STRUCTUARAL

S ARAL EE
TRUCTURAL NGINEERSAA
NGINEERS SSOCIATION
SSOCIATION
OF N
OF NORTHERN CCALIFORNIA
ALIFORNIA

GUIDELINES
FOR
WELDING PROCEDURE SPECIFICATIONS

Prepared by the
SEAONC Construction Quality Assurance Committee
 Board of Directors, 2006
Andrew Merovich, President
Douglas Hohbach, Vice President
Jamison Curry, Secretary
Michael Fretz, Treasurer
Simin Nasseh, Past President
William Andrews, Director
Gary Mochizuki, Director
David McCormick, Director
David Murphy, Director

Disclaimer
While the information presented in the document is believed to be correct, SEAONC and its Board and
Committees assume no liability for its accuracy or for the opinions expressed herein. The material presented in this
document should not be used or relied upon for any specific application without competent examination and
verification of its accuracy, suitability, and applicability by qualified professionals. Users of information from this
document assume all liability arising from such use.

Structural Engineers Association of Northern California

© 2006 SEAONC

All rights reserved. This document or any part thereof may not be reproduced in any form without the
written permission of the Structural Engineers Association of Northern California.
STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

Guidelines for Welding Procedure Specifications

STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

575 Market Street, Suite 2125
San Francisco, CA 94105-2870
Phone: (415) 974-5147 Fax: (415) 764-4915
Email: [email protected]
http://www..seaonc.org

These guidelines were written by members of

the SEAONC Construction Quality Assurance Committee.

Construction Quality Assurance Committee

Member Name
Member Name
Member Name
Member Name
Member Name
Member Name
Member Name
Member Name
Member Name
Member Name

The committee acknowledges the following SEAONC members

for their comments, suggestions, and assistance.

Peter Bank
A.L. Collin
Ronald O. Hamburger
Bret Lizundia
Ronald F. Middlebrook
Peter Revelli
Joseph R. Sutton
Andrew Whittaker
 STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

Guidelines for Welding

Procedure Specifications
SEAONC Construction Quality Assurance Committee

Introduction
Although the engineer of record (EOR) is not ex- process are often taken for granted and not properly
pected to be an expert in welding, the responsibility of documented in the required written form known as the
the EOR extends beyond the completion of the plans Welding Procedure Specifications (hereafter referred to
and specifications to the as-erected condition of a struc- as WPSs). Use of a prequalified joint without any fur-
ture. This is particularly the case for seismically loaded ther documentation is often mistakenly thought to be all
structures, where the performance may depend on the that is required. Welders and inspectors often work
properties and geometry of the erected structure. The without a written WPS and rely on their experience to
2002 AISC Seismic Provisions for Structural Steel Build- produce apparently good welds. As a result, welding is
ings (Section 7.3), for example, requires the EOR to ap- typically performed and inspected without the written
prove each welding procedure specification (WPS) used WPS “recipe” that AWS D1.1 requires to help ensure
in fabrication and erection. The need for this require- the consistent production of sound welds. All references
ment was demonstrated by the 1994 Northridge earth- in these guidelines to AWS D1.1 are to the 2004 edition.
quake, in which steel moment frames and other welded
connections fractured with minimal ductility, instead of Purpose
absorbing plastic strains as expected. The causes of This document has been produced to inform and ed-
these fractures included in adequate oversight, insuffi- ucate structural engineers about WPSs and their role in
cient toughness in the connection weldment, and WPSs the quality assurance of welded connections. Welding
that either did not exist or did not conform to the weld- consists of complicated and specialized processes. The
ing code, AWS D1.1. As a result, the EOR is now ex- structural engineer must have an understanding of the
pected to take an active role in the review of welding organizational relationships and processes by which a
documents.AWS D1.1 describes welding as an engi- specified weld on a drawing is converted to a finished
neered process. Requirements are specified for welding connection. The structural engineer should be aware of
electrode and usage parameters, equipment, steels to be the definition, use, purpose of, and difference between,
joined, joint configurations, welder (performance) quali- WPS, procedure qualification, welding procedure, and
fications and workmanship for the purpose of produc- welder qualification.
ing a sound weld joining the steel materials. Understanding these provisions, the engineer should
AWS provisions for confirming the workmanship specify submittal of WPSs analogous to other submittals
ability of the individual welder, called welder qualifica- such as concrete mix designs and shop drawings. The
tion (also known as “certification”), are well known and contractor is responsible for preparing the WPSs. AWS
widely enforced. The importance of the welder in the D1.1 states that WPSs that require qualification by test-
process is critical and is usually addressed by steel fabri- ing be approved by the engineer, and further states that
cators, erectors, and inspectors during the production “The Engineer shall determine the suitability of all joint
process.The materials and parameters of the welding details to be used in a welded assembly.”
1
 STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

This document is intended to help engineers perform Weldment: An assembly whose components are joined
the review without additional specialized expertise in the by welding.
detailed requirements of welding. It is not recommend-
ed that the engineer attempt such reviews if he or she Welder Qualification: The demonstration, by specified
does not feel technically qualified. A welding, metallur- tests, of a welder’s ability to produce welds meeting pre-
gical, or testing agency consultant can be called in for a scribed standards.
more technical review if necessary. Approval by the en-
gineer should be based on his or her own expertise, or Welding Procedure: Detailed methods and practices
the recommendations of a qualified consultant. required to produce an acceptable weldment, including
weld processes, connections, joint welding procedures,
Definitions and Terminology joint details, preheat, inspection requirements, sequence,
shrinkage allowance, postheat, and any other factors.
Essential variable: A welding process, base metal or
joint detail parameter that must be specified and limited Welding Procedure Specification (WPS): A docu-
in the WPS. Information on essential variables are in ment detailing the method and the welding variables re-
AWS D1.1, Sections 3.6 and 4.7.1 and Table 4.5. For quired to produce a welded joint. It directs the welder
prequalified procedures, changes outside the limits of how to weld a specific joint, and includes requirements
essential variables require additional qualification testing, such as joint preparation, weld process, electrode type
new PQR(s) and a revised WPS. and diameter, voltage and current, and travel speed. Its
purpose is to assure consistent production of sound
Joint: A single element of a connection where two or welds. The WPS is the focus of these guidelines.
more ends, surfaces, or edges are attached by welding, or
according to AWS D1.1:The junction of members or Qualification Requirements
the edges of members that are to be joined or have been AWS D1.1, section 4 defines the qualification require-
joined. ments for both WPSs and individual welders.

