 times the thickness of the material in which 197 . AWS D1.1 /D1.1 M:2008 CLAUSE 5. FABRICATION final welds, shall be removed when required by the Engineer. the hole is made. The height (h) of the access hole shall be adequate for deposition of sound weld metal in the adjacent plates and provide clearance for weld tabs for the weld in the· material in which the hole is made, but not less than the thickness of the material. In hot rolled shapes and built-up shapes, all beam copes and weld access holes shall be shaped free of notches or sharp reentrant comers except that when fillet web-to-flange welds are used in built-up shapes, access holes may terminate perpendicular to the flange. Fillet welds shall not be returned through weld access holes (see Figure 5.2). t .. 5.18.4 Additional Tack Weld Requirements (1) Tack welds incorporated into final welds shall be made with electrodes meeting the requirements of the final welds. These welds shall be cleaned prior to incorporation. (2) Multipass tack welds shall have cascaded ends or be otherwise prepared for incorporation into the final weld. 5.17.2 Heavy Shapes. For rolled shapes with flange thickness greater than 2 in [50 mm] and built-up shapes with web material thickness greater than 1-1/2 in [40 mm], the thermally cut surfaces of beam copes and weld access holes shall be ground to bright metal and inspected by either MT or PT. If the curved transition portion of weld access holes and beam copes are formed by predrilled or sawed holes, that portion of the access hole or cope need not be ground. Weld access holes and beam copes in other shapes need not be ground nor inspected by MTorPT. (3) Tack welds incorporated into final welds that are qualified with notch toughness or are required to be made with filler metal classified with notch toughness shall be made with compatible filler metals. 5.18.5 Additional Requirements for Tack Welds Incorporated into SAW Welds. The following shall apply in addition to 5.18.4 requirements. (1) Preheat is not required for single pass tack welds remelted by continuous SAW welds. This is an exception to the qualification requirements of 5.18.1. (2) Fillet tack welds shall not exceed 3/8 in [10 mm] and shall not produce objectionable changes in the •. appearance of the weld surface. • 5.18 Tack Welds and Construction Aid Welds (3) Tack welds in the roots of joints requiring specific root penetration shall not result in decreased penetration. 5.18.1 General Requirements (1) Tack welds and construction aid welds shall be made with a qualified or prequalified WPS and by qualified personnel. . (4) Tack welds not conforming to the requirements of (2) and (3) shall be removed or reduced in size by any suitable means before welding. (2) Tack welds that are not incorporated in final welds, and construction aid welds that are not removed, shall meet visual inspection requirements before a member is accepted. (5) Tack welds in the root of a joint with steel backing less than 5/16 in [8 mm] thick shall be removed or made continuous for the full length of the joint using SMAW with low-hydrogen electrodes, GMAW, or FCAW-G. 5.18.2 Exclusions. Tack welds and construction aid welds are permitted except that: (1) In tension zones of cyclically loaded structures, there shall be no tack welds not incorporated into the final weld except as permitted by 2.16.2, nor construction aid welds. Locations more than 1/6 of the depth of the web from tension flanges of beams or girders are considered outside the tension zone. 5.19 Camber in Built-Up Members 5.19.1 Camber. Edges of built-up beam and girder webs shall be cut to the prescribed camber with suitable allowance for shrinkage due to cutting and welding. However, moderate variation from the specified camber tolerance may be corrected by a careful application of heat. (2) On members made of quenched and tempered steel with specified yield strength greater than 70 ksi [485 MPa], tack welds outside the final weld and construction aid welds shall require the approval of the Engineer. 5.19.2 Correction. Corrections of errors in camber of • quenched and tempered steel shall require approval by , . the Engineer. 5.18.3 Removal At locations other than 5.18.2, tack welds and construction aid welds, not incorporated into 198 AWS D1.1/D1.1M:2008 CLAUSE 5. FABRICATION 5.20 Splices in Cyclically Loaded Structures balanced between the web and flange welds as well as about the major and minor axes ofthe member. Splices between sections of rolled beams or built-up girders shall preferably be made in a single transverse plane. Shop splices of webs and flanges in built-up girders, made before the webs and flanges are joined to each other, may be located in a single transverse plane or multiple transverse planes, but the fatigue stress provisions of the general specifications shall apply. 5.21.7 Temperature Limitations. In making welds under conditions of severe external shrinkage restraint, once the welding has started, the joint shall not be allowed to cool below the minimum specified preheat until the joint has been completed or sufficient weld has been deposited to ensure freedom from cracking. 5.22 Tolerance of Joint Dimensions 5.21 Control of Distortion and Shrinkage 5.22.1 Fillet Weld Assembly. The parts to be joined by fillet welds shall be brought into as close contact as practicable. The root opening shall not exceed 3/16 in [5 mm] except in cases involving either shapes or plates 3 in [75 mm] or greater in thickness if, after straightening and in assembly, the root opening cannot be closed sufficiently to meet this tolerance. In such cases, a maximum root opening of 5/16 in [8 mm] m~y be used, provided suitable backing is used. Backing may be of flux, glass tape, iron powder, or similar materials, or welds using a low-hydrogen process compatible with the filler metal deposited. If the separation is greater than 1116 in [2 mm], the leg~ of the fillet weld shall be increased by the amount of the root opening, or the Contractor shall demonstrate that the required effective throat has been obtained. 5.21.1 Procedure and Sequence. In assembling and joining parts of a structure or of built-up members and in welding reinforcing parts to members, the procedure and sequence shall be such as will minimize distortion and shrinkage. 5.21.2 Sequencing. Insofar as practicable, all welds shall be made in a sequence that will balance the applied heat of welding while the welding progresses. • 5.21.3 Contractor Responsibility. On members or structures where excessive shrinkage or distortion could be expected, the Contractor shall prepare a written welding sequence for that member or structure which meets the quality requirements specified. The welding sequence and distortion control program shall be submitted to the Engineer, for information and comment, before the start of welding on the member or structure in which shrinkage or distortion is likely to affect the adequacy of the member or structure. 5.22.1.1 Faying Surface. The separation between faying surfaces of plug and slot welds, and of butt joints landing on a backing, shall not exceed 1116 in [2 mm]. Where irregularities ill; rolled shapes occur after straightening do not allow contact within the above limits, the procedure necessary to bring the material within these limits shall be subject to the approval of the Engineer. The use of filler plates shall be prohibited except as specified on the drawings or as specially approved by the Engineer and made in conformance with 2.13. 5.21.4 Weld Progression. The direction of the general progression in welding on a member shall be from points where the parts are relatively fixed in position with respect to each other toward points having a greater relative freedom of movement. 5.21.5 Minimized Restraint. In assemblies, joints expected to have significant shrinkage should usually be welded before joints expected to have lesser shrinkage. They should also be welded with as little restraint as possible. 5.22.2 PJP Groove Weld Assembly. The parts to be joined by PIP groove .welds parallel to the length of the member shall be brought into as close contact as practicable. The root opening between parts shall not exceed 3/16 in [5 mm] except in cases involving rolled shapes or plates 3 in [75 mm] or greater in thickness if, after straightening and in assembly, the root opening cannot be closed sufficiently to meet this tolerance. In such cases, a maximum root opening of 5/16 in [8 rom] may be used, provided suitable backing is used and the final weld meets the requirements for weld size. Tolerances for bearing joints shall be in conformance with the applicable contract specifications. 5.21.6 Subassembly Splices. All welded shop splices in each component part of a cover-plated beam or built-up member shall be made before the component part is welded to other component parts of the member. Long girders or girder sections may be made by welding subassemblies, each made in conformance with 5.21.6. When making these subassembly splices, whether in the shop or field, the welding sequence should be reasonably 199 .. CLAUSE 5. FABRICATION AWS 01.1/01.1 M:2008 5.22.3 Butt Joint Alignment. Parts to be joined at butt joints shall be carefully aligned. Where the parts are effectively restrained against bending due to eccentricity in alignment, the offset from the theoretical alignment shall not exceed 10% of the thickness of the thinner part joined, or 1/8 in [3 mm], whichever is smaller. In correcting misalignment in such cases, the parts shall not be drawn in to a greater slope than 1/2 in [12 mm] in 12 in [300 mm]. Measurement of offset shall be based upon the centerline of parts unless otherwise shown on the drawings. thickness of the thinner part or 3/4 in [20 mm], whichever is less, may be corrected by welding to acceptable dimensions prior to joining the parts by welding. 5.22.4.4 Engineer's Approval. Root openings greater than allowed by 5.22.4.3 may be corrected by welding only with the approval of the Engineer. 5.22.5 Gouged Grooves. Grooves produced by gouging shall be in substantial conformance with groove profile dimensions as specified in Figllfe 3.3 and 3.4 and provisions of 3.12.3 and 3.13.1. Suitable access to the root shall be maintained. 5.22.3.1 Girth Weld Alignment (Tubular). Abutting parts to be joined by girth welds shall be carefully aligned. No two girth welds shall be located closer than one pipe diameter or 3 ft [1 m], whichever is less. There shall be no more than two girth welds in any 10 ft [3 m] interval of pipe, except as may be agreed upon by the Owner and Contractor. Radial offset of abutting edges of girth seams shall not exceed 0.2t (where t is the thickness of the thinner member) and the maximum allowable shall be 1/4 in [6 mm], provided that any offset exceeding 1/8 in [3 mm] is welded from both sides. However, with the approval of the Engineer, one localized area per girth seam may be offset up to O.3t with a maximum of 3/8 in [10 mm], provided the localized area is under 8t in length. Filler metal shall be added to this region to provide a 4 to 1 transition and may be added in conjunction with making the weld. Offsets in excess of this shall be corrected as provided in 5.22.3. Longitudinal weld seams of adjoining sections shall be staggered a minimum of 90°, unless closer spacing is agreed upon by the Owner and fabricator. 5.22.6 Alignment Methods. Members to be welded shall be brought into correct alignment and held in position by bolts, clamps, wedges, guy lines, struts, and other suitable devices, or by tack welds until welding has been completed. The use of jigs and fixtures is recommended where practicable. Suitable allowances shall be made for warpage and shrinkage. 5.23 Dimensional Tolerance of Welded ., Structural Members The dimensions of welded structural members shall conform to the tolerances of (1) the general specifications governing the work, and (2) the special dimensional tolerances in 5.23.1 to 5.23.11.3. (Note that a tubular column is interpreted as a compression tubular member.) 5.23.1 Straightness of Columns and Trusses. For welded columns and primary truss members, regardless of cross section, the maximum variation in straightness shall be 5.22.4 Groove Dimensions 5.22.4.1 Nontubular Cross-Sectional Variations. With the exclusion of ESW and EGW, and with the exception of 5.22.4.3 for root openings in excess of those allowed in Figure 5.3, the dimensions of the cross section of the groove welded joints which vary from those shown on the detail drawings by more than these tolerances shall be referred to the Engineer for approval or correction. Lengths ofless than 30 ft [9 m]: 1/8 . Ill. X No. offt of total length 10 1 mm x No. of meters of total length Lengths of 30 ft [10 m] to 45 ft [15 m] = 3/8 in [10 mm] 5.22.4.2 Tubular Cross-Sectional Variations. Variation in cross section dimension of groove welded joints, from those shown on the detailed drawings, shall be in conformance with 5.22.4.1 except Lengths over 45 ft [15 m]: 3/8 (1) Tolerances for T-, Y-, and K-connections are included in the ranges given in 3.13.4. . Ill. + 1/8 . Ill. X 10 mm + 3 mmx (2) The tolerances shown in Table 5.5 apply to CJP tubular groove welds in butt joints, made from one side only, without backing. No.offt of total length - 45 10 No. of meters of total length - 15 3 5.23.2 Beam and Girder Straightness (No Camber Specified). For welded beams or girders, regardless of •.' cross section, where there is no specified camber, the • maximum variation in straightness shall be 5.22.4.3 Correction. Root openings greater than those allowed in 5.22.4.1, but not greater than twice the 200 AWS 01.1/01.1 M:2008 • CLAUSE 5. FABRICATION . No. offt of total length 1/8 m.x 10 Regardless of how the camber is shown on the detail drawings, the sign convention for the allowable variation is plus (+) above, and minus (-) below, the detailed camber shape. These provisions also apply to an individual member when no field splices or shop assembly is required. Camber measurements shall be made in the noload condition. 1 mm x No. of meters oftotallength 5.23.3 Beam and Girder Camber (Typical Girder). For welded beams or girders, other than those whose top flange is embedded in concrete without a designed concrete haunch, regardless of cross section, the maximum variation from required camber at shop assembly (for drilling holes for field splices or preparing field welded splices) shall be 5.23.5 Beam and Girder Sweep. The maximum variation from straightness or specified sweep at the midpoint shall be + 1/8 . No. offeet of total length In. x 10 at midspan, -0, +1-1/2 in [40 mm] for spans;;:: 100 ft [30 m] -0, + 3/4 in [20 mm] for spans < 100 ft [30 m] ± 1 mm x No. of meters oftotallength at supports, 0 for end supports ±J/8 [3 mm] for interior supports provided the member has sufficient lateral flexibility to allow the attachment of diaphragms, cross-frames, lateral bracing, etc., without damaging the structural member or its attachments. . d· . 0 4(a)b(1 - a/S) at mterme late pomts, - ,+ S 5.23.6 Variation in Web Flatness 5.23.6.1 Measurements. Variations from flatness of girder webs shall be determined by measuring the offset from the actual web centerline to a straight edge whose length is greater than the least panel dimension and placed on a plane parallel to the nominal web plane. Measurements shall be taken prior to erection (see Commentary). where • a = distance in feet (meters) from inspection point to nearest support S = span length in feet (meters) b = 1-1/2 in [40 mm] for spans;;:: 100 ft [30 m] b = 3/4 in [20 mm] for spans < 100 ft [30 m] 5.23.6.2 Statically Loaded Nontubular Structures. Variations from flatness of webs having a depth, D, and a thickness, t, in panels bounded by stiffeners or flanges, or both, whose least panel dimension is· d shall not exceed the following: See Table 5.6 for tabuiated values. 5.23.4 Beam and Girder Camber (without Designed Concrete Haunch). For members whose top flange is embedded in concrete without a designed concrete haunch, the maximum variation from required camber at shop assembly (for drilling holes for field splices or preparing field welded splices) shall be Intermediate stiffeners on both sides of web where D/t < 150, maximum variation = dl100 where D/t ;;:: 150, maximum variation =dl80 Intermediate stiffeners on one side only of web where D/t < 100, maximum variation = dl100 where D/t ;;:: 100, maximum variation =dl67 at midspan, ± 3/4 in [20 mm] for spans;;:: 100 ft [30m] ± 3/8 in [10 mm] for spans < 100 ft [30 m] No intermediate stiffeners where D/t;;:: 100, maximum variation =D/150 (See Annex D for tabulation.) at supports, 0 for end supports ± 1/8 in [3 mm] for interior supports 5.23.6.3 Cyclically Loaded Nontubular Structures. Variation from flatness of webs having a depth, D, and a thickness, t, in panels bounded by stiffeners or flanges, or both, whose least panel dimension is d shall not exceed the following: . d· . 4(a)b(1 - a/S) at mterme late pomts, ± S where a and S are as defined above • Intermediate stiffeners on both sides of web Interior girderswhere D/t < ISO-maximum variation = dillS where D/t;;:: ISO-maximum variation =dl92 b = 3/4 in [20 mm] for spans;;:: 100 ft [30 m] b = 3/8 in [10 mm] for spans < 100 ft [30 m] See Table 5.7 for tabulated values. 201 .. AWS D1.1/D1.1 M:2008 CLAUSE 5. FABRICATION lFascia girders--where D/t < 150---maximum variation = dl130 where D/t ;;::: 150---maximum variation = dl105 the flanges. The outer surface of the flanges when bearing against a steel base or seat shall fit within 0.010 in • [0.25 mm] for 75% of the projected area of web and stiff- • eners and not more than 1/32 in [1 mm] for the remaining 25% of the projected area. Girders without stiffeners shall bear on the projected area of the web on the outer flange surface within 0.010 in [0.25 mm] and the included angle between web and flange shall not exceed 90° in the bearing length (see Commentary). Intermediate stiffeners on one side only of web Interior girders-'where D/t < 100---maximum variation = dl100 where D/t ;;::: 100---maximum variation = dl67 lFascia girders--where D/t < 100---maximum variation = dl120 where D/t ;;::: 100---maximum variation =dl80 5.23.11 Tolerance on Stiffeners No intermediate stiffeners---maximum variation = D/150 5.23.11.1 Fit of Intermediate Stiffeners. Where tight fit of intermediate stiffeners is specified, it shall be defined as allowing a gap of up to 1/16 in [2 mm] between stiffener and flange. (See Annex E for tabulation.) 5.23.6.4 Excessive Distortion. Web distortions of twice the allowable tolerances of 5.23.6.2 or 5.23.6.3 shall be satisfactory when occurring at the end of a girder which has been drilled, or subpunched and reamed; either during assembly or to a template for a field bolted splice; provided, when the splice plates are bolted, the web assumes the proper dimensional tolerances. 5.23.11.2 Straightness of Intermediate Stiffeners. The out-of-straightness variation of intermediate stiffeners shall not exceed 1/2 in [12 mm] for girders up to 6 ft [1.8 m] deep, and 3/4 in [20 mm] for girders over 6 ft [1.8 m] deep, with due regard for members which frame into them. 5.23.6.5 Architectural Consideration. If architectural considerations require tolerances more restrictive than described in 5.23.6.2 or 5.23.6.3, specific reference shall be included in the bid documents. 5.23.11.3 St~aightness and Location of Bearing Stiffeners. The out-of-straightness variation of bearing stiffeners shall not exceed 1/4 in [6 mm] up to 6 ft ~, [1.8 m] deep or 1/2 in [12 mm] over 6 ft [1.8 m] deep. The actual centerline of the stiffener shall lie within the· thickness of the stiffener as measured from the theoretical centerline location. t 5.23.7 Variation Between Web and Flange Centerlines.lFor built-up H or I members, the maximum variation between the centerline of the web and the centerline of the flange at contact surface shall not exceed 1/4 in [6 mm]. 5.23.11.4 Other Dimensional Tolerances. Twist of box members and other dimensional tolerances of members not covered by 5.23 shall be individually determined and mutually agreed upon by the Contractor and the Owner with proper regard for erection requirements. 5.23.8 Flange Warpage and Tilt. lFor welded beams or girders, the combined warpage and tilt of flange shall be determined by measuring the offset at the toe of the flange from a line normal to the plane of the web through the intersection of the centerline of the web with the outside surface of the flange plate. This offset shall not exceed 1% of the total flange width or 1/4 in [6 mm], whichever is greater, except that welded butt joints of abutting parts shall fulfill the requirements of 5.22.3. 5.24 Weld Profiles All welds meet the visual acceptance criteria of Table 6.1 and shall be free from cracks, overlaps, and the unacceptable profile discontinuities exhibited in Figure 5.4 except as otherwise allowed in 5.24. 5.23.9 Depth Variation.lFor welded beams and girders, the maximum allowable variation from specified depth measured at the web centerline shall be For depths up to 36 in [1 m] incl. For depths over 36 in [1 m] to 72 in [2 m] incl. For depths over 72 in [2 m] ± 1/8 in [3 rom] 5.24.1 Fillet Welds. The faces of fillet welds may be slightly convex, flat, or slightly concave as shown in Figure 5.4. Figure 5.4(C) shows typically unacceptable fillet weld profiles. ± 3/16 in [5 rom] +5/16 in [8 rom] -3/16 in [5 rom] 5.24.2 Intermittent Fillet Welds. Except for undercut, as allowed by the code, the profile requirements of • Hgure 5.4 shall not apply to the ends of intermittent fillet. welds outside their effective length. 5.23.10 Bearing at Points of Loading. The bearing ends of bearing stiffeners shall be square with the web and shall have at least 75% of the stiffener bearing cross-sectional area in contact with the inner surface of 202 AWS 01.1/01.1 M:2008 CLAUSE 5. FABRICATION 5.24.3 Convexity. Except at outside welds in comer joints, the convexity C of a weld or individual surface bead shall not exceed the values given in Figure 5.4. • 5.25.1.2 Vertical Position. For welds to be made in the vertical position, the arc is started at the root of the joint at the lower side of the hole and is carried upward, fusing into the face of the inner plate and to the side of the hole. The arc is stopped at the top of the hole, the slag is cleaned off, and the process is repeated on the opposite side of the hole. After cleaning slag from the weld, other layers should be similarly deposited to fill the hole to the required depth. 5.24.4 Groove or Bntt Welds. Groove welds shall be made with minimum face reinforcement unless otherwise specified. In the case of butt and comer joints, face reinforcement shall not exceed 1/8 in [3 mm] in height. All welds shall have a gradual transition to the plane of the base-metal surfaces with transition areas free from undercut except as allowed by this code. Figure 5.4(D) shows typically acceptable groove weld profiles in butt joints. Figure 5.4(E) shows typically unacceptable weld profiles for groove weld butt joints. 5.25.1.3 Overhead Position. For welds to be made in the overhead position, the procedure is the same as for the flat position, except that the slag should be allowed to cool and should be completely removed after depositing each successive bead until the hole is filled to the required depth. 5.24.4.1 Flush Surfaces. Butt welds required to be flush shall be finished so as to not reduce the thicknesses of the thinner base metal or weld metal by more than 1/32 in [l rom], or 5% of the material thickness, whichever is less. Remaining reinforcement shall not exceed 1/32 in [1 rom] in height. However, all reinforcement shall be removed where the weld forms part of a faying or contact surface. All reinforcement shall blend smoothly into the plate surfaces with transition areas free from undercut. • 5.24.4.2 Finish Methods and Values. Chipping and gouging may be used provided these are followed by grinding. Where surface finishing is required, roughness values (see ASME B46.1) shall not exceed 250 microinches [6.3 micrometers]. Surfaces finished to values of over 125 microinches [3.2 micrometers] through 250 microinches [6.3 micrometers] shall be finished parallel to the direction of primary stress. Surfaces finished to values of 125 microinches [3.2 micrometers] or less may be finished in any direction. 5.25 Technique for Plug and Slot Welds 5.25.1 Plug Welds. The technique used to make plug welds when using SMAW, GMAW, (except GMAW-S), and FCAW processes shall be as follows: • 5.25.1.1 Flat Position. For welds to be made in the flat position, each pass shall be deposited around the root of the joint and then deposited along a spiral path to the center of the hole, fusing and depositing a layer of weld metal in the root and bottom of the joint. The arc shall then be moved to the periphery of the hole and the procedure repeated, fusing and depositing successive layers to fill the hole to the required depth. The slag covering the weld metal should be kept molten until the weld is finished. If the arc is broken or the slag is allowed to cool, the slag must be completely removed before restarting the weld. 5.25.2 Slot Welds. Slot welds shall be made using techniques similar to those specified in 5.25.1 for plug welds, except that if the length of the slot exceeds three times the width, or if the slot extends to the edge of the part, the technique requirements of 5.25.1.3 shall apply. 5.26 Repairs The removal of weld metal or portions of the base metal may be done by machining, grinding, chipping, or gouging. It shall be done in such a manner that the adjacent weld metal or base metal is not nicked or gouged. Oxygen gouging shall not be used in quenched and tempered steel. Unacceptable portions of the weld shall be removed without substantial removal of the base metal. The surfaces shall be cleaned thoroughly before welding. Weld metal shall be deposited to compensate for any deficiency in size. 5.26.1 Contractor Options. The Contractor has the option of either repairing an unacceptable weld or removing and replacing the entire weld, except as modified by 5.26.3. The repaired or replaced weld shall be retested by the method originally used, and the same technique and quality acceptance criteria shall be applied. If the Contractor elects to repair the weld, it shall be corrected as follows: 5.26.1.1 Overlap, Excessive Convexity, or Excessive Reinforcement. Excessive weld metal shall be removed. 5.26.1.2 Excessive Concavity of Weld or Crater, Undersize Welds, Undercutting. The surfaces shall be prepared (see 5.30) and additional weld metal deposited. 5.26.1.3 Incomplete Fusion, Excessive Weld Porosity, or Slag Inclusions. Unacceptable portions shall be removed (see 5.26) and rewelded. 203, CLAUSE 5. FABRICATION AWS D1.1/D1.1 M:2008 ... 