AWS Inspector's Pocket Hand Book PDF

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Copyright American Welding Society

Provided by IHS under license with AWS
No reproduction or networking permitted without license from IHS 1Not for Resale
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© 2004 by American Welding Society. All rights reserved.

Printed in the United States of America
NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is
error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include all
available information, including with respect to safety and health issues. By publishing this guide, AWS does not insure
anyone using the information it contains against any liability or injury to property or persons arising from that use.
Provided by IHS under license with AWS 2
No reproduction or networking permitted without license from IHS Not for Resale
Introduction
The inspection requirements for the fabrication and welding of steel structures are very extensive. This Pocket
Handbook has been developed to provide a useful tool for inspectors to carry in their pockets or tool kits so
that selected pertinent portions of the AWS Structural Welding Code—Steel, D1.1/D1.1M:2004, can be easily
referenced at the job site. Underlining is as shown in the code.
This publication is not to be considered as a substitute for the D1.1 code book. Rather, the Handbook is provided
as a supplemental aid for the “deckplate” inspector. Only the complete code should be considered as the official
document to ensure that all of the quality attributes required for structural fabrication are performed correctly
and completely.
To assist the inspector, or other user, in verifying conformance to D1.1, the paragraph references, the table num-
bers, and the figure numbers contained in this book are directly from the D1.1/D1.1M:2004 code. In addition,
page numbering in this handbook is cross-referenced to reflect both the current page and the corresponding page
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from the D1.1/D1.1M:2004 code, separated by a “/.” This will provide an easy cross reference for the user to
ensure that the complete requirements are understood when questions develop during the course of any inspection.

No reproduction or networking permitted without license from IHS 3Not for Resale
Table of Contents
Requirements for Transitions Between Materials of Unequal Thickness.............................................................. 5
Thermal Cutting and Access Hole Requirements .................................................................................................. 9
Tolerance of Joint Dimensions............................................................................................................................. 13
Dimensional Tolerances of Welded Structural Members..................................................................................... 19
Base Material Surface Requirements ................................................................................................................... 25
Weld Profile Requirements .................................................................................................................................. 26
Acceptance Criteria for Visual Inspection of Welds ............................................................................................ 32
Index..................................................................................................................................................................... 37
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Requirements for Transitions Between Materials of Unequal Thickness
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Figure 2.21—Transition of Thickness of Butt Joints in Parts of
Copyright American Welding Society Unequal
Thickness (Tubular) (see 2.25 [pg. 22])
No reproduction or networking permitted without license from IHS 5/pg.
5Not55
for Resale
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Figure 2.21 (Cont’d)—Transition of Thickness of Butt Joints in Parts of
Copyright American Welding Society Unequal
Thickness (Tubular) (see 2.25 [pg. 22])
Provided by IHS under license with AWS 6/pg.
6 55
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Figure 2.2—Transition of Butt Joints in Parts of Unequal Thickness (Nontubular)