Nonessential variable: A welding process, base metal WPS

or joint detail parameter that must be specified in the Documenting welding processes and variables in a
WPS but may be changed during use. A change outside written WPS provides a standard method for reproduc-
the limits of a nonessential variable does not require a ing welds. A qualified WPS establishes that a weld joint
revision to the WPS. proposed for fabrication meets AWS D1.1 requirements
for weld quality. WPSs are qualified by testing according
Prequalified WPS: A WPS that is exempt from qualifi- to procedures outlined in the code. However, some
cation testing according to AWS D1.1. WPSs that use established procedures are “prequalified”
and exempt from testing.
Procedure Qualification: The demonstration by speci-
fied tests that welds made by a specific procedure can Prequalified WPS
meet prescribed standards. In AWS D1.1, a WPS is considered to be prequalified
if the selected joint configuration, welding process and
Procedure Qualification Test Record (PQR): Writ- variables, and other parameters conform to the manda-
ten documentation of the welding details and test results tory code requirements. A WPS that meets the criteria
demonstrating that welds using a particular WPS meet AWS D1.1, Section 3 is exempt from qualification
prescribed standards. A PQR is not required for testing.
prequalified WPSs.
2
 STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

Although prequalified procedures are exempt from Welder Qualification

tests, AWS D1.1 does require that the contractor prepare Individual welders must be qualified to perform spe-
written WPSs for the joints to be used in fabrication. cific welds. The contractor or fabricator qualifies each
These specifications indicate the limits and requirements welder for each WPS and position. The Commentary in
for material and welding variables, providing documen- AWS D1.1, section C4.18 states, “The welder qualifica-
tation that the joint welding meets the requirements for tion test is specifically designed to determine a welder’s
prequalified status. A sample prequalified WPS is in- ability to produce sound welds in any given test joint.
cluded as Exhibit 1. After successfully completing the welder qualification
tests, the welder should be considered to have minimum
WPS Qualified by Testing acceptable qualifications.”
A WPS that is not prequalified must be qualified by AWS D1.1 defines welder qualification requirements.
testing according to the requirements of AWS D1.1, Each welder’s qualification remains in effect indefinitely
Section 4.1.1. Qualification tests can demonstrate that a unless (1) the welder is not engaged in a given process
welded joint using a specific WPS meets the prescribed of welding for which the welder is qualified for a period
standards of the code. The contractor or fabricator is exceeding six months, or (2) there is some specific rea-
required to make a test sample, typically a butt-jointed son to question a welder’s ability. A sample welder quali-
plate using the joint in the proposed WPS, for mechani- fication test record is included as Exhibit 3.
cal testing and evaluation. In preparing the test plate,
the welder must follow the written details in the pro- Engineers’ Project Specifications for
posed WPS. A sample WPS qualified by testing is in- WPS
cluded as Exhibit 2. The structural engineer needs to request WPSs for
The test plate configurations and dimensions are each type of weld joint to be used on a project. The
shown in AWS D1.1, Tables 4.2-4.4. Tests may include structural engineer’s request for WPS will typically ap-
visual inspection, tensile strength, guided bends, macro-pear in the structural steel section of the project specifi-
etches, radiography, and impact tests. If the test results
cations. To ensure that WPSs are used, references need
do not meet the requirements of AWS D1.1 or project to be included in several places in the section. Sample
specifications, then a new WPS must be prepared and project requirements for WPS are included as Exhibit 4.
qualified by testing. An important item to consider for inclusion in the
project specifications is a requirement that the manufac-
Procedure Qualification Record turer and specific electrode be stated in the WPS. AWS
A procedure qualification record (PQR) is written to uses the concept of “essential variable”, which for our
document the actual welding variables used and the test purposes can be considered a parameter that cannot be
results for a proposed WPS. Each WPS qualified by changed without resubmittal by the contractor. Manu-
testing is supported by one or more PQRs. A sample facturer and specific electrode are not essential variables
PQR supporting the WPS in Exhibit 2 is included as Ex- in AWS D1.1. The code thus allows electrode substitu-
hibit 2A. tion by the contractor during fabrication. The structural
engineer can require the electrode be defined in the sub-
Revision and Requalification mittal, and certainly should in the case of critical struc-
If any welding variables are changed in a WPS, then a tural welds. This will prohibit substitution of an elec-
new WPS may have to be written to reflect the changes. trode with parameters that might not comply with the
Depending on which variables are changed, the revised WPS. Many in the welding industry recommend the
WPS may have to be requalified by testing. AWS D1.1 electrode be defined in all submittals.
specifies the type of changes requiring requalification.

3
 STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

Project specifications may also describe methods or sary to set and monitor the variables essential to each
preparation, welding parameters, inspection require- welding process and weld joint configuration. The in-
ments, and mitigation methods for rejected welds. Ad- spector can then assure that proper welding parameters
ditional requirements, such as steel chemical analysis and are being followed or note deviations. The structural
sequence of welded construction may also be included engineer should promptly address any nonconformance
in the project specifications. These are often referred to to an approved WPS.
as welding procedures but should not be confused with
WPSs.

