AWS D1.1/D1.1M:2002 An American National Standard. Structural Welding Code Steel

Transcription

1 AWS D1.1/D1.1M:2002 An American National Standard Structural Welding Code Steel

2 Key Words Allowable stress, cyclically loaded structures, structural details, statically loaded structures, steel welding, stud welding, tubular structures, welded joint details, welded steel structures AWS D1.1/D1.1M:2002 An American National Standard Approved by American National Standards Institute August 31, 2001 Structural Welding Code Steel 18th Edition Supersedes AWS D1.1:2000 Prepared by AWS D1 Committee on Structural Welding Under the Direction of AWS Technical Activities Committee Approved by 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. Sections 1 through 8 constitute a body of rules for the regulation of welding in steel construction. There are twelve mandatory and fifteen nonmandatory annexes in this code. A Commentary of the code is included with the document. 550 N.W. LeJeune Road, Miami, Florida 33126

3 Foreword (This Foreword is not a part of AWS D1.1/D1.1M:2002, Structural Welding Code Steel, but is included for information 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 The first bridge welding specification was published separately in The two documents were consolidated in 1972 in 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 dynamically loaded structures, respectively, in order to make the document applicable to a broader range of structural configurations. Underlined text in the subsections, tables, or figures indicates an editorial or technical change from the 2000 edition. A vertical line in the margin next to a figure drawing indicates a revision from the 2000 edition. The following is a summary of the most significant technical revisions contained in D1.1/D1.1M:2002: Section 1 New provisions have been added describing the responsibilities of Contractors, Inspectors, Engineers, Owners, and OEMs (Original Equipment Manufacturers). Section 2 Parts A, B, and C have been extensively reorganized. Many provisions have been modified or expanded, including new commentary and fatigue design parameters. Annex P has been created in order to facilitate correlating the previous edition s Section 2 provisions with the 2002 edition. Subsections 3.14 and C3.14 A new provision on PWHT has been added. Figures 4.7, 4.8, 4.10, and 4.11 Modifications have been made to address CVN testing. Tables 4.5 Shielding gas flow rate variables have been changed. Table 4.6 A supplementary essential variable table for WPSs requiring CVN testing has been added. Table 5.2 Holding times for stress relief have been adjusted. Subsections and C Provisions have been added describing UT of CJP groove welds with backing. Tables 6.2 and 6.3, Note 3 This note has been modified to address UT of backgouged, two-sided CJP groove welds. Annex III Modifications have been made to expand the scope of requirements when CVN testing is contractually required. Annex IX Changes have been made to address stud welding on decking. Annex B Acronyms for the most commonly used terms in the code have been added. Users should note that, beginning in this edition, the tables and figures for each section will be located at the end of each section. 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 insight information into provision rationale. Mandatory Annexes. These additions to the code are requirements that supplement the text. Nonmandatory Annexes. These annexes are not requirements but are provided as options that are allowed by the code. Though they are not mandatory, it is essential that all provisions of these annexes be followed when the option to use them is exercised. Index. As in previous codes, the entries in the Index are referred to by subsection 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, in the Society News Section of the AWS Welding Journal, any errata (major changes) that have been noted will be published in the July and November issues of the Welding Journal. Suggestions. Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, Structural Welding Committee, American Welding Society, 550 N.W. LeJeune Road., Miami, FL Interpretations. Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writing, to the Managing Director, Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL (see Annex F). ix

4 Table of Contents Page No. 1. General Requirements Scope Limitations Definitions Engineer Contractor Inspectors Contractor s Inspector Verification Inspector Inspector(s) (unmodified) OEM (Original Equipment Manufacturer) Owner Code Terms Shall, Should, and May Shall Should May Responsibilities Engineer s Responsibilities Contractor s Responsibilities Inspector s Responsibilities Contractor Inspection Verification Inspection Approval Welding Symbols Safety Precautions Standard Units of Measurement Reference Documents Design of Welded Connections Scope of Section Part A Common Requirements for Design of Welded Connections (Nontubular and Tubular Members) Scope of Part A Contract Plans and Specifications Plan and Drawing Information Notch Toughness Requirements Specific Welding Requirements Weld Size and Length Shop Drawing Requirements PJP Groove Welds Fillet Welds and Weld in Skewed T-Joints Symbols Prequalified Detail Dimensions Special Details Specific Inspection Requirements Effective Areas...6 xi