Copyright American Welding Society (see
2.7.1 [pg. 10] and 2.16.1.1 [pg. 14])
7Not42
for Resale
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Figure 2.12—Transition of Width (Cyclically Loaded Nontubular) (see 2.16.1.2 [pg. 14])
8 48
Thermal Cutting and Access Hole Requirements
5.15.4.3 Roughness Requirements. In thermal 5.15.4.4 Gouge or Notch Limitations. Rough-
cutting, the equipment shall be so adjusted and ness exceeding these values and notches or gouges
manipulated as to avoid cutting beyond (inside) the not more than 3/16 in. [5 mm] deep on other wise
prescribed lines. The roughness of all thermal cut satisfactory surfaces shall be removed by machining
surfaces shall be no greater than that defined by the or grinding. Notches or gouges exceeding 3/16 in.
American National Standards Institute surface rough- [5 mm] deep may be repaired by grinding if the
ness value of 1000 µin. [25 µm] for material up to nominal cross-sectional area is not reduced by more
4 in. [100 mm] thick and 2000 µin. [50 µm] for mate- than 2%. Ground or machined surfaces shall be fared
rial 4 in. to 8 in. [200 mm] thick, with the following to the original surface with a slope not exceeding one
exception: the ends of members not subject to calcu- in ten. Cut surfaces and adjacent edges shall be left
lated stress at the ends shall not exceed a surface free of slag. In thermal-cut surfaces, occasional
roughness value of 2000 µin. ANSI/ASME B46.1, notches or gouges may, with approval of the Engi-
Surface Texture (Surface Roughness, Waviness, and neer, be repaired by welding.
Lay) is the reference standard. AWS Surface Rough-
ness Guide for Oxygen Cutting (AWS C4.1-77) may
be used as a guide for evaluating surface roughness
5.16 Reentrant Corners
of these edges. For materials up to and including 4 in. Reentrant corners of cut material shall be formed
[100 mm] thick, Sample No. 3 shall be used, and to provide a gradual transition with a radius of not
for materials over 4 in. up to 8 in. [200 mm] thick, less than 1 in. [25 mm]. Adjacent surfaces shall meet
Sample No. 2 shall be used.
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without offset or cutting past the point of tangency.
No reproduction or networking permitted without license from IHS 9/pg.9Not
185for Resale
The reentrant corners may be formed by thermal cut- material in which the hole is made, but not less than
ting, followed by grinding, if necessary, to meet the the thickness of the material. In hot rolled shapes and
surface requirements of 5.15.4.3. built-up shapes, all beam copes and weld access
--```,,`-`-`,,`,,`,`,,`--- holes shall be shaped free of notches or sharp re-
5.17 Beam Copes and Weld Access entrant corners except that when fillet web-to-flange
welds are used in built-up shapes, access holes may
Holes terminate perpendicular to the flange. Fillet welds
Radii of beam copes and weld access holes shall not be returned through weld access holes (see
shall provide a smooth transition free of notches or Figure 5.2).
cutting past the points of tangency between adjacent
surfaces and shall meet the surface requirements of 5.17.2 Group 4 and 5 Shapes. For ASTM A6
5.15.4.3. Group 4 and 5 shapes and built-up shapes with web
material thickness greater than 1-1/2 in. [40 mm], the
5.17.1 Weld Access Hole Dimensions. All weld ac- thermally cut surfaces of beam copes and weld access
cess holes required to facilitate welding operations holes shall be ground to bright metal and inspected
shall have a length (A ) from the toe of the weld by either MT or PT. If the curved transition portion of
preparation not less than 1-1/2 times the thickness of weld access holes and beam copes are formed by pre-
the material in which the hole is made. The height drilled or sawed holes, that portion of the access hole
(h) of the access hole shall be adequate for depo- or cope need not be ground. Weld access holes and
sition of sound weld metal in the adjacent plates and beam copes in other shapes need not be ground nor
provide clearance for weld tabs for the weld in the inspected by MT or PT.

10 185
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Copyright American Welding Society Figure 5.2—Weld Access Hole Geometry (see 5.17.1 [pg. 185])
11 196
Not for Resale
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General Notes:
For ASTM A 6 Group 4 and 5 shapes and welded built-up shapes with web thickness more than 1-1/2 in. [40 mm], 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.
These are typical details for joints welded from one side against steel backing. Alternative joint designs should be considered.
Notes:
1. Radius shall provide smooth notch-free transition; R ≥ 3/8 in. [10 mm] (Typical 1/2 in. [12 mm]).
2. Access hole made after welding web to flange.
3. Access hole made before welding web to flange. Weld not returned through hole.
4. hmin = 3/4 in. [20 mm] or tw (web thickness), whichever is greater.
Figure 5.2 (Cont’d)—Weld Access Hole Geometry (see 5.17.1 [pg. 185])