5.26.1.4 Cracks in Weld or Base Metal. The extent of the crack shall be ascertained by use of acid etching, MT, PT, or other equally positive means; the crack and sound metal 2 in [50 mm] beyond each end of the crack shall be removed, and rewelded. the NDT methodes) specified in the contract documents for examination of tension groove welds or as approved jI by the Engineer. 11 (3) In addition to the requirements of (1) and (2), when holes in quenched and tempered base metals are restored by welding: 5.26.2 Localized Heat Repair Temperature Limitations. Members distorted by welding shall be straightened by mechanical means or by application of a limited amount of localized heat. The temperature of heated areas as measured by approved methods shall not exceed 1l00oP [600°C] for quenched and tempered steel nor 12000 P [650°C] for other steels. The part to be heated for straightening shall be substantially free of stress and from external forces, except those stresses resulting from the mechanical straightening method used in conjunction with the application of heat. (a) Appropriate filler metal, heat input, and PWHT (when PWHT is required) shall be used. (b) Sample welds shall be made using the repair WPS. (c) RT of the sample welds shall verify that weld soundness conforms to the requirements of 6.12.2.1. (d) One reduced section tension test (weld metal); two side bend tests (weld metal); and three CVN tests of the HAZ (coarse grain~d area) removed from sample welds shall be used to demonstrate that the mechanical properties of the repaired area conform to the specified requirements of the base metal (see Clause 4, Part D for CVN testing requirements). 5.26.3 Engineer's Approval. Prior approval of the Engineer shall be obtained for repairs to base metal (other than those required by 5.15), repair of major or delayed cracks, repairs to ESW and EGW with internal defects, or for a revised design to compensate for deficiencies. The Engineer shall be notified before welded members are cut apart. (4) Weld surfaces shall be finished as specified in 5.24.4.1. ... 5.26.4 Inaccessibility of Unacceptable Welds. If, after an unacceptable weld has been made, work is performed which has rendered that weld inaccessible or has created new conditions that make correction of the unacceptable weld dangerous or ineffectual, then the original conditions shall be restored by removing welds or members, or both, before the corrections are made. If this is not done, the deficiency shall be compensated for by additional work performed conforming to an approved revised design. 5.27 Peening Peening may be used on intermediate weld layers for control of shrinkage stresses in thick welds to prevent cracking or distortion, or both. No peening shall be done on the root or surface layer of the weld orthe base metal at the edges of the weld except as provided in 2.20.6.6(3). Care should be taken to prevent overlapping or cracking of the weld or base metal. 5.26.5 Welded Restoration of Base Metal with Mislocated Holes. Except where restoration by welding is necessary for structural or other reasons, punched or drilled mislocated holes may be left open or filled with bolts. When base metal with mislocated holes is restored by welding, the following requirements apply: 5.27.1 Tools. The use of manual slag hammers, chisels, and lightweight vibrating tools for the removal of slag and spatter is allowed and shall not be considered peening. (1) Base metal not subjected to cyclic tensile stress may be restored by welding, provided the Contractor prepares and follows a repair WPS. The repair weld soundness shall be verified by appropriate NDT, when such tests are specified in the contract documents for groove welds subject to compression or tension stress. (2) Base metal subject to cyclic tensile stress may be restored by welding provided: 5.28 Caulking Caulking shall be defined as plastic deformation of weld and base metal surfaces by mechanical means to seal or obscure discontinuities. Caulking shall be prohibited for base metals with minimum specified yield strength greater than 50 ksi [345 MPa]. Por base metals with minimum specified yield strength of 50 ksi [345" MPa] or less, caulking may be used, provided: (a) The Engineer approves repair by welding and the repair WPS. (1) all inspections have been completed and accepted _ (b) The repair WPS is followed in the work and the soundness of the restored base metal is verified by (2) caulking is necessary to prevent coating failures 204 AWS D1.1/D1.1 M:2008 • CLAUSE 5. FABRICATION (3) the technique and limitations on caulking are approved by the Engineer not be painted until after welding has been completed and the weld accepted. 5.29 Arc Strikes 5.31 Weld Tabs (See 5.2.2) Arc strikes outside the area of permanent welds should be avoided on any base metal. Cracks or blemishes caused by arc strikes shall be ground to a smooth contour and checked to ensure soundness. 5.31.1 Use of Weld Tabs. Welds shall be terminated at the end of a joint in a manner that will ensure sound welds. Whenever necessary, this shall be done by use of weld tabs aligned in such a manner to provide an extension of the joint preparation. 5.30 Weld Cleaning 5.31.2 Removal of Weld Tabs for Statically Loaded Nontubular Structures. For statically loaded nontubular structures, weld tabs need not be removed unless required by the Engineer. 5.30.1 In-Process Cleaning. Before welding over previously deposited metal, all slag shall be removed and the weld and adjacent base metal shall be cleaned by brushing or other suitable means. This requirement shall apply not only to successive layers but also to successive beads and to the crater area when welding is resumed after any interruption. It shall not, however, restrict the welding of plug and slot welds in conformance with 5.25. • 5.31.3 Removal of Weld Tabs for Cyclically Loaded Nontubular Structures. For cyclically loaded nontubular structures, weld tabs shall be removed upon completion and cooling of the weld, and the ends of the weld shall be made smooth and flush with the edges of abutting parts. 5.31.4 Ends of Welded Butt Joints. Ends of welded butt joints required to be flush shall be finished so as not to reduce the width beyond the detailed width or the actual width furnished, whichever is greater, by more than 1/8 in [3 mm] or so as not to leave reinforcement at each end that exceeds 1/8 in [3 mm]. Ends of welded butt joints shall be fared at a slope not to exceed 1 in 10. 5.30.2 Cleaning of Completed Welds. Slag shall be removed from all completed welds, and the weld and adjacent base metal shall be cleaned by brushing or other suitable means. Tightly adherent spatter remaining after the cleaning operation is acceptable, unless its removal is required for the purpose of NDT. Welded joints shall • 205 AWS D1.1/D1.1 M:2008 CLAUSE 5. FABRICATION ... Table 5.2 Minimum Holding Time (see 5.8.1) Table 5.1 Allowable Atmospheric Exposure of Low-Hydrogen Electrodes (see 5.3.2.2 and 5.3.2.3) Electrode Column A (hours) Column B (hours) 1/4 in [6mm] or Less Over 1/4 in [6 mm] Through 2 in [50mm] Over 2 in [50 mm] 15 min. 15 min. for each 1/4 in [6 mm] or fraction thereof 2 hrs plus 15 min. for each additional in [25 mm] or fraction thereof over 2 in [50 mm] A5.1 4 max. 9 max. 9 max. 9 max. E70XX E70XXR E70XXHZR E7018M A5.5 E70XX-X E80XX-X E90XX-X E100XX-X EllOXX-X 4 max. 2 max. 1 max. 1/2 max. 1/2 max. Over 4 to 10 max. Over 4 to 10 max. Over 2 to 10 max. Over 1 to 5 max. Over 1/2 to 4 max. Over 1/2 to 4 max. Table 5.3 Alternate Stress-Relief Heat Treatment (see 5.8.2) Decrease in Temperature below Minimum Specified Temperature, Notes: 1. Column A: Electrodes exposed to atmosphere for longer periods than shown shall be redried before use. 2. Column B: Electrodes exposed to atmosphere for longer periods than those established by testing shall be redried before use. 3. Electrodes shall be issued and held in quivers, or other small open containers. Heated containers are not mandatory. 4. 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 9 hours and has met the maximum level allowed in AWS A5.l/A5.IM, Specification for Carbon Steel Electrodesfor Shielded Metal Arc Welding. 50 100 150 200 . Minimum Holding Time at Decreased Temperature, Hours perInch [25 mm] of Thickness 2 4 30 60 90 120 10 20 Table 5.4 Limits on Acceptability and Repair of Mill Induced Laminar Discontinuities in Cut Surfaces (see 5.15.1) Repair Required Description of Discontinuity Any discontinuity 1 in [25 mm] in length or less None, need not be explored Any discontinuity over 1 in [25 mm] in length and 1/8 in [3 mm] maximum depth None, but the depth should be explored" Any discontfuuity over I in [25 mm] in length with depth over 1/8 in [3 mm] but not greater than 1/4 in [6 mm[ Remove, need not weld Any discontinuity over I in [25 mm] in length with depth over 1/4 in [6 mm] but not greater than I in [25 mm] Completely remove and weld Any discontinuity over 1 in [25 mm] in length with depth greater than 1 in [25 mm] See 5.15.1.1 a A spot check of 10% of the discontinuities on the cut surface in question should be explored by grinding to determine depth. If the depth of anyone of the discontinuities explored exceeds 1/8 in [3 mm], then all of the discontinuities over 1 in [25 mm] in length remaining on that cut surface shall be explored by grinding to determine depth. If none of the discontinuities explored in the 10% spot check have a depth exceeding 1/8 in [3 mm], then the remainder of the discontinuities on that cut surface need not be explored. 206 AWS D1.1/D1.1 M:2008 • CLAUSE 5. FABRICATION Table 5.7 Camber Tolerance for Girders without a Designed Concrete Haunch (see 5.23.4) Table 5.5 Tubular Root Opening Tolerances (see 5.22.4.2) Root Face of Joint SMAW GMAW FCAW Root Opening of Joints without Steel Backing Camber Tolerance (in inches) Groove Angle of Joint in mm in mm deg ±1/16 ±1/32 ±1/16 ±2 ±1 ±2 ±1/16 ±1/l6 ±1/l6 ±2 ±2 ±2 ±5 ±5 ±5 ~ 0.1 0.2 0.3 0.4 0.5 100 ft 1/4 1/2 5/8 3/4 3/4 < 100 ft 1/8 1/4 5/16 3/8 3/8 ~ Camber Tolerance (in millimeters) ~ Note: Root openings wider than allowed by the above tolerances, but not greater than the thickness of the thinner part, may be built up by welding to acceptable dimensions prior to the joining of the parts by welding. 0.1 0.2 0.3 0.4 0.5 ~30m 7 13 17 19 20 <30m 4 6 8 10 10 Table 5.8 Minimum Fillet Weld Sizes (see 5.14) Base-Metal Thickness (T)a in T~ 1/4 Minimum Size of Fillet Weldb mm in mm T~6 1/8 (Note c) 3 (Note c) 1/4 < T ~ 1/2 6 <T ~ 12 3/16 5 1/2 < T ~ 3/4 12 < T ~ 20 1/4 6 3/4<T 20<T 5/16 8 a For nonlow-hydrogen processes without preheat calculated in conformance with 4.7.4, T equals thickness of the thicker part joined; single-pass welds shall be used. For nonlow-hydrogen processes uSIng procedures established to prevent cracking in conformance with 4.7.4 and for low-hydrogen processes, T equals thickness of the thinner part joined; single-pass requirement shall not apply. b Except that the weld size need not exceed the thickness of the thinner part joined. C Minimum size for cyclically loaded structures shall be 3/16 in [5 mm]. • 207 .. AWS D1.1/D1.1M:2008 CLAUSE 5. FABRICATION Figure 5.l-Edge Discontinuities in Cut Material (see 5.15.1.1) . 208 AWS D1.1/D1.1 M:2008 CLAUSE 5. FABRICATION • BACKING IF USEDe L ~r­ l "--1-· h (Note d) L- __-'\ R (Note a) RADIUS PRECUT BY ~ > 1 5 t DRILL OR HOLE SAW • W D ;;::3/4 in [2Qmmj EJ ANGLE OF SLOPE NOT CRITICAL R NEED NOT BE TANGENT NOTCHES PROHIBITED (SEE FIGURE C-3.2) (Note a) I OPTIONAL METHOD FOR MAKING CORNER RADIUS ROLLED SHAPE OR GROOVE WELDED SHAPE b • FILLET WELDED SHAPEc a Radius shall provide smooth notch-free transition; R;;:: 3/8 in [10 mmj (Typical 1/2 in [12 mm]). b Access hole made after welding web to flange. Access hole made before welding web to flange. Weld shall not be returned through hole. d hmin = 3/4 in [20 mmj or t w (web thickness), whichever is greater. eThese are typical details for joints welded from one side against steel backing. Alternative joint designs should be considered. C Note: For rolled shapes with flange thickness greater than 2 in [50 mmj and built-up shapes with web material thickness greater than 1-1/2 in [40 mmj, preheat to 150°F [65°C] prior to thermal cutting, grind and inspect thermally cut edges of access hole using MT or PT methods prior to making web and flange splice groove welds. Figure 5.2-Weld Access Hole Geometry (see 5.17.1) 209 AWS 01.1/01.1 M:2008 CLAUSE 5. FABRICATION ... +100 ~a_50/ Da-fti~~t R ± 1/16 in [2mm] ---11-- ---r (A) GROOVE WELD WITHOUT BACKINGROOT NOT BACKGOUGED (B) GROOVE WELD WITH BACKING-" ROOT NOT BACKGOUGED +100 ~a_50/ fNOT 2\0 LIMITEO~ "t II +1/16 in [2 mm] -I I- R -1/8 in [3 mm] (C) GROOVE WELD WITHOUT BACKINGROOT BACKGOUGED Root Not Backgouged (1) Root face of joint (2) Root opening of joints without backing Root opening of joints with backing (3) Groove angle of joint in ±1/16 ±1/16 +1/4 -1/16 +100 _50 mm 2 2 6 2 Root Backgouged in mm Not limited +1/16 -1/8 2 3 Not applicable +10 0 _50 Note: See 5.22.4.2 for tolerances for CJP tubular groove welds made from one side without backing. Figure 5.3-Workmanship Tolerances in Assembly of Groove Welded Joints (see 5.22.4.1) 210 AWS 01.1/01.1 M:2008 CLAUSE 5. FABRICATION I f-- SIZE --1~ (NO~e a) (A) DESIRABLE FILLET WELD PROFILES (B) ACCEPTABLE FILLET WELD PROFILES - aConvexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table: WIDTH OF WELD FACE OR INDIVIDUAL SURFACE BEAD, W MAX. CONVEXITY, C W S; 5/16 in [8 mm] W > 5/16 in [8 mm] TO W < 1 in [25 mm] W ~ 1 in [25 mm] • 1/16 in [2 mm] 1/8 in [3 mm] 3/16 in [5 mm] ~ UNDERSIZE WELD EXCESSIVE CONVEXITY EXCESSIVE UNDERCUT OVERLAP SIZE --I ~ --I SIZE UNDERSIZE WELD INCOMPLETE FUSION (C) UNACCEPTABLE FILLET WELD PROFILES cR (Note b) ~::::::::::::::::::J===f T1 -L CR'(Note b) BUTT JOINTEQUAL THICKNESS PLATE b Reinforcement BUTT JOINT (TRANSITION)UNEQUAL THICKNESS PLATE R shall not exceed 1/8 in [3 mm] (see 5.24.4). (D) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT EXCESSIVE WELD REINFORCEMENT UNDERFILL EXCESSIVE UNDERCUT OVERLAP (E) UNACCEPTABLE GROOVE WELD PROFILES IN BUTT JOINTS • Note: All welds shall meet the visual acceptance criteria of Table 6.1 . Figure 5.4-Acceptable and Unacceptable Weld Profiles (see 5.24) 211 .. AWS D1.1/D1.1 M:2008 This page is intentionally blank... 212 AWS D1.1/D1.1 M:2008 • 6. Inspection Part A General Requirements Contractor on all inspection and quality matters within the scope of the contract documents. 6.1.3.2 Verification Inspector. This inspector is the duly designated person who acts for, and in behalf of, the Owner or Engineer on all inspection and quality matters within the scope of the contract documents. 6.1 Scope Clause 6 contains all of the requirements for the Inspector's qualifications and responsibilities, acceptance criteria for discontinuities, and procedures for NDT. • 6.1.3.3 Inspector(s). When the term inspector is used without further qualification as to the specific inspector category described above, it applies equally to inspection and verification within the limits of responsibility described in 6.1.2. 6.1.1 Information Furnished to Bidders. When NDT other than visual is to be required, it shall be so stated in the information furnished to the bidders. This information shall designate the categories of welds to be examined, the extent of examination of each category, and the method or methods of testing. 6.1.4 Inspector Qualification Requirements 6.1.4.1 Basis for Qualification. Inspectors responsible for acceptance or rejection of material and workmanship shall be qualified. The bases of Inspector qualification shall be documented. If the Engineer elects to specify the bases of inspector qualification, it shall be so specified in contract ~ocuments. 6.1.2 Inspection and Contract Stipulations. For the purpose of this code, fabrication/erection inspection and testing, and verification inspection and testing shall be separate functions. 6.1.2.1 Contractor's Inspection. This type of inspection and test shall be performed as necessary prior to assembly, during assembly, during welding, and after welding to ensure that materials and workmanship meet the requirements of the contract documents. Fabrication/erection inspection and testing shall be the responsibilities of the Contractor unless otherwise provided in the contract documents. The acceptable qualification basis shall be the following: (1) Current or previous certification as an AWS Certified Welding Inspector (CWI) in conformance with the provisions of AWS QCl, Standardfor AWS Certification of Welding Inspectors, or (2) Current or previous qualification by the Canadian Welding Bureau (CWE) in conformance with the requirements of the Canadian Standard Association (CSA) Standard W178.2, Certification of Welding Inspectors, or 6.1.2.2 Verification Inspection. This type of inspection and testing shall be performed and their results reported to the Owner and Contractor in a timely manner to avoid delays in the work. Verification inspection and testing are the prerogatives of the Owner who may perform this function or, when provided in the contract, waive independent verification, or stipulate that both inspection and verification shall be performed by the Contractor. (3) An individual who, by training or experience, or both, in metals fabrication, inspection and testing, is competent to perform inspection of the work. 6.1.4.2 Term of Effectiveness. The qualification of an Inspector shall remain in effect indefinitely, provided the Inspector remains active in inspection of welded steel fabrication, unless there is specific reason to question the Inspector's ability. 6.1.3 Definition of Inspector Categories • 6.1.3.1 Contractor's Inspector. This inspector is the duly designated person who acts for, and in behalf of, the 213 CLAUSE 6. INSPECTION PARTA . AWS 01.1/01.1 M:2008 6.3.3 WPSs in Production. The Contractor's Inspector shall ensure that all welding operations are performed in conformance with WPSs that meet the requirements of this code and the contract documents. 6.1.4.3 Assistant Inspector. The Inspector may be supported by Assistant Inspectors who may perform specific inspection functions under the supervision of the Inspector. Assistant Inspectors shall be qualified by training and experience to perform the specific functions to which they are assigned. The work of Assistant Inspectors shall be regularly monitored by the Inspector, generally on a daily basis. 6.4 Inspection of Welder, Welding Operator, and Tack Welder Qualifications 6.1.4.4 Eye Examination. Inspectors and Assistant Inspectors shall have passed an eye examination with or without corrective lenses to prove near vision acuity of Jaeger J-2 at a distance of 12 in-I? in [300 mm-430 mm). Eye examination of all inspection personnel shall be required every three years or less if necessary to demonstrate adequacy. 6.4.1 Determination of Qualification. The Inspector shall allow welding to be performed only by welders, welding operators, and tack welders who are qualified in conformance with the requirements of Clause 4, or shall ensure that each welder, welding operator, or tack welder has previously demonstrated such qualification under other acceptable supervision and approved by the Engineer in conformance with 4.1.2.1. 6.1.4.5 Verification Authority. The Engineer shall have authority to verify the qualification of Inspectors. 6.1.5 Inspector Responsibility. The Inspector shall ascertain that all fabrication and erection by welding is performed in conformance with the requirements of the contract documents. 6.4.2 Retesting Based on Quality of Work. When the quality of a qualified welder's, welding operator's, or tack welder's work appears to be below the requirements of this code, the Inspector may require that the welder, welding operator, or tack welder demonstrate an ability to produce sound welds by means of a simple test, such as the fillet weld break test, or by requiring complete requalification in conformance with Clause 4. 6.1.6 Items to be Furnished to the Inspector. The Inspector shall be furnished complete detailed drawings showing the size, length, type, and location of all welds to be made. The Inspector shall also be furnished the portion of the contract documents that describes material and quality requirements for the products to be fabricated or erected, or both. 6.4.3 Retesting Based on Qualification Expiration. The Inspector shall require requalification of any qualified welder or welding operator who has not used the process (for which they are qualified) for a period exceeding six months (see 4.1.3.1). 6.1.7 Inspector Notification. The Inspector shall be notified in advance of the start of operations subject to inspection and verification. 6.5 Inspection of Work and Records 6.2 Inspection of Materials and Equipment 6.5.1 Size, Length, and Location of Welds. The Inspector shall ensure 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 the approval of the Engineer. The Contractor's Inspector shall ensure that only materials and equipment conforming to the requirements of this code shall be used. 6.5.2 Scope of Examinations. The Inspector shall, at suitable intervals, observe joint preparation, assembly practice, the welding techniques, and performance of each welder, welding operator, and tack welder to ensure that the applicable requirements of this code are met. 6.3 Inspection of WPSs 6.3.1 Prequalified WPS. The Contractor's Inspector shall ensure that all prequalified WPSs to be used for the work conform with the requirements Clause 3, Clause 5, and the contract documents. 6.5.3 Extent of Examination. The Inspector shall examine the work to ensure that it meets the requirements of this code. Other acceptance criteria, different from those described in the code, may be used when approved by the Engineer. Size and contour of welds shall be mea- I sured with suitable gages. Visual inspection for cracks in 6.3.2 WPSs Qualified by Test. The Contractor's Inspector shall ensure that all WPSs qualified by test conform with the requirements of Clauses 4 and 5, and contract documents. 214 AWS D1.1/D1.1 M:2008 PARTS A, B, & C welds and base metal and other discontinuities should be aided by a strong light, magnifiers, or such other devices may be found helpful. CLAUSE 6. INSPECTION with 6.14. The Owner shall be responsible for all associated costs including handling, surface preparation, NDT, and repair of discontinuities other than those described in 6.9, whichever is applicable, at rates mutually agreeable between Owner and Contractor. However, if such testing should disclose an attempt to defraud or gross nonconformance to this code, repair work shall be done at the Contractor's expense. 6.5.4 Inspector Identification of Inspections Performed. Inspectors shall identify with a distinguishing mark or other recording methods all parts or joints that they have inspected and accepted. Any recording method which is mutually agreeable may be used. Die stamping of cyclically loaded members without the approval of the Engineer shall be prohibited. 6.5.5 Maintenance of Records. The Inspector shall keep a record of qualifications of all welders, welding operators, and tack welders; all WPS qualifications or other tests that are made; and such other information as may be required. PartC .Acceptance Criteria 6.7 Scope Acceptance criteria for visual and NDT inspection of tubular connections and statically and cyclically loaded nontubular connections are described in Part C. The extent of examination and the acceptance criteria shall be specified in the contract documents on information furnished to the bidder. PartB Contractor Responsibilities 6.6 Obligations of the Contractor • 6.6.1 Contractor Responsibilities. The Contractor shall be responsible for visual inspection and necessary correction of all deficiencies in materials and workmanship in conformance with the requirements of this code. 6.8 Engineer's Approval for Alternate Acceptance Criteria The fundamental premise of the code is to provide general stipulations applicable to most situations. Acceptance criteria for production welds different from those described in the code may be used for a particular application, provided they are suitably documented by the proposer and approved by the Engineer. These alternate acceptance criteria may 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. 6.6.2 Inspector Requests. The Contractor shall comply with all requests of the Inspector(s) to correct deficiencies in materials and workmanship as provided in the contract documents. 6.6.3 Engineering Judgment. In the event that faulty welding, or its removal for rewelding, damages the base metal so that in the judgment of the Engineer its retention is not in conformance with the intent of the contract documents, the Contractor shall remove and replace the damaged base metal or shall compensate for the deficiency in a manner approved by the Engineer. 6.9 Visual Inspection 6.6.4 Specified NDT Other than Visual. When NDT other than visual inspection is specified in the information furnished to bidders, it shall be the Contractor's responsibility to ensure that all specified welds shall meet the quality requirements of Clause 6, Part C, whichever is applicable. • All welds shall be visually inspected and shall be acceptable if the criteria of Table 6.1 are satisfied. 6.10 PT and MT 6.6.5 Nonspecified NDT Other than Visual. If NDT other than visual inspection is not specified in the original contract agreement but is subsequently requested by the Owner, the Contractor shall perform any requested testing or shall allow any testing to be performed in conformance Welds that are subject to MT and PT, in addition to visual inspection, shall be evaluated on the basis of the applicable requirements for visual inspection. The testing shall be performed in conformance with 6.14.4 or 6.14.5, whichever is applicable. 215 CLAUSE 6. INSPECTION PARTe 6.11 NDT .. AWS D1.1/D1.1M:2008 indication may be 3/8 in [10 mm]. The minimum clearance of rounded discontinuities greater than or equal to ~ 3/32 in [2.5 mm] to an acceptable elongated or rounded discontinuity or to an edge or end of an intersecting weld shall be three times the greatest dimension of the larger of the discontinuities being considered. Except as provided for in 6.18, all NDT methods including equipment requirements and qualifications, personnel qualifications, and operating methods shall be in conformance with Clause 6, Inspection. Acceptance criteria shall be as described in this section. Welds subject to NDT shall have been found acceptable by visual inspection in conformance with 6.9. (4) At the intersection of a weld with another weld or a free edge (i.e., an edge beyond which no material extension exists), acceptable discontinuities shall conform to the limitations of Figure 6.1, Cases I-IV. For welds subject to NDT in conformance with 6.10, 6.11,6.12..1, and 6.13.3, the testing may begin immediately after the completed welds have cooled to ambient temperature. Acceptance criteria for ASTM A 514, A 517, and A 709 Grade 100 and 100W steels shall be based on NDT performed not less than 48 hours after completion of the welds. ~) Isolated discontinuities such as a cluster of rounded indications, having a sum of their greatest dimensions exceeding the maximum size single discontinuity allowed in Figure 6.1. The minimum clearance to another cluster or an elongated or rounded discontinuity or to an edge or end of an intersecting weld shall be three times the greatest dimension of the larger of the discontinuities being considered. 