Review of WPS
Submittal of WPSs should be in a timely manner to
allow for adequate review. WPSs should be included
with any shop drawings referencing welds. The structur-
al engineer should review WPSs for completeness and
conformance to project specifications. The structural
engineer need not be a welding specialist to be able to
review the completeness and accuracy of WPSs. As a
minimum the structural engineer should verify that the
joint details, material thickness and grades, and welding
positions in the design documents are covered by the
submitted WPSs. If the structural engineer determines
additional review is necessary, the documents can be for-
warded to a testing agency or welding consultant. The
consultant should provide comments to the structural
engineer for incorporation in the WPS submittal re-
sponse.
The testing agency verifies individual welder qualifica-
tions during steel fabrication and erection. Welder quali-
fications do not ordinarily need to be submitted to the
structural engineer for review. Structural engineers
should be alert to the possibility of receiving welder
qualifications when WPS submittals are required.

Use During Project

The use of written WPSs during appropriate phases
of a project provides the welder with the basic welding
and weld joint requirements and the inspector and struc-
tural engineer with the criteria to evaluate the quality of
welding. AWS D1.1, Sections 3.6 and 4.2.3 requires
WPSs to be available to those “authorized to use or ex-
amine them”. Written WPSs should be available at the
work site for both welders and inspectors. The WPSs
provide the welder and inspector the information neces-

4
STRUCTURAL ENGINEERS ASSOCIATION OF NORTHERN CALIFORNIA

Exhibits

Exhibit 1 PREQUALIFIED Welding Procedure Specification

Exhibit 2 QUALIFIED BY TESTING Welding Procedure Specification
Exhibit 2A Procedure Qualification Record
Exhibit 3 Welder Performance Qualification Test Record
Exhibit 4 Project Specification

5
 LE
PREQUALIFIED
Exhibit 1 Welding Procedure Specification
M P
WPS P-1
S A
COMPANY____Pacific Fabrication Inc.__________________________ DATE_____June 6, XXXX_____________________________________
WELDING PROCESS__Flux Cored Arc Welding (FCAW)____________
q TYPE: Manual Semi-Automatic r
WELDING CODE___AWS D1.1-XX_____________________________
w Machine Automatic
SUPPORTING PQRs__not required for prequalified WPS____________
e
JOINT DESIGN USED WELDING POSITIONS
TYPE: Single Double Weld t POSITION OF GROOVE________Vertical (3G)___________________
d
BACKING: Yes No y POSITION OF FILLET_____________-------______________________
f
BACKING MATERIAL____1/4” x 1” flat bar_______________________ VERTICAL PROGRESSION: Up Down g
ROOT OPENING_3/8”_ u ROOT FACE DIMENSION_0________
i ELECTRICAL CHARACTERISTICS
GROOVE ANGLE_30°_o RADIUS (J-U)____n/a_____________
a TRANSFER MODE (GMAW): n/a h
BACKGOUGING: Yes No METHOD_______________
s Short-Circuiting Globular Spray Pulsed
BASE METALS CURRENT: AC DCEP DCEN j
MATERIAL SPECIFICATION_____ASTM A36-96__________________
; k
OTHER____electrical stickout: 3/4” to 1”_________________________
TYPE OR GRADE___________________________________________ TUNGSTEN ELECTRODE (GTAW): n/a l
THICKNESS: GROOVE_3/4” to 1”_2
) FILLET___n/a_________
2! SIZE _____________________ TYPE_____________________
DIAMETER (PIPE)___________n/a_____________________________
2@ TECHNIQUE
FILLER METALS STRINGER or WEAVE BEAD_______Stringer Passes______________
3!
AWS SPECIFICATION______A5.20-95__________________________
2# MULTI-PASS or SINGLE PASS (per side)______Multi-pass__________
3@
AWS CLASSIFICATION__E71T-8 (Lincoln Innershield NR-232)_______
2$ NUMBER OF ELECTRODES________1_________________________
3#
SHIELDING ELECTRODE SPACING: LONGITUDINAL _______n/a_____________
3$
2%
FLUX________n/a____________ GAS__________n/a____________
2^ LATERAL ____________n/a_____________
3%
COMPOSITION___n/a__________
2& ANGLE _____________n/a______________
3^
ELECTRODE-FLUX CLASS FLOW RATE_____n/a__________
2* CONTACT TUBE TO WORK DISTANCE___________n/a____________
3&
_________n/a___________
2( GAS CUP SIZE___n/a__________
3) PEENING____optional, may be performed with slag hammer when weld
pass is hot, peening not allowed on root or cover passes_____________
3*
INTERPASS CLEANING_____needle gun, wire brush______________
3(
PREHEAT POSTWELD HEAT TREATMENT
PREHEAT TEMP., MIN. ______up to 3/4” thickness: none___________ TEMPERATURE ___________none_____________________________
4#
__________________________over 3/4” to 1”: 150°F______________
4) TIME _____________________n/a_____________________________
INTERPASS TEMP., MIN. __same as preheat temp.____ 4@
4! MAX.______
WELDING PROCEDURE
PASS OR FILLER METALS CURRENT TRAVEL
WELD PROCESS TYPE & VOLTS SPEED, JOINT DETAILS
LAYER CLASS DIA. AMPS ipm
POLARITY

1 to 2 FCAW E71T-8 0.068” DCEN 195-220 18-20 6-9

3 to 17 FCAW E71T-8 0.072” DCEN 200-240 19-22 7-11

4$ 4% 4^ 4& 4* 4( 5)
5!
Approved for production by_______________________________________________________________________
Fabricator Date
 Exhibit 1 - cont.
Type of welding process to be used.
q
w AWS D1.1-XX is titled Structural Welding Code – Steel. Other structural welding codes for sheet
steel and rebar are, respectively, AWS D1.3-XX and AWS D1.4-XX.

e For a prequalified WPS, a procedure qualification record (PQR) is not required.

r In this sample WPS, FCAW is a semi-automatic process using a hand-held welding gun with an
automated electrode feed.

t A single welded joint is welded from one side only. A double welded joint is welded from both
sides.

y Backing is a material or device placed against the back side of the joint, or at both sides of the
weld (for electrogas welding (EGW) and electroslag welding (ESW) to support and retain molten
weld metal.

u The root opening is a separation at the joint root between the workpieces. The nonstandard term
is root gap.

i The root face is the portion of the groove face at the weld root.