12 196
Tolerance of Joint Dimensions
5.22.1 Fillet Weld Assembly. The parts to be joined 1/16 in. [2 mm]. Where irregularities in rolled shapes
by fillet welds shall be brought into as close contact as occur after straightening do not allow contact within
practicable. The root opening shall not exceed 3/16 in. the above limits, the procedure necessary to bring the
[5 mm] except in cases involving either shapes or material within these limits shall be subject to the
plates 3 in. [75 mm] or greater in thickness if, after approval of the Engineer. The use of filler plates shall
straightening and in assembly, the root opening cannot be prohibited except as specified on the drawings or
be closed sufficiently to meet this tolerance. In such as specially approved by the Engineer and made in
cases, a maximum root opening of 5/16 in. [8 mm] accordance with 2.13.
may be used, provided suitable backing is used. Back-
5.22.2 PJP Groove Weld Assembly. The parts to be
ing may be of flux, glass tape, iron powder, or similar
joined by PJP groove welds parallel to the length of
materials, or welds using a low-hydrogen process
the member shall be brought into as close contact as
compatible with the filler metal deposited. If the sepa-
practicable. The root opening between parts shall not
ration is greater than 1/16 in. [2 mm], the leg of the
exceed 3/16 in. [5 mm] except in cases involving
fillet weld shall be increased by the amount of the root
rolled shapes or plates 3 in. [75 mm] or greater in
opening, or the contractor shall demonstrate that the
thickness if, after straightening and in assembly, the
required effective throat has been obtained.
root opening cannot be closed sufficiently to meet this
5.22.1.1 Faying Surface. The separation be- tolerance. In such cases, a maximum root opening of
tween faying surfaces of plug and slot welds, and --```,,`-`-`,,`,,`,`,,`--- 5/16 in. [8 mm] may be used, provided suitable back-
of butt
Copyright joints
American landing
Welding Society on a backing, shall not exceed
ing is used and the final weld meets the requirements
13 187
Not for Resale
for weld size. Tolerances for bearing joints shall be in member) and the maximum allowable shall be 1/4 in.
conformance with the applicable contract specifications. [6 mm], provided that any offset exceeding 1/8 in.
[3 mm] is welded from both sides. However, with
5.22.3 Butt Joint Alignment. Parts to be joined at the approval of the Engineer, one localized area per
butt joints shall be carefully aligned. Where the parts girth seam may be offset up to 0.3t with a maximum
are effectively restrained against bending due to of 3/8 in. [10 mm], provided the localized area is
eccentricity in alignment, the offset from the theoreti- under 8t in length. Filler metal shall be added to this
cal alignment shall not exceed 10% of the thickness region to provide a 4 to 1 transition and may be added
of the thinner part joined, or 1/8 in. [3 mm], which- in conjunction with making the weld. Offsets in
ever is smaller. In correcting misalignment in such excess of this shall be corrected as provided in 5.22.3.
cases, the parts shall not be drawn in to a greater Longitudinal weld seams of adjoining sections shall
slope than 1/2 in. [12 mm] in 12 in. [300 mm]. Mea- be staggered a minimum of 90°, unless closer spacing
surement of offset shall be based upon the centerline is agreed upon by the Owner and Fabricator.
of parts unless otherwise shown on the drawings.
5.22.4 Groove Dimensions
5.22.3.1 Girth Weld Alignment (Tubular).
Abutting parts to be joined by girth welds shall be 5.22.4.1 Nontubular Cross-Sectional Variations.
carefully aligned. No two girth welds shall be located With the exclusion of ESW and EGW, and with the
closer than one pipe diameter or 3 ft [1 m], whichever exception of 5.22.4.3 for root openings in excess of
is less. There shall be no more than two girth welds in those permitted in Figure 5.3, the dimensions of the
any 10 ft [3 m] interval of pipe, except as may be cross section of the groove welded joints which vary
agreed upon by the Owner and Contractor. Radial from those shown on the detail drawings by more
offset of abutting edges of girth seams shall not --```,,`-`-`,,`,,`,`,,`---
than these tolerances shall be referred to the Engineer
exceed
Copyright 0.2tWelding
American (where t is the thickness of the thinner
Society for approval or correction.
14 187
5.22.4.2 Tubular Cross-Sectional Variations. whichever is less, may be corrected by welding to
Variation in cross section dimension of groove welded acceptable dimensions prior to joining the parts by
joints, from those shown on the detailed drawings, welding.
shall be in accordance with 5.22.4.1 except:
(1) Tolerances for T-, Y-, and K-connections are 5.22.4.4 Engineer’s Approval. Root openings
included in the ranges given in 3.13.4. greater than allowed by 5.22.4.3 may be corrected by
(2) The tolerances shown in Table 5.5 apply to welding only with the approval of the Engineer.
CJP tubular groove welds in butt joints, made from
5.22.5 Gouged Grooves. Grooves produced by
one side only, without backing.
gouging shall be in substantial conformance with
5.22.4.3 Correction. Root openings greater than groove profile dimensions as specified in Figure 3.3
those permitted in 5.22.4.1, but not greater than twice and 3.4 and provisions of 3.12.3 and 3.13.1. Suitable
the thickness of the thinner part or 3/4 in. [20 mm], access to the root shall be maintained.
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No reproduction or networking permitted without license from IHS 15/pgs.15
187–188
Not for Resale
Figure 5.3—Workmanship Tolerances in Assembly of Groove Welded Joints (see 5.22.4.1 [pg. 187])
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16 197
Root Not Root
Backgouged Backgouged
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in. mm in. mm
(1) Root face of joint ±1/16 2 Not limited
(2) Root opening of
±1/16 2 +1/16 2
joints without
–1/80 3
backing
Root opening of +1/40 6
Not applicable
joints with backing –1/16 2
(3) Groove angle of +10° +10°
joint –5°0 –5°0
General Note: See 5.22.4.2 for tolerances for CJP
tubular groove welds made from one side without
backing.
Figure 5.3 (Cont’d)—Workmanship Tolerances in Assembly of Groove Welded Joints (see 5.22.4.1 [pg. 187])