6.11.1 Tubular Connection Requirements. For CJP groove butt welds welded from one side without backing, the entire length of all completed tubular production welds shall be examined by either RT or UT. The acceptance criteria shall conform to 6.12-1 or 6.13.3 as applicable. (§) The sum of individual discontinuities each having a greater dimension of less than 3/32 in [2.5 mm] shall not exceed 2E/3 or 3/8 in [10 mm], whichever is less, in any linear 1 in [25 mm] of weld. This requirement is independent ot(1), (2), and (3) above. 6.12 RT CD In-line discontinuities, where the sum of the greatest dimensions exceeds E in any length of 6E. When 1. the length of the weld being examined is less than 6E, the ~ allowable sum of the greatest dimensions shall be proportionally less. Welds shown by RT that do not meet the requirements of Part C, or alternate acceptance criteria per 6.8, shall be repaired in conformance with 5.26. Discontinuities other than cracks shall be evaluated on the basis of being either elongated or rounded. Regardless of the type of discontinuity, an elongated discontinuity shall be defined as one in which its length exceeds three times its width. A rounded discontinuity shall be defined as one in which its length is three times its width or less and may be round or irregular and may have tails. 6.12.2 Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections. Welds that are subject to RT in addition to visual inspection shall have no cracks and shall be unacceptable if the RT shows any of the types of discontinuities described in 6.12.2.1 6.12.2.2, or 6.12.2.3. The limitations given by Figures 6.2 and 6.3 for 1-112 in [38 mm] weld size (E) shall apply to all weld sizes greater than 1-112 in [38 mm]. 6.12.1 Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections. Welds that are subject to RT in addition to visual inspection shall have no cracks and shall be unacceptable if the RT shows any discontinuities exceeding the following limitations. The limitations given by Figure 6.1 for 1-118 in [30 mm] weld size (E) shall apply to all weld sizes greater than 1-118 in [30 mm]. 6.12.2.1 Cyclically Loaded Nontubular Connections in Tension (1) Discontinuities exceeding the maximum size of Figure 6.2. (2) Discontinuities closer than the minimum clearance allowance of Figure 6.2. (1) Elongated discontinuities exceeding the maximum size of Figure 6.1. (2) Discontinuities closer than the minimum clearance allowance of Figure 6.1. (3) At the intersection of a weld with another weld or a free edge (i.e., an edge beyond which no material extension exists), acceptable discontinuities shall conform to the limitations of Figure 6.2, Cases I-IV. (3) Rounded discontinuities greater than a maximum size of E/3, not to exceed 114 in [6 mm]. However, when E is greater than 2 in [50 mmJ, the maximum rounded (4) Isolated discontinuities such as a cluster of ~ rounded indications, having a sum of their greatest ~ dimensions exceeding the maximum size single disconti- 216 AWS D1.1/D1.1 M:2008 PARTe CLAUSE 6. INSPECTION 6.13 UT nuity allowed in Figure 6.2. The minimum clearance to . . another cluster or an elongated or rounded discontinuity • or to an edge or end of an intersecting weld shall be three times the greatest dimension of the larger of the discontinuities being considered. 6.13.1 Acceptance Criteria for Statically Loaded Nontubular Connections. The acceptance criteria for welds subject to UT in addition to visual inspection shall meet the requirements of Table 6.2. For CJP web-toflange welds, acceptance of discontinuities detected by scanning movements other than scanning pattern 'E' (see 6.32.2.2) may be based on weld thickness equal to the actual web thickness plus 1 in [25 mm]. Discontinuities detected by scanning pattern 'E' shall be evaluated to the criteria of Table 6.2 for the actual web thickness. When CJP web-to-flange welds are subject to calculated tensile stress normal to the weld, they should be so designated on the design drawing and shall conform to the requirements of Table 6.2. Ultrasonically tested welds are evaluated on the basis of a discontinuity reflecting ultrasound in proportion to its effect on the integrity of the weld. Indications of discontinuities that remain on the display as the search unit is moved towards and away from the discontinuity (scanning movement "b") may be indicative of planar discontinuities with significant through-throat dimension. (5) The sum of individual discontinuities each having a greater dimension of less than 3/32 in [2.5 mm] shall not exceed 2E/3 or 3/8 in [10 mm], whichever is less, in any linear 1 in [25 mm] of weld. This requirement is independent of (1), (2), and (3) above. (6) In-line discontinuities, where the sum of the greatest dimensions exceeds E in any length of 6E. When the length of the weld being examined is less than 6E, the allowable sum of the greatest dimensions shall be proportionally less. 6.12.2.2 Cyclically Loaded Nontubular Connections in Compression (1) Discontinuities exceeding the maximum size of Figure 6.3. (2) Discontinuities closer than the minimum clearance allowance of Figure 6.3. Since the major reflecting surface of the most critical discontinuities is oriented a minimum of 20° (for a 70° search unit) to 45° (for a 45° search unit) from perpendicular to the sound beam, amplitude evaluation (dB rating) does not allow reliable disposition. When indications exhibiting these planar characteristics are present at scanning sensitivity, a more detailed evaluation of the discontinuity by other means shall be required (e.g., alternate UT techniques, RT, grinding or gouging for visual inspection, etc.). (3) At the intersection of a weld with another weld or a free edge (i.e., an edge beyond which no material extension exists), acceptable discontinuities shall conform to the limitations of Figure 6.3, Cases I-V. • (4) Isolated discontinuities such as a cluster of rounded indications, having a sum of their greatest dimensions exceeding the maximum size single discontinuity allowed in Figure 6.3. The minimum clearance to another cluster or an elongated or rounded discontinuity or to an edge or end of an intersecting weld shall be three times the greatest dimension of the larger of the discontinuities being considered. 6.13.2 Acceptance Crlteria for Cyclically Loaded Nontubular Connections. The acceptance criteria for welds subject to UT in addition to visual inspection shall meet the following requirements: (1) Welds subject to tensile stress under any condition of loading shall conform to the requirements of Table 6.3. (5) The sum of individual discontinuities each having a greater dimension of less than 3/32 in [2.5 mm] shall not exceed 2E/3 or 3/8 in [10 mm], whichever is less, in any linear 1 in [25 mm] of weld. This requirement is independent of (1), (2), and (3) above. (2) Welds subject to compressive stress shall conform to the requirements of Table 6.2. (6) In-line discontinuities, where the sum of the greatest dimensions exceeds E in any length of 6E. When the length of the weld being examined is less than 6E, the allowable sum of the greatest dimensions shall be proportionally less. 6.13.2.1 Indications. Ultrasonically tested welds are evaluated on the basis of a discontinuity reflecting ultrasound in proportion to its effect on the integrity of the weld. Indications of discontinuities that remain on the display as the search unit is moved towards and away from the discontinuity (scanning movement "b") may be indicative of planar discontinuities with significant through throat dimension. As the orientation of such discontinuities, relative to the sound beam, deviates from the perpendicular, dB ratings which do not allow direct, 6.12.2.3 Discontinuities Less than 1/16 in [2 mm]. In addition to the requirements of 6.12.2.1 and 6.12.2.2, discontinuities having a greatest dimension of less than 1/16 in [2 mm] shall be unacceptable if the sum of their greatest dimensions exceeds 3/8 in [10 mm] in any linear inch of weld. • 217 CLAUSE 6. INSPECTION .. PARTSC&D reliable evaluation of the welded joint integrity may result. When indications that exhibit these planar characteristics are present at scanning sensitivity, a more detailed evaluation of the discontinuity by other means may be required (e.g., alternate UT techniques, RT, grinding, or gouging for visual inspection, etc.). AWS D1.1 /D1.1 M:2008 Tough Weldments). All indications having half (6 dB) or less amplitude than the standard sensitivity level (with due regard for 6.27.6) shall be disregarded. Indications exceeding the disregard level shall be evaluated as follows: I (l) Spherical reflectors shall be as described in Class R, except that any indications within the following limits for linear or planar shall be acceptable. 6.13.2.2 Scanning. CJP web-to-flange welds shall conform to the requirements of Table 6.2, and acceptance for discontinuities detected by scanning movements other than scanning pattern 'E' (see 6.32.2.2) may be based on a weld thickness equal to the actual web thickness plus 1 in [25 mm]. Discontinuities detected by scanning pattern 'E' shall be evaluated to the criteria of 6.13.2 for the actual web thickness. When such web-toflange welds are subject to calculated tensile stress normal to the weld, they shall be so designated on design drawings and shall conform to the requirements of Table 6.3. (2) Linear or planar reflectors shall be evaluated by means of beam boundary techniques, and those whose dimensions exceeded the limits of Figure 6.~ shall be rejected. The root area shall be defined as that lying within 1/4 in [6 mm] or tw /4, whichever is greater, of the root of the theoretical weld, as shown in Figure 3.8. PartD NDT Procedures 6.13.3 Acceptance Criteria for Tubular Connections. Acceptance criteria for UT shall be as provided in contract documents. Class R or Class X, or both,may be incorporated by reference. Amplitude based acceptance criteria as given by 6.13.1 may also be used for groove welds in butt joints in tubing 24 in [600 mm] in diameter and over, provided all relevant provisions of Clause 6, Part F, are followed. However, these amplitude criteria shall not be applied to tubular T-, Y-, and K-connections. 6.14 Procedures The NDT procedures as described in this code have been in use for many years and provide reasonable assurance of weld integrity; however, it appears that some users of the code incorrectly consider each method capable of detecting all unacceptable discontinuities. Users of the code should become familiar with all the limitations of NDT methods to be used, particularly the inability to detect and characterize planar discontinuities with specific orientations. (The limitations and complementary use of each method are explained in the latest edition of AWS B1.lO, Guide for Nondestructive Examination of Welds.) 6.13.3.1 Class R (Applicable When UT is Used as an Alternate to RT). All indications having one-half (6 dB). or less amplitude than the standard sensitivity level (with due regard for 6.27.6) shall be disregarded. Indications exceeding the disregard level shall be evaluated as follows: (1) Isolated random spherical reflectors, with 1 in [25 mm] minimum separation up to the standard sensitivity level shall be accepted. Larger reflectors shall be evaluated as linear reflectors. ~ 6.14.1 RT. When RT is used, the procedure and technique shall be in conformance with Part E of this section. 6.14.2 Radiation Imaging Systems. When examination is performed using radiation imaging systems, the procedures and techniques shall be in conformance with Part G of this section. (2) Aligned spherical reflectors shall be evaluated as linear reflectors. (3) Clustered spherical reflectors having a density of more than one per square inch [645 square millimeters] with indications above the disregard levels (projected area normal to the direction of applied stress, averaged over a 6 in [150 mm] length of weld) shall be rejected. 6.14.3 UT. When UT is used, the procedure and technique shall be in conformance with Part F of this section. (4) Linear or planar reflectors whose lengths (extent) exceed the limits of Figure 6.1 shall be rejected. Additionally, root reflectors shall not exceed the limits of Class X. 6.14.4 MT. When MT is used, the procedure and technique shall be in conformance with ASTM E 709, and the standard of acceptance shall be in conformance with Clause 6, Part C, of this code, whichever is applicable. 6.13.3.2 Class X (Experience-Based, Fitnessfor-Purpose Criteria Applicable to T -, Y-, and KConnections in Redundant Structures with Notch- 6.14.5 PT. For detecting discontinuities that are open to A the surface, PT may be used. The standard methods set , forth in ASTM E 165 shall be used for PT inspection, and 218 AWS 01.1/01.1 M:2008 • PARTSD& E When either of the two additional spots show defects that require repair, the entire segment of weld represented by the original spot shall be completely tested. If the weld involves more than one segment, two additional spots in each segment shall be tested at locations agreed upon by the Contractor and the verification Inspector, subject to the foregoing interpretation. the standards of acceptance shall be in conformance with Clause 6, Part C, of this code, whichever is applicable. 6.14.6 Personnel Qualification 6.14.6.1 ASNT Requirements. Personnel performing NDT other than visual shall be qualified in conformance with the current edition of the American Society for Nondestructive Testing Recommended Practice No. SNT-TC-IA. Individuals who perform NDT shall be qualified for: 6.15.4 Relevant Information. NDT personnel shall, prior to testing, be furnished or have access to rel~vant information regarding weld joint geometries, material thicknesses, and welding processes used in making the weldment. NDT personnel shall be apprised of any subsequent repairs to the weld. (1) NDT Level II, or (2) NDT Level I working under the NDT Level II 6.14.6.2 Certification. Certification of Level I and Level II individuals shall be performed by a Level III individual who. has been certified by (1) The American Society for Nondestructive Testing, or (2) has the education, training, experience, and has successfully passed the written examination described in SNT-TC-IA. PartE Radiographic Testing (RT) 6.16 RT of Groove Welds in Butt Joints 6.14.6.3 Exemption of QC1 Requirements. Personnel performing NDT under the provisions of 6.14.6 need not be qualified and certified under the provisions of AWSQCl. • 6.16.1 Procedures and Standards. The procedures and standards set forth in Part E shall govern RT of welds when such inspection is required by· the contract documents as provided in 6.14. The requirements described herein are specifically for testing groove welds in butt joints in plate, shapes, and bars by X-ray or gamma-ray sources. The methodology shall conform to ASTM E 94, Standard Recommended Practice for Radiographic Testing, ASTM E 142, Standard Method for Controlling Quality ofRadiographic Testing, ASTM E 747, Controlling Quality of Radiographic Testing Using Wire Penetrameters, and ASTM E 1032, Radiographic Examination of Weldments. 6.15 Extent of Testing Information furnished to the bidders shall clearly identify the extent of NDT (types, categories, or location) of welds to be tested. 6.15.1 Full Testing. Weld joints requiring testing by contract specification shall be tested for their full length, unless partial or spot testing is specified. 6.15.2 Partial Testing. When partial testing is specified, the location and lengths of welds or categories of weld to be tested shall be clearly designated in the contract documents. • CLAUSE 6. INSPECTION 6.16.2 Variations. Variations in testing procedures, equipment, and acceptance standards may be used upon agreement between the Contractor and the Owner. Such variations include, but are not limited to, the following: RT of fillet, T, and comer welds; changes in source-tofilm distance; unusual application of film; unusual holetype or wire-type image quality indicators (IQI) applications (including film side IQI); and RT of thicknesses greater than 6 in [150 rom] film types, densities, and variations in exposure, development, and viewing techniques. 6.15.3 Spot Testing. When spot testing is specified, the number of spots in each designated category of welded joint to be tested in a stated length of weld or a designated segment of weld shall be included in the information furnished to the bidders. Each spot test shall cover at least 4 in [100 mm] of the weld length. When spot testing reveals indications of unacceptable discontinuities that require repair, the extent of those discontinuities shall be explored. Two additional spots in the same segment of weld joint shall be taken at locations away from the original spot. The location of the additional spots shall be agreed upon between the Contractor and the verification Inspector. 6.17 RT Procedures 6.17.1 Procedure. Radiographs shall be made using a single source of either X-or gamma radiation. The radiographic sensitivity shall be judged based on hole-type 219 CLAUSE 6. INSPECTION PARTE AWS 01.1/01.1 M:2008 ... 6.17.5.3 Source-to-Subjeet Distance Limitations. The source-to-subject distance shall not be less than seven times the thickness of weld plus reinforcement and backing, if any, nor such that the inspecting radiation shall penetrate any portion of the weld represented in the radiograph at an angle greater than 26-112° from a line normal to the weld surface. image or wire IQIs. Radiographic technique and equipment shall provide sufficient sensitivity to clearly delineate the required hole-type IQIs and the essential holes or wires as described in 6.17.7, Tables 6.4 and 6.5, and Figures 6.§. and 6.1. Identifying letters and numbers shall show clearly in the radiograph. 6.17.2 Safety Requirements. RT shall be performed in conformance with all applicable safety requirements. ~ 6.17.6 Sources. X-ray units, 600 kVp maximum, and iridium 192 may be used as a source for all RT provided they have adequate penetrating ability. Cobalt 60 shall only be used as a radiographic source when the steel being radiographed exceeds 2-1/2 in [65 mm] in thickness. Other radiographic sources may be used with the approval of the Engineer. 6.17.3 Removal of Reinforcement. When the contract documents require the removal of weld reinforcement, the welds shall be prepared for RT by grinding as described in 5.24.4.1. Other weld surfaces need not be ground or otherwise smoothed for purposes of RT unless surface irregularities or the junction between weld and base metal may cause objectionable weld discontinuities to be obscured in the radiograph. 6.17.7 IQI Selection and Placement. IQIs shall be selected and placed on the weldment in the area of interest being radiographed as shown in Table 6.6. 6.17.3.1 Tabs. Weld tabs shall be removed prior to RT unless otherwise approved by the Engineer. 6.17.8 Technique. Welded joints shall be radiographed and the film indexed by methods that will provide complete and continuous inspection of the joint within the limits specified to be examined. Joint limits shall show clearly in the radiographs. Short film, short screens, excessive undercut by scattered radiation, or any other process that obscures portions of the total weld length shall render the radiograph unacceptable. 6.17.3.2 Steel Backing. When required by 5.10 or other provisions of the contract documents, steel backing shall be removed, and the surface shall be finished flush by grinding prior to RT. Grinding shall be as described in 5.24.4.1. 6.17.3.3 Reinforcement. When weld reinforcement or backing, or both, is not removed, or wire IQI alternate placement is not used, steel shims which extend at least 1/8 in [3 mm] beyond three sides of the required holetype IQI or wire IQI shall be placed under the hole-type IQI or wire IQI, so that the total thickness of steel between the hole-type IQI and the film is approximately equal to the average thickness of the' weld measured through its reinforcement and backing. 6.17.8.1 Film Length. Film shall have sufficient length and shall be placed to provide at least 1/2 in [12 mm] offilm beyond the projected edge of the weld. ~ 6.17.8.2 Overlapping Film. Welds longer than 14 in [350 mm] may be radiographed by overlapping film cassettes and making a single exposure, or by using single film cassettes and making separate exposures. The provisions of 6.17.5 shall apply. 6.17.4 Radiographic Film. Radiographic film shall be as described in ASTM E 94. Lead foil screens shall be used as described in ASTM E 94. Fluorescent screens shall be prohibited. 6.17.8.3 Backscatter. To check for backscatter radiation, a lead symbol "B," 1/2 in [12 mm] high, 1/16 in [2 mm] thick shall be attached to the back of each film cassette. If the "B" image appears on the radiograph, the radiograph shall be considered unacceptable. 6.17.5 Technique. Radiographs shall be made with a single source of radiation centered as near as practicable with respect to the length and width of that portion of the weld being examined. 6.17.9 Film Width. Film widths shall be sufficient to depict all portions of the weld joint, including the HAZs, and shall provide sufficient additional space for the required hole-type IQIs or wire IQI and film identification without infringing upon the area of interest in the radiograph. 6.17.5.1 Geometric Unsharpness. Gamma ray sources, regardless of size, shall be capable of meeting the geometric unsharpness limitation of ASME Boiler and Pressure Vessel Code, Section V, Article 2. 6.17.10 Quality of Radiographs. All radiographs shall be free from mechanical, chemical, or other blemishes to the extent that they cannot mask or be confused with the image of any discontinuity in the area of interest in the radiograph. Such blemishes include, but are not limited to the following: ~ 6.17.5.2 Source-to-Subject Distance. The sourceto-subject distance shall not be less than the total length of film being exposed in a single plane. This provision shall not apply to panoramic exposures made under the provisions of 6.16.2. (1) fogging 220 AWS D1.1/D1.1M:2008 I PARTE (2) processing defects such as streaks, water marks, or chemical stains identification mark, the date, and the weld repair number, if applicable. (3) scratches, finger marks, crimps, dirtiness, static marks, smudges, or tears 6.17.13 Edge Blocks. Edge blocks shall be used when radiographing butt welds greater than 1/2 in [12 mm] thickness. The edge blocks shall have a length sufficient to extend beyond each side of the weld centerline for a minimum distance equal to the weld thickness, but no less than 2 in [50 mm], and shall have a thickness equal to or greater than the thickness of the weld. The minimum width of the edge blocks shall be equal to half the weld thickness, but not less than 1 in [25 mm]. The edge blocks shall be centered on the weld against the plate being radiographed, allowing no more than 1/16 in [2 mm] gap for the minimum specified length of the edge blocks. Edge blocks shall be made of radiographically clean steel and the surface shall have a finish of ANSI 125 Ilin [3 jlill] or smoother (see Figure 6.12). (4) loss of detail due to poor screen-to-film contact (5) false indications due to defective screens or internal faults 6.17.11 Density Limitations. The transmitted film density through the radiographic image of the body of the required hole-type IQI(s) and the area of interest shall be 1.8 minimum for single film viewing for radiographs made with an X-ray source and 2.0 minimum for radiographs made with a gamma-ray source. For composite viewing of double film exposures, the minimum density shall be 2.6. Each radiograph of a composite set shall have a minimum density of 1.3. The maximum density shall be 4.0 for either single or composite viewing. 6.18 Supplementary RT Requirements for Tubular Connections 6.17.11.1 H & D Density. The density measured shall be H & D density (radiographic density), which is a measure of film blackening, expressed as: D = log IJI 6.18.1 Circumferential Groove Welds in Butt Joints. The technique used to radiograph circumferential butt joints shall be capable of covering the entire circumference. The technique shall preferably be single-wall exposure/single-wall view. Where accessibility or pipe size prohibits this, the technique may be double-wall exposure/single-wall view or double-wall exposure/ double-wall view. where: I D = H & D (radiographic) density 10 = light intensity on the film, and I = light transmitted through the film. 6.17.11.2 Transitions. When weld transitions in thickness are radiographed and the ratio of the thickness of the thicker section to the thickness of the thinner section is 3 or greater, radiographs should be exposed to produce single film densities of 3.0 to 4.0 in the thinner section. When this is done, the minimum density requirements of 6.17.11 shall be waived unless otherwise provided in the contract documents. • CLAUSE 6. INSPECTION 6.18.1.1 Single-Wall Exposure/Single-Wall View. The source of radiation shall be placed inside the pipe and the film on the outside of the pipe (see Figure 6.TI). Panoramic exposure may be made if the source-to-object requirements are satisfied; if not, a minimum of three exposures shall be made. The IQI may be selected and placed on the source side of the pipe. If not practicable, it may be placed on the film side of the pipe. 6.17.12 Identification Marks. A radiograph identification mark and two location identification marks shall be placed on the steel at each radiograph location. A corresponding radiograph identification mark and two location identification marks, all of which shall show in the radiograph, shall be produced by placing lead numbers or letters, or both, over each of the identical identification and location marks made on the steel to provide a means for matching the developed radiograph to the weld. Additional identification information may be preprinted no less than 3/4 in [20 mm] from the edge of the weld or shall be produced on the radiograph by placing lead figures on the steel. Information required to show on the radiograph shall include the Owner's contract identification, initials of the RT company, initials of the fabricator, the fabricator shop order number, the radiographic 6.18.1.2 Double-Wall Exposure/Single-Wall View. Where access or geometrical conditions prohibit singlewall exposure, the source may be placed on the outside of the pipe and film on the opposite wall outside the pipe (see Figure 6.14). A minimum of three exposures shall be required to cover the complete circumference. The IQI may be selected and placed on the film side of the pipe. 6.18.1.3 Double-Wall ExposurelDouble-Wall View. When the outside diameter of the pipe is 3-1/2 in [90 mm] or less, both the source side and film side weld may be projected onto the film and both walls viewed for acceptance. The source of radiation shall be offset from 221 CLAUSE 6. INSPECTION PARTSE& F the pipe by a distance that is at least seven times the outside diameter. The radiation beam shall be offset from the plane of the weld centerline at an angle sufficient to separate the images of the source side and film side welds. There shall be no overlap of the two zone interpreted. A minimum of two exposures 90° to each other shall be required (see Figure 6.15). The weld may also be radiographed by superimposing the two welds, in which case there shall be a minimum of three exposures 60° to each other (see Figure 6..!