5 2.3.1 Groove Welds Effective Length Effective Size of CJP Groove Welds Minimum Size of PJP Groove Welds Effective Weld Size (Flare Groove) Effective Area of Groove Welds Fillet Welds Effective Length (Straight) Effective Length (Curved) Minimum Length Intermittent Fillet Welds (Minimum Length) Maximum Effective Length Calculation of Effective Throat Reinforcing Fillet Welds Minimum Size Maximum Weld Size in Lap Joints Effective Area of Fillet Welds Skewed T-Joints General Welds in Acute Angles Between 80 and 60 and in Obtuse Angles Greater than Welds in Acute Angles Between 60 and Welds in Angles Less than Effective Length of Skewed T-Joints Minimum Skewed T-Joint Weld Size Effective Throat of Skewed T-Joints Effective Area of Skewed T-Joints Fillet Welds in Holes and Slots Diameter and Width Limitations Slot Ends Effective Length of Fillet Welds in Holes or Slots Effective Area of Fillet Welds in Holes or Slots Plug and Slot Welds Diameter and Width Limitations Slot Length and Slope Effective Area of Plug and Slot Welds...8 Part B Specific Requirements for Design of Nontubular Connections (Statically or Cyclically Loaded) General Stresses Calculated Stresses Calculated Stresses Due to Eccentricity Allowable Base Metal Stresses Allowable Weld Metal Stresses Stress in Fillet Welds Alternative Allowable Fillet Weld Stress Instantaneous Center of Rotation Allowable Stress Increase Joint Configuration and Details General Considerations Compression Member Connections and Splices Connections and Splices Designed to Bear Other than Connections to Base Plates Connections and Splices Not Finished to Bear Except for Connections to Base Plates Connections to Base Plates...9 xii

6 2.6.3 Base Metal Through-Thickness Loading Combinations of Welds Corner and T-Joint Surface Contouring Weld Access Holes Welds with Rivets or Bolts Joint Configuration and Details Groove Welds Transitions in Thicknesses and Widths Partial Length CJP Groove Weld Prohibition Intermittent PJP Groove Welds Weld Tab Removal Joint Configuration and Details Fillet Welded Joints Lap Joints Transverse Fillet Welds Minimum Overlap Longitudinal Fillet Welds Fillet Weld Terminations General Lap Joints Subject to Tension Maximum End Return Length Transverse Stiffener Welds Opposite Sides of a Common Plane Fillet Welds in Holes or Slots Intermittent Fillet Welds Joint Configuration and Details Plug and Slot Welds Minimum Spacing (Plug Welds) Minimum Spacing (Slot Welds) Prequalified Dimensions Prohibition in Quenched and Tempered Steels Filler Plates Thin Filler Plates Thick Filler Plates Shop Drawing Requirement Built-Up Members Minimum Required Welding Maximum Spacing of Intermittent Welds General Compression Members Unpainted Weathering Steel...12 Part C Specific Requirements for Design of Nontubular Connections (Cyclically Loaded) General Applicability Other Pertinent Provisions Engineer s Responsibility Limitations Stress Range Threshold Low Cycle Fatigue Corrosion Protection Redundant Nonredundant Members Calculation of Stresses Elastic Analysis Axial Stress and Bending Symmetrical Sections...12 xiii

7 Angle Members Allowable Stresses and Stress Ranges Allowable Stresses Allowable Stress Ranges Detailing, Fabrication, and Erection Transitions in Thickness and Width Butt-Joint Thickness Transitions Butt-Joint Width Transitions Backing Welds for Attaching Steel Backing CJP T- and Corner Joints Made from One Side CJP Butt Splices Longitudinal Groove Welds and Corner Joints Contouring Weld at Corner and T-Joints Flame-Cut Edges Transversely Loaded Butt Joints Fillet Weld Terminations Prohibited Joints and Welds One-Sided Groove Welds Flat Position Groove Welds Fillet Welds Less than 3/16 in. [5 mm] T- and Corner CJP Welds with Backing Left in Place Inspection...15 Part D Specific Requirements for Design of Tubular Connections (Statically or Cyclically Loaded) General Eccentricity Allowable Stresses Base-Metal Stresses Circular Section Limitations Weld Stresses Fiber Stresses Load and Resistance Factor Design Fatigue Stress Range and Member Type Fatigue Stress Categories Basic Allowable Stress Limitation Cumulative Damage Critical Members Fatigue Behavior Improvement Size and Profile Effects Identification Symbols Weld Design Fillet Welds Effective Area Beta Limitation for Prequalified Details Lap Joints Groove Welds Prequalified PJP Groove Weld Details Prequalified CJP Groove Weld Details Welded from One Side without Backing in T-, Y-, and K-Connections Stresses in Welds...17 xiv