17 197
Not for Resale
Table 5.5
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Tubular Root Opening Tolerances (see 5.22.4.2 [pg. 187])
Root Opening of Joints Groove Angle

Root Face of Joint without Steel Backing of Joint
in. mm in. mm deg
SMAW ±1/16 ±2 ±1/16 ±2 ±5

GMAW ±1/32 ±1 ±1/16 ±2 ±5
FCAW ±1/16 ±2 ±1/16 ±2 ±5
General 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.

18 194
Dimensional Tolerances of Welded Structural Members
5.23 Dimensional Tolerances of Welded Lengths over 45 ft [15 m]:
Structural Members No. of ft of total length – 45
3/8 in. + 1/8 in. × ---------------------------------------------------------------------
The dimensions of welded structural members 10
shall conform to the tolerances of (1) the general
No. of meters of total length – 15
specifications governing the work, and (2) the special 10 mm + 3 mm × --------------------------------------------------------------------------------
dimensional tolerances in 5.23.1 to 5.23.11.3. (Note 3
that a tubular column is interpreted as a compression 5.23.2 Beam and Girder Straightness (No Cam-
tubular member.) ber Specified). For welded beams or girders, regard-
5.23.1 Straightness of Columns and Trusses. For less of cross section, where there is no specified
welded columns and primary truss members, regard- camber, the maximum variation in straightness shall
less of cross section, the maximum variation in be
straightness shall be No. of ft of total length
1/8 in. × -------------------------------------------------------
Lengths of less than 30 ft [9 m]: 10
No. of ft of total length 1 mm × No. of meters of total length
1/8 in. × -------------------------------------------------------
10 5.23.3 Beam and Girder Camber (Typical
Girder). For welded beams or girders, other than
1 mm × No. of meters of total length
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those whose top flange is embedded in concrete with-

