AWS C4.4/C4.

4M:2007
An American National Standard

Recommended
Practices for
Heat Shaping
and Straightening
with Oxyfuel Gas
Heating Torches
 AWS C4.4/C4.4M:2007
An American National Standard

Approved by the
American National Standards Institute
September 11, 2007

Recommended Practices
for Heat Shaping and Straightening
with Oxyfuel Gas Heating Torches

2nd Edition

Supersedes AWS C4.4/C4.4M:2004

Prepared by the
American Welding Society (AWS) C4 Committee on Oxyfuel Gas Welding and Cutting

Under the Direction of the

AWS Technical Activities Committee

Approved by the
AWS Board of Directors

Abstract
This second edition of Recommended Practices for Heat Shaping and Straightening covers the shaping of metal products
by prudent use of heat to obtain a desired configuration. The text reviews the theory and analytical calculations that
explain how heat shaping and straightening occurs. Sample calculations and tables are presented for typical materials.
General heating patterns and heat shaping and straightening techniques are discussed. Specific heating applications are
illustrated for various sections.

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 AWS C4.4/C4.4M:2007

Table of Contents
Page No.
Personnel......................................................................................................................................................................v
Foreword ....................................................................................................................................................................vii
List of Tables ...............................................................................................................................................................xi
List of Figures..............................................................................................................................................................xi
1. Scope.....................................................................................................................................................................1
2. Normative References .........................................................................................................................................1
3. Terms and Definitions.........................................................................................................................................2
4. Theory of Heat Shaping......................................................................................................................................2
5. Distortion..............................................................................................................................................................6
6. Fundamentals and Precautions..........................................................................................................................7
7. Equipment and Supplies.....................................................................................................................................8
7.1 Standard Equipment.....................................................................................................................................8
7.2 Special Equipment .......................................................................................................................................8
7.3 Oxygen Supply ............................................................................................................................................8
7.4 Fuel Supply..................................................................................................................................................8
7.5 Maximum Acetylene Pressure.....................................................................................................................9
7.6 Pressure Regulators .....................................................................................................................................9
7.7 Hoses and Fittings .....................................................................................................................................11
7.8 Heating Torches.........................................................................................................................................12
7.9 Heating Tip/Head.......................................................................................................................................12
7.10 Maintenance of Heating Tips or Heads .....................................................................................................12
7.11 Personal Protective Equipment (PPE) .......................................................................................................13
7.12 Safe Use, Handling, and Storage of Gas Cylinders ...................................................................................14
8. Startup and Shutdown Procedure ...................................................................................................................15
8.1 Setting Up Equipment ...............................................................................................................................15
8.2 Lighting the Torch .....................................................................................................................................16
8.3 Equipment Shutdown ................................................................................................................................17
8.4 Equipment Not in Use ...............................................................................................................................17
8.5 Reuse of Equipment Already Connected...................................................................................................17
9. Flame Adjustment .............................................................................................................................................17
9.1 Types of Flames.........................................................................................................................................17
9.2 Flashback Arrestors and Check Valves .....................................................................................................18
10. General Technique ............................................................................................................................................19
11. Procedures for General Applications ..............................................................................................................20
11.1 Mechanically Restrained Structures ..........................................................................................................20
11.2 Freestanding Unrestrained Members.........................................................................................................21
11.3 Shaping of Plate.........................................................................................................................................23
11.4 Flattening Plates ........................................................................................................................................23
11.5 Plate Tightening.........................................................................................................................................23

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AWS C4.4/C4.4M:2007

Page No.
12. Procedures for Specific Applications...............................................................................................................23
12.1 Bending of Flat Bar, V Heat ......................................................................................................................23
12.2 Bending of Channel, V Heat......................................................................................................................26
12.3 Bending of Beams......................................................................................................................................26
12.4 Bending of Angle.......................................................................................................................................27
12.5 Bending of T Sections ...............................................................................................................................27
12.6 Bending of Plate ........................................................................................................................................30
12.7 Pipe ............................................................................................................................................................30
13. Line Heating and Flame Bending in Shipyards..............................................................................................30
13.1 Background................................................................................................................................................30
13.2 Basic Concepts...........................................................................................................................................32
13.3 Planning and Methods ...............................................................................................................................32
13.4 Recommended Practices............................................................................................................................33
13.5 Code Compliance.......................................................................................................................................33
13.6 Conclusions ...............................................................................................................................................33
14. Safety and Health ..............................................................................................................................................33
Annex A (Informative)—Informative References .....................................................................................................35
Annex B (Informative)—Fuel Gas Withdrawal Rates ...............................................................................................39
Annex C (Informative)—Guidelines for the Preparation of Technical Inquiries.......................................................41
List of AWS Documents on Oxyfuel Gas Welding and Cutting................................................................................43

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 AWS C4.4/C4.4M:2007

List of Tables
Table Page No.
B.1 Acetylene Withdrawal..................................................................................................................................39
B.2 Methylacetylene-Propadiene Stabilized (MPS) Withdrawal .......................................................................39
B.3 Propylene Withdrawal..................................................................................................................................40
B.4 Propane Withdrawal.....................................................................................................................................40