8 Circular Connection Lengths Box Connection Lengths K- and N-Connections T-, Y-, and X-Connections Limitations of the Strength of Welded Connections Circular T-, Y-, and K-Connections Local Failure General Collapse Uneven Distribution of Load (Weld Sizing) Transitions Other Configurations and Loads Overlapping Connections Box T-, Y- and K-Connections Local Failure General Collapse Uneven Distribution of Load (Effective Width) Overlapping Connections Bending Other Configurations Thickness Transition Material Limitations Limitations Yield Strength Reduced Effective Yield Box T-, Y-, and K-Connections ASTM A 500 Precaution Tubular Base-Metal Notch Toughness CVN Test Requirements LAST Requirements Alternative Notch Toughness Prequalification of WPSs Scope Welding Processes Prequalified Processes Code Approved Processes Other Welding Processes Base Metal/Filler Metal Combinations Engineer s Approval for Auxiliary Attachments Minimum Preheat and Interpass Temperature Requirements Base Metal/Thickness Combination Annex XI Option Alternate SAW Preheat and Interpass Temperatures Hardness Requirements Limitation of WPS Variables Combination of WPSs General WPS Requirements Vertical-Up Welding Requirements Width/Depth Pass Limitation Weathering Steel Requirements Single-Pass Groove Welds Single-Pass Fillet Welds Common Requirements for Parallel Electrode and Multiple Electrode SAW...59 xv

9 3.8.1 GMAW Root Pass Fillet Weld Requirements Details (Nontubular) Details (Tubular) Skewed T-Joints Dihedral Angle Limitations Minimum Weld Size for Skewed T-Joints Plug and Slot Weld Requirements Diameter Limitations Slot Length Depth of Filling Common Requirements of PJP and CJP Groove Welds FCAW/GMAW in SMAW Joints Corner Joint Preparation Root Openings PJP Requirements Definition Weld Size Minimum Prequalified Weld Sizes Joint Dimensions Details (Tubular) Matched Box Connections CJP Groove Weld Requirements Joint Dimensions J- and U-Groove Preparation Tubular Butt Joints Tubular T-, Y-, and K-Connections Joint Details Postweld Heat Treatment Qualification Scope Part A General Requirements General Welding Procedure Specification (WPS) Qualification Responsibility Previous WPS Qualification CVN Test Requirements Performance Qualification of Welding Personnel Previous Performance Qualification Qualification Responsibility Period of Effectiveness Welders and Welding Operators Tack Welders Common Requirements for WPS and Welding Personnel Performance Qualification Qualification to Earlier Editions Aging Records Positions of Welds Part B Welding Procedure Specification (WPS) Production Welding Positions Qualified xvi

10 4.4 Type of Qualification Tests Weld Types for WPS Qualification Preparation of WPS Essential Variables SMAW, SAW, GMAW, GTAW, and FCAW ESW and EGW Base-Metal Qualification Methods of Testing and Acceptance Criteria for WPS Qualification Visual Inspection NDT RT or UT RT or UT Acceptance Criteria Mechanical Testing Root, Face, and Side Bend Specimens Longitudinal Bend Specimens Acceptance Criteria for Bend Tests Reduced-Section Tension Specimens Acceptance Criteria for Reduced-Section Tension Test All-Weld-Metal Tension Specimen Macroetch Test Acceptance Criteria for Macroetch Test Retest CJP Groove Welds for Nontubular Connections Corner or T-Joints PJP Groove Welds for Nontubular Connections Type and Number of Specimens to be Tested Weld Size Verification by Macroetch Verification of CJP Groove WPS by Macroetch Other WPS Verifications by Macroetch Flare-Groove Welds Fillet Weld Qualification Requirements for Tubular and Nontubular Connections Type and Number of Specimens Fillet Weld Test Consumables Verification Test CJP Groove Welds for Tubular Connections CJP Butt Joints with Backing or Backgouging CJP Butt Joints without Backing Welded from One Side Only T-, Y-, or K-Connections with Backing or Backgouging T-, Y-, or K-Connections without Backing Welded from One Side Only WPSs without Prequalified Status CJP Groove Welds in a T-, Y-, or K-Connection WPS with Dihedral Angles Less than CJP Groove Welds in a T-, Y-, or K-Connection WPS Using GMAW-S Weldments Requiring CVN Toughness PJP Tubular T-, Y-, or K-Connections and Butt Joints Plug and Slot Welds for Tubular and Nontubular Connections Welding Processes Requiring Qualification ESW, EGW, GTAW, and GMAW-S Other Welding Processes WPS Requirements (GTAW) WPS Requirements (ESW/EGW) Previous Qualification All-Weld-Metal Tension Test Requirements xvii