Lengths of 30 ft [10 m] to 45 ft [14 m] = 3/8 in. [10 mm]
out a designed concrete haunch, regardless of cross
19 188
Not for Resale
section, the maximum variation from required cam- top flange is embedded in concrete without a
ber at shop assembly (for drilling holes for field designed concrete haunch, the maximum variation
splices or preparing field welded splices) shall be from required camber at shop assembly (for drilling
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at midspan, – 0, +1-1/2 in. [40 mm] for spans ≥ 100 ft holes for field splices or preparing field welded
[30 m] splices) shall be
– 0, + 3/4 in. [20 mm] for spans < 100 ft at midspan, ± 3/4 in. [20 mm] for spans ≥ 100 ft
[30 m] [30 m]
at supports, 0 for end supports ± 3/8 in. [10 mm] for spans < 100 ft
± 1/8 [3 mm] for interior supports [30 m]
at supports, 0 for end supports
4(a)b(1 – a/S) ± 1/8 in. [3 mm] for interior supports
at intermediate points, –0, + ---------------------------------
S
4(a)b(1 – a/S)
where at intermediate points, ± ---------------------------------
S
a = distance in feet [meters] from inspection
point to nearest support where a and S are as defined above
S = span length in feet [meters] b = 3/4 in. [20 mm] for spans ≥ 100 ft [30 m]
b = 1-1/2 in. [40 mm] for spans ≥ 100 ft [30 m] b = 3/8 in. [10 mm] for spans < 100 ft [30 m]
b = 3/4 in. [20 mm] for spans < 100 ft [30 m] See Table 5.7 for tabulated values.
See Table 5.6 for tabulated values. Regardless of how the camber is shown on the detail
5.23.4 Beam and Girder Camber (without drawings, the sign convention for the allowable vari-
Designed Concrete Haunch). For members whose
ation is plus (+) above, and minus (–) below, the
Provided by IHS under license with AWS 20/pgs.20
188–189
Table 5.6 Table 5.7
Camber Tolerance Camber Tolerance for Girders
for Typical Girder without a Designed Concrete Haunch
(see 5.23.3 [pg. 188–189]) (see 5.23.4 [pg. 188–189])
Camber Tolerance (in inches) Camber Tolerance (in inches)
a/S a/S
Span 0.1 0.2 0.3 0.4 0.5 Span 0.1 0.2 0.3 0.4 0.5
≥ 100 ft 9/16 1 1-1/4 1-7/16 1-1/2 ≥ 100 ft 1/4 1/2 5/8 3/4 3/4
< 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) Camber Tolerance (in millimeters)
a/S a/S
Span 0.1 0.2 0.3 0.4 0.5 Span 0.1 0.2 0.3 0.4 0.5
≥ 30 m 14 25 34 38 40
--```,,`-`-`,,`,,`,`,,`--- ≥ 30 m 7 13 17 19 20
< 30 m 7
13 17 19 20 < 30 m 4 6 8 10 10
21 194
Not for Resale
detailed camber shape. These provisions also apply nal web plane. Measurements shall be taken prior to
to an individual member when no field splices or erection (see Commentary).
shop assembly is required. Camber measurements 5.23.6.2 Statically Loaded Nontubular Struc-
shall be made in the no-load condition. tures. Variations from flatness of webs having a
5.23.5 Beam and Girder Sweep. The maximum depth, D, and a thickness, t, in panels bounded by
variation in specified sweep at the midpoint shall be stiffeners or flanges, or both, whose least panel
dimension is d shall not exceed the following:
No. of feet of total length Intermediate stiffeners on both sides of web
± 1/8 in. × ------------------------------------------------------------- where D/t < 150, maximum variation = d/100
10
where D/t ≥ 150, maximum variation = d/80
1 mm × No. of meters of total length Intermediate stiffeners on one side only of web
provided the member has sufficient lateral flexibility where D/t < 100, maximum variation = d/100
to permit the attachment of diaphragms, cross- where D/t ≥ 100, maximum variation = d/67
frames, lateral bracing, etc., without damaging the No intermediate stiffeners
structural member or its attachments. where D/t ≥ 100, maximum variation = D/150
5.23.6 Variation in Web Flatness (See Annex VI for tabulation.)
5.23.6.1 Measurements. Variations from flatness 5.23.6.3 Cyclically Loaded Nontubular Struc-
of girder webs shall be determined by measuring the tures. Variation from flatness of webs having a
offset from the actual web centerline to a straight depth, D, and a thickness, t, in panels bounded by
edge whose length is greater than the least panel --```,,`-`-`,,`,,`,`,,`---
stiffeners or flanges, or both, whose least panel
dimension and placed on a plane parallel to the nomi-
dimension is d shall not exceed the following:
22 189
Intermediate stiffeners on both sides of web reamed; either during assembly or to a template for a
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Interior girders— field bolted splice; provided, when the splice plates
where D/t < 150—maximum variation = d/115 are bolted, the web assumes the proper dimensional
where D/t ≥ 150—maximum variation = d/92 tolerances.
Fascia girders— 5.23.6.5 Architectural Consideration. If archi-
where D/t < 150—maximum variation = d/130 tectural considerations require tolerances more
where D/t ≥ 150—maximum variation = d/105 restrictive than described in 5.23.6.2 or 5.23.6.3, spe-
cific reference must be included in the bid documents.
Intermediate stiffeners on one side only of web
Interior girders— 5.23.7 Variation Between Web and Flange Center-
where D/t < 100—maximum variation = d/100 lines. For built-up H or I members, the maximum
where D/t ≥ 100—maximum variation = d/67 variation between the centerline of the web and the
centerline of the flange at contact surface is 1/4 in.
Fascia girders— [6 mm].
where D/t < 100—maximum variation = d/120
where D/t ≥ 100—maximum variation = d/80 5.23.8 Flange Warpage and Tilt. For welded beams
No intermediate stiffeners—maximum variation = D/150 or girders, the combined warpage and tilt of flange
shall be determined by measuring the offset at the toe
(See Annex VII for tabulation.) of the flange from a line normal to the plane of the
5.23.6.4 Excessive Distortion. Web distortions of web through the intersection of the centerline of the
twice the allowable tolerances of 5.23.6.2 or 5.23.6.3 web with the outside surface of the flange plate. This
shall be satisfactory when occurring at the end of a offset shall not exceed 1% of the total flange width
girderby IHS
Provided which has with
under license beenAWS drilled, or subpunched and or 1/4 in. [6 mm], whichever is greater, except that
23 189
Not for Resale
welded butt joints of abutting parts shall fulfill the flange shall not exceed 90° in the bearing length (see
requirements of 5.22.3. Commentary).
5.23.9 Depth Variation. For welded beams and 5.23.11 Tolerance on Stiffeners
girders, the maximum allowable variation from spec-
ified depth measured at the web centerline shall be 5.23.11.1 Fit of Intermediate Stiffeners. Where
For depths up to 36 in. [1 m] incl. ± 1/8 in. [3 mm] tight fit of intermediate stiffeners is specified, it shall
For depths over 36 in. [1 m] to be defined as allowing a gap of up to 1/16 in.
72 in. [2 m] incl. ± 3/16 in. [5 mm] [1.6 mm] between stiffener and flange.
For depths over 72 in. [2 m] + 5/16 in. [8 mm] 5.23.11.2 Straightness of Intermediate Stiffen-
– 3/16 in. [5 mm] ers. The out-of-straightness variation of intermediate
5.23.10 Bearing at Points of Loading. The bearing stiffeners shall not exceed 1/2 in. [12 mm] for girders
ends of bearing stiffeners shall be square with the web up to 6 ft [1.8 m] deep, and 3/4 in. [20 mm] for
and shall have at least 75% of the stiffener bearing girders over 6 ft [1.8 m] deep, with due regard for
cross-sectional area in contact with the inner surface of members which frame into them.
the flanges. The outer surface of the flanges when
bearing against a steel base or seat shall fit within 5.23.11.3 Straightness and Location of Bearing
0.010 in. [0.25 mm] for 75% of the projected area of Stiffeners. The out-of-straightness variation of bear-
web and stiffeners and not more than 1/32 in. [1 mm] ing stiffeners shall not exceed 1/4 in. [6 mm] up to
for the remaining 25% of the projected area. Girders 6 ft [1.8 m] deep or 1/2 in. [12 mm] over 6 ft [1.8 m]
without stiffeners shall bear on the projected area of deep. The actual centerline of the stiffener shall lie
the web on the outer flange surface within 0.010 in.
--```,,`-`-`,,`,,`,`,,`--- within the thickness of the stiffener as measured from
[0.25 mm] and the included angle between web and
the theoretical centerline location.
Provided by IHS under license with AWS 24/pgs.2489–190
5.23.11.4 Other Dimensional Tolerances. Twist determined and mutually agreed upon by the Con-
of box members and other dimensional tolerances of tractor and the Owner with proper regard for erection
members not covered by 5.23 shall be individually requirements.
pg. 190
Base Material Surface Requirements