The groove angle is the total included angle of the groove between the workpieces.
o
a Groove radius in a J-groove or a U-groove joint weld.

s Backgouging is the removal of weld metal and base metal from the weld root back side of a
welded joint to facilitate complete fusion and complete joint penetration upon subsequent welding
from that side.

d A prequalified WPS for complete and partial joint penetration groove welds is valid only for the
permitted groove weld positions shown in AWS D1.1, Figures 3.3 and 3.4. See Figures 4.1, 4.3
and 4.4 for types of groove weld positions.

f A prequalified WPS for fillet welds shall meet the requirements of AWS D1.1, section 3.9. See
Figures 4.5 and 4.6 for types of fillet weld positions.

g Welding in the vertical position for a prequalified WPS requires the progression of passes to be in
the upwards direction. Welding in the vertical down position would require the WPS to be quali-
fied by testing. Note: welding of tubulars may be upwards or downwards but only in the direction
for which the welder is qualified.

h For Gas Metal Arc Welding (GMAW) there are four types of transfer modes of molten metal from
the electrode tip to the work: short-circuiting (which is not prequalified), globular, axial spray, and
pulsed.
 Exhibit 1 - cont.

j DCEN indicates the power source is DC and the welding leads are arranged so that the electrode
is the negative pole, i.e., the polarity is “straight”.

k See 3&
l For Gas Tungsten Arc Welding (GTAW), the size and type of the tungsten electrode shall be
recorded. GTAW is not prequalified.

; ASTM, ABS, or API designation for the base metal material(s). If applicable, the type or grade
should be included. Base metals approved for prequalified WPSs are listed in AWS D1.1, Table
3.1.

2) Base metal thickness range for groove welds.

2! Base metal thickness range for fillet welds.
2@ Size or diameter range of pipe.
2# A5.20-XX is the AWS specification no. for Carbon Steel Electrodes for Flux Cord Arc Welding.
2$ E71T-8 is the AWS classification no. of electrode listed in the specification A5.20-XX. Electrodes
are classified according to as-welded mechanical properties, suitable welding positions, and
usability characteristics, such as the use or absence of shielding gas. In this sample the
manufacturer’s name and type of electrode are provided for information only.

2% An external flux is not required for FCAW but would be specified for Submerged Arc Welding
(SAW).

2^ External shielding gases are used with GMAW, GTAW, EGW, and some FCAW electrodes. For
the E71T-8 classification electrode in this sample, shielding is provided by the flux contained in
the electrode core.

2& Percentage composition of any shielding gas(es).

2* Flow rate of shielding gases.
2( AWS classification of electrode/flux combinations for ESW and SAW.
3) Size of a gas cup or nozzle which directs the shielding gas (es) to the weld zone from the end of
the welding gun for FCAW-G and GMAW.

3! Awithout
weave bead is a weld bead or layer made with transverse oscillation. A stringer bead is made
appreciable oscillation.

3@ A single pass weld is made with one weld bead. Multiple passes consist of multiple weld beads.
 Exhibit 1 - cont.

3# For machine or automatic purposes, multiple electrodes may be used.

3$ Longitudinal spacing between multiple electrodes.
3% Lateral spacing between multiple electrodes.
3^ Angle of multiple electrodes.
3& Distance from the contact tube in welding gun to the work for SAW. Electrical stickout, which is
the electrode length between the point of electrical contact in the welding gun and the arc can be
indicated for FCAW and GMAW.

3* Peening is the mechanical working of metals using impact blows to relieve shrinkage stresses.
peening is performed, the method, such as striking with a hammer or using pneumatic tools,
If

should be indicated.

3( After each weld pass, the weld surface should be cleaned to remove any deleterious material
such as slag, spatter, etc.

4) Preheating is the application of heat to the base metal prior to welding. Proper preheat (and
elevated interpass temperatures) reduces the possibility of cracking by slowing the cooling rate in
a workpiece. Preheating also equalizes the temperature in the workpiece to reduce local expan-
sion and the tendency to warp or distort. Methods of preheating include using an oxyfuel torch,
electrical resistance equipment, and induction heating. Prequalified minimum preheat and
interpass temperature requirements for different base metals, thicknesses and welding processes
are shown in AWS D1.1, Table 3.2.

4! The minimum interpass temperature must conform to minimum preheat requirements as dis-
cussed in 4)
4@ Maximum interpass temperature must conform to minimum preheat requirements as discussed
in 4
)
4# Postweld heat treatment may be required for stress relieving the weldment.
4$ Designates the weld pass.
4% See 2$
4^ Electrode size(s).
4& See j
 Exhibit 1 - cont.

4* The amperage is an essential variable for FCAW. To be prequalified, the amperage must be
within the electrode manufacturer’s recommended range. A single amperage value has a + 10%
tolerance for FCAW. Each range specified should not exceed this tolerance. See AWS D1.1,
Section 3.6 and Table 4.5, item 13. In this sample WPS, an acceptable range of amperages is
provided for each electrode size.

4( The voltage is an essential variable for FCAW. To be prequalified, the voltage must be within the
electrode manufacturer’s recommended range. A single voltage value has a + 7% tolerance for
FCAW. Each range specified should not exceed this tolerance. See AWS D1.1, Section 3.6 and
Table 4.5, item 15. In this sample WPS, an acceptable range of voltages is provided for each
electrode size.

5) Travel speed is the rate of travel of the arc in the direction of the weld progression. Travel speed
is an essential variable for FCAW. A new or revised WPS must be written if there is an increase
or decrease from the mean travel speed by 25 percent. See AWS D1.1, Section 3.6 and Table
4.5, item 17. In this sample WPS, an acceptable range of travel speeds is provided for each
electrode size.