List of Figures
Figure Page No.
1 Shortening of Bar from Application of Heat .................................................................................................3
2 Variation in Yield Strength and Modulus of Elasticity with Respect to Temperature for
ASTM A 36 Steel...........................................................................................................................................4
3 Imperceptible Welding Distortion of a Thick Steel Plate ..............................................................................5
4 Welding Distortion of a Thin Steel Plate .......................................................................................................7
5 Oxygen Cylinder ............................................................................................................................................9
6 Typical Fuel Gas Cylinders............................................................................................................................9
7 Pressure Regulators......................................................................................................................................10
8 Hoses and Fittings ........................................................................................................................................11
9 Manual Heating Torch .................................................................................................................................12
10 Multi-Flame Heating Heads.........................................................................................................................13
11 Water-Cooled Flame Hardening Head.........................................................................................................13
12 Carburizing Flame........................................................................................................................................18
13 Neutral Flame...............................................................................................................................................18
14 Oxidizing Flame...........................................................................................................................................18
15 Basic Heating Patterns .................................................................................................................................20
16 Externally Restrained Plate ..........................................................................................................................21
17 Externally Restrained Beam.........................................................................................................................21
18 V Shape Heat Pattern for Straightening or Shaping a Flat Bar....................................................................22
19 Dimensions for Calculating Upset ...............................................................................................................23
20 Behavior of ASTM A 36 Steel Perfectly Confined in One Axis as a Function of Temperature .................24
21 Heat Patterns in Rolled Shapes ....................................................................................................................25
22 Spot Heat Repair of Dent in Plate ................................................................................................................25
23 Spot Heat Repair (Tightening) on Irregular Plate ........................................................................................26
24 Application of V Shape Heat Pattern and Direction of Movement .............................................................26
25 Bending of Channel Toward Flange ............................................................................................................27
26 Bending of Channel Toward Web ...............................................................................................................27
27 Bending of Channel Toward Open Side ......................................................................................................27
28 Bending of Beam Toward Open Side ..........................................................................................................28
29 Bending of Beam Toward Flange ................................................................................................................28
30 Bending of Angle Toward Face of Leg .......................................................................................................28
31 Bending of Angle Toward Edge of Leg.......................................................................................................29
32 Bending of T Section Toward Web .............................................................................................................29

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AWS C4.4/C4.4M:2007

Figure Page No.

33 Bending of T Section Toward Flange ..........................................................................................................29
34 Bending of Plate...........................................................................................................................................29
35 Bending of Plate (More Movement) ............................................................................................................30
36 Decreasing Diameter of Heavy Wall Pipe ...................................................................................................31
37 Straightening of Pipe or Round....................................................................................................................31
38 Straightening Pipe or Round Stock—V Shape Heating with Serpentine Path ............................................31
39 Straightening Pipe or Round Stock—V Shape Heating with Line Heating Pattern ....................................32

xii
 AWS C4.4/C4.4M:2007

Recommended Practices for Heat Shaping and

Straightening with Oxyfuel Gas Heating Torches

1. Scope recommended practice is limited to fundamentals and sim-

ple applications (see Annex A for additional information).
This publication describes some causes of distortion and
This standard makes use of both U.S. Customary Units and
corrective actions through the use of heat. It also
the International System of Units (SI). The latter are shown
describes some heat shaping techniques and the direction
within brackets [ ] or in appropriate columns in tables
of movement expected in the heated metal. Equations are
and figures. The measurements may not be exact equiva-
provided to aid in estimating the amount of movement
lents; therefore, each system must be used independently.
for a given heating technique. The methods discussed are
specifically applicable to ferrous metals, but many of the Safety and health issues may not be fully addressed by
methods can be applied to nonferrous metals as well. For this standard. Users of this standard should consult ANSI
a more comprehensive description of specific applica- Z49.1, Safety in Welding, Cutting, and Allied Processes,
tions, see Annex A, Informative References. applicable federal, state, and local regulations and other
relevant documents concerning safety and health issues
Heat has been used to shape and straighten structural ele- not addressed herein.
ments in bridges, buildings, and marine constructions for
over a hundred years. Since the late 1930s, the use of
oxyfuel gas torches to do this work has become more
prevalent. This publication is a recommended practice 2. Normative References
for using the torch process for work on bridges and The following standard contains provisions, which,
buildings, and to some extent, shipbuilding. through reference in this text, constitute mandatory pro-
visions of this AWS standard. For undated references,
Mechanical forces in fabrication and erection, forces
the latest edition of the referenced standard shall apply.
occurring in service, accidental impacts from external
For dated references, subsequent amendments to, or revi-
forces, fire, and explosion, all cause stress in a structural
sions of, any of these publications do not apply.
member or a part of a member. If that stress exceeds the
elastic limit of the material, distortion will occur, and the AWS documents:1
member will not conform to its desired shape. Heat shap-
ing and straightening is an economical method to pro- AWS A3.0, Standard Welding Terms and Definitions,
duce the desired movement to bring the member into Including Terms for Adhesive Bonding, Brazing, Solder-
conformance. ing, Thermal Cutting, and Thermal Spraying; and
AWS F4.1, Recommended Safe Practices for Prepara-
The shipbuilding industry throughout the world has
tion for Welding and Cutting of Containers and Piping.
taken heat shaping to new heights in shaping technology.
Particularly, the use of line heating to shape complex Other documents:
curves in hull structures has become an integral part of a
group technology in shipbuilding which also includes ANSI Z49.1, Safety in Welding, Cutting, and Allied
product work packages and accuracy control. Processes;2

Basically, straightening and shaping involves controlled 1 AWS standards are published by the American Welding Society,

thermal expansion and contraction of a structural ele- 550 N.W. LeJeune Road, Miami, FL 33126.
2 ANSI Z49.1 is published by the American Welding Society,
ment. The method, location, and shape of the heat appli-
cation are covered briefly in this publication. This 550 N.W. LeJeune Road, Miami, FL 33126.