5.15 Preparation of Base Metal or antispatter compound may remain with the
following exception: for girders in cyclically loaded
Surfaces on which weld metal is to be deposited
structures, all mill scale shall be removed from the
shall be smooth, uniform, and free from fins, tears,
surfaces on which flange-to-web welds are to be
cracks, and other discontinuities which would
made.
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, 5.29 Arc Strikes
slag, rust, moisture, grease, and other foreign mate- Arc strikes outside the area of permanent welds
rial that would prevent proper welding or produce should be avoided on any base metal. Cracks or
objectionable fumes. Mill scale that can withstand blemishes caused by arc strikes shall be ground to a
vigorous wire brushing, a thin rust-inhibitive coating, smooth contour and checked to ensure soundness.
--```,,`-`-`,,`,,`,`,,`---

No reproduction or networking permitted without license from IHS 25/pgs.25
184;
Not for192
Resale
Weld Profile Requirements
5.24 Weld Profiles joints, face reinforcement shall not exceed 1/8 in.
[3 mm] in height. All welds shall have a gradual tran-
All welds, except as otherwise permitted below,
sition to the plane of the base-metal surfaces with
shall be free from cracks, overlaps, and the unaccept-
transition areas free from undercut except as allowed
able profile discontinuities exhibited in Figure 5.4.
by this code. Figure 5.4(D) shows typically accept-
5.24.1 Fillet Welds. The faces of fillet welds may be able groove weld profiles in butt joints. Figure 5.4(E)
slightly convex, flat, or slightly concave as shown in shows typically unacceptable weld profiles for
Figure 5.4. Figure 5.4(C) shows typically unaccept- groove weld butt joints.
able fillet weld profiles.
5.24.4.1 Flush Surfaces. Butt welds required to
5.24.2 Exception for Intermittent Fillet Welds. be flush shall be finished so as to not reduce the
Except for undercut, as allowed by the code, the pro- thicknesses of the thinner base metal or weld metal
file requirements of Figure 5.4 shall not apply to the by more than 1/32 in. [1 mm], or 5% of the material
ends of intermittent fillet welds outside their effective thickness, whichever is less. Remaining reinforce-
length. ment shall not exceed 1/32 in. [1 mm] in height.
5.24.3 Convexity. Except at outside welds in corner However, all reinforcement shall be removed where
joints, the convexity C of a weld or individual surface the weld forms part of a faying or contact surface. All
bead shall not exceed the values given in Figure 5.4. reinforcement shall blend smoothly into the plate sur-
5.24.4 Groove or Butt Welds. Groove welds shall faces with transition areas free from undercut.
be made with minimum face reinforcement unless
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5.24.4.2 Finish Methods and Values. Chipping and
otherwise specified. In the case of butt and corner gouging may be used provided these are followed by
26 190
grinding. Where surface finishing is required, roughness through 250 microinches [6.3 micrometers] shall be fin-
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values (see ASME B46.1) shall not exceed ished parallel to the direction of primary stress. Surfaces
250 microinches [6.3 micrometers]. Surfaces finished finished to values of 125 microinches [3.2 micrometers]
to values of over 125 microinches [3.2 micrometers] or less may be finished in any direction.
pg. 190
Copyright American WeldingFigure