5! Prequalified joint details and the limitations for weld processes, base metal thicknesses, groove
dimensions, welding positions, and weld sizes for partial and complete joint penetration groove
welds are given in AWS D1.1, Figures 3.3 and 3.4.
 LE
QUALIFIED BY TESTING
Exhibit 2 Welding Procedure Specification
M P
WPS P-2
S A
COMPANY____Pacific Fabrication Inc.__________________________ DATE_____January 11, XXXX_________________________________
WELDING PROCESS__Shielded Metal Arc Welding (SMAW)_________
q TYPE: Manual Semi-Automatic r
WELDING CODE___AWS D1.1-XX_____________________________
w Machine Automatic
SUPPORTING PQRs__P-2___________________________________
e
JOINT DESIGN USED WELDING POSITIONS
TYPE: Single Double Weld t d
POSITION OF GROOVE______Flat (1G), Horizontal (2G)___________
BACKING: Yes No y f
POSITION OF FILLET_____________-------______________________
BACKING MATERIAL____3/16” x 1” flat bar______________________ VERTICAL PROGRESSION: Up Down g
ROOT OPENING_3/8”_ u i
ROOT FACE DIMENSION_0________ ELECTRICAL CHARACTERISTICS
GROOVE ANGLE_45°_o a
RADIUS (J-U)____n/a_____________ TRANSFER MODE (GMAW): n/a h
BACKGOUGING: Yes No s
METHOD_______________ Short-Circuiting Globular Spray Pulsed
BASE METALS CURRENT: AC DCEP DCEN j
l
MATERIAL SPECIFICATION_____ASTM A36-XX__________________ OTHER____________________________________________________
TYPE OR GRADE___________________________________________ TUNGSTEN ELECTRODE (GTAW): n/a k
THICKNESS: GROOVE_1/2” to 3/4”_; 2)
FILLET___n/a_________ SIZE _____________________ TYPE_____________________
2!
DIAMETER (PIPE)___________n/a_____________________________ TECHNIQUE
FILLER METALS 3)
STRINGER or WEAVE BEAD_______Stringer Passes______________
2@
AWS SPECIFICATION______A5.20-XX__________________________ 3!
MULTI-PASS or SINGLE PASS (per side)______Multi-pass__________
2#
AWS CLASSIFICATION__E7018 (Lincoln Electric LH-70)____________ 3@
NUMBER OF ELECTRODES________1_________________________

SHIELDING 3#
ELECTRODE SPACING: LONGITUDINAL _______n/a_____________
2$
FLUX________n/a____________ 2%
GAS__________n/a____________ 3$
LATERAL ____________n/a_____________
2^
COMPOSITION___n/a__________ 3%
ANGLE _____________n/a______________

ELECTRODE-FLUX CLASS 2&

FLOW RATE_____n/a__________
3^
CONTACT TUBE TO WORK DISTANCE___________n/a____________
2*
_________n/a___________ 2(
GAS CUP SIZE___n/a__________ PEENING____optional, may be performed with slag hammer when weld
3&
pass is hot, peening not allowed on root or cover passes_____________
3*
INTERPASS CLEANING_____needle gun, wire brush______________
PREHEAT POSTWELD HEAT TREATMENT
PREHEAT TEMP., MIN. ______________40°F____________________
3( 4@
TEMPERATURE ___________none_____________________________
__________________________________________________________ TIME _____________________n/a_____________________________
4!
4) MAX.______
INTERPASS TEMP., MIN. __________40°F___________

WELDING PROCEDURE
PASS OR FILLER METALS CURRENT TRAVEL
WELD PROCESS TYPE & VOLTS SPEED, JOINT DETAILS
LAYER CLASS DIA. AMPS ipm
POLARITY

1 to 2 SMAW E7018 1/8” DCEP 130-140 20-21 8-10

3 to 9 SMAW E7018 5/32” DCEP 150-180 23-26 10-15

4# 4$ 4% 4^ 4& 4* 4(
5)
Approved for production by_______________________________________________________________________
Fabricator Date
Exhibit 2 - cont.
Type of welding process to be used.
q
w AWS D1.1-XX is titled Structural Welding Code – Steel. Other structural welding codes for sheet
steel and rebar are, respectively, AWS D1.3-XX and AWS D1.4-XX.

e A WPS qualified by testing is supported by a procedure qualification record (PQR). See Exhibit
2A: PQR P-2.

r SMAW is a manual process whereby the welder uses a hand-held holder to grip the electrode.

t A single welded joint is welded from one side only. A double welded joint is welded from both
sides.

y Backing is a material or device placed against the back side of the joint, or at both sides of the
weld (for electrogas welding (EGW) and electroslag welding (ESW) to support and retain molten
weld metal.

u The root opening is a separation at the joint root between the workpieces. The nonstandard term
is root gap.

i The root face is the portion of the groove face at the weld root.

o The groove angle is the total included angle of the groove between the workpieces.

a Groove radius in a J-groove or U-groove joint weld.

s Backgouging is the removal of weld metal and base metal from the weld root back side of a
welded joint to facilitate complete fusion and complete joint penetration upon subsequent welding
from that side.

d This sample WPS for the joint designation TC-U4a was qualified by testing for a corner joint
welded in the horizontal position. See AWS D1.1, Figures 4.1, 4.3 and 4.4 for types of groove
weld positions. Because the WPS was qualified by welding the PQR test plate in the horizontal
position (See Exhibit 2A: PQR P-2), the 1996 AWS D1.1, Table 4.1, also qualifies the WPS for
groove and fillet welds in the flat position.

f See AWS D1.1, Figures 4.2, 4.5 and 4.6 for types of fillet weld positions.

g A WPS qualified by testing for the vertical position must indicate the direction of the weld progres-
sion – up or down. A change from up to down, or vice versa, would require requalification, i.e,
another PQR test.

h For Gas Metal Arc Welding (GMAW) there are four types of transfer modes of molten metal from
the electrode tip to the work: short-circuiting, globular, axial spray, and pulsed. Any WPS using
GMAW with the short-circuiting transfer mode requires qualification by testing.
 Exhibit 2 - cont.
DCEP indicates the power source is DC and the welding leads are arranged so that the electrode
j is the positive pole, i.e., the polarity is “reverse”.

k For Gas Tungsten Arc Welding (GTAW), the size and type of the tungsten electrode shall be
recorded. Any WPS using GTAW requires qualification by testing.

l ASTM, ABS, API or other designation for the base metal material(s) qualified by testing. If appli-
cable, the type or grade should be included.