11 Part C Performance Qualification General Production Welding Positions Qualified Welders Welding Operators Tack Welders Production Thicknesses and Diameters Qualified Welders or Welding Operators Tack Welders Welder and Welding Operator Qualification Through WPS Qualification Type of Qualification Tests Required Welders and Welding Operators Substitution of RT for Guided Bend Tests Guided Bend Tests Tack Welders Extent of Qualification Weld Types for Welder and Welding Operator Performance Qualification Preparation of Performance Qualification Forms Essential Variables CJP Groove Welds for Nontubular Connections Welder Qualification Plates Welding Operator Qualification Plates for ESW/EGW PJP Groove Welds for Nontubular Connections Fillet Welds for Nontubular Connections CJP Groove Welds for Tubular Connections Other Joint Details or WPSs 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 Visual Inspection Macroetch Test Plug and Fillet Weld Macroetch Tests Macroetch Test for T-, Y-, and K-Connections Macroetch Test Acceptance Criteria RT RT Acceptance Criteria Fillet Weld Break Test Acceptance Criteria for Fillet Weld Break Test Root, Face, and Side Bend Specimens Method of Testing and Acceptance Criteria for Tack Welder Qualification Visual Acceptance Criteria Destructive Testing Acceptance Criteria Retest Welder and Welding Operator Retest Requirements Immediate Retest Retest After Further Training or Practice Retest After Lapse of Qualification Period of Effectiveness Exception Failure of a Requalification Retest Tack Welder Retest Requirements Retest without Additional Training Retest After Further Training or Practice xviii

12 5. Fabrication Scope Base Metal Specified Base Metal Base Metal for Weld Tabs, Backing, and Spacers Weld Tabs Backing Spacers Welding Consumables and Electrode Requirements General Certification for Electrodes or Electrode-Flux Combinations Suitability of Classification Shielding Gas Storage Condition SMAW Electrodes Low-Hydrogen Electrode Storage Conditions Approved Atmospheric Time Periods Alternative Atmospheric Exposure Time Periods Established by Tests Baking Electrodes Electrode Restrictions for ASTM A 514 or A 517 Steels SAW Electrodes and Fluxes Electrode-Flux Combination Requirements Condition of Flux Flux Reclamation Crushed Slag GMAW/FCAW Electrodes Low-Alloy Electrodes for GMAW Low-Alloy Electrodes for FCAW GTAW Tungsten Electrodes Filler Metal ESW and EGW Processes Process Limitations Condition of Electrodes and Guide Tubes Condition of Flux Weld Starts and Stops Preheating Repairs Weathering Steel Requirements WPS Variables Preheat and Interpass Temperatures Heat Input Control for Quenched and Tempered Steels Stress-Relief Heat Treatment Requirements Alternative PWHT Steels Not Recommended for PWHT Backing, Backing Gas, or Inserts Backing Fusion Full-Length Backing Backing Thickness Cyclically Loaded Nontubular Connections xix

13 External Attached Backing Statically Loaded Connections Welding and Cutting Equipment Welding Environment Maximum Wind Velocity Minimum Ambient Temperature Conformance with Design Minimum Fillet Weld Sizes Preparation of Base Metal Mill-Induced Discontinuities Acceptance Criteria Repair Joint Preparation Material Trimming Thermal Cutting Processes Other Processes Profile Accuracy Roughness Requirements Gouge or Notch Limitations Reentrant Corners Beam Copes and Weld Access Holes Weld Access Hole Dimensions Group 4 and 5 Shapes Temporary and Tack Welds Temporary Welds General Requirements for Tack Welds Incorporated Tack Welds Additional Requirements for Tack Welds Incorporated in SAW Welds Nonincorporated Tack Welds Camber in Built-Up Members Camber Correction Splices in Cyclically Loaded Structures Control of Distortion and Shrinkage Procedure and Sequence Sequencing Contractor Responsibility Weld Progression Minimized Restraint Subassembly Splices Temperature Limitations Tolerance of Joint Dimensions Fillet Weld Assembly Faying Surface PJP Groove Weld Assembly Butt Joint Alignment Girth Weld Alignment (Tubular) Groove Dimensions Nontubular Cross-Sectional Variations Tubular Cross-Sectional Variations Correction Engineer s Approval Gouged Grooves xx