§). In each of these two techniques, the IQI shall be placed on the source side of the pipe. AWS D1.1/D1.1M:2008 ... required by 6.14 of this code. For thicknesses less than 5/16 in [8 mm] or greater than 8 in [200 mm], testing shall be performed in conformance with Annex S. These procedures and standards shall be prohibited for testing tube-to-tube T-, Y-, or K-connections. 6.20.2 Variations. Annex S is an example of an alternative technique for performing UT examination of groove welds. Variations in testing procedure, equipment, and acceptance standards not included in Part F of Clause 6 may be used with the approval of the Engineer. Such variations include other thicknesses, weld geometries, transducer sizes, frequencies, couplant, painted surfaces, testing techniques, etc. Such approved variations shall be recorded in the contract records. 6.19 Examination, Report, and Disposition of Radiographs 6.20.3 Piping Porosity. To detect possible piping porosity, RT is recom~ended to supplement UT of ESW or EGWwelds. 6.19.1 Equipment Provided by Contractor. The Contractor shall provide a suitable variable intensity illuminator (viewer) with spot review or masked spot review capability. The viewer shall incorporate a means for adjusting the size of the spot under examination. The viewer shall have sufficient capacity to properly illuminate radiographs with an H & D density of 4.0. Film review shall be done in an area of subdued light. 6.20.4 Base Metal. These procedures are not intended to be employed for the procurement testing of base metals. However, welding related discontinuities (cracking, lamellar tearing, delaminations, etc.) in the adjacent base metal which would not be acceptable under the provisions of this..s;ode shall be reported to the Engineer for disposition. 6.19.2 Reports. Before a weld subject to RT by the Contractor for the Owner is accepted, all of its radiographs, including any that show unacceptable quality prior to repair, and a report interpreting them shall be submitted to the verification Inspector. 6.21 Qualification Requirements In satisfying the requirements of 6.14.6, the qualification of the UT operator shall include a specific and practical examination which shall be based on the requirements of this code. This examination shall require the UT operator to demonstrate the ability to apply the rules of this code in the accurate detection and disposition of discontinuities. 6.19.3 Record Retention. A full set of radiographs for welds subject to RT by the Contractor for the Owner, including any that show unacceptable quality prior to repair, shall be delivered to the Owner upon completion of the work. The Contractor's obligation to retain radiographs shall cease: (l) upon delivery of this full set to the Owner, or (2) one full year after the completion of the Contractor's work, provided the Owner is given prior written notice. 6.22 UT Equipment 6.22.1 Equipment Requirements. The UT instrument shall be the pulse echo type suitable for use with transducers oscillating at frequencies between 1 and 6 megahertz. The display shall be an "A" scan rectified video trace. PartF Ultrasonic Testing (UT) of Groove Welds 6.20 General 6.22.2 Horizontal Linearity. The horizontal linearity of the test instrument shall be qualified over the full soundpath distance to be used in testing in conformance with 6.30.1. 6.20.1 Procedures and Standards. The procedures and standards set forth in Part F shall govern the UT of groove welds and HAZs between the thicknesses of 5/16 in and 8 in [8 mm and 200 mm] inclusive, when such testing is 6.22.3 Requirements for Test Instruments. Test instruments shall include internal stabilization so that after warm-up, no variation in response greater than ± 1 dB occurs with a supply voltage change of 15% nominal or, 222 AWS D1.1/D1.1M:2008 PARTF 6.22.7.7 IIW Block. The qualification procedure using the IIW reference block shall be in conformance with 6.29.2.6 and as shown in Figure 6.~. in the case of a battery, throughout the charge operating life. There shall be an alarm or meter to signal a drop in battery voltage prior to instrument shutoff due to battery exhaustion. 6.22.4 Calibration of Test Instruments. The test instrument shall have a calibrated gain control (attenuator) adjustable in discrete 1 or 2 dB steps over a range of at least 60 dB. The accuracy of the attenuator settings shall be within plus or minus 1 dB. The procedure for qualification shall be as described in 6.24.2 and 6.30.2. 6.23 Reference Standards 6.23.1 IIW Standard. The International Institute of Welding (IIW) UT reference block, shown in Figure 6.19, shall be the standard used for both distance and sensitivity calibration. Other portable blocks may be used, provided the reference level sensitivity for instrument/ search unit combination shall be adjusted to be the equivalent of that achieved with the IIW Block (see Annex H, for examples). 6.22.5 Display Range. The dynamic range of the instrument's display shall be such that a difference of 1 dB of amplitude can be easily detected on the display. 6.22.6 Straight·Beam (Longitudinal Wave) Search Units. Straight-beam (longitudinal wave) search unit transducers shall have an active area of not less than 1/2 in2 [323 mm2] nor more than 1 in2 [645 mm2]. The transducer shall be round or square. Transducers shall be capable of resolving the three reflections as described in 6.29.1.3. • 6.23.2 Prohibited Reflectors. The use of a "comer" reflector for calibration purposes shall be prohibited. 6.23.3 Resolution Requirements. The combination of search unit and instrument shall resolve three holes in the RC resolution reference test block shown in Figure 6.20. The search unit position is described in 6.29.2.5. The resolution shall be evaluated with the instrument controls set at normal test settings and with indications from the holes brought to midscreen height. Resolution shall be sufficient to distinguish at least the peaks of indications from the three holes. Use of the RC resolution reference block for calibration shall be prohibited. Each combination of instrument search unit (shoe and transducer) shall be checked prior to its initial use. This equipment verification shall be done initially with each search unit and UT unit combination. The verification need not .be done again provided documentation is maintained that records the following items: 6.22.7 Angle-Beam Search Units. Angle-beam search units shall consist of a transducer and an angle wedge. The unit may be comprised of the two separate elements or may be an integral unit. 6.22.7.1 Frequency. The transducer frequency shall be between 2 and 2.5 MHz, inclusive. 6.22.7.2 Transducer Dimensions. The transducer crystal shall be square or rectangular in shape and may vary from 5/8 in to 1 in [15 mm to 25 mm] in width and from 5/8 in to 13/16 in [15 mm to 20 mm] in height (see Figure 6.17). The maximum width to height ratio shall be 1.2 to 1.0, and the minimum width-to-height ratio shall be 1.0 to 1.0. (1) UT machine's make, model and serial number (2) Search unit's manufacturer, type, size, angle, and serial number 6.22.7.3 Angles. The search unit shall produce a sound beam in the material being tested within plus or minus 2° of one of the following proper angles: 70°, 60°, or 45°, as described in 6.29.2.2. (3) Date of verification and technician's name 6.24 Equipment Qualification 6.22.7.4 Marking. Each search unit shall be marked to clearly indicate the frequency of the transducer, nominal angle of refraction, and index point. The index point location procedure is described in 6.29.2.1. • CLAUSE 6. INSPECTION 6.22.7.5 Internal Reflections. Maximum allowable internal reflections from the search unit shall be as described in 6.24.3. 6.24.1 Horizontal Linearity. The horizontal linearity of the test instrument shall be requalified at two-month intervals in each of the distance ranges that the instrument" will be used. The qualification procedure shall be in conformance with 6.30.1 (see Annex H, for alternative method). 6.22.7.6 Edge Distance. The dimensions of the search unit shall be such that the distance from the leading edge of the search unit to the index point shall not exceed 1 in [25 mm]. 6.24.2 Gain Control. The instrument's gain control (attenuator) shall meet the requirements of 6.22.4 and shall be checked for correct calibration at two month intervals in conformance with 6.30.2. Alternative methods 223 CLAUSE 6. INSPECTION PARTF AWS D1.1/D1.1 M:2008 ... 6.25.5 Calibration for Angle-Beam Testing. Calibration for angle-beam testing shall be performed as follows (see Annex H, H2.4 for alternative method). may be used for calibrated gain control (attenuator) qualification if proven at least equivalent with 6.30.2. 6.24.3 Internal Reflections. Maximum internal reflections from each search unit shall be verified at a maximum time interval of 40 hours of instrument use in conformance with 6.30.3. 6.25.5.1 Horizontal Sweep. The horizontal sweep shall be adjusted to represent the actual sound-path distance by using the IIW block or alternative blocks as described in 6.23.1. The distance calibration shall be made using either the 5 in [125 mm] scale or 10 in [250 mm] scale on the display, whichever is appropriate. If, however, the joint configuration or thickness prevents full examination of the weld at either of these settings, the distance calibration shall be made using 15 in or 20 in [400 mm or 500 mm] scale as required. The search unit position is described in 6.29.2.3. 6.24.4 Calibration of Angle-Beam Search Units. With the use of an approved calibration block, each anglebeam search unit shall be checked after each eight hours of use to determine that the contact face is flat, that the sound entry point is correct, and that the beam angle is within the allowed plus or minus 2° tolerance in conformance with 6.29.2.1 and 6.29.2.2. Search units which do not meet these requirements shall be corrected or replaced. NOTE: The horizontal location of all screen indications is based on the location at which the left side of the trace deflection breaks the horizontal base line. 6.25 Calibration for Testing 6.25.5.2 Zero Reference Level. The zero reference level sensitivity used for discontinuity evaluation ("b" on the ultrasonic test report, Annex M, Form M-11) shall be attained by adjusting the calibrated gain control (attenuator) of the discontinuity detector, meeting the requirements of 6.fJ., so that a maximized horizontal trace deflection (adjusted to horizontal reference line height with calibrated gain control [attenuator]) results on the display between 40% and 60% screen height, in conformance with 6.29.2.4. 6.25.1 Position of Reject Control. All calibrations and tests shall be made with the reject (clipping or suppression) control turned off. Use of the reject (clipping or suppression) control may alter the amplitude linearity of the instrument and invalidate test results. 6.25.2 Technique. Calibration for sensitivity and horizontal sweep (distance) shall be made by the UT operator just prior to and at the location of testing of each weld. 6.25.3 Recalibration. Recalibration shall be made after a change of operators, each two-hour maximum time interval, or when the electrical circuitry is disturbed in any way which includes the following:' 6.26 Testing Procedures 6.26.1 "X" Line. An "X" line for discontinuity location shall be marked on the test face of the weldment in a direction parallel to the weld axis. The location distance perpendicular to the weld axis shall be based on the dimensional figures on the detail drawing and usually falls on the centerline of the butt joint welds, and always falls on the near face of the connecting member of T and comer joint welds (the face opposite Face C). (1) Transducer change (2) Battery change (3) Electrical outlet change (4) Coaxial cable change (5) Power outage (failure) 6.26.2 "Y" Line. A "Y" accompanied with a weld identification number shall be clearly marked on the base metal adjacent to the weld that is subject to UT. This marking is used for the following purposes: 6.25.4 Straight-Beam Testing of Base Metal. Calibration for straight-beam testing of base metal shall be made with the search unit applied to Face A of the base metal and performed as follows: (l ) Weld identification 6.25.4.1 Sweep. The horizontal sweep shall be adjusted for distance calibration to present the equivalent of at least two plate thicknesses on'the display. (2) Identification of Face A (3) Distance measurements and direction (+ or -) from the "X" line 6.25.4.2 Sensitivity. The sensitivity shall be adjusted at a location free of indications so that the first back reflection from the far side of the plate will be 50% to 75% of full screen height. (4) Location measurement from weld ends or edges 6.26.3 Cleanliness. All surfaces to which a search unit is applied shall be free of weld spatter, dirt, grease, oil 224 AWS D1.1/D1.1M:2008 PARTF the weld axis only. All welds shall be tested using the applicable scanning pattern or patterns shown in Figure 6.21 as necessary to detect both longitudinal and transverse discontinuities. It is intended that, as a minimum, all welds be tested by passing sound through the entire volume of the weld and the HAZ in two crossing directions, wherever practical. (other than that used as a couplant), paint, and loose scale and shall have a contour allowing intimate coupling. 6.26.4 Couplants. A couplant material shall be used between the search unit and the test material. The couplant shall be either glycerin or cellulose gum and water mixture of a suitable consistency. A wetting agent may be added if needed. Light machine oil may be used for couplant on calibration blocks. 6.26.6.3 Maximum Indication. When a discontinuity indication appears on the screen, the maximum attainable indication from the discontinuity shall be adjusted to produce a horizontal reference level trace deflection on the display. This adjustment shall be made with the calibrated gain control (attenuator), and the instrument reading in decibels shall be used as the "Indication Level, a," for calculating the "Indication Rating, d," as shown on the test report (Annex M, Form M-11). 6.26.5 Extent of Testing. The entire base metal through which ultrasound must travel to test the weld shall be tested for laminar reflectors using a straight-beam search unit conforming to the requirements of 6.22.6 and calibrated in conformance with 6.25.4. If any area of base metal exhibits total loss of back reflection or an indication equal to or greater than the original back reflection height is located in a position that will interfere with the normal weld scanning procedure, its size, location, and depth from the A face shall be determined and reported on the UT report, and an alternate weld scanning procedure shall be used. 6.26.6.4 Attenuation Factor. The "Attenuation Factor, c," on the test report shall be attained by subtracting 1 in [25 mm] from the sound-path distance and multiplying the remainder by 2. This factor shall be rounded out to the nearest dB value. Fractional values ·less than 1/2 dB shall be reduced to the lower dB level and those of 1/2 dB or greater increased to the higher level. 6.26.5.1 Reflector Size. The reflector size evaluation procedure shall be in conformance with 6.31.1. e .g! . CLAUSE 6. INSPECTION 6.26.5.2 Inaccessibility. If part of a weld is inaccessible to testing in conformance with the requirements of Table 6.7, due to laminar content recorded in COnform.ance with 6.26.5, the testing shall be conducted using one or more of the following alternative procedures as necessary to attain full weld coverage: 6.26.6.5 Indication Rating. The "Indication Rating, d," in the UT Report, Annex M, Form M-ll, represents the algebraic difference in decibels between the indication level and the reference level with correction for attenuation as indicated in the following expressions: (1) Weld surface(s) shall be ground flush in conformance with 5.24.4.1. Instruments with gain in dB: a-b-'-c=d (2) Testing from Faces A and B shall be performed. Instruments with attenuation in dB: b-a-c=d (3) Other search unit angles shall be used. 6.26.7 Length of Discontinuities. The length of discontinuities shall be determined in conformance with the procedure described in 6.31.2. 6.26.6 Testing of Welds. Welds shall be tested using an angle beam search unit conforming to the requirements of 6.22.7 with the instrument calibrated in conformance with 6.25.5 using the angle as shown in Table 6.7. Following calibration and during testing, the only instrument adjustment allowed is the sensitivity level adjustment with the calibrated gain control (attenuator). The reject (clipping or suppression) control shall be turned off. Sensitivity shall be increased from the reference level for weld scanning in conformance with Table 6.2 or 6.3, as applicable. 6.26.6.1 Scanning. The testing angle and scanning procedure shall be in conformance with those shown in Table 6.7. 6.26.8 Basis for Acceptance or Rejection. Each weld discontinuity shall be accepted or rejected on the basis of its indication rating and its length, in conformance with Table 6.2 for statically loaded structures or Table 6.3 for cyclically loaded structures, whichever is applicable. Only those discontinuities which are unacceptable need be recorded on the test report, except that for welds designated in the contract documents as being "Fracture Critical," acceptable ratings that are within 6 dB, inclusive, of the minimum unacceptable rating shall be recorded on the test report. 6.26.6.2 Butt Joints. All butt joint welds shall be tested from each side of the weld axis. Comer and T-joint welds shall be primarily tested from one side of 6.26.9 Identification of Rejected Area. Each unacceptable discontinuity shall be indicated on the weld by a mark directly over the discontinuity for its entire length. 225 CLAUSE 6. INSPECTION PARTF AWS D1.1/D1.1M:2008 ... The depth from the surface and indication rating shall be noted on nearby base metal. (6) Type of calibration test block and reference reflector 6.26.10 Repair. Welds found unacceptable by UT shall be repaired by methods allowed by 5.26 of this code. Repaired areas shall be retested ultrasonically with results tabulated on the original form (if available) or additional report forms. (7) Method of calibration and required accuracy for distance (sweep), vertical linearity, beam spread, angle, sensitivity, and resolution 6.26.11 Retest Reports. Evaluation of retested repaired weld areas shall be tabulated on a new line on the report form. If the original report form is used, an RI, R2, ... Rn shall prefix the indication number. If additional report forms are used, the R number shall prefix the report number. (9) Method for determining acoustical continuity of base metal (see 6.27.4), and for establishing geometry as a function of local dihedral angle and thickness (8) Recalibration interval for each item in (7) above (10) Scanning pattern and sensitivity (see 6.27.5). (11) Transfer correction for surface curvature and roughness (where amplitude methods are used (see 6.27.3). 6.26.12 Steel Backing. UT of CJP groove welds with steel backing shall be performed with a UT procedure that recognizes potential reflectors created by the base metal-backing interface (see Commentary C-6.26.12 for additional guidance scanning groove welds containing steel backing). (12) Methods for determining effective beam angle (in curved material), indexing root area, and discontinuity locations (13) Method of discontinuity length and height determination 6.27 UT of Tubular T-, Y-, and K-Connections (14) Method of discontinuity verification during excavation andJepair 6.27.1 Procedure. All UT shall be in conformance with a written procedure which has been prepared or approved by an individual certified as SNT-TC-1A, Level III, and experienced in UT of tubular structures. The procedure shall be based upon the requirements of this section and Clause 6, Part F, as applicable. The procedure shall contain, as a minimum, the following information regarding the UT method and techniques: 6.27.2 Personnel. In addition to personnel requirements of 6.14.6, when examination of T-, Y-, and K-connections is to be performed, the operator shall be required to demonstrate an ability to apply the special techniques required for such an examination. Practical tests for this purpose shall be performed upon mock-up welds that represent the type of welds to be inspected, including a representative range of dihedral angle and thickness to be encountered in production, using the applicable qualified and approved procedures. Each mock-up shall contain natural or artificial discontinuities that yield UT indications above and below the reject criteria specified in the approved procedure. (1) The type of weld joint configuration to be examined (i.e., the applicable range of diameter, thickness, and local dihedral angle). Conventional techniques are generally limited to diameters of 12-3/4 in [325 mm] and larger, thicknesses of 1/2 in [12 mm] and above, and local dihedral angles of 30° or greater. Special techniques for smaller sides may be used, provided they are qualified as described herein, using the smaller size of application. Performance shall be judged on the basis of the ability of the operator to determine the size and classification of each discontinuity with an accuracy required to accept or reject each weldment and accurately locate the unacceptable discontinuities along the weld and within the cross section of the weld. At least 70% of the unacceptable discontinuities shall be correctly identified as unacceptable. For work on nonredundant structures, every discontinuity exceeding its maximum acceptable dimensions by a factor of two, or by an amplitude of 6 dB shall be located and reported. (2) Acceptance criteria for each type and size weld (3) Type(s) ofUT instrumentation (make and model) (4) Transducer (search unit) frequency, size and shape of active area, beam angle, and type of wedge on angle beam probes. Procedures using transducers with frequencies up to 6 MHz, sized down to 1/4 in [6 mm], and of different shape than specified elsewhere, may be used, provided they are qualified as described herein. 6.27.3 Calibration. UT equipment qualification and calibration methods shall meet the requirements of the approved procedure and Clause 6, Part F, except as follows: (5) Surface preparation and couplant (where used) 226 AWS 01.1/01.1 M:2008 • PARTF 6.27.3.1 Range. Range (distance) calibration shall include, as a minimum, the entire sound path distance to be used during the specific examination. This may be adjusted to represent either the sound-path travel, surface distance, or equivalent depth below contact surface, displayed along the instrument horizontal scale, as described in the approved procedure. 6.27.7 Discontinuity Evaluation. Discontinuities shall be evaluated by use of a combination of beam boundary and amplitude techniques. Sizes shall be given as length and height (depth dimension) or amplitude, as applicable. Amplitude shall be related to "standard calibration." In addition, discontinuities shall be classified as linear or planar versus spherical, by noting changes in amplitude as the transducer is swung in an arc centered on the reflector. The location (position) of discontinuities within the weld cross section, as well as from an established reference point along the weld axis, shall be determined. 6.27.3.2 Sensitivity Calibration. Standard sensitivity for examination of production welds using amplitude techniques shall be: basic sensitivity + distant amplitude correction + transfer correction. This calibration shall be performed at least once for each joint to be tested; except that, for repetitive testing of the same size and configuration, the calibration frequency of 6.25.3 may be used. 6.27.8 Reports 6.27.8.1 Forms. A report form that clearly identifies the work and the area of inspection shall be completed by the UT technician at the time of inspection. A detailed report and sketch showing the location along the weld axis, location within the weld cross section, size (or indication rating), extent, orientation, and classification for each discontinuity shall be completed for each weld in which significant indications are found. (1) Basic Sensitivity. Reference level screen height obtained using maximum reflection from the 0.060 in [1.5 mm] diameter hole in the IIW block (or other block which results in the same basic calibration sensitivity) as described in 6.25 (or 6.29). • (2) Distance Amplitude Correction. The sensitivity level shall be adjusted to provide for attenuation loss throughout the range of sound path to be used by either distance amplitude correction curves, electronic means, or as described in 6.26.6.4. Where high frequency transducers are used, the greater attenuation shall be taken into account. Transfer correction may be used to accommodate UT through tight layers of paint not exceeding 10 mils [0.25 mm] in thickness. 6.27.8.2 Reported Discontinuities. When specified, discontinuities approaching unacceptable size, particularly those about which there is some doubt in their evaluation, shall also be reported. 6.27.8.3 Incomplete Inspection. Areas for which complete inspection was not practicable shall also be noted, along with the reason why the inspection was incomplete. 6.27.4 Base-Metal Examination. The entire area subject to UT scanning shall be examined by the longitudinal wave technique to detect laminar reflectors that could interfere with the intended, directed sound wave propagation. All areas containing laminar reflectors shall be marked for identification prior to weld examination and the consequences considered in selection of search unit angles and scanning techniques for examination of the welds in that area. The Engineer shall be notified of base material discontinuities that exceed the limits of 5.15.1.1. ' •\ CLAUSE 6. INSPECTION 6.27.8.4 Reference Marks. Unless otherwise specified, the reference position and the location and extent of unacceptable discontinuities shall also be marked physically on the workpiece. 