; Base metal thickness range for groove welds. This sample WPS is written only for complete joint
penetration groove welds for plate thicknesses of ½ to ¾”. However, PQR P-2 in Exhibit 2A
qualifies a WPS for a plate thickness range of 1/8" to 1-1/2", for complete joint penetration and
partial penetration groove welds, and fillet welds, based on the PQR test plate thickness of ¾”.
Refer to AWS D1.1, Table 4.2 for qualified plate, pipe, and tube thicknesses.

2) Base metal thickness range for fillet welds.

2! Size or diameter range of pipe.
2@ A5.1-XX is the AWS specification no. for Carbon Steel Electrodes for Shielded Metal Arc Welding.
2# E7018 is the AWS classification no. for a low hydrogen type of electrode listed in the specification
no. A5.1-XX. Electrodes are classified according to as-welded mechanical properties, suitable
welding positions, and usability characteristics. In this sample the manufacturer’s name and type
of electrode are provided for information only.

2$ An external flux is not used with SMAW. The Submerged Arc Welding (SAW) process would
require specifying an external flux.

2% External shielding gases are used with GMAW, GTAW, EGW, and some FCAW electrodes. The
covering on the SMAW electrode creates a gas during the welding to shield the arc and prevent
excessive atmospheric contamination of the weld metal.

2^ Percentage composition of any shielding gas(es).

2& Flow rate of any changing gases.
2* AWS classification of electrode/flux combinations for ESW and SAW.
2( Size of gas cup or nozzle which directs the shielding gas (es) to the weld zone from the end of
the welding gun for FCAW-G or GMAW.

3) A weave bead is a weld bead or layer made with transverse oscillation. A stringer bead is made
without appreciable oscillation.
 Exhibit 2 - cont.

3! A single pass weld is made with one weld bead. Multiple passes consist of multiple weld beads.
3@ For machine or automatic processes, multiple electrodes may be used.
3# Longitudinal spacing between multiple electrodes.
3$ Lateral spacing between multiple electrodes.
3% Angle of multiple electrodes.
3^ Distance from the contact tube in welding gun to the work for SAW. Electrical stickout, which is
the electrode length between the point of electrical contact in the welding gun and the arc, can be
indicated for FCAW and GMAW.

3& Mechanical working of metals using impact blows to relieve shrinkage stresses. If peening is
performed, the method, such as striking with a hammer or using pneumatic tools, should be
indicated.

3* After each weld pass, the weld surface may be cleaned to remove any deleterious material such
as slag, spatter, etc.

3( The minimum preheat temperature for a FCAW, GMAW, SAW, or SMAW WPS qualified by testing
is 25°F less than the preheat temperature used during the welding of the PQR test plate. See
Exhibit 2A: PQR P-2. Refer to AWS D1.1, Table 45, and Section 5.6 for allowable decreases in
preheat temperatures.

4) The minimum interpass temperature is equal to the minimum preheat temperature. Refer to AWS
D1.1, Table 4.5, note 7, and Section 5.6.

4! Maximum interpass temperatures may be specified for welding of steels with toughness require-
ments, high strength steels, quenched and tempered steels, etc.

4@ Postweld heat treatment may be required for stress relieving the weldment.
4# Designates the weld pass.
4$ See 2#
4% Electrode size(s). See j
4^ Aoutside
SMAW WPS qualified by testing must be re-qualified if the amperage, an essential variable, is
the range recommended by the electrode manufacturer. For other processes, re-qualifi-
cation is required if the amperage varies from that used in the PQR test by more than the toler-
ance given in AWS D1.1, Table 4.5.
 Exhibit 2 - cont.

4& Aoutside
SMAW WPS qualified by testing must be re-qualified if the voltage, an essential variable, is
the range recommended by the electrode manufacturer. For other processes, re-qualifi-
cation is required if the voltage varies from that used in the PQR test by more than the tolerance
given in AWS D1.1, Table 4.5.

4* A SMAW WPS qualified by testing must be re-qualified of the voltage, an essential variable, is
outside the range recommended by the electrode manufacturer. For other processes, re-qualifica-
tion is required if the voltage varies from that used in the PQR test by more than the tolerance
given in AWS D1.1, Table 4.5.

4( Travel speed is the speed of the arc in the direction of the weld progression. Travel speed is not
an essential variable for SMAW. However, for other processes, requalification is required if the
travel speed varies from that used in the PQR test by more than the tolerance given in AWS D1.1,
Table 4.5.

5) Joint details for the corner weld joint.