14 Alignment Methods Dimensional Tolerance of Welded Structural Members Straightness of Columns and Trusses Beam and Girder Straightness (No Camber Specified) Beam and Girder Camber (Typical Girder) Beam and Girder Camber (without Designed Concrete Haunch) Beam and Girder Sweep Variation in Web Flatness Measurements Statically Loaded Nontubular Structures Cyclically Loaded Nontubular Structures Excessive Distortion Architectural Consideration Variation Between Web and Flange Centerlines Flange Warpage and Tilt Depth Variation Bearing at Points of Loading Tolerance on Stiffeners Fit of Intermediate Stiffeners Straightness of Intermediate Stiffeners Straightness and Location of Bearing Stiffeners Other Dimensional Tolerances Weld Profiles Fillet Welds Exception for Intermittent Fillet Welds Convexity Groove or Butt Welds Flush Surfaces Finish Methods and Values Technique for Plug and Slot Welds Plug Welds Flat Position Vertical Position Overhead Position Slot Welds Repairs Contractor Options Overlap, Excessive Convexity, or Excessive Reinforcement Excessive Concavity of Weld or Crater, Undersize Welds, Undercutting Incomplete Fusion, Excessive Weld Porosity, or Slag Inclusions Cracks in Weld or Base Metal Localized Heat Repair Temperature Limitations Engineer s Approval Inaccessibility of Unacceptable Welds Welded Restoration of Base Metal with Mislocated Holes Peening Tools Caulking Arc Strikes Weld Cleaning In-Process Cleaning Cleaning of Completed Welds Weld Tabs xxi

15 Use of Weld Tabs Removal of Weld Tabs for Statically Loaded Nontubular Structures Removal of Weld Tabs for Cyclically Loaded Nontubular Structures Ends of Welded Butt Joints Inspection Part A General Requirements Scope Information Furnished to Bidders Inspection and Contract Stipulations Contractor s Inspection Verification Inspection Definition of Inspector Categories Contractor s Inspector Verification Inspector Inspector(s) Inspector Qualification Requirements Bases for Qualification Term of Effectiveness Assistant Inspector Eye Examination Verification Authority Inspector Responsibility Items to be Furnished to the Inspector Inspector Notification Inspection of Materials Inspection of WPSs and Equipment WPS Welding Equipment Inspection of Welder, Welding Operator, and Tack Welder Qualifications Determination of Qualification Retesting Based on Quality of Work Retesting Based on Qualification Expiration Inspection of Work and Records Size, Length, and Location of Welds WPS Electrode Classification and Usage Scope of Examinations Extent of Examination Inspector Identification of Inspections Performed Maintenance of Records Part B Contractor Responsibilities Obligations of the Contractor Contractor Responsibilities Inspector Requests Engineering Judgment Specified NDT Other than Visual Nonspecified NDT Other than Visual Part C Acceptance Criteria Scope Engineer s Approval for Alternate Acceptance Criteria Visual Inspection xxii

16 6.10 PT and MT NDT Tubular Connection Requirements RT Acceptance Criteria for Statically Loaded Nontubular Connections Discontinuities Illustration of Requirements Acceptance Criteria for Cyclically Loaded Nontubular Connections Tensile Stress Welds Compressive Stress Welds Discontinuities Less than 1/16 in. [2 mm] Limitations Annex V Illustration Acceptance Criteria for Tubular Connections Discontinuities Illustration UT Acceptance Criteria for Statically Loaded Nontubular Connections Acceptance Criteria for Cyclically Loaded Nontubular Connections Indications Scanning Acceptance Criteria for Tubular Connections Class R (Applicable When UT is Used as an Alternate to RT) Class X (Experience-Based, Fitness-for-Purpose Criteria Applicable to T-, Y-, and K-Connections in Redundant Structures with Notch-Tough Weldments) Part D NDT Procedures Procedures RT Radiation Imaging Systems UT MT PT Personnel Qualification ASNT Requirements Certification Exemption of QC1 Requirements Extent of Testing Full Testing Partial Testing Spot Testing Relevant Information Part E Radiographic Testing (RT) RT of Groove Welds in Butt Joints Procedures and Standards Variations RT Procedures Procedure Safety Requirements Removal of Reinforcement Tabs Steel Backing Reinforcement xxiii

17 Radiographic Film Technique Geometric Unsharpness Source-to-Subject Distance Source-to-Subject Distance Limitations Sources IQI Selection and Placement Technique Film Length Overlapping Film Backscatter Film Width Quality of Radiographs Density Limitations H & D Density Transitions Identification Marks Edge Blocks Supplementary RT Requirements for Tubular Connections Circumferential Groove Welds in Butt Joints Single-Wall Exposure/Single-Wall View Double-Wall Exposure/Single-Wall View Double-Wall Exposure/Double-Wall View Examination, Report, and Disposition of Radiographs Equipment Provided by Contractor Reports Record Retention Part F Ultrasonic Testing (UT) of Groove Welds General Procedures and Standards Variations Piping Porosity Base Metal Qualification Requirements UT Equipment Equipment Requirements Horizontal Linearity Requirements for Test Instruments Calibration of Test Instruments Display Range Straight-Beam (Longitudinal Wave) Search Units Angle-Beam Search Units Frequency Transducer Dimensions Angles Marking Internal Reflections Edge Distance IIW Block Reference Standards IIW Standard Prohibited Reflectors xxiv

