A summary of differences between D1.5:2008 and D1.

1:2008 (feel free to add

to this list). In short D1.1 and D1.5 are different enough that when you switch
between the codes you need to leave any preconceived notions behind
otherwise you will likely get burned.

WELDING PROCESSES
In D1.5, only SMAW WPS's are pre-qualified, as long as they are in
accordance with other sections of the code. FCAW and SAW WPS's are not
pre-qualified and have to be tested. D1.5 doesn't provide for prequalified
welding except with Low hydrogen SMAW electrodes. In fact the commentary
section does a nice job explaining it clearly. "C-1.3.1 A major difference
between this code and AWS D1.1 for welding primary members and
connections is that only WPS's using listed SMAW electrodes with a specified
minimum yield strngth less than [90 ksi] are to be considered pre-qualified and
exempt from testing in this code. Other WPS's for primary connections are to
be qualified as described per clause 5."
D1.1 allows a broarder range of pre-qualifed WPS's.

FABRICATOR CERTIFICATION
D1.5 requires bridge fabricators to be AISC certified or equilevent.
D1.1 doesn't have this requirment.

CALIBRATION OF EQUIPMENT
D1.5 requires that, "The contractor shall verify, at least every 3 months, the
accuracy of meters and other devices used to record or display welding
variables."
D1.1 only requires that welding equipment be kept in such condition as to
enable personnel to follow procedures and obtain required results. No specific
calibration interval is mandated.

WPS REQUALIFICATION DUE TO TIME LIMITS

D1.5 requires that all WPS's, except those specifically exempt, shall be based
on tests which have been performed not more than 60 months in advance of
production welding.
In D1.5 for FCM, PQR's are good for only 36 months.
D1.1 does not have a limitation on the time frame they are good for.

CHIPPING AND BRUSHING DURING WELDER TESTING

In D1.5, the welder can't grind on his test plate during the test.The no grinding
requirement on welder qualifications is often misunderstood. That does not
mean that grinding is prohibited on production work, just on the test (although
major grinding could be weld removal and that requires engineer's approval).
Excessive grinding and re-welding in production could adversely affect the
steel.
D1.1 does not matter if you grind on the test plate.

WITNESS FOR WPS QUALIFICATION

D1.5 requires that "Welding and machining shall be witnessed by a state
representative or an independant third party acceptable to the state."
D1.1 does not require a state nor third party to witness welding of a WPS
plate.

FILLET WELDS - MULITPLE PASS LIMITATIONS

IN D1.5, up to 5/16" fillets must be single pass welds (heat input control).
D1.1, does not have a lower limit on multiple pass weld size.

WPS QUALIFICATION
In D1.5 you can either qualify WPSs by testing by controlling heat input
requirements (5.12) or by essential variables (5.13). You could also qualify a
D1.5 maximum heat input PQR, or a min/max heat input PQR. D1.5-5.13
allows amps at +/-10%, volts +/- 7%, travel +/- 10%, and heat input is +10%/-
30%. (These are for FCAW and there are other differences I didn't mention.)
The point is that heat input control is important with D1.5.
In D1.1 you control WPSs through essential variables. With D1.1 PQR amps
can vary by +/- 10%, volts +/- 7% , travel +/- 25%, and heat input by + 10%
(no limit shown for reduction in heat input). A lot of D1.1 welding is
prequalified if within the manufacturer's recommended ranges; which are
pretty wide ranges.

BASE METALS
D1.5 wants you to use ASTM A709 (AASHTO M270) steels. It makes is very
difficult to use steels other than A709 by making the qualification of those
unlisted steels more difficult than qualifying unlisted steels in D1.1.
D1.1 requires the qualification of unlisted steels, just as D1.5 does, but it does
not require evidence of the steels acceptability to other codes, a minimum
history of five years use under similar conditions of loading, past records
showing the steels resistance to hydrogen cracking, and history of max/min
heat inputs for each process to be used.

OPTIONAL HORIZONTAL PLATE - WELDER QUALIFICATION - UNLIMITED

THICKNESS
D1.5 requires the plate to be a minimum of 5-1/4 in.
D1.1 requires the plate to be a minimum of 5 in.

PRETESTING WPSs
D1.5 allows as contractor to use a PQR qualified by someone else as the
basis of a WPS if he performs a verification test.
D1.1 requires to the contractor to run all PQRs himself.

VERIFICATION TESTING
D1.5 allows for a simplified qualification test (verification test) if the contractor
wants to use a PQR obtained from a third party as the basis for a WPS.
D1.1 does not allow for verification testing.

WPS QUALIFICATION TEST PLATES

Between D1.5 and D1.1, the minimum lengths of the plates and location of the
specimens are different enough to make an item by item comparison
cumbersome in this particular list. In short they are similar but they are not the
same.

PREQUALIFIED JOINT DETAILS - SINGLE BEVEL AND DOUBLE BEVEL

JOINTS
The D1.5, in many cases, is much more restrictive on the allowable positions
for single and bevel joint. For instance, B-U4a can only be used in F and H
positions.
D1.1 is more permissive with the allowable positions for single and bevel joint.
For instance, B-U4a can only be used in ALL positions.