 SAMPLE
Procedure Qualification Record
Exhibit 2A PQR P-2
COMPANY____Pacific Fabrication Inc.__________________________ DATE_____January 11, XXXX_________________________________
WELDING PROCESS__Shielded Metal Arc Welding (SMAW)_________ WELDING CODE___AWS D1.1-XX_____________________________

WELDING POSITION _______Horizontal (2G)____________________

w TEST ASSEMBLY _AWS D1.1-XX, Fig.4.10 [Fig.5.10]_______________
a
BASE METAL _______ASTM A36-XX, 3/4” plate___________________
e FILLER METAL _____AWS A5.1-XX, E7018______________________
s
BACKING MATERIAL ___3/16” x 1” flat bar_______________________
r ELECTRODE SIZE __________1/8” dia._________________________
d
BACKGOUGING: Yes No t CURRENT: AC DCEP DCEN f
PREHEAT TEMP. ______none (65°F ambient)____________________
y VOLTAGE ______20_____
g AMPERAGE _______130_____
h
INTERPASS TEMP. _________325°F___________________________
u ARC TRAVEL SPEED _________8-10 ipm_______________________
j
POSTWELD HEAT TREATMENT ____none______________________
i STRINGER or WEAVE BEAD __________Stringer_________________
k
INTERPASS CLEANING _____needle gun, wire brush______________
o MULTI-PASS or SINGLE PASS (per side) ______Multi-pass__________
l
WELDER’S NAME ________Ryan F. Tana_______________________ PEENING ______________none_______________________________
;
WELDER’S SOCIAL SECURITY NO. _____666-55-7777____________ TEST DATE ___________January 9, XXXX_______________________

TEST RESULTS 2)
VISUAL INSPECTION 2!
Appearance __Acceptable__ Undercut __Acceptable__ Piping Porosity __Acceptable__ Convexity __-----------__
RADIOGRAPHIC EXAMINATION or ULTRASONIC TESTING 2@
RT Report No. __96-101__ Result __Passed__ UT Report No. ___-------___ Result __--------__
GUIDED BEND TESTS 2#
Specimen
Type of Bend Result Remarks
No.
1 Side Passed complete fusion, no discontinuities
2 Side Passed complete fusion, no discontinuities
3 Side Passed complete fusion, no discontinuities
4 Side Passed complete fusion, no discontinuities
TENSILE TESTS 2 $
Specimen Width, Thickness, Area, Ultimate Ultimate Fracture
No. in. in. sq. in. Tensile Load, lbs. Tensile Stress, psi Location
1 0.751 0.747 0.561 35,900 64,000 Base Metal
2 0.748 0.747 0.599 35,100 62,800 Base Metal
Tests conducted by ____Acme Testing Laboratory_______ Lab No. ____Z-1957-24-23____
We, the undersigned, certify that the information in this record is correct, and that the test weld was prepared, welded, and tested in accordance with
the requirements of Section 1, Part B, [Section 5, Part B] of AWS D1.1-XX,
Structural Welding Code - Steel.
Signed by ________________________________________________________________
Exhibit 2A - cont.

Joint details for the test assembly. Also shown are the sequence of weld passes. To qualify the
q corner joint for WPS P-2 in Exhibit 2, a butt jointed PQR test plate, with the same joint configura-
tion to be used in production, is welded. Specimens are removed from the completed test plate
to evaluate the mechanical properties of the welded joint. See AWS D1.1, Figure 4.10 for di-
mensions of the PQR test plate.

w In this sample the complete joint penetration groove weld was welded in the horizontal (2G)
position. Passing results for the PQR test plate qualifies the WPS for welding in the horizontal
and flat positions for groove and fillet welds per the AWS D1.1, Table 4.1.

e Base metal material(s) used for the PQR test plate.

r Backing is a material or device placed against the back side of the joint, or at both sides of the
weld in electroslag and electrogas welding, to support and retain molten weld metal.

t Backgouging is the removal of weld metal and base metal from the weld root back side of a
welded joint to facilitate complete fusion and complete joint penetration upon subsequent weld-
ing from that side.

y Preheat temperature used for welding of the PQR test plate. In this sample a preheat was not
applied to the test plate. Therefore, the temperature of the test plate, which was at the shop
ambient temperature, is recorded.

u Interpass temperature during welding of the PQR test plate is recorded.

i Postweld heat treatment used on the PQR test plate.

o Method used to clean each weld pass.

a See AWS D1.1, Figures 4.9, 4.10, and 4.11 for PQR test plate dimensions and locations of test
specimens.

s AWS filler metal specification no. and classification no.

d Size of electrode to weld PQR test plate.

f DCEP indicates the power source is DC and the welding leads are arranged so that the elec-
trode is the positive pole, i.e., the polarity is “reverse”.

g Voltage used during welding of the PQR test plate.

h Amperage used during welding of the PQR test plate.

j Rate of travel for the arc stream in the direction of the weld progression.
Exhibit 2A - cont.

A weave bead is a weld bead or layer made with transverse oscillation. A stringer bead is made
k without appreciable oscillation.

l Technique used to weld the PQR test plate.

; Peening is the mechanical working of metals using impact blows to relieve shrinkage stresses. If
peening is performed, the method, such as striking with a hammer or using pneumatic tools,
should be indicated.

2) Typical procedure qualification tests include visual inspection, non-destructive testing, and me-
chanical testing such as guided bend tests and reduced-section tensile tests. Macroetch tests
may be required to check weld size and/or fusion. See AWS D1.1, Tables 4.2 – 4.4 for number
and type or test specimens required. Charpy V-notch impact tests for toughness shall be per-
formed when required by the contract drawings or the project specifications.

2! Visual inspection includes checking for items such as appearance, undercut, underfill, porosity,
cracks, slag inclusions, excessive reinforcement, etc. Excessive convexity, insufficient throat,
overlap, and insufficient leg are other items to be checked for fillet welds.

2@ Non-destructive testing is required, radiographic examination (x-ray) or ultrasonic testing D1.1 –

04 Section 4.8.2.

2# For groove weld test plates or pipes, four bend tests are required. For base metal thicknesses
less than or equal to 3/8 inch, two face bend tests and two root bend tests are performed. For
base metal thicknesses greater than 3/8 inch, four side bend tests are conducted.

