Section 14

Welding
14.1 Field Welding Welding Processes Stud Welding Welding Positions 1 6 9 13

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Field Welding Section 14.1

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Field Welding
Bridge Structures AWS D1 D1.5 5 (00560 (00560.26(a)) 26(a)) Reinforcement AWS D1.4 (00530.42(d)) Non-Bridge Structures AWS D1.1 (00560.26(b)) Sign Supports Luminaire Poles Expansion Joints Bridge Rail Seismic Retrofit

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Welding Codes

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Special Provisions
Ch k Special Check S i l Provisions P i i f for project j t specific ifi requirements. i t

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Documentation
WPS Welding W ldi Procedure P d Specifications S ifi ti PQR Procedure Qualification Records WQTR Welder Qualification Test Records MTR Mill Test Reports

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Welding Procedure Specifications (WPS)

Recipe R i welders ld f follow. ll Includes following variables: Base Metal Material, Process, Position, Volts, Amps, Travel speed, Preheat, Interpass Temperature, Joint Configuration, Shielding Gas etc. Also lists allowable ranges for those variables variables. These values are taken from the PQR.
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Procedure Qualification Records (PQR)

C Contains t i all ll weld ld parameters t f for th the weld ld procedure d qualification: Base Metal Material, Process, Position, Volts, Amps, Travel speed, Preheat, Interpass Temperature, Joint Configuration, Shielding Gas etc. This document serves as written confirmation of the WPS.

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Welder Qualification Test Records (WQTR)

Welder W ld T Test t Record R d results lt qualifying lif i the th individual i di id l f for specific weld processes, materials, joint configurations, positions, etc.

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Mill Test Reports (MTR)

Test T t indicating i di ti material t i l composition, iti strength, t th physical h i l properties, etc. for material being welded.

Welding Certification Card

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Welding Processes

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SMAW

Shi ld d Metal Shielded M t l Arc A Welding W ldi (Stick (Sti k welding): ldi ) An arc is generated between the electrode and the weld pool. The electrode flux coating decomposition provides the shielding gas.

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SAW

Submerged Arc Welding: A process that generates an arc between a bare metal electrode and weld pool. The arc and molten metal are shielded by granular flux.

GMAW
Gas Metal Arc Welding (MIG): A semi or full automatic process with a continuous continuous, consumable wire electrode and shielding gas fed through a welding gun.

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GTAW

Gas Tungsten Arc Welding (TIG): Creates an arc between a tungsten electrode and the weld pool. Shielding is from an external gas source.

FCAW

Flux Cord Arc Welding: Continuous, consumable tubular electrode containing the flux. Constant voltage or current power supply.

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Stud Welding

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Stud Welding
Stud St d Welding: W ldi Automatically timed equipment with a ferrule base.

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Tests
Stud St d Welding W ldi Application A li ti Qualification Q lifi ti T Test t Pre-production Test Production Bend Test

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Stud Welding Application Qualification Test (AWS D1.5 Chapter 7.6)

10 stud specimens to qualify welding Process/Operator. 900 Bend Test or 300 & 300 Bend Test on all 10 studs. If any of the 10 specimens fail, the test must be repeated. Certified Welding Inspector (CWI) will be required to perform bend tests tests, review the procedure and write a report after completion of welding.

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Pre-production Test
2 stud t dt test t specimens i required. i d 30 Degree Bend (one way) prior to beginning production welding each day or shift change or when any modification to the welding setup occurs.

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Production Bend Test

B Bend d 15 D Degrees ( (one way) ) any specimen i th that t weld ld does not go completely around the stud. Stud welding has typically been done in the fabrication shops but in the future stud welding will be done in the field.

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Stud Welding
St Stud d welding ldi h has t typically i ll b been d done i in th the f fabrication b i ti shops but in the future stud welding will be done in the field on steel girders. Keep Studs free of rust, oil, moisture (Chp. 7.4.1) Keep Ferrules dry. If wet, oven dry at 250 for 2 hours (Ch 7.4.4) (Chp. 7 4 4) Repair failed stud locations so surface is smooth and flush (Chp. 7.5)
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Stud Failure
Wet Conditions Painted Surface Inadequate Preheating

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Stud Failure

F Failure il l ft left pits & ridges Repair pits Grind smooth

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Welding Positions

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Fillet Weld Positions AWS D1.5 & D1.1

Groove Weld Positions AWS D1.5 & D1.1

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Pile Exercise
A252 Grade 2 Pipe Piling. SMAW (Stick) Welding Process. Groove Weld or Fillet Weld? AWS D1.1 or D1.5? What WPS or PQR Welding Position Qualifies this Weld? Welder is Qualified SMAW 1G & 2F Is he qualified?

Steel Plate Girder Exercise

A709 Grade 50 Steel Plate Girders. SAW Welding Process. Groove Weld or Fillet Weld? AWS D1.1 or D1.5? What WPS or PQR Welding Position Qualifies this Weld? Welder is Qualified SMAW 1G & 2F Is he qualified?

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Field Welding
C t Contractor t R Responsibilities: ibiliti AWS D1.5 & D1.1 Section 6 Inspection: Contractor shall perform inspection and testing prior to assembly, during assembly, during welding and after welding (NDT) as necessary to assure material and workmanship k hi conform f t to th the requirements i t of f the th contract t t documents.

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Bridge Construction Inspector Training

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Field Welding
ODOT QA Inspector I t Responsibilities: R ibiliti Review submittal package Assure proper documentation is provided (includes WPS, PQR, MTRs, WQTR, etc.). Forward copies of welding submittals to: St Steve Lovejoy L j (503-986-3326) (503 986 3326) Welding submittals for QA Inspection to: Jim Sabel (971-673-7007) or Scott Nelson (503-986-3056)
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Bridge Construction Inspector Training

Inspector Quality Assurance Program

Field Welding
ODOT QA Inspector I t Responsibilities: R ibiliti Assure proper QC Inspection by the Contractor. Perform appropriate QA Inspection including but not limited to: Fit Up, Equipment Setup, In Process Welding, WPS Compliance, Post Welding Visual (including Weld Size, Profile, Defects etc.), review NDT Reports as necessary.

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