18 Resolution Requirements Equipment Qualification Horizontal Linearity Gain Control Internal Reflections Calibration of Angle-Beam Search Units Calibration for Testing Position of Reject Control Technique Recalibration Straight-Beam Testing of Base Metal Sweep Sensitivity Calibration for Angle-Beam Testing Horizontal Sweep Zero Reference Level Testing Procedures X Line Y Line Cleanliness Couplants Extent of Testing Reflector Size Inaccessibility Testing of Welds Scanning Butt Joints Maximum Indication Attenuation Factor Indication Rating Length of Discontinuities Basis for Acceptance or Rejection Identification of Rejected Area Repair Retest Reports Steel Backing UT of Tubular T-, Y-, and K-Connections Procedure Personnel Calibration Range Sensitivity Calibration Base-Metal Examination Weld Scanning Optimum Angle Discontinuity Evaluation Reports Forms Reported Discontinuities Incomplete Inspection Reference Marks Preparation and Disposition of Reports Content of Reports xxv

19 Prior Inspection Reports Completed Reports Calibration of the UT Unit with IIW or Other Approved Reference Blocks Longitudinal Mode Distance Calibration Amplitude Resolution Horizontal Linearity Qualification Gain Control (Attenuation) Qualification Shear Wave Mode (Transverse) Index Point Angle Distance Calibration Procedure Amplitude or Sensitivity Calibration Procedure Resolution Approach Distance of Search Unit Equipment Qualification Procedures Horizontal Linearity Procedure db Accuracy Procedure Decibel Equation Annex D Procedure Nomograph Internal Reflections Procedure Discontinuity Evaluation Procedures Straight-Beam (Longitudinal) Testing Angle-Beam (Shear) Testing Scanning Patterns Longitudinal Discontinuities Scanning Movement A Scanning Movement B Scanning Movement C Transverse Discontinuities Ground Welds Unground Welds ESW or EGW Welds (Additional Scanning Pattern) Examples of db Accuracy Certification Part G Other Examination Methods General Requirements Radiation Imaging Systems Including Real-Time Imaging General Procedures Procedure Qualification Personnel Qualifications IQI Image Enhancement Records Stud Welding Scope General Requirements Stud Design xxvi

20 7.2.2 Arc Shields Flux Stud Bases Stud Finish Stud Material Base Metal Thickness Mechanical Requirements Standard Mechanical Requirements Testing Engineer s Request Absence of Quality Control Tests Engineer s Option to Select Studs Workmanship Cleanliness Coating Restrictions Base-Metal Preparation Moisture Spacing Requirements Arc Shield Removal Acceptance Criteria Technique Automatic Machine Welding Multiple Welding Guns Movement of Welding Gun Ambient and Base-Metal Temperature Requirements FCAW, GMAW, SMAW Fillet Weld Option Surfaces Stud End Stud Fit (Fillet Welds) Fillet Weld Minimum Size Preheat Requirements SMAW Electrodes Visual Inspection Stud Application Qualification Requirements Purpose Responsibilities for Tests Preparation of Specimens Test Specimens Recorded Information Number of Specimens Test Required Test Methods Bend Test Torque Test Tension Test Application Qualification Test Data Production Control Pre-Production Testing Start of Shift Production Member Option Flash Requirement Bending Event of Failure xxvii

21 7.7.2 Production Welding Repair of Studs Operator Qualification Removal Area Repair Fabrication and Verification Inspection Requirements Visual Inspection Additional Tests Bent Stud Acceptance Criteria Torque Test Acceptance Criteria Engineering Judgment Owner s Option Strengthening and Repairing Existing Structures General Base Metal Investigation Suitability for Welding Other Base Metals Design for Strengthening and Repair Design Process Stress Analysis Fatigue History Restoration or Replacement Loading During Operations Existing Connections Use of Existing Fasteners Fatigue Life Enhancement Methods Stress Range Increase Workmanship and Technique Base-Metal Condition Member Discontinuities Weld Repairs Base Metal of Insufficient Thickness Heat Straightening Welding Sequence Quality Visual Inspection NDT Annexes Mandatory Information Annex I Effective Throat Annex II Effective Throats of Fillet Welds in Skewed T-Joints Annex III Requirements for CVN Testing Annex IV WPS Requirements Annex V Weld Quality Requirements for Tension Joints in Cyclically Loaded Structures Annex VI Flatness of Girder Webs Statically Loaded Structures Annex VII Flatness of Girder Webs Cyclically Loaded Structures Annex VIII Temperature-Moisture Content Charts Annex IX Manufacturers Stud Base Qualification Requirements Annex X Qualification and Calibration of UT Units with Other Approved Reference Blocks Annex XI Guideline on Alternative Methods for Determining Preheat Annex XII Symbols for Tubular Connection Weld Design xxviii