6.28 Preparation and Disposition of Reports 6.27.5 Weld Scanning. Weld scanning of T-, Y-, and K-connections shall be performed from the branch member surface (see Figure 6.22). All examinations shall be made in leg I and II where possible. For initial scanning, the sensitivity shall be increased by 12 dB above that established in 6.27.3 for the maximum sound path. Indication evaluation shall be performed with reference to the standard sensitivity. 6.28.1 Content of Reports. A report form which clearly identifies the work and the area of inspection shall be completed by the UT operator at the time of inspection. The report form for welds that are acceptable need only contain sufficient information to identify the weld, the operator (signature), and the acceptability of the weld. An example of such a form is shown in Annex M, Form M-11. 6.27.6 Optimum Angle. Indications found in the root areas of groove welds in butt joints and along the fusion face of all welds shall be further evaluated with either 70°, 60°, or 45° search angle, whichever is nearest to being perpendicular to the expected fusion face. 6.28.2 Prior Inspection Reports. Before a weld subje,ct to UT by the Contractor for the Owner is accepted, all report forms pertaining to the weld, including any that show unacceptable quality prior to repair, shall be submitted to the Inspector. 227 CLAUSE 6. INSPECTION PARTF AWS D1.1 /D1.1 M:2008 ... (2) The transducer shall be moved until the signal from the radius is maximized. The point on the transducer which aligns with the radius line on the calibration block is the point of sound entry (see Annex H, H2.I for alternative method). 6.28.3 Completed Reports. A full set of completed report forms of welds subject to UT by the Contractor for the Owner, including any that show unacceptable quality prior to repair, shall be delivered to the Owner upon completion of the work. The Contractor's obligation to retain UT reports shall cease (1) upon delivery of this full set to the Owner, or (2) one full year after completion of the Contractor's work, provided that the Owner is given prior written notice. 6.29.2.2 Angle. The transducer sound-path angle shall be checked or determined by one of the following procedures: (1) The transducer shall be set in position B on IIW block for angles 40° through 60°, or in position C on IIW block for angles 60° through 70° (see Figure 6.23). 6.29 Calibration of the UT Unit with IIW or Other Approved Reference Blocks (Annex H) (2) For the selected angle, the transducer shall be moved back and forth over the line indicative of the transducer angle until the signal from the radius is maximized. The sound entry point on the transducer shall be compared with the angle mark on the calibration block (tolerance ± 2°) (see Annex H, H2.2 for alternative methods). See 6.23 and Figures 6.19, 6.20, and 6.23. 6.29.1 Longitudinal Mode 6.29.1.1 Distance Calibration. See Annex H, HI for alternative method. (1) The transducer shall be set in position G on the IIW block. 6.29.2.3 Distance Calibration Procedure. The transducer shall be set in position D on the IIW block (any angle). The instrument shall then be adjusted to attain indications at 4 in [100 mm on a metric block] and 8 in [200 mm on a metric block] or 9 in [225 mm on a metric block] on the-display; 4 in [100 mm] and 9 in [230 mm] on Type 1 block; or 4 in [100 mm] and 8 in [200 mm] on a Type 2 block (see Annex H, H2.3 for alternative method). (2) The instrument shall be adjusted to produce indications at 1 in [25 mm on a metric block], 2 in [50 mm on a metric block], 3 in [75 mm on a metric block], 4 in [100 mm on a metric block], etc., on the display. 6.29.1.2 Amplitude. See Annex H, H1.2 for alternative method. (1) The transducer shall be set in position G on the IIW block. (2) The gain shall be adjusted until the maximized indication from first back reflection attains 50 to 75% screen height. 6.29.2.4 Amplitude or Sensitivity Calibration Procedure. The transducer shall be set in position A on the IIW block (any angle). The maximized signal shall then be adjusted from the 0.060 in [1.59 mm] hole to attain a horizontal reference-line height indication (see Annex H, H2.4 for alternative method). The maximum decibel reading obtained shall be used as the "Reference Level, b" reading on the Test Report sheet (Annex M, Form M-ll) in conformance with 6.23.1. 6.29.1.3 Resolution (1) The transducer shall be set in position F on the IIW block. (2) Transducer and instrument shall resolve all three distances. 6.29.2.5 Resolution 6.29.1.4 Horizontal Linearity Qualification. Qualification procedure shall be per 6.24.1. (1) The transducer shall be set on resolution block RC position Q for 70° angle, position R for 60° angle, or position S for 45° angle. 6.29.1.5 Gain Control (Attenuation) Qualification. The qualification procedure shall be in conformance with 6.24.2 or an alternative method, in conformance with 6.24.2, shall be used. (2) Transducer and instrument shall resolve the three test holes, at least to the extent of distinguishing the peaks of the indications from the three holes. 6.29.2.6 Approach Distance of Search Unit. The minimum allowable distance between the toe of the search unit and the edge of IIW block shall be as follows (see Figure 6.18): 6.29.2 Shear Wave Mode (Transverse) 6.29.2.1 Index Point. The transducer sound entry point (index point) shall be located or checked by the following procedure: for 70° transducer, X = 2 in [50 mm] (1) The transducer shall be set in position D on the IIW block. for 60° transducer, 228 AWS D1.1/D1.1M:2008 PARTF x = 1-7/16 in [37 rnm] (2) The distance calibration shall be adjusted so that the first 2 in [50 rnm] back reflection indication (hereafter called the indication) is at horizontal mid-screen. for 45° transducer, X = 1 in [25 mm] (3) The calibrated gain or attenuation control shall be adjusted so that the indication is exactly at or slightly above 40% screen height. 6.30 Equipment Qualification Procedures (4) The search unit shall be moved toward position D, see Figure 6.23, until the indication is at exactly 40% screen height. 6.30.1 Horizontal Linearity Procedure. NOTE: Since this qualification procedure is peiformed with a straightbeam search unit which produces longitudinal waves with a sound velocity of almost double that of shear waves, it is necessary to double the shear wave distance ranges to be used in applying this procedure. (5) The sound amplitude shall be increased 6 dB with the calibrated gain or attenuation control. The indication level theoretically should be exactly at 80% screen height. (6) The dB reading shall be recorded under "a" and actual % screen height under "b" from step 5 on the certification report (Annex M, Form M-8), Line 1. Example: The use of a 10 in [250 mm] screen calibration in shear wave wouldrequire a 20 in [500 rnm] screen calibration for this qualification procedure. (7) The search unit shall be moved further toward position D, Figure 6.23, until the indication is at exactly 40% screen height. The following procedure shall be used for instrument qualification (see Annex H, H3, for alternative method): • (1) A straight-beam search unit shall be coupled meeting the requirements of 6.22.6 to the IIW or DS block in Position G, T, or D (see Figure 6.23) as necessary to attain five back reflections in the qualification range being certified (see Figure 6.23). (8) Step 5 shall be repeated. (9) Step 6 shall be repeated; except, information should be applied to the next consecutive line on Annex M,FormM-8. (10) Steps 7, 8, and 9 shall be repeated consecutively until the full range of the gain control (attenuator) is reached (60 dB minimum). (2) The first and fifth back reflections shall be adjusted to their proper locations with use of the distance calibration and zero delay adjustments. (11) The information from Rows "a" and "b" shall be applied to equation 6.30.2.2 or the nomograph described in 6.30.2.3 to calculate the corrected dB. (3) Each indication shall be adjusted to reference level with the gain or attenuation control for horizontal location examination. (12) Corrected dB from step 11 to Row "c" shall be applied. (4) Each intermediate trace deflection location shall be correct within 2% of the screen width. (13) Row "c" value shall be subtri!cted from Row "a" value and the difference in Row "d," dB error shall be applied. 6.30.2 dB Accuracy • CLAUSE 6. INSPECTION 6.30.2.1 Procedure. NOTE: In order to attain the required accuracy (± 1 %) in reading the indication height, the display shall be graduated vertically at 2% intervals, or 2.5% for instruments with digital amplitude readout, at horizontal mid-screen height. These graduations shall be placed on the display between 60% and 100% of screen height. This may be accomplished with use of a graduated transparent screen overlay. If this overlay is applied as a permanent part of the DT unit, care should be taken that the overlay does not obscure normal testing displays. NOTE: These values may be either positive or negative and so noted. Examples of Application of Forms M-8, M-9, and M-lO arefound in Annex M. (14) Information shall be tabulated on a form, including minimum equivalent information as displayed on Form M-8, and the unit evaluated in conformance with instructions shown on that form. (15) Form M-9 provides a relatively simple means of evaluating data from item (14). Instructions for this evaluation are given in (16) through (18). (1) A straight-beam search unit shall be coupled, meeting the requirements of 6.22.6 to the DS block shown in Figure 6.20 and position "T," Figure 6.23. (16) The dB information from Row "e" (Form M-8) shall be applied vertically and dB reading from Row "a" 229 CLAUSE 6. INSPECTION PARTF AWS D1.1 /D1.1 M:2008 '" (Form M-8) horizontally as X and Y coordinates for plotting a dB curve on Form M-9. (3) A second straight line from the average % point on the A scale through the pivot point developed in step 2 and on to the dB scale C shall be extended. (17) The longest horizontal length, as represented by the dB reading difference, which can be inscribed in a rectangle representing 2 dB in height, denotes the dB range in which the equipment meets the code requirements. The minimum allowable range is 60 dB. (4) This point on the C scale is indicative of the corrected dB for use in Row "c." 6.30.2.5 Nomograph. For an example of the use of the nomograph, see Annex M, Form M-lO. (18) Equipment that does not meet this minimum requirement may be used, provided correction factors are developed and used for discontinuity evaluation outside the instrument acceptable linearity range, or the weld testing and discontinuity evaluation is kept within the acceptable vertical linearity range of the equipment. 6.30.3 Internal Reflections Procedure (1) Calibrate the equipment in conformance with 6.25.5. (2) Remove the search unit from the calibration block without changing any other equipment adjustments. NOTE: The dB error figures (Row "d") may be used as correction factor figures. (3) Increase the calibrated gain or attenuation 20 dB more sensitive than reference level. 6.30.2.2 Decibel Equation. The following equation shall be used to calculate decibels: (4) The screen area beyond 1/2 in [12 mm] sound path and above reference level height shall be free of any indication. 6.31 Discontinuity Size Evaluation Procedures As related to Annex M, Form M-8 6.31.1 Straight-Beam (Longitudinal) Testing. The size of lamellar discontinuities is not always easily determined, especially those that are smaller than the transducer size. When the discontinuity is larger than the transducer, a full loss of back reflection will occur and a 6 dB loss of amplitude and measurement to the centerline of the transducer is usually reliable for determining discontinuity edges. However, the approximate size evaluation of those reflectors, which are smaller than the transducer, shall be made by beginning outside of the discontinuity with equipment calibrated in conformance with 6.25.4 and moving the transducer toward the area of discontinuity until an indication on the display begins to form. The leading edge of the search unit at this point is indicative of the edge of the discontinuity. dB 1 = Row "a" dB 2 = Row "c" %1 = Row "b" % 2 = Defined on Form M-8 6.30.2.3 Annex M. The following !tOtes apply to the use of the nomograph in Annex M, Form M-lO: (1) Rows a, b, c, d, and e are on certification sheet, Annex M, Form M-8. (2) The A, B, and C scales are on the nomograph, Annex M, Form M-lO. (3) The zero points on the C scale shall be prefixed by adding the necessary value to correspond with the instrument settings; i.e., 0, 10, 20, 30, etc. 6.31.2 Angle-Beam (Shear) Testing. The following procedure shall be used to determine lengths of indications which have dB ratings more serious than for a Class D indication. The length of such indication shall be determined by measuring the distance between the transducer centerline locations where the indication rating amplitude drops 50% (6 dB) below the rating for the applicable discontinuity classification. This length shall be recorded under "discontinuity length" on the test report. Where warranted by discontinuity amplitude, this procedure shall be repeated to determine the length of Class A, B, and C discontinuities. 6.30.2.4 Procedure. The following procedures shall apply to the use of the nomograph in Annex M, Form M-lO: (1) A straight line between the decibel reading from Row "a" applied to the C scale and the corresponding percentage from Row "b" applied to the A scale shall be extended. (2) The point where the straight line from step 1 crosses the pivot line B as a pivot point for a second straight line shall be used. 230 PARTSF& G AWS D1.1/D1.1M:2008 6.32 Scanning Patterns • 6.35 Radiation Imaging Systems (See Figure 6.21) 6.32.1 Longitudinal Discontinuities Examination of welds may be performed using ionizing radiation methods other than RT, such as electronic imaging, including real-time imaging systems. Sensitivity of such examination as seen on the monitoring equipment (when used for acceptance and rejection) and the recording medium shall be no less than that required for RT. 6.32.1.1 Scanning Movement A. Rotation angle a = 10°. 6.32.1.2 Scanning Movement B. Scanning distance b shall be such that the section of weld being tested is covered. 6.32.1.3 Scanning Movement C. Progression distance c shall be approximately one-half the transducer width. 6.35.1 Procedures. Written procedures shall contain the following essential variables: (1) Equipment identification including manufacturer, make, model, and serial number, NOTE: movements A, B, and C may be combined into one scanning pattern. (2) Radiation and imaging control setting for each combination of variables established herein, 6.32.2 Transverse Discontinuities 6.32.2.1 Ground Welds. Scanning pattern D shall be used when welds are ground flush. (3) Weld thickness ranges, (4) Weldjointtypes, 6.32.2.2 Unground Welds. Scanning pattern E shall be used when the weld reinforcement is not ground flush. Scanning angle e = 15° max. .. "• CLAUSE 6. INSPECTION (5) Scanning speed, (6) Radiation source to weld distance, NOTE: The scanning pattern shall cover the full weld section. (7) Image conversion screen to weld distance, 6.32.3 ESW or EGW Welds (Additional Scanning Pattern). Scanning Pattern E Search unit rotation angle e between 45° and 60°. (9) IQI location (source side or screen side), (8) Angle of X-rays through the weld (from normal), (10) Type of recording medium (video recording, photographic still film, photographic movie film, or other acceptable mediums), NOTE: The scanning pattern shall cover the full weld section. (11) Computer enhancement (if used), (12) Width of radiation beam, 6.33 Examples of dB Accuracy Certification (13) Indication characterization protocol and acceptance criteria, if different from this code. Annex M shows examples of the use of Forms M-8, M-9, and M-I0 for the solution to a typical application of 6.30.2. 6.35.2 IQI. The wire-type IQI, as described in Part B, shall be used. IQI placement shall be "as specified in Part B for static examination. For in-motion examination, placement shall be as follows: (1) Two IQIs positioned at each end of area of interest and tracked with the run, PartG Other Examination Methods (2) One IQI at each end of the run and positioned at a distance no greater than 10 ft. (3 m) between any two IQIs during the run. 6.34 General Requirements • • This part contains NDT methods not addressed in Parts D, E, or F of Clause 6 of this code. The NDT methods set forth in part G may be used as an alternative to the methods outlined in Parts D, E, or F of Clause 6, pro. viding procedures, qualification criteria for procedures and personnel, and acceptance criteria are documented in writing and approved by the Engineer. 6.36 Advanced Ultrasonic Systems Advanced Ultrasonic Systems includes but is not limited to, multiple probe, multi-channel systems, automated inspection, time-of-flight diffraction (TOFD), and phased array systems. 231 CLAUSE 6. INSPECTION PARTG AWS 01.1/01.1 M:2008 ... on the recording medium that is to be used for production examination. Procedures shall be approved by an individual qualified as ASNT SNT-TC-IA, Level III (see 6.37.2). 6.36.1 Procedures. Written procedures shall contain the following essential variables: (1) Equipment identification including manufacturer, make, model and serial numbers, 6.37.2 Personnel Qualifications. In addition to the personnel qualifications of 6.14.6 the following shall apply. (2) Type of probes, including size, shape and anglefor phased array: number of transducer elements per probe, beam angle, focal distance, focal spot size, and frequency (MHz), (1) Level III-shall have minimum of six months experience using the same or similar equipment and procedures for examination of welds in structural or piping metallic materials. (3) Scanning control settings for each combination of variables established herein, (2) Levels I and II-shall be certified by the Level III above and have a minimum of three months experience using the same or similar equipment and procedures for examination of welds in structural or pipe metallic materials. Qualification shall consist of written and practical examinations for demonstrating capability to use the equipment and procedures to be used for production examination. (4) Setup and calibration procedure for equipment and probes using industry standards or workmanship samples, (5) Weld thickness ranges, (6) Weld joint type, (7) Scanning speeds, 6.37.3 Image Enhancement. Computer enhancement of the recording images shall be acceptable for improving the recorded image and obtaining additional information, providing required minimum sensitivity and accuracy of characterizin~ discontinuities are maintained. Computer enhanced images shall be clearly marked that enhancement was used and enhancement procedures identified. (8) Number of probes, (9) Scanning angle, (10) Type of scan (A, B, C, other), (11) Type of recording medium (video recording, computer assisted, or other acceptable mediums), (12) Computer based enhancement (if used), 6.37.4 Records-Radiation Imaging Examinations. Examinations, which are used for acceptance or rejection of welds, shall be recorded on an acceptable medium. The record shall be in-motion or static, whichever is used to accept or reject the welds. A written record shall be included with the recorded images giving the following information as a minimum: (13) Identification of computer software (if used), (14) Indication characterization protocol and acceptance criteria, if different from this code. 6.37 Additional Requirements (1) Identification and description of welds examined 6.37.1 Procedure Qualification. Procedures shall be qualified by testing the NDT method (system) and recording medium to establish and record all essential variables and conditions. Qualification testing shall consist of determining that each combination of the essential variables or ranges of variables can provide the minimum required sensitivity. Test results shall be recorded (2) Procedure(s) used (3) Equipment used (4) Location of the welds within the recorder medium (5) Results, including a list of unacceptable welds and repairs and their locations within the recorded medium. 232 AWS D1.1 /D1.1 M:2008 • CLAUSE 6. INSPECTION Table 6.1 Visual Inspection Acceptance Criteria (see 6.9) Statically Cyclically Loaded Loaded Tubular Nontubular Nontubular Connections Connections Connections (All Loads) Discontinuity Category and Inspection Criteria (1) Crack Prohibition Any crack shall be unacceptable, regardless of size or location. X X X (2) WeldlBase-Metal Fusion Thorough fusion shall exist between adjacent layers of weld metal and between weld metal and base metal. X X X (3) Crater Cross Section All craters shall be filled to provide the specified weld size, except for the ends of intermittent fillet welds outside of their effective length. X X X (4) Weld Profiles Weld profiles shall be in conformance with 5.24. X X X (5) Time of Inspection Visual inspection of welds in all steels may begin immediately after the completed welds have cooled to ambient temperature. Acceptance criteria for ASTM A 514, A 517, and A 709 Grade 100 and ioo W steels shall be based on visual inspection performed not less than 48 hours after completion of the weld. X X X (6) Undersized Welds The size of a fillet weld in any continuous weld may be less than the specified nominal size (L) without correction by the following amounts (U): L, U, specified nominal weld size, in [mm] allowable decrease from L, in [mm] ~ 1/16 [2] ~ 3/16 [5] ~ 3/32 [2.5] 1/4 [6] ~ 5/16 [8] ~ 1/8 [3] In all cases, the undersize portion of the weld shall not exceed 10% of the weld length. On web-to-flange welds on girders, underrun shall be prohibited at the ends for a length equal to twice the width of the flange. X X X • (7) Undercut (A) For material less than 1 in [25 mm] thick, undercut shall not exceed 1/32 in [1 mm], with the following exception: undercut shall not exceed 1/16 in [2 mm] for any accumulated length up to 2 in [50 mm] in any 12 in [300 mm]. For material equal to or greater than 1 in thick, undercut shall not exceed 1/16 in [2 mm] for any length of weld. ·i X i (B) In primary members, undercut shall be no more than 0.01 in [0.25 mm] deep when the weld is transverse to tensile stress under any design loading condition. Undercut shall be no more than 1/32 in [1 mm] deep for all other cases. (8) Porosity (A) CJP groove welds in butt joints transverse to the direction of computed tensile stress shall have no visible piping porosity. For all other groove welds and for fillet welds, the sum of the visible piping porosity 1/32 in [1 mm] or greater in diameter shall not exceed 3/8 in [10 mm] in any linear inch of weld and shall not exceed 3/4 in [20 mm] in any 12 in [300 mm] length of weld. (B) The frequency of piping porosity in fillet welds shall not exceed one in each 4 in [100 mm] of weld length and the maximum diameter shall not exceed 3/32 in [2.5 mm]. Exception: for fillet welds connecting stiffeners to web, the sum of the diameters of piping porosity shall not exceed 3/8 in [10 mm] in any linear inch of weld and shall not exceed 3/4 in [20 mm] in any 12 in [300 mm] length of weld. • (C) CJP groove welds in butt joints transverse to the direction of computed tensile stress shall have no piping porosity. For all other groove welds, the frequency of piping porosity shall not exceed one in 4 in [100 mm] of length and the maximum diameter shall not exceed 3/32 in [2.5 mm]. Note: An "X" indicates applicability for the connection type; a shaded area indicates non-applicability. 233 ... X X ;t t; ....... X ; .. X X X X . AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION Table 6.2 UT Acceptance-Rejection Criteria (Statically Loaded Nontubular Connections) (see 6.13.1) Weld Sizea in inches [mm] and Search Unit Angle 5/l6 through 3/4 Discontinuity [8-20] Severity Class 70° Class A Class B Class C Class D a > 3/4 through 1-1/2 [20-38] > 1-1/2 through 2-112 [38-65] > 2-1/2 through 4 [65-100] > 4 through 8 [100-200] 70° 70° 60° 45° 70° 60° 45° 70° 60° 45° +5& lower +2& lower -2& lower +1 & lower +3& lower -5& lower -2& lower 0& lower -7& lower -4& lower -1 & lower +6 +3 -1 0 +2 +3 +4 +5 -4 -3 -1 0 +1 +2 -6 -5 -3 -2 0 +1 +7 +4 +1 +2 +4 +5 +6 +7 -2 to +2 +1 +2 +3 +4 -4 to +2 -1 to +2 +2 +3 +8 &up +5 &up +3 &up +6 &up +8 &up +3 &up +3 &up +5 &up +3 &up +3 &up +4 &up Weld size in butt joints shall be the nominal thickness of the thinner of the two parts being joined. Notes: 1. Class B and C discontinuities shall be separated by at least 2L, L being the length of the longer discontinuity, except that when two or more such discontinuities are not separated by at least 2L, but the combined length of discontinuities and their separation distance is equal to or less than the maximum allowable length under the provisions of Class B or C, the discontinuity shall be c~nsidered a single acceptable discontinuity. 2. Class B and C discontinuities shall not begin at a distance less than 2L from weld ends carrying primary tensile stress, L being the discontinuity length. 3. Discontinuities detected at "scanning level" in the root face area of CJP double groove weld joints shall be evaluated using an indication rating 4 dB more sensitive than described in 6.26.6.5 when such welds are designated as "tension welds" on the drawing (subtract 4 dB from the indication rating "d"). This shall not apply if the weld joint is backgouged to sound metal to remove the root face and MT used to verify that the root face has been removed. 4. ESW or EGW: Discontinuities detected at "scanning level" which exceed 2 in [50 mm] in length shall be suspected as being piping porosity and shall be further evaluated with radiography. 5. For indications that remain on the display as the search unit is moved, refer to 6.13.1. Class A (large discontinuities) Any indication in this category shall be rejected (regardless of length). Scanning Levels Class B (medium discontinuities) Any indication in this category having a length greater than 3/4 in [20 mm] shall be rejected. Sound pathb in inches [mm] Class C (small discontinuities) Any indication in this category having a length greater than 2 in [50 mm] shall be rejected. through 2-112 [65 mm] > 2-112 through 5 [65-125 mm] > 5 through 10 [125-250 mm] > 10 through 15 [250-380 mm] Class D (minor discontinuities) Any indication in this category shall be accepted regardless of length or location in the weld. b 234 Above Zero Reference, dB 14 19 29 39 This column refers to sound path distance; NOT material thickness. AWS 01.1/01.1 M:2008 • CLAUSE 6. INSPECTION Table 6.3 UT Acceptance-Rejection Criteria (Cyclically Loaded Nontubular Connections) (see 6.13.2) Weld Size" in inches [mm] and Search Unit Angle 5/16 through 3/4 Discontinuity [8-20] Severity Class 70° Class A Class B Class C Class D a Weld > 3/4 through 1-112 [20-38] > 1-1/2 through 2-112 > 2-1/2 through 4 > 4 through 8 [38-65] [65-100] [100-200] 70° 70° 60° 45° 70° 60° 45° 70° 60° 45° +10& lower +8& lower +4& lower +7& lower +9& lower +1 & lower +4& lower +6& lower -2& lower +1 & lower +3& lower +11 +9 +5 +6 +8 +9 +10 +11 +2 +3 +5 +6 +7 +8 -1 0 +2 +3 +4 +5 +12 +10 +7 +8 +10 +11 +12 +13 +4 +5 +7 +8 +9 +10 +1 +2 +4 +5 +6 +7 +13 &up +11 &up +9 &up +12 &up +14 &up +6 &up +9 &up +11 &up +3 &up +6 &up +8 &up size in butt joints shall be the nominal thickness of the thinner of the two parts being joined. Notes: 1. Class B and C discontinuities shall be separated by at least 2L, L being the length of the longer discontinuity, except that when two or more such discontinuities are not separated by at least 2L, but the combined length of discontinuities and their separation distance is equal to or less than the maximum allowable length under the provisions of Class B or C, the discontinuity shall be considered a single acceptable discontinuity. 