Society 5.4—Acceptable and Unacceptable Weld Profiles (see 5.24 [pg. 190])
27 198
Not for Resale
Figure 5.4 (Cont’d)—Acceptable and Unacceptable Weld Profiles (see 5.24 [pg. 190])
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28 198
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Figure
Copyright American Welding 5.4 (Cont’d)—Acceptable
Society and Unacceptable Weld Profiles (see 5.24 [pg. 190])
29 198
Not for Resale
Table 5.8
Minimum Fillet Weld Size (see 5.14 [pg. 183])
Base Metal Thickness (T)1 Minimum Size of Fillet Weld2
in. mm in. mm
1/8 3
T ≤ 1/4 T≤6
(Note 3) (Note 3)
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
Notes:
1. For non-low-hydrogen processes without preheat calculated in accordance with 3.5.2, T equals thickness of the thicker part
joined; single-pass welds shall be used.
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For non-low-hydrogen processes using procedures established to prevent cracking in accordance with 3.5.2 and for low-
hydrogen processes, T equals thickness of the thinner part joined; single-pass requirement does not apply.
2. Except that the weld size need not exceed the thickness of the thinner part joined.
3. Minimum size for cyclically loaded structures is 3/16 in. [5 mm].

30 194
Figure 2.1—Maximum Fillet Weld Size
Along Edges in Lap Joints (see 2.3.2.9 [pg. 7])
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31
Not41
for Resale
Acceptance Criteria for Visual Inspection of Welds
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Table 6.1
Visual Inspection Acceptance Criteria (see 6.9 [pg. 201])
Statically Cyclically
Loaded Loaded Tubular
Nontubular Nontubular Connections
Discontinuity Category and Inspection Criteria Connections Connections (All Loads)
(1) Crack Prohibition
X X X
Any crack shall be unacceptable, regardless of size or location.
(2) Weld/Base-Metal Fusion
Thorough fusion shall exist between adjacent layers of weld metal and X X X
between weld metal and base metal.
(3) Crater Cross Section
All craters shall be filled to provide the specified weld size, except for X X X
the ends of intermittent fillet welds outside of their effective length.
(4) Weld Profiles
X X X
Weld profiles shall be in conformance with 5.24.
32 218
Table 6.1 (Continued)
(5) Time of Inspection
Visual inspection of welds in all steels may begin immediately after the
completed welds have cooled to ambient temperature. Acceptance
X X X
criteria for ASTM A 514, A 517, and A 709 Grade 100 and 100 W
steels shall be based on visual inspection performed not less than
48 hours after completion of the weld.
(6) Underrun
The size of a fillet weld in any continuous weld may be less than the spec-
ified nominal size (L) without correction by the following amounts (U):
L, specified U, allowable
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X X X
nominal weld size, in. [mm] decrease from L, in. [mm]
≤ 3/16 [5] ≤ 1/16 [2]
≤ 1/4 [6] .0 ≤ 3/32 [2.5]
≤ 5/16
Copyright American Welding Society [8] ≤ 1/8 [3]
33 218
Not for Resale
(6) Underrun (Cont’d)
In all cases, the undersize portion of the weld shall not exceed 10% of
X X
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.
(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 except that a maximum 1/16 in. [2 mm] for any accumulated X
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.
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34 218
(7) Undercut (Cont’d)
(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 X X
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 com-
puted tensile stress shall have no visible piping porosity. For all other
groove welds and for fillet welds, the sum of the visible piping porosity X
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. --```,,`-`-`,,`,,`,`,,`---