22 Annexes Nonmandatory Information Annex A Short Circuiting Transfer (GMAW-S) Annex B Terms and Definitions Annex C Guide for Specification Writers Annex D UT Equipment Qualification and Inspection Forms Annex E Sample Welding Forms Annex F Guidelines for Preparation of Technical Inquiries for the Structural Welding Committee Annex G Local Dihedral Angle Annex H Contents of Prequalified WPS Annex J Safe Practices Annex K UT Examination of Welds by Alternative Techniques Annex L Ovalizing Parameter Alpha Annex M Code-Approved Base Metals and Filler Metals Requiring Qualification per Section Annex N List of Reference Documents Annex O Filler Metal Strength Properties Annex P Section 2 Reorganization Commentary Foreword C1. General Requirements C1.1 Scope C1.2 Limitations C1.3.1 Engineer C Contractor s Inspector C Verification Inspector C Inspector(s) unmodified C1.3.4 OEM (Original Equipment Manufacturer) C Should C May C1.4.1 Responsibilities C1.4.2 Contractor s Responsibilities C1.4.3 Verification Inspection C2. Design of Welded Connections C2.2.2 CVN Test Requirements C Prequalified Detail Dimensions C Maximum Effective Length C2.5.1 Calculated Stresses C2.5.2 Calculated Stresses due to Eccentricity C2.5.4 Allowable Weld Metal Stresses C Alternative Allowable Fillet Weld Stress C Instantaneous Center of Rotation C2.6.1 General Considerations C2.6.3 Base Metal Through-Thickness Loading C2.6.4 and C2.6.5 Combinations of Welds C2.6.6 Weld Access Holes C2.7.1 Transitions of Thickness and Width C Transverse Fillet Welds C2.8.2 Longitudinal Fillet Welds C Fillet Weld Terminations General C Lap Joints Subject to Tension C Maximum End Return Length C Transverse Stiffener Welds C Opposite Sides of a Common Plane xxix

23 C General C Compression Members C Unpainted Weathering Steel C Applicability C Low Cycle Fatigue C Redundant Nonredundant Members C Elastic Analysis C Allowable Stress Range C Fillet Weld Terminations C2.19 General (Tubular Connections) C2.20 Allowable Stresses (Tubular) C Base-Metal Stresses C Weld Stresses C Fatigue Stress Categories C Basic Allowable Stress Limitation C Fatigue Behavior Improvement C Size and Profile Effects C2.24 Limitations of the Strength of Welded Connections C Local Failure C General Collapse C Uneven Distribution of Load (Weld Sizing) C Box T-, Y-, and K-Connections C Local Failure C General Collapse C Uneven Distribution of Load (Effective Width) C Overlapping Connections C Bending C Other Configurations C2.26 Material Limitations C Box T-, Y-, or K-Connections C Tubular Base-Metal Notch Toughness C CVN Test Requirements C LAST Requirements C Alternate Notch Toughness C3. Prequalification of WPSs C3.2.1 Prequalified Processes C3.3 Base Metal/Filler Metal Combinations C3.5 Minimum Preheat and Interpass Temperature Requirements C3.6 Limitation of WPS Variables C3.7.2 Width/Depth Pass Limitation C3.7.3 Weathering Steel Requirements C Table 3.7 Electrical Limitations C Table 3.7 Requirement for Multiple Electrode SAW C Table 3.7 Requirements for GMAW/FCAW C3.10 Plug and Slot Weld Requirements C Corner Joint Preparation C Joint Dimensions C Figure 3.3 Effective Weld Size of Flare-Bevel-Groove Welded Joints C3.14 Postweld Heat Treatment C4. Qualification C Qualification Responsibility C4.1.2 Performance Qualification of Welding Personnel C Period of Effectiveness Welders and Welding Operators xxx