2. Class Band C discontinuities shall not begin at a distance less than 2L from weld ends carrying primary tensile stress, L being the discontinuity length. 3. Discontinuities detected at "scanning level" in the root face area of CJP double groove weld joints shall be evaluated using an indication rating 4 dB more sensitive than described in 6.26.6.5 when such welds are designated as "tension welds" on the drawing (subtract 4 dB from the indication rating "d"). This shall not apply if the weld joint is backgouged to sound metal to remove the root face and MT used to verify that the root face has been removed. 4. For indications that remain on the display as the search unit is moved, refer to 6.13.2.1. Class A (large discontinuities) Any indication in this category shall be rejected (regardless of length). Scanning Levels Class B (medium discontinuities) Any indication in thIS category having a length greater than 3/4 in [20 mm] shall be rejected. Sound pathb in [mm] Class C (small discontinuities) Any indication in this category having a length greater than 2 in [50 mm] in the middle half or 3/4 in [20 mm] length in the top or bottom quarter of weld thickness shall be rejected. > 2-1/2 through 5 [65-125 mm] > 5 through 10 [125-250 mm] through 2-112 [65 mm] > 10 through 15 [250-380 mm] Class D (minor discontinuities) Any indication in this category shall be accepted regardless of length or location in the weld. b This • 235 Above Zero Reference, dB 20 25 35 45 column refers to sound path distance; NOT material thickness. AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION ... Table 6.4 Hole-Type IQI Requirements (see 6.17.1) Nominal Material Thickness' Range, in Nominal Material Thickness' Range,mm Up to 0.25 inc!. Over 0.25 to 0.375 Over 0.375 to 0.50 Over 0.50 to 0.625 Over 0.625 to 0.75 Over 0.75 to 0.875 Over 0.875 to 1.00 Over 1.00 to 1.25 Over 1.25 to 1.50 Over 1.50 to 2.00 Over 2.00 to 2.50 Over 2.50 to 3.00 Over 3.00 to 4.00 Over 4.00 to 6.00 Over 6.00 to 8.00 Up to 6 inc!. Over 6 through 10 Over 10 through 12 Over 12 through 16 Over 16 through 20 Over 20 through 22 Over 22 through 25 Over 25 through 32 Over 32 through 38 Over 38 through 50 Over 50 through 65 Over 65 through 75 Over 75 through 100 Over 100 through 150 Over 150 through 200 Film Sideb Source Side Designation Essential Hole Designation Essential Hole 10 12 15 15 17 20 20 25 30 35 40 45 50 60 80 4T 4T 4T 4T 4T 4T 4T 4T 2T 2T 2T 2T 2T 2T 2T 7 10 12 12 15 17 17 20 25 30 35 40 45 50 60 4T 4T 4T 4T 4T 4T 4T 4T 2T 2T 2T 2T 2T 2T 2T • Single-wall radiographic thickness (for tubulars). b Applicable to tubular structures only. Table 6.5 Wire IQI Requirements (see 6.17.1) Nominal Material Thickness' Range, in Nominal Material Thickness' Range,mm Up to 0.25 inc!. Over 0.25 to 0.375 Over 0.375 to 0.625 Over 0.625 to 0.75 Over 0.75 to 1.50 Over 1.50 to 2.00 Over 2.00 to 2.50 Over 2.50 to 4.00 Over 4.00 to 6.00 Over 6.00 to 8.00 Up to 6 inc!. Over 6 to 10 Over 10 to 16 Over 16 to 20 Over 20 to 38 Over 38 to 50 Over 50 to 65 Over 65 to 100 Over 100 to 150 Over 150 to 200 Source Side Maximum Wire Diameter in mm in mm 0.010 0.013 0.016 0.020 0.025 0.032 0.040 0.050 0.063 0.100 0.25 0.33 0.41 0.51 0.63 0.81 1.02 1.27 1.60 2.54 0.008 0.010 0.013 0.016 0.020 0.025 0.032 0.040 0.050 0.063 0.20 0.25 0.33 0.41 0.51 0.63 0.81 1.02 1.27 1.60 a Single-wall b Film Sideb Maximum Wire Diameter radiographic thickness (for tubulars). Applicable to tubular structures only. 236 AWS 01.1/01.1 M:2008 • CLAUSE 6. INSPECTION Table 6.6 IQI Selection and Placement (see 6.17.7) Equal T ;::: 10 in [250 mm] L Equal T < 10 in [250 mm] L Unequal T ;::: 10 in [250 mm] L Unequal T < 10 in [250 mm] L Hole Wire Hole Wire Hole Wire Hole Wire Nontubular 2 2 -+1 1 3 2 2 1 Pipe Girth 3 3 3 3 3 3 3 3 E 1025 E747 E1025 E747 E 1025 E747 E 1025 E747 6.4 6.5 6.4 6.5 6.4 6.5 6.4 6.5 IQITypes Number ofIQIs ASTM Standard SelectionTable Figures 6.8 6.9 6.10 - 6.11 - T = Nominal base metal thickness (Tl and T2 of Figures). L = Weld Length in area of interest of each radiograph. Notes: 1. Steel backing shall not be considered part of the weld or weld reinforcement in IQI selection. 2. T may be increased to provide for the thickness of allowable weld reinforcement provided shims are used under hole IQls per 6.17.3.3. 3. When a complete circumferential pipe weld is radiographed with a single exposure and the radiation source is placed at the center of the curvature, at least three equally spaced hole type IQls shall be used. • • 237 .. AWS 01.1/01.1 M:2008 CLAUSE 6. INSPECTION Table 6.7 Testing Angle (see 6.26.5.2) Procedure Chart Material Thickness, in [mm] Weld Type 5/l6 [8] to 1-1/2 [38] > 1-1/2 [38] > 1-3/4 [45] >2-l/2 [60] >3-1/2 [90] >4-1/2 [1I0] >5 [130] >6-l/2 [160] >7[180] to to to to to to to to 5 [130] 6-l/2 [160] 7 [180] 8 [200] 1-3/4 [45] 2-l/2 [60] 3-l/2 [90] 4-l/2 [110] * * * * * * * * Butt 0 F 10 or 4 F IG or 5 F 6 or 7 F 8 or 10 F 9 or II F 12 or 13 F T- O F or XF 4 F or XF 5 F or XF 7 F or XF 10 F or XF II F or XF 13 F or XF Corner 0 F or XF IG or 4 F or XF IG or 5 F or XF 6 or 7 F or XF 8 or 10 F or XF 9 or II F or XF 13 or 14 F or XF Electrogas & Electroslag 0 0 IG or 4 1** IG or 3 PI or P3 6 or 7 P3 II or 15 P3 II or 15 P3 II or 15 P3 * 12 F II or 15** P3 '" RECEIVER TRANSMITTER FACE A FACE FACE C C I X BUTT JOINT PITCH-AND-CATCH CORNER JOINT GROUND FLUSH TOP QUARTER-70° MIDDLE HALF-70° ---'I" BOTTOM QUARTER-60° Notes: 1. Where possible, all examinations shall be made from Face A and in Leg I, unless otherwise specified in this table. 2. Root areas of single groove weld joints which have backing not requiring removal by contract, shall be tested in Leg I, where possible, with Face A being that opposite the backing. (Grinding of the weld face or testing from additional weld faces may be necessary to permit complete scanning of the weld root.) 3. Examination in Leg.II or III shall be made only to satisfy provisions of this table or when necessary to test weld areas made inaccessible by an unground weld surface, or interference with other portions of the weldment, or to meet the requirements of 6.26.6.2. 4. A maximum of Leg III shall be used only where thickness or geometry prevents scanning of complete weld areas and HAZs in Leg I or Leg II. 5. On tension welds in cyclically loaded structures, the top quarter of thickness shall be tested with the fmalleg of sound progressing from Face B toward Face A, the bottom quarter of thickness shall be tested with the final leg of sound progressing from Face A toward Face B; i.e., the top quarter of thickness shall be tested either from Face A in Leg II or from Face B in Leg I at the contractor's option, unless otherwise specified in the contract documents. 6. The weld face indicated shall be ground flush before using procedure IG, 6, 8, 9, 12, 14, or 15. Face A for both connected members shall be in the same plane. (See Legend on next page) 238 AWS 01.1/01.1 M:2008 • CLAUSE 6. INSPECTION Table 6.7 (Continued) Legend: -Check from Face "C." X G - Grind weld face flush. o - Not required. A Face - the face of the material from which the initial scanning is done (on T- and comer joints, follow above sketches). B Face ---,--opposite the "A" face (same plate). C Face - the face opposite the weld on the connecting member or a T- or comer joint. * - Required only where display reference height indication of discontinuity is noted at the weld metal-base metal interface while searching at scanning level with primary procedures selected from first column. - Use 15 in [400 mm] or 20 in [500 mm] screen distance calibration. ** - Pitch and catch shall be conducted for further discontinuity evaluation in only the middle half of the P material thickness with only 45° or 70° transducers of equal specification, both facing the weld. (Transducers must be held in a fixture to control positioning-see sketch.) Amplitude calibration for pitch and catch is normally made by calibrating a single search unit. When switching to dual search units for pitch and catch inspection, there should be assurance that this calibration does not change as a result of instrument variables. - Weld metal-base metal interface indications shall be further evaluated with either 70°, 60°, or 45° F transducer-whichever sound path is nearest to being perpendicular to the suspected fusion surface. Procedure Legend Area of Weld Thickness • Top Quarter Middle Half Bottom Quarter 70° 70° 70° 2 60° 60° 60° 3 45° 45° 45° 4 60° 70° 70° 5 45° 70° 70° 6 70 0 GA 70° 60° 7 60° B 70° 60° 8 70 0 GA 60° 60° 9 70 0 GA 60° 45° 10 60° B 60° 60° 11 45° B 70°** 45° 12 70 0 GA 45° 700 GB 13 45° B 45° 45° 14 70 0 GA 45° 45° No. 15 0 0 70 GA 70 AB • 239 70 0 GB AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION ... Legend for Figures 6.1 , 6.2, and 6.3 Dimensions of Discontinuities B = Maximum allowed dimension of a radiographed discontinuity. L = Largest dimension of a radiographed discontinuity. L' = Largest dimension of adjacent discontinuities. C = Minimum clearance measured along the longitudinal axis of the weld between edges of porosity or fusion-type discontinuities (larger of adjacent discontinuities governs), or to an edge or an end of an intersecting weld. C l = Minimum allowed distance between the nearest discontinuity to the free edge of a plate or tubular, or the intersection of a longitudinal weld with a girth weld, measured parallel to the longitudinal weld axis. W = Smallest dimension of either of adjacent discontinuities. Material Dimensions E = Weld size. T = Plate or pipe thickness for CJP groove welds. Definitions of Discontinuities • An elongated discontinuity shall have the largest dimension (L) exceed 3 times the smallest dimension. • A rounded discontinuity shall have the largest dimension (L) less than or equal to 3 times the smallest dimension. • A cluster shall be defmed as a group of nonaligned, acceptably-sized, individual adjacent discontinuities with spacing less than the minimum allowed (C) for the largest individual adjacent discontinuity (L'), but with the sum of the greatest dimensions (L) of all discontinuities in the cluster equal to or less than the maximum allowable individual discontinuity size (B). Such clusters shall be considered as individual discontinuities of size L for the purpose of assessing minimum spacing. • Aligned discontinuities shall have the major axes of each discontinuity approximately aligned. 240 CLAUSE 6. INSPECTION AWS D1.1/D1.1M:2008 • 3/4 MAX. 1-118 OR GREATER y 7/8 .5 ui N en 1/~/ 3/4 5/8 0 y/' ~.~ ~\~s,~ 1------ - - - - - i- - - <;;,O~ ...I w 1/2 ~\~'0\ 3/8 --- -- ------ CP~ 0\'3 1/4~S\-C ;: I r.. w 3/8 t>--J..~ ~--~ 1/8 1/4 3~3~ 1/8 I I I I o 1/4 3/4 1/2 1-1/4 1-1/2 1-3/4 2-1/4 2 CININCHES 20 MAX. 30 OR GREATER • y/' y 25 22 12"./ E E ui N 20 ~~~ ~\~s: 16 en 0 ...I w SCP I( O\; ----- --- -- 12 ;: J w ~'\\~U 10 - - - - 6r..-~S\1.-~O ~~t>-~ ~-- 10 6 3 2V I I I 3 I I o 6 12 20 25 32 40 44 50 57 C IN MILLIMETERS Notes: 1. To determine the maximum size of discontinuity allowed in any joint or weld size, project E horizontally to B. 2. To determine the minimum clearance allowed between edges of discontinuities of any size greater than or equal to 3/32 in [2.5 mm), project B vertically to C. 3. See Legend on page 240 for definitions. • Figure 6.1-Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections (see 6.12.1) 241 AWS D1.1 ID1.1 M:2008 CLAUSE 6. INSPECTION ... KEY FOR FIGURE 6.1, CASES I, II, III, AND IV DISCONTINUITY A = ROUNDED OR ELONGATED DISCONTINUITY LOCATED IN WELD A DISCONTINUITY B = ROUNDED OR ELONGATED DISCONTINUITY LOCATED IN WELD B LAND W = LARGEST AND SMALLEST DIMENSIONS, RESPECTIVELY, OF DISCONTINUITY A L' AND W' = LARGEST AND SMALLEST DIMENSIONS, RESPECTIVELY, OF DISCONTINUITY B E = WELD SIZE C1 = SHORTEST DISTANCE PARALLEL TO THE WELD A AXIS, BETWEEN THE NEAREST DISCONTINUITY EDGES CJP WELD "A" WIDTH W' CASE I DISCONTINUITY L1MITATIONsa DISCONTINUITY DIMENSION LIMITATIONS CONDITIONS < E/3, :::; 1/4 in [6 mm] E :::; 2 in [50 mm] :::; 3/8 in [10 mm] E > 2 in [50 mm] L C1 ~ (A)ONE DISCONTINUITY ROUNDED, THE OTHER ROUNDED OR ELONGATEDa 3L (B) L ~ 3/32 in [2.5 mm] a The elongated discontinuity may be located in either weld "A" or "B." For the purposes of this illustration the elongated discontinuity "B" was located in weld "B." Case I-Discontinuity at Weld Intersection Figure 6.1 (Continued)-Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections (see 6.12.1) 242 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION • FREE EDGE LENGTH L CASE II DISCONTINUITY LIMITATIONS DISCONTINUITY DIMENSION CONDITIONS LIMITATIONS <E/3, ::;;1/4 in [6 mm] E ::;; 2 in [50 mm] ::;;3/8 in [10 mm] E > 2 in [50 mm] L C1 ~3L L ~ 3/32 in [2.5 mm] Case II-Discontinuity at Free Edge of CJP Groove Weld • Figure 6.1 (Continued)-Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections (see 6.12.1) • 243 CLAUSE 6. INSPECTION AWS D1.1/D1.1 M:2008 ... WIDTH\ CJP WELD "A" .. LENGTHL~/... Cj ~ (f- LENGTH L' CASE III DISCONTINUITY LIMITATIONS DISCONTINUITY DIMENSION L Cj CONDITIONS LIMITATIONS :S;2E/3 LIW > 3W ~3L OR 2E, WHICHEVER IS GREATER L ~ 3/32 in [2.5 mm] Case III-Discontinuity at Weld Intersection Figure 6.1 (Continued)-Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections (see 6.12.1) 244 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION FREE EDGE LENGTH L CASE IV DISCONTINUITY LIMITATIONS DISCONTINUITY DIMENSION CONDITIONS LIMITATIONS L :::;2E/3 LIW > 3 Cr :<:3L OR 2E, WHICHEVER IS GREATER L :<: 3/32 in [2.5 mm] Case IV-Discontinuity at Free Edge of CJP Groove Weld Figure 6.1 (Continued)-Discontinuity Acceptance Criteria for Statically Loaded Nontubular and Statically or Cyclically Loaded Tubular Connections (see 6.12.1) • 245 .. AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION 1/2 MAX. 1-112 OR GREATER 1-1/4 3/8 ~ .......-::~\~'O,\'(\ ~~\~"0\ O~ ~ 0«- 0\'0 '?,(/...~ 0 .!: W N Ci5 Cl 3/4 fo----- ----- ----- ...J W ~ I W 1/2 1/16~ 1/4 Y - .1{y "j..\~"0~ ----- V~ . . ~~ ~ I I I V I I I o o 2 1-1/2 1/2 2-1/2 3-1/2 3 4-1/2 :4 CININCHES 12 MAX. 38 ~ OR GREATER 32 E E 0 O~ ---- ----20 ----- - - - - - - -~~i-\~"0~ ~V~ . . Cl ...J W ~ I W ~ ~/(.\~S.'" ~\~"0 ~ 0«- 0\'0 'O\1.-~ 25 wN Ci5 . 12 2 V- 6 Y I I . I I I ./ I I o o 12 25 40 50 65 75 90 100 C IN MILLIMETERS Notes: 1 To determine the maximum size of discontinuity allowed in any joint or weld size, project E horizontally to B. 2. To determine the minimum clearance allowed between edges of discontinuities of any size, project B vertically to C. 3. See Legend on page 240 for definitions. Figure 6.2-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension (Limitations of Porosity and Fusion Discontinuities) (see 6.12.2.1) 246 115 AWS D1.1/D1.1 M:2008 • CLAUSE 6. INSPECTION KEY FOR FIGURE 6.2, CASES I, II, III, AND IV DISCONTINUITY A DISCONTINUITY B = ROUNDED = ROUNDED OR ELONGATED DISCONTINUITY LOCATED IN WELD A OR ELONGATED DISCONTINUITY LOCATED IN WELD B LAND W = LARGEST AND SMALLEST DIMENSIONS, RESPECTIVELY, OF DISCONTINUITY A L' AND W' = LARGEST AND SMALLEST DIMENSIONS; RESPECTIVELY, OF DISCONTINUITY B E = WELD SIZE Cj = SHORTEST DISTANCE PARALLEL TO THE WELD A AXIS, BETWEEN THE NEAREST DISCONTINUITY EDGES CJP WELD "A" WIDTH W' CJP WELD "B" CASE I DISCONTINUITY L1MITATIONsa • DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.2 GRAPH (B DIMENSION) Cj SEE FIGURE 6.2 GRAPH (C DIMENSION) CONDITIONS L ~ 1/16 in [2 mm] - a The elongated discontinuity may be located in either weld "A" or "B." For the purposes of this illustration the elongated discontinuity "B" was located in weld "B." Case I-Discontinuity at Weld Intersection Figure 6.2 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension (Limitations of Porosity and Fusion Discontinuities) (see 6.12.2.1) • 247 CLAUSE 6. INSPECTION AWS 01.1/01.1 M:2008 ... FREE EDGE LENGTH L CASE II DISCONTINUITY LIMITATIONS DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.2 GRAPH (B DIMENSION) Cj SEE FIGURE 6.2 GRAPH (C DIMENSION) CONDITIONS L ~ 1/16 in [2 mm] - Case II-Discontinuity at Free Edge of CJP Groove Weld Figure 6.2 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension (Limitations of Porosity and Fusion Discontinuities) (see 6.12.2.1) 248 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION • WIDTH\ CJP WELD "A" .- LENGTHL~/... Cj ~ rt- LENGTH L' CASE III DISCONTINUITY LIMITATIONS • DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.2 GRAPH (8 DIMENSION) Cj SEE FIGURE 6.2 GRAPH (C DIMENSION) CONDITIONS L ~ 1/16 in [2 mm] - Case III-Discontinuity at Weld Intersection Figure 6.2 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension (Limitations of Porosity and Fusion Discontinuities) (see 6.12.2.1) 249 AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION ... FREE EDGE LENGTH L CASE IV DISCONTINUITY LIMITATIONS DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.2 GRAPH (8 DIMENSION) Cj SEE FIGURE 6.2 GRAPH (C DIMENSION) CONDITIONS L ~ 1/16 in [2 mm] - .. Case IV-Discontinuity at Free Edge of CJP Groove Weld Figure 6.2 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Tension (Limitations of Porosity and Fusion Discontinuities) (see 6.12.2.1) 250 AWS 01.1/01.1 M:2008 • CLAUSE 6. INSPECTION 3/4 MAX. 1-1/2 OR GREATER 1-1/4 ~ .~ 5/8 ~~\~S'~ ~ O~~\~'0\ ~y:- 0«- \)\SG .5 u.f --- -. ----. - ---- - ---- N (j) Cl 3/4 ....I Y W ;: I W 1/2 1/8 1/4 ~(Note a) rt' ./ y ~ S\'V 1/2 - - ~ j.\~'0 "", ~--~'" I I I I I o I o 2 1-1/2 1/2 2-1/2 3 4 3·1/2 4-1/2 CININCHES 20 MAX. 38 OR GREATER ~ /., ~~ ~ \~'0\~\~S, 32 • E E u.f 25 (j) 20 N 4 - - -- - --- ----- Cl ....I W ;: I 12 w 3 6 --(Note a) ~ Y ./ o~~ LY': V y:- 0«- ~ S\'V ----- --~~"'~~'0 12 \)\sG ~-- I I I • I I o I o 12 25 40 50 65 75 90 100 115 C IN MILLIMETERS aThe maximum size of a discontinuity located within this distance from an edge of plate shall be 1/8 in [3 mm], but a 1/8 in [3 mm] discontinuity shall be 1/4 in [6 mm] or more away from the edge. The sum of discontinuities less than 1/8 in. [3 mm] in size and located Within this distance from the edge shall not exceed 3/16 in [5 mm]. Discontinuities 1/16 in [2 mm] to less than 1/8 in [3 mm] shall not be restricted in other locations unless they are separated by less than 2 L (L being the length of the larger discontinuity); in which case, the discontinuities shall be measured as one length equal to the total length of the discontinuities and space and evaluated as shown in this figure. Notes: 1. To determine the maximum size of discontinuity allowed in any joint or weld size, project E horizontally to B. 2. To determine the minimum clearance allowed between edges of discontinuities of any size, project B vertically to C. 3. See Legend on page 240 for definitions. • Figure 6.3-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Compression (Limitations of Porosity or Fusion-Type Discontinuities) (see 6.12.2.2) 251 CLAUSE 6. INSPECTION AWS D1.1/D1.1 M:2008 ... KEY FOR FIGURE 6.3, CASES I, II, III, IV, AND V DISCONTINUITY A = ROUNDED OR ELONGATED DISCONTINUITY LOCATED IN WELD A DISCONTINUITY B = ROUNDED OR ELONGATED DISCONTINUITY LOCATED IN WELD B LAND W = LARGEST AND SMALLEST DIMENSIONS, RESPECTIVELY, OF DISCONTINUITY A L' AND W' = LARGEST AND SMALLEST DIMENSIONS, RESPECTIVELY, OF DISCONTINUITY B E = WELD SIZE Cj = SHORTEST DISTANCE PARALLEL TO THE WELD A AXIS, BETWEEN THE NEAREST DISCONTINUITY EDGES CJP WELD "A" WIDTH W' CASE I DISCONTINUITY L1MITATI~sa DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.3 GRAPH (B DIMENSION) Cj SEE FIGURE 6.3 GRAPH (C DIMENSION) CONDITIONS L ~ 1/8 in [3 mm] Cj ~ 2L or 2L', WHICHEVER IS GREATER a The elongated discontinuity may be located in either weld "A" or "B:' For the purposes of this illustration the elongated discontinuity "B" was located in weld "B." Case I-Discontinuity at Weld Intersection Figure 6.3 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Compression (Limitations of Porosity or Fusion-Type Discontinuities) (see 6.12.2.2) 252 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION • FREE EDGE LENGTH L CASE II DISCONTINUITY LIMITATIONS • DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.3 GRAPH (8 DIMENSION) C1 SEE FIGURE 6.3 GRAPH (C DIMENSION) CONDITIONS L::': 1/8 in [3 mm) C1 ::': 5/8 in [16 mm) Case II-Discontinuity at Free Edge of CJP Groove Weld Figure 6.3 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Compression (Limitations of Porosity or Fusion-Type Discontinuities) (see 6.12.2.2) • 253 AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION ... CJP WELD "A" CASE III DISCONTINUITY LIMITATIONS DISCONTINUITY DIMENSION LIMITATIONS L SEE FIGURE 6.3 GRAPH (8 DIMENSION) L ;:; 1/8 in [3 mm] Cr SEE FIGURE 6.3 GRAPH (C DIMENSION) .. Cr ;:; 2L or 2L', WHICHEVER IS GREATER CONDITIONS Case III-Discontinuity at Weld Intersection Figure 6.3 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Compression (Limitations of Porosity or Fusion-Type Discontinuities) (see 6.12.2.2) 254 AWS 01.1/01.1 M:2008 • CLAUSE 6. INSPECTION 5/8 in [16 mm] -l~"--.I FREE EDGE (A) MINIMUM DIMENSION FROM FREE EDGE TO 1/8 in [3 mm] DISCONTINUITY o (B) SUM OF ALL L (LARGEST) DISCONTINUITY DIMENSIONS, EACH LESS THAN 1/8 in [3 mm], SHALL BE EQUAL TO OR LESS THAN 3/16 in [5 mm]. • .. Note: All dimensions between discontinuities • ~ 2L (L being largest of any two) Case IV-Discontinuities Within 5/8 in [16 mm] of a Free Edge (A) ALL L DIMENSIONS ARE GREATER THAN 1/16 in [2 mm] BUT LESS THAN 1/8 in [3 mm] (B) IF C1 IS LESS THAN THE LARGER OF L1 AND L2 AND C2 IS LESS THAN THE LARGER OF L2 AND La. ADD L1 + L2 + La + C1 + C2 AND TREAT AS SINGLE DISCONTINUITY Note: The weld shown above is for illustration only. These limitations apply to all locations or intersections. The number of discontinuities is also for illustration only. Case V-Discontinuities Separated by Less Than 2L Anywhere in Weld (Use Figure 6.3 Graph "B" Dimension for Single Flaw) Figure 6.3 (Continued)-Discontinuity Acceptance Criteria for Cyclically Loaded Nontubular Connections in Compression (Limitations of Porosity or Fusion-Type Discontinuities) (see 6.12.2.2) • 255 .. AWS 01.1/01.1 M:2008 CLAUSE 6. INSPECTION tw WELD THICKNESS, mm o W ...J a:l 1/4 1/2 ~U I-~ cnu. 3/4 U~ ~ ww <!:llI: lI:...J °5 1- <!:l~ 1-1/2 38 ~ See Note a 12 ~ 20 25 "{ r w ...J a:l ~E E a. w . UlI: U~ «U I-W cn...J wu. <!:lw lI:lI: :5<i! u.::::l See Note b oQ 40 ~ '-. 'I.-. 2 o OVER 50 6 '\ Z W ...J 50 ... "' :5~ u.o :1:0 25 ~ ~ .!: a. wlI:- 12 - 1-112 1/2 I.-. 2 :I:=:: <!:lZ ZW ...J 1-0 50 OVER 2 WELD THICKNESS, in tw a Internal linear or planar reflectors above standard sensitivity (except root of single welded T-, Yo, and K-connections [see Figure 6..2)). b Minor reflectors (above disregard level up to and including standard sensitivity) (except root of single welded T-, Yo, and K-connections [see Figure 6..2)). Adjacent reflectors separated by less than their average length shaH' be treated as continuous. Figure 6.~Class R Indications (see 6.13.3.1) 256 AWS 01.1/01.1 M:2008 CLAUSE 6. INSPECTION tw WELD THICKNESS, mm rl;·· .:§ UNDER 75 75 150 225 300 UNDER 12 12 25 38 50 I I I EVALUATE OVER THIS LENGTH (NOT TO EXCEED 0/2 OVER 3 0 0 - WHERE 0 IS DIAMETER) OVER 50 - ~ INTERNAL LINEAR OR PLANAR 1/2 REFLECTORS ABOVE STANDARDSENSITIVITY (EXCEPT ROOT OF SINGLE WELDED T-, Yo, AND K-CONNECTIONS) --- \ II: \ W 6 1-112 \ C/) II: .f: go w a w!;( ...J::::> tt...J II:~ I~ \, 2 \ u.w 00 J:...J I-w (!)$ Zu. ~O • a a « II: w 40 ~ C/)E ga OE- 50 65 \ 75 3 ABOVE~ ALL RELECTORS 3-1/2 I - DISREGARD LEVEL INCLUDING ROOT REFLECTORS OF SINGLE WELDED T-, Yo, AND K-CONNECTIONS (Note a) 4 I UNDER 1/2 1/2 UNDER 3 3 WW ...J!;( u.::::> w...J 1I:.:r; u.> OW J:o I-...J (!}w z$ wu. ...JO oJ: wI!;«!) ...Jz ::::>w ::2:...J ::::> a ~ \ "\ 90 \ I 6 6 II: \ ~~ ::::>...J ::2: ::::> 25 \ OJ: wI- ,~ 12 \ 2-1/2 FOR THIS WELD SIZE \ ""- - 100 1-1/2 2 OVER 2 - FOR THIS WELD SIZE 9 12 OVER 12 - EVALUATE OVER THIS LENGTH (NOT TO EXCEED 0/2 WHERE 0 IS DIAMETER) WELD THICKNESS, in tw a Root area discontinuities falling outside theoretical weld (dimensions "tw" or "~' in Figures 3.8, 3.9, and 3.10) are to be disregarded. Figure 6.~ (Continued)-Class R Indications (see 6.13.3.1) • 257 CLAUSE 6. INSPECTION AWS D1.1/D1.1 M:2008 ... BRANCH MEMBER Notes: 1. Aligned discontinuities separated by less than (L1 + L2)/2 and parallel discontinuities separated by less than (H1 + H2)/2 shall be evaluated as continuous. 2. Accumulative discontinuities shall be evaluated over 6 in [150 mm] or D/2 length of weld (whichever is less), where tube diameter = D. HEIGHT (H) LENGTH (L) LAND H BASED ON A RECTANGLE WHICH TOTALLY ENCLOSES INDICATED DISCONTINUITY LENGTH, mm 12 25 50 I 150 OR D/2 I I REJECT ..... ..., 1/4 [6] OR t w /4 - T-, Y-, AND K-ROOT DISCONTINUITIES I, ACCUMULATIVE E Lt _DISCONTINUITIES .§. .5 100 I· -I 1/8 l [3] ---./L-__..... _ 1/16 I [2] INDIVIDUAL DISCONTINUITIES ACCEPT I I I I I 1/2 1 2 4 6 OR D/2 Notes: 1. For CJP weld in single welded T-, Y-, and K-tubular con~ctions made without backing. 2. Discontinuities in the backup weld in the root, Details C and D of Figures 3.8, 3.9, and 3.10 shall jj.. be disregarded. • LENGTH, in LENGTH, mm 6 12 25 I I I 1 .5 g lI (!' iii I L I E 1/8 [3] 100 I 150 OR D/2 I REJECT 1/4 [6] OR t w/4 .§. 50 I f- INTERNAL REFLECTORS AND ALL OTHER WELDS ACCUMULATIVE DISCONTINUITIES 1/16 [2] INDIVIDUAL DISCONTINUITIES J I I 1/4 1/2 I 1 I I 1 I I 2 shall be disregarded. Note: Discontinuities that are within H or t w/6 of the outside surface shall be sized as if extending to the surface of the weld. ACCEPT ANY (Note a) a Reflectors below standard sensitivity (see 6.13.3.2) ....., 4 6 OR D/2 LENGTH, in Figure 6.