35 218
Not for Resale
(8) Porosity (Cont’d)
(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 connect- X X
ing 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) CPP 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 X X
in 4 in. [100 mm] of length and the maximum diameter shall not exceed
3/32 in. [2.5 mm].
General Note: An “X” indicates applicability for the connection type; a shaded area indicates non-applicability.
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36 218
Index
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Acceptance Criteria for Visual Inspection of Welds .... 32 Tolerance of Joint Dimensions
Base Material Surface Requirements Fillet Weld Assembly .................................................... 13
Preparation of Base Metal ............................................. 25 Faying Surfaces ............................................................. 13
Arc Strikes ..................................................................... 25 PJP Groove Weld Assembly.......................................... 13
Beam Copes and Weld Access Holes Butt Joint Alignment ..................................................... 14
Weld Access Hole Dimensions ..................................... 10 Girth Weld Alignment (Tubular)................................... 14
Group 4 and 5 Shapes.................................................... 10 Groove Dimensions (Nontubular) ................................. 14
Dimensional Tolerances of Welded Structural Members Groove Dimensions (Tubular)....................................... 15
Straightness of Columns and Trusses............................ 19 Corrections of Groove Dimensions............................... 15
Beam and Girder Straightness ....................................... 19 Gouged Grooves............................................................ 15
Beam and Girder Camber.............................................. 20 Transitions Between Materials of Unequal Thickness
Beam and Girder Sweep................................................ 22 Tubular .......................................................................... 5
Variation in Web Flatness.............................................. 22 Nontubular..................................................................... 7
Variation Between Web and Flange Centerline............. 23 Width Nontubular.......................................................... 8
Flange Warpage and Tilt................................................ 23 Weld Profile Requirements
Depth Variation.............................................................. 24 Fillet Welds.................................................................... 26
Bearing and Points of Loading ...................................... 24 Exception for Intermittent Fillet Welds......................... 26
Tolerance on Stiffeners.................................................. 24 Convexity ...................................................................... 26
Thermal Cutting Groove or Butt Welds.................................................... 26
Roughness Requirements .............................................. 9 Flush Surfaces ............................................................... 26
Gouge or Notch Limitations.......................................... 9 Finish Methods and Values ........................................... 26
Reentrant
Copyright AmericanCorners..........................................................
Welding Society 9 Minimum Fillet Weld Size ............................................ 30
No reproduction or networking permitted without license from IHS 37
Not for Resale
Other Publications Available from AWS
Order No. Title
D1.1M/D1.1:2004 Structural Welding Code—Steel
Covers essential welding requirements for most types of welded structures made from carbon and
low-alloy constructional steels.
WI Welding Inspection
Perennial best seller; straight forward introduction.
B1.10 Guide for the Nondestructive Examination of Welds
DoD adopted. concise reference tool.
CM Certification Manual for Welding Inspectors
Aid to studying for the AWS Certified Welding Inspector exam as well as excellent introduction to
welding inspection.
WHB-2.9 Welding Handbook, 9th Ed., Vol. 2 “Welding Processes,” Part 1
29 chapters, detailed charts, drawings. Industry’s premier series.
JWE Jefferson’s Welding Encyclopedia
Completely revised 18th edition, CD ROM format.
PHB-2 The Everyday Pocket Handbook for Visual Inspection and Weld Discontinuities—Causes
and Remedies
Number two in the series. 34 pages, spiral bound.
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For more information on AWS publications go to www.aws.org.
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Copyright American Welding Society

© 2004 by American Welding Society. All rights reserved.

Copyright American Welding Society

Figure 2.2—Transition of Butt Joints in Parts of Unequal Thickness (Nontubular)

Copyright American Welding Society

Copyright American Welding Society

Copyright American Welding Society

Copyright American Welding Society

Copyright American Welding Society

Root Opening of Joints Groove Angle

in. mm in. mm deg

SMAW ±1/16 ±2 ±1/16 ±2 ±5

Copyright American Welding Society

those whose top flange is embedded in concrete with-

Camber Tolerance (in inches) Camber Tolerance (in inches)

Camber Tolerance (in millimeters) Camber Tolerance (in millimeters)

Base Material Surface Requirements

Copyright American Welding Society

Copyright American WeldingFigure

Copyright American Welding Society

Base Metal Thickness (T)1 Minimum Size of Fillet Weld2

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Copyright American Welding Society

Copyright American Welding Society

Copyright American Welding Society

Copyright American Welding Society

Copyright American Welding Society

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