24 C4.2.4 Positions of Test Welds C4.4 Type of Qualification Tests C Table 4.2 WPS Qualification CJP Groove Welds; Number and Type of Test Specimens and Range of Thickness and Diameter Qualified C4.7 Essential Variables C4.7.1 SMAW, SAW, GMAW, GTAW and FCAW C Table C4.8.2 NDT C Longitudinal Bend Tests C Acceptance Criteria for Bend Tests C Type and Number of Specimens to be Tested C Type and Number of Specimens Fillet Welds C4.12 CJP Groove Welds for Tubular Connections C T-, Y-, and K-Connections without Backing Welded from One Side Only C Weldments Requiring Notch Toughness C4.15 Welding Processes Requiring Qualification C4.17 WPS Requirements (ESW/EGW) C All-Weld-Metal Tension Test Requirements C4.18 General C4.22 Essential Variables C Table C Table C4.26 CJP Groove Welds for Tubular Connections C5. Fabrication C5.1 Scope C5.2 Base Metal C Dew Point/Manufacturer s Certification C5.3.2 SMAW Electrodes C Low-Hydrogen Electrode Storage Condition C Electrode-Flux Combinations C Condition of Flux C Flux Reclamation C Crushed Slag C5.3.4 GMAW/FCAW Electrodes C5.4 ESW and EGW Processes C5.5 WPS Variables C5.7 Heat Input Control for Quenched and Tempered Steel C5.8 Stress Relief Heat Treatment C5.10 Backing C Full-Length Backing C Cyclically Loaded Nontubular Connections C Minimum Ambient Temperature C5.13 Conformance with Design C5.14 Minimum Fillet Weld Sizes C5.15 Preparation of Base Metal C Repair C Joint Preparation C Roughness Requirements C5.16 Reentrant Corners C5.17 Beam Copes and Weld Access Holes C Weld Access Hole Dimensions C General Requirements for Tack Welds C5.19 Camber in Built-Up Members xxxi

25 C Fillet Weld Assembly C PJP Groove Weld Assembly C Butt Joint Alignment C Tubular Cross-Sectional Variations C Correction C and C Beam and Girder Straightness C Beam and Girder Camber (without Designed Concrete Haunch) C Measurements C Statically Loaded Nontubular Structures C Excessive Distortion C Flange Warpage and Tilt C Bearing at Points of Loading C Other Dimensional Tolerances C5.24 Weld Profiles C Contractor Option (Repair) C Localized Heat Repair Temperature Limitations C Welded Restoration of Base Metal with Mislocated Holes C5.27 Peening C5.28 Caulking C5.29 Arc Strikes C5.30 Weld Cleaning C5.31 Weld Tabs C6. Inspection C6.1 Scope C6.1.1 Information Furnished to Bidders C6.1.2 Inspection and Contract Stipulations C6.1.3 Definition of Inspector Categories C6.1.5 Inspector Responsibility C6.1.6 Items to be Furnished to the Inspector C6.1.7 Inspector Notification C6.2 Inspection of Materials C6.3 Inspection of WPS Qualification and Equipment C6.4 Inspection of Welder, Welding Operator, and Tack Welder Qualifications C6.4.1 Determination of Qualification C6.4.2 Retesting Based on Quality of Work C6.4.3 Retesting Based on Certification Expiration C6.5 Inspection of Work and Records C6.6.1 Contractor Responsibilities C6.6.2 Inspector Requests C6.6.4 Specified NDT Other than Visual C6.7 Scope C6.8 Engineer s Approval for Alternate Acceptance Criteria C Table 6.1, Item 8 Piping Porosity C6.9 Visual Inspection C6.10 PT and MT C6.11 NDT C Acceptance Criteria for Cyclically Loaded Nontubular Connections C Acceptance Criteria for Statically Loaded Nontubular Connections C Acceptance Criteria for Cyclically Loaded Nontubular Connections C UT Acceptance Criteria for Tubular Connections C6.14 Procedures C Personnel Qualification C6.15 Extent of Testing xxxii

26 C Spot Testing C Procedures and Standards (RT) C Variations C6.17 RT Procedure C Safety Requirements C Removal of Reinforcement C Tabs C Reinforcement C Radiographic Film C Technique C Geometric Unsharpness C , C Source-to-Subject Distance and Limitations C Sources C IQI Selection and Placement C Backscatter C Film Width C Quality of Radiographs C H & D Density C Transitions C Identification Marks C Edge Blocks C6.19 Examination, Report, and Disposition of Radiographs C Equipment Provided by Contractor C6.19.2, C Reports and Retention C UT Procedures and Standards C Variations C Piping Porosity C6.22 UT Equipment C Straight Beam (Longitudinal Wave) Search Unit C Transducer Dimensions C IIW Standard C Figure C Prohibited Reflectors C Horizontal Linearity C Gain Control C Calibration of Angle Beam Search Units C Sweep C Horizontal Sweep C Couplants C Extent of Testing C Reflector Size C Inaccessibility C Table Legend P C Testing of Welds C Attenuation Factor C Length of Discontinuities C Basis for Acceptance or Rejection C Groove Welds Containing Steel Backing C6.27 UT of Tubular T-, Y-, and K-Connections C7. Stud Welding C7.1 Scope C7.2 General Requirements xxxiii