~-Class X Indications (see 6.13.3.2) 258 AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION 4 T DIA (MINIMUM SIZE 0.040 in [1.02 mm]) T DIA (MINIMUM SIZE 0.010 in [0.25 mm]) 2 T DIA (MINIMUM SIZE 0.020 in [0.51 mm]) I E L ~T~ C ~---B---~ 14--------A-------.j DESIGN FOR IQls UP TO BUT NOT INCLUDING 180. Table of Dimensions of IQI (in) ~ IQI Thickness and Hole Diameter· Tolerances Number" A B C D E F 5-20 1.500 ± 0.015 0.750 ± 0.015 0.438 ± 0.015 0.250 ± 0.015 0.500 ± 0.015 0.250 ± 0.030 ± 0.0005 21-59 1.500 ± 0.015 0.750 ± 0.015 0.438 ± 0.015 0.250 ± 0.015 0.500 ± 0.015 0.250 ± 0.030 ±0.0025 60-179 2.250 ± 0.030 1.375 ±0.030 0.750 ± 0.030 0.375 ± 0.030 1.000 ± 0.030 0.375 ± 0.030 ± 0.005 Table of Dimensions of IQI (mm) IQI Thickness and Hole Diameter Tolerances Number" A B C D E F 5-20 38.10 ±0.38 19.05 ±0.38 11.13 ± 0.38 6.35 ± 0.38 12.70 ±0.38 6.35 ±0.80 ± 0.013 21-59 38.10 ±0.38 19.05 ±0.38 11.13 ±0.38 6.35 ±0.38 12.70 ±0.38 6.35 ±0.80 ±0.06 60-179 57.15 ±0.80 34.92 ±0.80 19.05 ±0.80 9.52 ±0.80 25.40 ±0.80 9.525 ±0.80 ± 0.13 a IQls NO.5 through 9 are not n, 2T, and 4T. Note: Holes shall be true and normal to the IQI. Do not chamfer. Figure 6.~Hole-Type IQI (see 6.17.1) (Reprinted by permission of the American Society for Testing and Materials, copyright.) 259 . AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION ENCAPSULATED BETWEEN CLEAR "VINYL:' PLASTIC 0.060 in [1.52 mm] MAXIMUM ASTM THE MINIMUM DISTANCE BETWEEN THE AXIS OF WIRES SHALL NOT BE LESS THAN 3 TIMES THE DIAMETER AND NOT MORE THAN 0.200 in [5.08 mm] 1/4 in [6.35 mm] MINIMUM LEAD LETTERS 0.200 in H-[5.08mm] LENGTH 1 in [25.4 mm] MINIMUM FOR SETS A AND B 1/4 in [6.35 mm] MINIMUM LEAD LETTERS AND NUMBERS o1 1 A 6 WIRES EQUALLY SPACED ... LARGEST WIRE NUMBER SET IDENTIFICATION LETTER MATERIAL GRADE NUMBER Image Quality Indicator (Wire Penetrameter) Sizes Wire Diameter, in [mm] SetA . Set B Set C Set D 0.0032 [0.08] 0.010 [0.25] 0.032 [0.81] 0.10 [2.5] 0.004 [0.1] 0.013 [0.33] 0.040 [1.02] 0.125 [3.2] 0.005 [0.13] 0.016 [0.4] 0.050 [1.27] 0.160 [4.06] 0.0063 [0.16] 0.020 [0.51] 0.063 [1.6] 0.20 [5.1] 0.008 [0.2] 0.025 [0.64] 0.080 [2.03] 0.25 [6.4] 0.010 [0.25] 0.032 [0.81] 0.100 [2.5] 0.32 [8] Figure 6.Z-Wire IQI (see 6.17.1) (Reprinted by permission of the American Society for Testing and Materials, copyright.) 260 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION CONTRACT NUMBER, WELD, ~ AND FABRICATOR IDENTIFICATION , (LOCATION OPTIONAL) (SEE 6.17.12). ALTERNATE WIRE IQI PLACEMENT (Note a) ~ T2~ 3/8 in [10 mmj MIN (TYP) HOLE-TYPE IQI OR WIRE IQI ON SOURCE SIDE - - - T1 =T2 LEAD FILM IDENTIFICATION NUMBER SHALL BE PLACED DIRECTLY OVER THE NUMBERS MARKED ON THE STEEL FOR THE PURPOSE OF MATCHING FILM TO WELD AFTER PROCESSING (SEE 6.17.12). CONTRACT NUMBER, WELD, AND FABRICATOR IDENTIFICATION (LOCATION OPTIONAL) (SEE 6.17.12). a Alternate source side IQI placement allowed for tubular applications and other applications when approved by the Engineer. Figure 6.~RT Identification and Hole-Type or Wire IQI Locations on Approximately Equal Thickness Joints 10 in [250 mm] and Greater in Length (see 6.17.7) 261 CLAUSE 6. INSPECTION AWS D1.1/D1.1M:2008 ... CONTRACT NUMBER, WELD, AND FABRICATOR IDENTIFICATION (LOCATION OPTIONAL) (SEE 6.17.12). HOLE-TYPE IQI OR WIRE IQI ON SOURCE SIDE MAY BE PLACED ANYWHERE ALONG AND ON EITHER SIDE OF THE JOINT ALTERNATE WIRE -~"'c-~~---:::;; IQI PLACEMENT (Note a) T1 =T2 LEAD FILM IDENTIFICATION NUMBER SHALL BE PLACED DIRECTLY OVER THE NUMBERS MARKED ON THE STEEL FOR THE PURPOSE OF MATCHING FILM TO WELD AFTER PROCESSING (SEE 6.17.12). CONTRACT NUMBER, WELD, AND FABRICATOR IDENTIFICATION (LOCATION OPTIONAL) (SEE 6.17.12). .. a Alternate source side IQI placement allowed for tubular applications and other applications when approved by the Engineer. Figure 6.~-RT Identification and Hole-Type or Wire IQI Locations on Approximately Equal Thickness Joints Less than 10 in [250 mm] in Length (see 6.17.7) 262 AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION HOLE-TYPE 101 OR WIRE 101 ON SOURCE SIDE ALTERNATE WIRE 101 PLACEMENT (Note a) 3/4 in [20 mm] MIN. (TYP) MEASURE T2 AT POINT OF MAXIMUM THICKNESS UNDER HOLE-TYPE 101 OR WIRE 101 PLACED ON SLOPE LEAD FILM IDENTIFICATION NUMBER SHALL BE PLACED DIRECTLY OVER THE NUMBERS MARKED ON THE STEEL FOR THE PURPOSE OF MATCHING FILM TO WELD AFTER PROCESSING (SEE 6.17.12). CONTRACT NUMBER, WELD, AND FABRICATOR IDENTIFICATION (LOCATION OPTIONAL) (SEE 6.17.12). a Alternate source side 101 placement allowed for tubular applications and other applications when approved by the Engineer. Figure 6.1o-RT Identification and Hole-Type or Wire IQI Locations on Transition Joints 10 in [250 mm] and Greater in Length (see 6.17.7) 263 .. CLAUSE 6. INSPECTION AWS D1.1/D1.1M:2008 HOLE-TYPE 101 OR WIRE 101 ON SOURCE SIDE MAY BE PLACED ANYWHERE ALONG THE JOINT- ALTERNATE WIRE 101 PLACEMENT (Note a) 3/4 in [20 mm] MIN. (TYP) MEASURE T2 AT POINT OF MAXIMUM THICKNESS UNDER HOLE-TYPE 101 OR WIRE 101 PLACED ON SLOPE LEAD FILM IDENTIFICATION NUMBER SHALL BE PLACED DIRECTLY OVER THE NUMBERS MARKED ON THE STEEL FOR THE PURPOSE OF MATCHING FILM TO WELD AFTER PROCESSING (SEE 6.17.12). CONTRACT NUMBER, WEL , AND FABRICATOR IDENTIFICATION (LOCATION OPTIONAL) (SEE 6.17.12). a Alternate source side 101 placement allowed for tubular applications and other application~when approved by the Engineer. Figure 6.11-RT Identification and Hole-Type or Wire IQI Locations on Transition Joints Less than 10 in [250 mm] in Length (see 6.17.7) ~ ~T (2 in [50 mm] MIN.) ,X ~T (2 in [50 mm] MIN.) > ~T EDGE BLOCK ~T/2 (1 in [25 mm] MIN.) Note: T ~ r = Max. weld thickness at joint. Figure 6.12-RT Edge Blocks (see 6.17.13) 264 ( AWS 01.1/01.1 M:2008 CLAUSE 6. INSPECTION FILM SOURCE PANORAMIC EXPOSURE ONE EXPOSURE FILM MINIMUM THREE EXPOSURES Figure 6.13-Single-Wall ExposureSingle-Wall View (see 6.18.1.1) MINIMUM THREE EXPOSURES o--SOURCE Figure 6.14-Double-Wall ExposureSingle-Wall View (see 6.18.1.2) 265 . CLAUSE 6. INSPECTION AWS D1.1/D1.1M:2008 r~SOURCE I.OFFSE~ SOURCE t I 7DMIN. _!-----=~~ I -----~"'" WELD " " - FILM Figure 6.IS-Double-Wall Exposure-Double-Wall (Elliptical) View, Minimum Two Exposures (see 6.18.1.3) .. r~SOURCE CENTERLINE ~ AXISOFWELD~ SOURCE 7DMIN. J-----:;;;;azIZ2~ WELD ~FILM Figure 6.16-Double-Wall Exposure-Double-Wall View, Minimum Three Exposures (see 6.18.1.3) ~.; • .... 266 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION 1"'----., 1"'----"1 I I I I 1. I I .1 WIDTH -+--.1 Figure 6.17-Transducer Crystal (see 6.22.7.2) 1 in [25.4 mm] SEARCH UNIT 0.060 in HOLE [1.59 mm] j - -...--+--~~,;lIo'---~..., 0.6 in (15.2 mm) ~ 1.4in [36mm] Figure 6.18-Qualification Procedure of Search Unit Using IIW Reference Block (see 6.22.7.7) 267 .. AWS 01.1/01.1 M:2008 CLAUSE 6. INSPECTION ~---165 - - - . - . j - - - 6.600 -----l~ 0.920 r: L.l ~ 0.065 -l~= __ J_ _-----:.O-._~-..L..I---J 1.0q 0.080 SI DIMENSIONS (mm) U.S. CUSTOMARY DIMENSIONS (in) (A) TYPE 1 (TYPICAL) 11;= 0.920 !-fnj=--J_ _ tT~ 1.000 I 0.020 6 ~0.5 23 ~q=--~--~:t--'--:i --J ---"='T'-:f----'-0·r__ (0.156 25 2 0.080 r 4.000 L 2 4 6 v II I " " II " " " "800 I" 1I1.L1 " " " " " " " I: 8.000 100 8 L IL_---- 12.00;1---•. 000 5 10 15 20 III" I.LIIII"""" """" v 800"II"""" ,,,___- , I: U.S. CUSTOMARY DIMENSIONS (in) 200 300 .1---,00 SI DIMENSIONS (mm) (B) TYPE 2 (TYPICAL) Notes: 1. The dimensional tolerance between all surfaces involved in referencing or calibrating shall be within ±0.005 in [0.13 mm] of detailed dimension. 2. The surface finish of all surfaces to which sound is applied or reflected from shall have a maximum of 125 loIin [3.17 101m] r.m.s. 3. All material shall be ASTM A 36 or acoustically equivalent. 4. All holes shall have a smooth internal finish and shall be drilled 90 0 to the material surface. 5. Degree lines and identification markings shall be indented into the material surface so that permanent orientation can be maintained. 6. Other approved reference blocks with slightly different dimensions or distance calibration slots are permissible (see Annex H). 7. These notes shall apply to all sketches in Figures 6.19 and 6.20. Figure 6.19-lnternationallnstitute of Welding (HW) UT Reference Blocks (see 6.23.1) 268 AWS 01.1101.1 M:2008 CLAUSE 6. INSPECTION 6.000 3.966 3.544 ·1 2.533 lo.l75 1.026 ~ 1.177 ~ 1.967 2.121 2.275 "I ·1 "I I I I 60° 70° 45° ~OO t:)- + + 1 1.344 I + 1.656 t~-~ 70° +) 60° I 3 .000 G- ++- 45° --- 0.691 0.731 0.771 11I-- -.J 1.000 \.- 1.819 1.846 1.873 5.117 5.131 5.145 Note: All holes are 1/16 inch in diameter. DIMENSIONS IN INCHES RC - RESOLUTION REFERENCE BLOCK 11, 2 t 4 ------ 11------.. C= 2--.J- --.J-2=:l -.J 2 \.2 ~ TYPE - DISTANCE AND SENSITIVITY REFERENCE BLOCK Figure 6.2~ualification Blocks (see 6.23.3) 269 AWS D1.1/D1.1M:2008 CLAUSE 6. INSPECTION ... 152.40 100.74 90.02 64.34 .12123 26.06 ~ 29.90 ~ 49.96 53.87 57.79 -I "I -, I I I 60° 70° 45° "I 1:.~~--~ (£)- + + 1 34.14 I 10 + 70° 42.06 +). 60° I 76.20 Q+ +- 45° -- Ie- 25.40 17.55 18.57 I 19.58 ~ J - - - - 46.20 - - i l l ~--46.89----O~I J - - - - 47.57 - - - . j 1----------129.97----------11 1----------130.33---------1 1 - - - - - - - - - - 1 3 0 . 6 8 - - - - - - =..= - - - - - - . j Note: All holes are 1.59 mm in diameter. DIMENSIONS IN MILLIMETER4 RC - RESOLUTION REFERENCE BLOCK r----a---+Ir ~ ---101.60 L . . __.. .1 l.. . __~I-- 50.80 -!-50.80-!-50.80--:' ~---- 152.40----~ ~ 50.80 TYPE - DISTANCE AND SENSITIVITY REFERENCE BLOCK Figure 6.20 (Continued)-Qualification Blocks (see 6.23.3) (Metric) ( 270 AWS D1.1/D1.1 M:2008 CLAUSE 6. INSPECTION e e .. PATIERN D PATIERN E -, B I--c-j ---I\--I\-~- 1\ 1 1 r-+-, ~-f-~ ., ,I ... 1-1 r: :; 1\ / I \1; +' - -++-+--------MOVEMENT A 1\ 1-- --I 1 \..... ··r Sii I--c-j .. * - -- MOVEMENTC MOVEMENTS ~ . ~ . 1. Testing patterns are all symmetrical around the weld axis with the exception of pattern D, which shall be conducted directly over the weld axis. 2. Testing from both sides of the weld axis shall be made wherever mechanically possible. Figure 6.21-Plan View of UT Scanning Patterns (see 6.32) 271 CLAUSE 6. INSPECTION AWS D1.1/D1.1 M:2008 ... (A) BEAM DIRECTION. MAINTAIN SOUND PERPENDICULAR TO WELD. MAIN OR THROUGH MEMBER (B) V-PATHS. USE SINGLE AND MULTIPLE LEGS AND VARIOUS ANGLES AS REQUIRED TO COVER THE COMPLETE WELD INCLUDING THE ROOT AREA. Figure 6.22-Scanning Techniques (see 6.27.5) 272 AWS 01.1/01.1M:2008 CLAUSE 6. INSPECTION o o IIW BLOCK 3 o RESOLUTION BLOCK OS BLOCK Figure 6.23-Transducer Positions (Typical) (see 6.29) 273 AWS D1.1/D1.1M:2008 This page is intentionally blank.• 274 AWS D1.1/D1.1M:2008 7. Stud Welding 7.1 Scope 7.2.4 Stud Bases. A stud base, to be qualified, shall have passed the test described in 7.9. Only studs with qualified stud bases shall be used. Qualification of stud bases in conformance with 7.9 shall be at the manufacturer's expense. The arc shield used in production shall be the same as used in qualification tests or as recommended by the manufacturer. When requested by the Engineer, the Contractor shall provide the following information: Clause 7 contains general requirements for welding of steel studs to steel, and stipulates specific requirements: Q) For mechanical properties and material of steel studs, and requirements for qualification of stud bases~ @ For application qualification testing, operator qualification, preproduction testing, and workmanship. (1) A description of the stud and arc shield Q) For stud welding during production, fabrication/erection, and inspection. • • (2) Certification from the manufacturer that the stud base is qualified in conformance with 7.9. (4) For the stud manufacturer's certification of stud base weldability. (3) Qualification tests data NOTE: Approved steels; for studs, see 7.2.6; for base metals, see Table 3.1 (Groups I and Il). For guidance, see C7. 6. J. 7.2.5 Stud Finish. Finish shall be produced by heading, rolling, or machining. Finished studs shall be of uniform quality and condition, free of injurious laps, fins, seams, cracks, twists, bends, or other injurious discontinuities. Radial cracks or bursts in the head ofa stud shall not be the cause for rejection, provided that the cracks or bursts do not extend more than half the distance from the head periphery to the shank, as determined by visual inspection. Heads of shear connectors or anchor studs are subject to cracks or bursts, which are names for the same thing. Cracks or bursts designate an abrupt interruption of the periphery of the stud head by radial separation of the metal. Radial cracks or bursts in the head of a stud shall not be cause for rejection, provided that the cracks or bursts, as determined by visual inspection, do not exceed the value: 0.25 (H-C) (see Figure 7.1). 7.2 General Requirements 7.2.1 Stud Design. Studs shall be of suitable design for arc welding to steel members with the use of automatically timed stud welding equipment. The type and size of the stud shall be as specified by the drawings, specifications, or special provisions. For headed-type studs, see Figure 7.1. Alternative head configurations may be used with proof of mechanical and embedment tests confrrming full-strength development of the design, and with the approval of the Engineer. 7.2.6 Stud Material. Studs shall be made from cold drawn bar conforming to the requirements of ASTM A 29, Standard Specification for Steel Bars, Carbon and Alloy, 80t-Wrought, General Requirements for Grades 1010 through 1020, inclusive either semi-killed or killed aluminum or silicon deoxidation. 7.2.2 Arc Shields. An arc shield (ferrule) of heatresistant ceramic or other suitable material shall be furnished with each stud. 7.2.3 Flux. A suitable deoxidizing and arc stabilizing flux for welding shall be furnished with each stud of 5/16 in [8 mm] diameter or larger. Studs less than 5/16 in [8 mm] in diameter may be furnished with or without flux. 7.2.7 Base Metal Thickness. When welding directly to base metal, the base metal shall be no thinner than 1/3 275 .. CLAUSE 7. STUD WELDING AWS D1.1/D1.1M:2008 the stud diameter. When welding through deck, the stud diameter shall be no greater than 2.5 times the base material thickness. In no case shall studs be welded through more than two plies of metal decking. 7.4.2 Coating Restrictions. The stud base shall not be painted, galvanized, or cadmium-plated prior to welding. 4 7.4.3 Base-Metal Preparation. The areas to which the studs are to be welded shall be free of scale, rust, moisture, paint, or other injurious material to the extent necessary to obtain satisfactory welds and prevent objectionable fumes. These areas may be cleaned by wire brushing, scaling, prick-punching, or grinding. 7.3 Mechanical Requirements 7.3.1 Standard Mechanical Requirements. At the manufacturer's option, mechanical properties of studs shall be determined by testing either the steel after cold finishing or the full diameter finished studs. In either case, the studs shall conform to the standard properties shown in Table 7.1. 7.4.4 Moisture. The arc shields or ferrules shall be kept dry. Any arc shields which show signs of surface moisture from dew or rain shall be oven dried at 250°F [l20°e] for two hours before use. 7.4.5 Spacing Requirements. Longitudinal and lateral spacings of stud shear connectors (type B) may vary a maximum of 1 in [25 mm] from the location shown in the drawings. The minimum distance from the edge of a stud base to the edge of a flange shall be the diameter of the stud plus 1/8 in [3 mm], but preferably not less than 1-1/2 in [40 mm]. 7.3.2 Testing. Mechanical properties shall be determined in conformance with the applicable sections of ASTM A 370, Mechanical Testing of Steel Products. A typical test fixture is used, similar to that shown in Figure 7.2. 7.3.3 Engineer's Request. Upon request by the Engineer, the Contractor shall furnish: 7.4.6 Arc Shield Removal. After welding, arc shields shall be broken free from studs to be embedded in concrete, and, where practical, from all other studs. .. (1) The stud manufacturer's certification that the studs, as delivered, conform to the applicable requirements of7.2 and 7.3. 7.4.7 Acceptance Criteria. The studs, after welding, shall be free of any discontinuities or substances that would interfere with their intended function and have a full 360° flash. However, nonfusion on the legs of the flash and small shrink fissures shall be acceptable. The fillet weld profiles shown in Figure 5.4 shall not apply to the flash of automatically timed stud welds. (2) Certified copies of the stud manufacturer's test reports covering the last completed set of in-plant quality control mechanical tests, required by 7.3 for each diameter delivered. (3) Certified material test reports (CMTR) from the steel supplier indicating diameter, chemical properties, and grade on each heat number delivered. ~ ~ 7.5 Technique 7.3.4 Absence of Quality Control Tests. When quality control tests are not available, the Contractor shall furnish a chemical test report conforming to 7.2.6 and a mechanical test report conforming to the requirements of 7.3 for each lot number. Unidentified and untraceable studs shall not be used. 7.5.1 Automatic Machine Welding. Studs shall be welded with automatically timed stud welding equipment connected to a suitable source of direct current electrode negative power. Welding voltage, current, time, and gun settings for lift and plunge should be set at optimum settings, based on past practice, recommendations of stud and equipment manufacturer, or both. AWS C5.4, Recommended Practices for Stud Welding, should also be used for technique guidance. 7.3.5 Additional Studs. The Contractor is. responsible for furnishing additional studs of each type and size, at the request of the Engineer, for checking the requirements of 7.2 and 7.3. Testing shall be at the owner's expense. 7.5.2 Multiple Welding Guns. If two or more stud welding guns shall be operated from the same power source, they shall be interlocked so that only one gun can operate at a time, and so that the power source has fully recovered from making one weld before another weld is started. 7.4 WorkmanshiplFabrication 7.4.1 Cleanliness. At the time of welding, the studs shall be free from rust, rust pits, scale, oil, moisture, or other deleterious matter that would adversely affect the welding operation. 7.5.3 Movement of Welding Gun. While in operation, ~ the welding gun shall be held in position without move- ~ ment until the weld metal has solidified. 276 CLAUSE 7. STUD WELDING manufacturer's stud base qualification tests (see 7.9), and no further application testing shall be required. The limit of flat position is defined as 0°-15° slope on the surface to which the stud is applied. 7.5.4 Ambient and Base-Metal Temperature Requirements. Welding shall not be done when the base metal temperature is below O°F [-18°C] or when the surface is wet or exposed to falling rain or snow. When the temperature of the base metal is below 32°F [O°C], one additional stud in each 100 studs welded shall be tested by methods described in 7.7.1.3 and 7.7.1.4, except that the angle of testing shall be approximately 15°. This is in addition to the first two studs tested for each start of a new production period or change in set-up. Set-up includes stud gun, power source, stud diameter, gun lift and plunge, total welding lead length, and changes greater than ±5% in current (amperage) and time. Examples of stud applications that require tests of this section are the following: (1) Studs which are applied on nonplanar surfaces or to a planar surface in the vertical or overhead positions. (2) Studs which are welded through decking. The tests shall be with material representative of the condition to be used in construction. (3) Studs welded to other than Groups I or II steels listed in Table 3.1. 7.5.5 FCAW, GMAW, SMAW Fillet Weld Option. At the option of the Contractor, studs may be welded using prequalified FCAW, GMAW, or SMAW processes, provided the following requirements are met: 7.6.2 Responsibilities for Tests. The Contractor shall be responsible for the performance of these tests. Tests may be performed by the Contractor, the stud manufacturer, or by another testing agency satisfactory to all parties involved. 7.5.5.1 Surfaces. Surfaces to be welded and surfaces adjacent to a weld shall be free from loose or thick scale, slag, rust, moisture, grease, and other foreign material that would prevent proper welding or produce objectionable fumes. 7.6.3 Preparation of Specimens 7.6.3.1 Test Specimens. To qualify applications involving materials listed in Table 3.1, Groups I and II: specimens may be prepared using ASTM A 36 steel base materials or base materials listed in Table 3.1, Groups I and II. 7.5.5.2 Stud End. For fillet welds, the end of the stud shall also be clean. 7.5.5.3 Stud Fit (Fillet Welds). For fillet welds, the stud base shall be prepared so that the base of the stud fits against the base metal. 7.6.3.2 Recorded Information. To qualify applications involving materials other than those listed in Table 3.1, Groups I and II, the test specimen base material shall be of the chemical, physical and grade specifications to be used in production. 7.5.5.4 Fillet Weld Minimum Size. When fillet welds shall be used, the minimum size shall be the larger of those required in Table 5.8 or Table 7.2. 7.6.4 Number of Specimens. Ten specimens shall be welded consecutively using recommended procedures and settings for each diameter, position, and surface geometry. 7.5.5.5 Preheat Requirements. The base metal to which studs are welded shall be preheated in conformance with the requirements of Table 3.2. 7.6.5 Test Required. The ten specimens shall be tested using one or more of the following methods: bending, torquing, or tensioning. 7.5.5.6 SMAW Electrodes. SMAW welding shall be performed using low-hydrogen electrodes 5/32 in or 3/16 in [4.0 mm or 4.8 mm] in diameter, except that a smaller diameter electrode may be used on studs 7/16 in [11.1 mm] or less in diameter for out-of-position welds. 7.6.6 Test Methods 7.6 Stud Application Qualification Requirements 7.6.6.1 Bend Test. Studs shall be tested by alternately bending 30° in opposite directions in a typical test fixture as shown in 7.9, Figure 7.4 until failure occurs. Alternatively, studs may be bent 90° from their original axis. Type C studs, when bent 90°, shall be bent over a pin with a diameter of 4 times the diameter of the stud. In either case, a stud application shall be considered qualified if the studs are bent 90° and fracture occurs in the plate or shape material or in the shank of the stud and not in the weld. 7.6.1 Purpose. Studs which are shop or field applied in the flat (down-hand) position to a planar and horizontal surface shall be considered prequalified by virtue of the 7.6.6.2 Torque Test. Studs shall be torque tested using a torque test arrangement that is substantially in conformance with Figure 7.3. A stud application shall be 7.5.5.7 Visual Inspection. FCAW, GMAW, and SMAW welded studs shall be visually inspected in conformance with 6.9. 277 . AWS 01.1/01.1 M:2008 CLAUSE 7. STUD WELDING considered qualified if all test specimens are torqued to destruction without failure in the weld. plication of load. For threaded studs, the torque test of Figure 7.3 shall be substituted for the bend test. 7.6.6.3 Tension Test. Studs shall be tension tested to destruction using any machine capable of supplying the required force. A stud application shall be considered qualified if the test specimens do not fail in the weld. 7.7.1.5 Event of Failure. If on visual examination the test studs do not exhibit 360° flash, or if on testing, failure occurs in the weld zone of either stud, the procedure shall be corrected, and two more studs shall be welded to separate material or on the production member and tested in conformance with the provisions of 7.7.1.3 and 7.7.1.4. If either of the second two studs fails, additional welding shall be continued on separate plates until two consecutive studs are tested and found to be satisfactory before any more production studs are welded to the member. 7.6.7 Application Qualification Test Data. Application Qualification Test Data shall include the following: (1) Drawings that show shapes and dimensions of studs and arc shields. (2) A complete description of stud and base materials, and a description (part number) of the arc shield. t . 7.7.2 Production Welding. Once production welding has begun, any changes made to the welding setup, as determined in 7.7.1, shall require that the testing in 7.7.1.3 and 7.7.1.4 be performed prior to resuming production welding. (3) Welding position and settings (current, time). (4) A record, which shall be made for each qualification and shall be available for each contract. A suggested WPSIPQR form for nonprequalified application may be found in Annex Form N-9. 7.7.3 Repair of Studs. In production, studs on which a full 360° flash is not obtained may, at the option of the Contractor, be repaired by adding the minimum fillet weld as required by 7.5.5 in place of the missing flash. The repair weld spall extend at least 3/8 in [10 mm] beyond each end of the discontinuity being repaired. 7.7 Production Control 7.7.1 Pre-Production Testing 7.7.4 Operator Qualification. The pre-production test .~ required by 7.7.1, if successful, shall also serve to qualify • the stud welding operator. Before any production studs are welded by an operator not involved in the preproduction set-up of 7.7.1, the first two studs welded by the operator shall have been tested in conformance with the provisions of 7.7.1.3 and 7.7.1.4. When the two welded studs have been tested and found satisfactory, the operator may then weld production studs. 7.7.1.1 Start of Shift. Before production welding with a particular set-up and with a given size and type of stud, and at the beginning of each day's or shift's production, testing shall be performed on the first two studs that are welded. The stud technique may be developed on a piece of material similar to the production member in thickness and properties. If actual productkm thickness is not available, the thickness may vary ± 25%. All test studs shall be welded in the same general position as required on the production member (flat, vertical, or overhead). 7.7.5 Removal Area Repair. If an unacceptable stud has been removed from a component subjected to tensile stresses, the area from which the stud was removed shall be made smooth and flush. Where in such areas the base metal has been pulled out in the course of stud removal, SMAW with low-hydrogen electrodes in conformance with the requirements of this code shall be used to fill the pockets, and the weld surface shall be flush. 7.7.1.2 Production Member Option. Instead of being welded to separate material, the test studs may be welded on the production member, except when separate plates are required by 7.7.1.5. 7.7.1.3 Flash Requirement. Studs shall exhibit full 360° flash with no evidence of undercut into the stud base. In compression areas of members, if stud failures are confmed to shanks or fusion zones of studs, a new stud may be welded adjacent to each unacceptable area in lieu of repair and replacement on the existing weld area (see 7.4.5). If base metal is pulled out during stud removal, the repair provisions shall be the same as for tension areas except that when the depth of discontinuity is the lesser of 1/8 in [3 mm] or 7% of the base metal thickness, the discontinuity may be faired by grinding in lieu of filling with weld metal. Where a replacement stud is to be 7.7.1.4 Bend Test. In addition to visual examination, the test shall consist of bending the studs after they are allowed to cool, to an angle of approximately 30° from their original axes by either striking the studs with a hammer on the unwelded end or placing a pipe or other suitable hollow device over the stud and manually or mechanically bending the stud. At temperatures below 50°F [looq, bending shall preferably be done by continuous slow ap- 278 AWS D1.1/D1.1M:2008 CLAUSE 7. STUD WELDING provided, the base metal repair shall be made prior to • welding the replacement stud. Replacement studs (other . ,than threaded type which should be torque tested) shall be tested by bending to an angle of approximately 15 0 from their original axes. The areas of components exposed to view in completed structures shall be made smooth and flush where a stud has been removed. 7.9 Manufacturers' Stud Base Qualification Requirements 7.9.1 Purpose. The purpose of these requirements is to prescribe tests for the stud manufacturers' certification of stud base weldability. 7.9.2 Responsibility for Tests. The stud manufacturer shall be responsible for the performance of the qualification test. These tests may be performed by a testing agency satisfactory to the Engineer. The agency performing the tests shall submit a certified report to the manufacturer of the studs giving procedures and results for all tests including the information described in 7.9.10. 7.8 Fabrication and Verification Inspection Requirements 7.8.1 Visual Inspection. If a visual inspection reveals any stud that does not show a full 360 0 flash or any stud that has been repaired by welding, such stud shall be bent to an angle of approximately 15 0 from its original axis. Threaded studs shall be torque tested. The method of bending shall be in conformance with 7.7.1.4. The direction of bending for studs with less than a 360 0 flash shall be opposite to the missing portion of the flash. Torque testing shall be in conformance with Figure 7.3. 7.9.3 Extent of Qualification. Qualification of a stud base shall constitute qualification of stud bases with the same geometry, flux, and arc shield, having the same diameter and diameters that are smaller by less than 1/8 in [3 mm]. A stud base qualified with an approved grade of ASTM A 29 steel and meets the standard mechanical properties (see 7.3.1) shall constitute qualification for all other approved grades of ASTM A 29 steel (see 7.2.6), provided that conformance with all other provisions stated herein shall be achieved. 7.8.2 Additional Tests. The Verification Inspector, where conditions warrant, may select a reasonable num• ber of additional studs to be subjected to the tests de• scribed in 7.8.1. 7.9.4 Duration of Qualification. A size of stud base with arc shield, once qualified, shall be considered qualified until the stud manufacturer makes any change in the stud base geometry, material, flux, or arc shield which affects the welding characteristics. 7.8.3 Bent Stud Acceptance Criteria. The bent stud shear connectors (Type B) and deformed anchors (Type C) and other studs to be embedded in concrete (Type A) that show no sign of failure shall be acceptable for use and left in the bent position. When bent studs are required by the contract documents to be straightened, the straightening operation shall be done without heating, and before completion of the production stud welding operation. 7.9.5 Preparation of Specimens 7.9.5.1 Test specimens shall be prepared by welding representative studs to suitable specimen plates of ASTM A 36 steel or any of the other materials listed in Table 3.1 or Table 4.9. Studs to be welded through metal decking shall have the weld base qualification testing done by welding through metal decking representative of that used in construction, galvanized per ASTM A 653 coating designation G90 for one thickness of deck or G60 for two deck plies. When studs are to be welded through decking, the stud base qualification test shall include decking representative of that to be used in construction. Welding shall be done in the flat position (plate surface horizontal). Tests for threaded studs shall be on blanks (studs without threads). 7.8.4 Torque Test Acceptance Criteria. Threaded studs (Type A) torque tested to the proof load torque level in Figure 7.3 that show no sign of failure shall be acceptable for use. 7.8.5 Corrective Action. Welded studs not conforming to the requirements of the code shall be repaired or replaced by the Contractor. The Contractor shall revise the welding procedure as necessary to ensure that subsequent stud welding will meet code requirements. • • 7.9.5.2 Studs shall be welded with power source, welding gun, and automatically controlled equipment as recommended by the stud manufacturer. Welding voltage, current, and time (see 7.9.6) shall be measured and recorded for each specimen. Lift and plunge shall be at the optimum setting as recommended by the manufacturer. 7.8.6 Owner's Option. At the option and the expense of the owner, the Contractor may be required, at any time, to submit studs of the types used under the contract for a qualification check in conformance with the procedures of7.9. 279 CLAUSE 7. STUD WELDING AWS D1.1/D1.1M:2008 ... 7.9.7.2 Bend Tests (Studs 7/8 in [22 mm] or less in diameter). Twenty of the specimens welded in conform-. ance with 7.9.6.1 and twenty in conformance with ~ 7.9.6.2 shall be bend tested by being bent alternately 30° from their original axes in opposite directions until failure occurs. Studs shall be bent in a bend testing device as shown in Figure 7.4, except that studs less than 1/2 in [12 mm] diameter may be bent using a device as shown in Figure 7.5. A stud base shall be considered as qualified if, on all test specimens, fracture occurs in the plate material or shank of the stud and not in the weld or HAZ. All test specimens for studs over 7/8 in [22 mm] shall only be subjected to tensile tests. 7.9.6 Number of Test Specimens 7.9.6.1 For studs 7/8 in [22 mm] or less in diameter, 30 test specimens shall be welded consecutively with constant optimum time, but with current 10% above optimum. For studs over 7/8 in [22 mm] diameter, 10 test specimens shall be welded consecutively with constant optimum time. Optimum current and time shall be the midpoint of the range normally recommended by the manufacturer for production welding. 7.9.6.2 For studs 7/8 in [22 mm] or less in diameter, 30 test specimens shall be welded consecutively with constant optimum time, but with current 10% below optimum. For studs over 7/8 in [22 mrn] diameter, 10 test specimens shall be welded consecutively with constant optimum time, but with current 5% below optimum. 7.9.7.3 Weld through Deck Tests. All 10 of the welds through deck stud specimens shall be tested by bending 30° in opposite directions in a bend testing device as shown in Figure 7.4, or by bend testing 90° from their original axis or tension testing to destruction in a machine capable of supplying the required force. With any test method used, the range of stud diameters from maximum to minimum shall be considered as qualified weld bases for through deck welding if, on all test specimens, fracture occurs in the plate material or shank of the stud and not in the weld or HAZ. 7.9.6.3 For studs to be welded through metal deck, the range of weld base diameters shall be qualified by welding 10 studs at the optimum current and time as recommended by the manufacturer conforming to the following: (1) Maximum and mmlmum diameters welded through one thickness of 16 gage deck, coating designation G90. .. 7.9.8 Retests. If failure occurs in a weld or the HAZ in any of the bend test groups of 7.9.7.2 or at less than spec- •.•. ified minimum tensile strength of the stud in any of the. tension groups in 7.9.7.1, a new test group (described in 7.9.6.1 or 7.9.6.2, as applicable) shall be prepared and tested. If such failures are repeated, the stud base shall fail to qualify. (2) Maximum and minimum diameters welded through two plies of 16 gage deck coating designation G60. (3) Maximum and minimum diameters welded through one thickness of 18 gage G60 deck over one thickness of 16 gage G60 deck. (4) Maximum and minimum diameters welded through two plies of 18 gage deck, both -with G60 coating designation. 7.9.9 Acceptance. For a manufacturer's stud base and arc shield combination to be qualified, each stud of each group of 30 studs shall, by test or retest, meet the requirements described in 7.9.7. Qualification of a given diameter of stud base shall be considered qualification for stud bases of the same nominal diameter (see 7.9.3, stud base geometry, material, flux, and arc shield). The range of diameters from maximum to minimum welded through two plies of 18 gage metal deck with G60 galvanizing shall be qualified for welding through one or two plies of metal deck 18 gage or less in thickness. 7.9.7 Tests 7.9.10 Manufacturer's Qualification Test Data. The test data shall include the following: 7.9.7.1 Tension Tests. Ten of the specimens welded in conformance with 7.9.6.1 and ten in conformance with 7.9.6.2 shall be subjected to a tension test in a fixture similar to that shown in Figure 7.2, except that studs without heads may be gripped on the unwelded end in the jaws of the tension testing machine. A stud base shall be considered as qualified if all test specimens have a tensile strength equal to or above the minimum described in 7.3.1. (l) Drawings showing shapes and dimensions with tolerances of stud, arc shields, and flux; (2) A complete description of materials used in the studs, including the quantity and type of flux, and a description of the arc shields; and (3) Certified results of tests. 280 AWS D1.1/D1.1M:2008 CLAUSE 7. STUD WELDING Table 7.1 Mechanical Property Requirements for Studs (see 7.3.1) TypeN TypeBb psi min. MPamin. 61000 420 65000 450 Yield strength psi min. (0.2% offset) MPamin. 49000 340 51000 350 Tensile strength (0.5% offset) psi min. MPamin. Elongation % in2 in min. % in 5x dia. min. 17% 14% 20% 15% Reduction of area % min. 50% 50% Table 7.2 Minimum Fillet Weld Size for Small Diameter Studs (see 7.5.5.4) Stud Diameter TypeCC 80000 552 70000 485 Type A studs shall be genc::ral purpose of any type and size used for purposes other than shear transfer in composite beam design and construction. b Type B studs shall be studs that are headed, bent, or of other configuration in 3/8 in (10 mm), 1/2 in [12 mm], 5/8 in [16 mm], 3/4 in [20 mm], 7/8 in [22 mm], and 1 in [25 mm] diameter that are used as an essential component in composite beam design and construction. C Type C studs shall be cold-worked deformed steel bars manufactured in conformance with specification ASTM A 496 having a nominal diameter equivalent to the diameter of a plain wire having the same weight per foot as the deformed wire. ASTM A 496 specifies a maximum diameter of 0.628 in [16 mm] maximum. Any bar supplied above that diameter shall have the same physical characteristics regarding deformations as required by ASTM A 496. a 281 Min. Size Fillet in mm in mm 1/4 thru 7/16 1/2 5/8, 3/4, 7/8 1 6 thru 11 12 16,20,22 25 3/16 1/4 5/16 3/8 5 6 8 10 CLAUSE 7. STUD WELDING AWS D1.1/D1.1M:2008 ... SLOTIED FIXTURES TO HOLD STUD HEAD AND SPECIMEN PLATE a Manufactured length before welding. Standard Dimensions, in Shank Diameter (C) Length Tolerances (L) Head Diameter (H) Minimum Head Height (T) 1/2 +0.000 -0.010 ± 1/16 1 ± 1/64 9/32 5/8 +0.000 -0.010 ± 1/16 1-1/4 ± 1/64 9/32 3/4 +0.000 -0.015 ± 1/16 1-1/4 ± 1/64 3/8 7/8 +0.000 -0.015 ± 1/16 1-3/8 ± 1/64 3/8 +0.000 -0.015 ± 1/16 1-5/8 ± 1/64 1/2 Figure 7.2-Typical Tension Test Fixture (see 7.3.2) .. Standard Dimensions, mm 12.7 +0.00 -0.25 ± 1.6 25.4± 0.4 7.1 15.9 +0.00 -0.25 ± 1.6 31.7 ± 0:4 7.1 19.0 +0.00 -0.38 ± 1.6 31.7±0.4 9.5 22.1 +0.00 -0.38 ± 1.6 34.9 ±0.4 9.5 25.4 +0.00 -0.38 ± 1.6 41.3 ± 0.4 12.7 Figure 7.1-Dimension and Tolerances of Standard-Type Shear Connectors (see 7.2.1) 282 AWS D1.1/D1.1M:2008 CLAUSE 7. STUD WELDING STUD STEEL NUT WELD AREA MEMBER Note: Dimensions of test fixture details should be appropriate to the size of the stud. The threads of the stud shall be clean and free of lubricant other than the residue of cutting/cold forming lubricants in the "as received" condition from the manufacturer. Required Proof Torque for Testing Threaded Studs a M.E.TAb Nominal Diameter in 0.236 t t mm M6 Proof Testing TorqueC Thread in 2 mm 2 0.031 20.1 no.lin Ib-ft pitch-mm Series 1.0 ISO-724 5.4 Joule 7.4 1/4 6.4 0.036 0.032 23.2 20.6 28 20 UNF UNC 6.6 5.9 9.0 7.8 5/16 7.9 0.058 0.052 37.4 33.5 24 18 UNF UNC 13.3 11.9 18.1 16.1 ISO-724 13.2 17.9 UNF UNC 24.3 21.5 32.9 29.2· ISO-724 26.2 35.5 UNF UNC 37.9 34.8 51.4 47.2 ISO-724 45.7 61.9 UNF UNC 58.8 52.2 79.7 7ei.8 ISO-724 72.7 98.5 0.315 M8 0.057 36.6 1.25 3/8 9.5 0.088 0.078 56.8 50.3 0.394 M10 0.090 58.0 7/16 11.1 0.118 0.106 76.1 68.4 0.472 M12 0.131 84.3 1/2 12.7 0.160 0.142 103.2 91.6 0.551 M14 0.178 115.0 9/16 14.3 0.203 0.182 131.0 117.4 18 12 UNF UNC 83.9 75.2 113.8 102.0 5/8 15.9 0.255 0.226 164.5 145.8 18 11 UNF UNC 117.1 103.8 158.8 140.8 0.630 M16 0.243 157.0 3/4 19.1 0.372 0.334 240.0 215.5 0.787 M20 0.380 245.0 0.866 M22 0.470 303.0 7/8 22.2 0.509 0.462 328.4 298.1 0.945 M24 0.547 353.0 1 25.4 0.678 0.606 437.4 391.0 24 16 1.5 20 14 1.75 20 13 2.0 2.0 ISO-724 113.4 153.7 UNF UNC 205.0 184.1 278.0 249.7 2.5 ISO-724 221.2 299.9 2.5 ISO-724 300.9 408.0 UNF UNC 327.3 297.1 443.9 402.9 ISO-724 382.4 518.5 UNF UNC 498.3 445.4 675.7 604.0 16 10 14 9 3.0 12 8 a Torque figures are based on Type A threaded studs with a minimum yield stress of 49 000 psi (340 MPa). bMean Effective Thread Area (M.E.T.A) shall be defined as the effective stress area based on a mean diameter taken approximately midway between the minor and the pitch diameters. C Values are calculated on a proof testing torque of 0.9 times Nominal Stud Diameter times 0.2 Friction Coefficient Factor times Mean Effective Thread Area times Minimum Yield Stress for unplated studs in the as-received condition. Plating, coatings, or oil/grease deposits will change the Friction Coefficient Factor. Figure 7.3-Torque Testing Arrangement and Table of Testing Torques (see 7.6.6.2) 283 AWS D1.1 /D1.1 M:2008 CLAUSE 7. STUD WELDING ... DOUBLE-ACTING HYDRAULIC CYLINDER 2 in [50 mm] MAXIMUM ANGLE OF CENTERLINE OF DEFLECTED STUD SHALL BE MEASURED AT CENTERLINE OF PLUNGER Notes: 1. Fixture holds specimen and stud is bent 30° alternately in opposite directions. 2. Load can be applied with hydraulic cylinder (shown) or fixture adapted for use with tension test machine. FRACTURE LINE I . I I ~+++- 1JJ I -~': I : ... STUD DIAM +1/64 in [004 mm] .----PIPE DIMENSIONS APPROPRIATE FOR ~IZE OF STUD [V} TYPICAL FRACTURES IN SHANK OF STUD FRACTURE LINE 1/4 in [6 mm] Note: Fracture in weld near stud fillet remains on plate. 2 in. [50 mm MAX. Note: Fracture through flash torn from plate. SPECIMEN PLATE TYPICAL WELD FAILURES Figure 7.4-Bend Testing Device (see 7.9.7.2) Figure 7.5-Suggested Type of Device for Qualification Testing of Small Studs (see 7.9.7.2) 284 AWS 01.1/01.1 M:2008 8. Strengthening and Repairing Existing Structures 8.3.2 Stress Analysis. An analysis of stresses in the area affected by the strengthening or repair shall be made. Stress levels shall be established for all in-situ dead and live load cases. Consideration shall be made for accumulated damage that members may have sustained in past service. 8.1 General Strengthening or repairing an existing structure shall consist of modifications to meet design requirements specified by the Engineer. The Engineer shall prepare a comprehensive plan for the work. Such plans shall include, but are not limited to, design, workmanship, inspection and documentation. Except as modified in this section, all provisions of this code shall apply equally to the strengthening and repairing of existing structures, including heat straightening of distorted members. 8.3.3 Fatigue History. Members subject to cyclic loading shall be designed according to the requirements for fatigue stresses. The previous loading history shall be considered in the design. When the loading history is not available, it shall be estimated. 8.3.4 Restoration or Replacement. Determination shall be made whether the repairs should consist of restoring corroded or otherwise damaged parts or of replacing entire members. 1t8.2 Base Metal 8.2.1 Investigation. Before preparing drawings and specifications for strengthening or repairing existing structures, the types of base metal used in the original structure shall be determined either from existing drawings, specifications or from representative base-metal tests. 8.3.5 Loading During Operations. The Engineer shall determine the extent to which a member will be allowed to carry loads while heating, welding or thermal cutting is performed. When necessary, the loads shall be reduced. The local and general stability of the member shall be investigated, considering the effect of elevated temperature extending over parts of the cross-sectional area. 8.2.2 Suitability for Welding. The suitability of the base metal for welding shall be established (see Table C8.1 for guidance). 8.3.6 Existing Connections. Existing connections in structures requiring strengthening or repair shall be evaluated for design adequacy and reinforced as necessary. 8.2.3 Other Base Metals. Where base metals other than those listed in Table 3.1 are to be joined, special consideration by the Engineer shall be given to the selection of filler metal and WPSs. 8.3.7 Use of Existing Fasteners. When design calculations show rivets or bolts will be overstressed by the new total load, only existing dead load shall be assigned to them. If rivets or bolts are overstressed by dead load alone or are subject to cyclic loading, then sufficient base metal and welding shall be added to support the total load. 8.3 Design for Strengthening and Repair • • 8.3.1 Design Process. The design process shall consider applicable governing code provisions and other parts of the general specifications. The Engineer shall specify the type and extent of survey necessary to identify existing conditions that require strengthening or repair in order to satisfy applicable criteria. 8.4 Fatigue Life Enhancement 8.4.1 Methods. The following methods of reconditioning critical weld details may be used when written procedures have been approved by the Engineer: 285 AWS 01.1/01.1 M:2008 CLAUSE 8. STRENGTHENING AND REPAIRING EXISTING STRUCTURES ... 8.5.3 Weld Repairs. If weld repairs are required, they shall be made in conformance with 5.26, as applicable. (1) Profile Improvement. Reshaping the weld face by grinding with a carbide burr to obtain a concave profile with a smooth transition from base material to weld. t 8.5.4 Base Metal of Insufficient Thickness. Base metal having insufficient thickness to develop the required weld size or required capacity shall be, as determined by the Engineer: (1) built up with weld metal to the required thickness, (2) cut back until adequate thickness is available, (3) reinforced with additional base metal, or (4) removed and replaced with base metal of adequate thickness or strength. (2) Toe Grinding. Reshaping only the weld toes by grinding with a burr or pencil grinder. (3) Peening. Shot peening of weld surface, or hammer peening of weld toes. (4) TIG Dressing. Reshaping of weld toe by the remelting of existing weld metal with heat from GTAW arc (no filler metal used). 8.5.5 Heat Straightening. When heat straightening or heat curving methods are used, the maximum temperature of heated areas as measured using temperature sensitive crayons or other positive means shall not exceed 1100 P [600°C] for quenched and tempered steel, nor 1200 P [650°C] for other steels. Accelerated cooling of steel above 600 P [315°C] shall be prohibited. (5) Toe Grinding plus Hammer Peening. When used together, the benefits are cumulative. 8.4.2 Stress Range Increase. The Engineer shall establish the appropriate increase in the allowable stress range. 0 0 0 8.5 Workmanship and Technique 8.5.6 Welding Sequence. In strengthening or repairing members by the addition of base metal or weld metal, or both, welding and weld sequencing shall, as far as practicable, result in a balanced heat input about the neutral axis to minimi:ae distortion and residual stresses. 8.5.1 Base-Metal Condition. Base metal to be repaired and surfaces of existing base metal in contact with new base metal shall be cleaned of dirt, rust and other foreign matter except adherent paint film as per SSPC SP2 (Surface· Preparation Specification #2-Hand Tool Cleaning). The portions of such surfaces which will be welded shall be thoroughly cleaned of all foreign matter including paint for at least 2 in [50 mm] from the root o(the weld. 8.6 Quality 8.6.1 Visual Inspection. All members and welds affected by the work shall be visually inspected in conformance with the Engineer's comprehensive plan. 8.5.2 Member Discontinuities. When required by the Engineer, unacceptable discontinuities in the member being repaired or strengthened shall be corrected prior to heat straightening, heat curving, or welding. 8.6.2 NDT. The method, extent, and acceptance criteria of NDT shall be specified in the contract documents. 286 C' '~.:' ...'.' tg AWS 01.1/01.1 M:2008 Annexes Normative Information These annexes contain information and requirements that are considered a part of the standard. AnnexA Effective Throat AnnexB Effective Throats of Fillet Welds in Skewed T-Joints AnnexD Flatness of Girder Webs-Statically Loaded Structures AnnexE Flatness of Girder Webs-Cyclically Loaded Structures AnnexF Temperature-Moisture Content Charts AnnexG Manufacturers Stud Base Qualification Requirements AnnexH Qualification and Calibration of UT Units with Other Approved Reference Blocks Annex I Guideline on Alternative Methods for Determining Preheat AnnexJ Symbols for Tubular Connection Weld Design t Informative Information These annexes are not considered a part of the standard and are provided for informational purposes only. AnnexK Terms and Definitions AnnexL Guide for Specification Writers AnnexM UT Equipment Qualification and Inspection Forms AnnexN Sample Welding Forms Annexa Guidelines for Preparation of Technical Inquiries for the Structural Welding Committee AnnexP Local Dihedral Angle AnnexQ Contents of Prequalified WPS AnnexR Safe Practices Annex S UT Examination of Welds by Alternative Techniques Annex T Ovalizing Parameter Alpha AnnexU List of Reference Documents Annex V Filler Metal Strength Properties 287 AWS 01.1/01.1 M:2008 ... This page is intentionally blank. .. . ~; •.•.................. 288 AWS D1.1/D1.1M:2008 Annex A (Normative) Effective Throat This annex is part of AWS Dl.l/Dl.lM:2008, Structural Welding Code-Steel, and includes mandatory elements for use with this standard. Note: The effective throat of a weld shall be defined as the minimum distance from the root of the joint to its face, with or without a deduction of 1/8 in [3 mm], less any convexity. 289 AWS D1.1/D1.1M:2008 ... This page is intentionally blank. .. 290 AWS D1.1/D1.1 M:2008 Annex B (Normative) Effective Throats of Fillet Welds in Skewed T-Joints This annex is part of AWS Dl.l1Dl.lM:2008, Structural Welding Code-Steel, and includes mandatory elements for use with this standard. t Required: Table B.1 is a tabulation showing equivalent leg size factors for the range of dihedral angles between 60° and 135°, assuming no root opening. Root opening(s) 1/16 in [2 mm] or greater, but not exceeding 3/16 in [5 mm], shall be added directly to the leg size. The required leg size for fillet welds in skewed joints shall be calculated using the equivalent leg size factor for correct dihedral angle, as shown in the example. Procedure: (1) Factor for 75° from Table'B.1: 0.86 (2) Equivalent leg size, w, of skewed joint, without root opening: . =6.9 mm w =0.86 x 8 2 mm (3) With root opening of: (4) Required leg size, w, of 8.9 mm skewed fillet weld: [(2) + (3)] (5) Rounding up to a practical dimension: w=9.0mm EXAMPLE (U.S. Customary Units) Given: Skewed T-joint, angle: 75°; root opening: 1/16 (0.063) in Required: Strength equivalent to 90° fillet weld of size: 5/16 (0.313) in For fillet welds having equal measured legs (wn ), the distance from the root of the joint to the face of the diagrammatic weld (In) may be calculated as follows: For root openings> 1/16 in [2 mm] and ::;; 3/16 in [5 mm], use Procedure: (1) Factor for 75° from Table B.1: 0.86 (2) Equivalent leg size, w, of skewed joint, without root opening: w = 0.86 x 0.313 = 0.269 in 0.063 in (3) With root opening of: (4) Required leg size, w = 0.332 in of skewed fillet weld: [(2) + (3)] (5) Rounding up to a practical dimension: w = 3/8 in For root openings < 1/16 in [2 mm], use where the measured leg of such fillet weld (wn ) is the perpendicular distance from the surface of the joint to the opposite toe, and (R) is the root opening, if any, between parts (see Figure 3.11). Acceptable root openings are defined in 5.22.1. EXAMPLE (SI Units) Given: Strength equivalent to 90° fillet weld of size: 8 mm Skewed T-joint, angle: 75°; root opening: 2mm 291 ANNEX B AWS D1.1/D1.1M:2008 ... Table 8.1 Equivalent Fillet Weld Leg Size Factors for Skewed T-Joints Dihedral angle, 'P 60° 65° 70° 75° 80° 85° 90° 95° Comparable fillet weld size for same strength 0.71 0.76 0.81 0.86 0.91 0.96 1.00 1.03 Dihedral angle, 'P 100° 105° 110° 115° 120° 125° 130° 135° Comparable fillet weld size for same strength 1.08 1.12 1.16 1.19 1.23 1.25 1.28 1.31 292 AWS D1.1/D1.1M:2008 AnnexC There is no Annex C. Annex C has been omitted in order to avoid potential confusion with references to Commentary clauses. 293 AWS D1.1/D1.1 M:2008 This page is intentionally blank.... 294 AWS·D1.1/D1.1 M:2008 Annex D (Normative) Flatness of Girder Webs-Statically Loaded Structures This annex is part of AWS Dl.l/Dl.lM:2008, Structural Welding Code-Steel, and includes mandatory elements for use with this standard. (FLAN GE PLATE /STIFFENER / V I.. d D \ d- -\ WEB FLANGE PLATE / "- WHICHEVER IS THE LAST PANEL DIMENSION Notes: 1. D = Depth of web. 2. d = Least panel dimension. 295 < ANNEX D AWS D1.1/D1.1 M:2008 Table 0.1 Intermediate Stiffeners on Both Sides of Web Thickness of Web, in 5116 3/8 7/16 1/2 9116 5/8 Depth of Web, in Less than 47 47 andover Less than 56 56 and over Less than 66 66 andover Less than 75 75 and over Less than 84 84 and over Less than 94 94 and over ~ Least Panel Dimension, in 25 20 25 20 25 20 25 20 25 20 25 20 31 25 31 25 31 25 31 25 31 25 31 25 50 40 50 40 50 40 50 40 50 40 50 40 44 38 30 38 30 38 30 38 30 38 30 38 30 35 44 35 44 35 44 35 44 35 44 35 45 56 45 56 45 56 45 56 45 56 45 50 63 50 63 50 63 50 63 50 63 50 55 60 65 70 75 80 85 55 69 55 69 55 69 55 69 55 60 65 70 75 80 85 60 75 60 75 60 75 60 65 81 65 81 65 81 65 70 75 80 85 70 88 70 88 70 75 80 85 75 94 75 80 85 80 85 13/16 7/8 15/16 1.52 1.65 1.78 1.90 2.03 2.16 1.52 1.65 1.78 1.90 2.03 2.16 1.52 1.90 1.52 1.90 1.52 1.90 1.52 1.65 2.06 1.65 2.06 1.65 2.06 1.65 1.78 1.90 2.03 2.16 1.78 2.24 1.