2$ For groove weld test plates or pipes, two reduced section tensile tests are required.
 Exhibit 3
SAMPLE
WELDER PERFORMANCE QUALIFICATION TEST RECORD

WELDER’S NAME ________Joseph D. Smith_________________________ SOCIAL SECURITY NO. or ID NO. ___555-66-8888_____________

WELDING PROCEDURE SPECIFICATION (WPS) NO. __P-1__(06/06/XX)_____
q REV. NO. ______---------------________________________
WELDING PROCESS ___Flux Cored Arc Welding (FCAW)_______
w manual semi-automatic automatic machinee
r
FILLER METAL _____AWS A5.20-XX, E71T8__________________ t
CURRENT ___DC____ POLARITY _____straight (-)_____
y
ELECTRODE SIZE __________0.068” dia.____________________ VOLTS ______20____
u i
AMPERAGE _____210_________
BASE METAL _____ASTM A36-96, plate, 1” thickness________________________________
o BACKING Yes No a
s
SHIELDING GAS(ES) _________none______________________ FLUX _______________n/a_________________________________
d
TEST WELD __single V-groove weld w/ backing - AWS D1.1-XX, Fig.4.21 [Fig.5.19]__
f TEST POSITION __Vertical (3G) up______________
g

TEST RESULTS h
VISUAL INSPECTION Acceptable: Yes No
RADIOGRAPHIC EXAMINATION Acceptable: Yes No
GUIDED BEND TESTS Side Bend #1: SATISFACTORY Side Bend #2: SATISFACTORY

The welder is qualified for the welding process, weld types, positions, and material thicknesses shown below.
Welding Process Qualified For: FCAW (without shielding gas)
Welding Positions and Material Thicknesses Qualified For: j
Plate Flat Horizontal Vertical (up) Overhead Material thickness: Groove welds on pipe only
Groove qualified for pipe over 24 in. dia.
Welds Pipe Flat Horizontal Vertical (up) Overhead 1/8” to unlimited with backing

Fillet Plate Flat Horizontal Vertical (up) Overhead Material thickness:

Welds Pipe Flat Horizontal Vertical (up) Overhead 1/8” to unlimited

The undersigned certifies that the statements in this record are correct and the test welds were prepared, welded, and tested in accordance with the
requirements of Section 4 of AWS D1.1-XX, Structural Welding Code - Steel.

Date _____January 27, XXXX_______________ Signed by ____________________________________________

Exhibit 3 - cont.

Identifies the fabricator’s WPS that the welder used for welding of the test plate. AWS D1.1-04,
q Sec. 4.18 requires that a WPS applicable to the performance qualification test be followed.

w Welding process used by the welder.

In this sample WPS, FCAW is a semi-automatic process using a hand-held welding gun with an
e automated electrode feed.

r AWS filler metal specification no. and classification no.

t DC or AC power source.

y The polarity might be “straight” (negative) or “reverse” (positive). In this sample welder qualifica-
tion, the direct current welding leads are arranged so that the electrode is the negative pole and
the workpiece is the positive pole of the welding arc.

u Voltage used during the welding test.

i Amperage used during the welding test.

o Base metal material.

a Backing is a material or device placed against the back side of the joint, or at both sides of the
weld in electroslag and electrogas welding, to support and retain molten weld metal.

s Protective gas used to prevent or reduce atmospheric contamination to molten weld metal.

d A material used to hinder or prevent the formation of oxides and other undesirable substances in
molten weld metal an don solid metal surfaces, and to dissolve or otherwise facilitate the re-
moval of such substances. In the FCAW process the flux is contained in the electrode. For
other processes such as Electroslag Welding (ESW) and Submerged Arc Welding (SAW), the
flux is supplied externally to the molten metal.

f Joint configuration and test assembly used. For groove welds, see AWS D1.1, Figures 4.21 –
4.22, 4.24 – 4.25 and 4.27 – 4.31. For fillet welds, see Figures 4.19, 4.32, and 4.36. For plug
welds, see Figure 4.37. For tack welds, see Figure 4.38.

g Position of test assembly used to qualify the welder. See AWS D1.1, Figures 4.3 – 4.6 for posi-
tions of groove and fillet welds. In this sample, the welder welded the test plate in the vertical
position with the progression of passes in the upwards direction. If the welder must weld verti-
cally with the progression of passes in the downwards direction, the welder shall take another
performance qualification test by welding vertically down.
Exhibit 3 - cont.

Typical welder performance qualification tests for groove welds include a visual inspection of the
h welding followed by mechanical testing. Visual inspection includes checking for items such as
appearance, undercut, underfill, porosity, cracks, slag inclusions, excessive reinforcement, etc.
In this sample, machined specimens were removed from the 1 inch thick welded test plate for
two side bend tests. If a test plate is less than or equal to 3/8 inch, one face bend test and one
root bend test are required instead of two side bends. In lieu of conducting bend tests, the code
states the test assembly can be radiographically examined (x-rayed). Refer to AWS D1.1, Table
4.9 for the required number and type of tests for all configurations of welder performance qualifi-
cation test assemblies.

The table indicates the welding positions and material thicknesses for both groove and fillet
j welds that the welder has been qualified to weld. These are based on the passing test results
for the 1 inch test plate welded in the vertical (up) position. See AWS D1.1, Table 4.9, for weld-
ing positions qualified, Table 4.10 for material thickness range qualified, and Table 4.11 for
welder essential variables requiring requalification.
 SAMPLE
Exhibit 4
PROJECT SPECIFICATION

SECTION 05120 – STRUCTURAL STEEL

PART 1 GENERAL

1.01 REFERENCES

A. American Welding Society, AWS D1.XX, Structural Welding Code – Steel

1.02 SUBMITTALS

A. Written Welding Procedure Specifications (WPSs) in accordance with AWS D1.1

requirements for each different welded joint proposed for use whether prequalified
or qualified by testing.

B. Procedure Qualification Record (PQR) in accordance with AWS D1.1 for all procedures
qualified by testing.

C. Electrode manufacturer’s data

1.03 QUALITY ASSURANCE

A. Perform work in accordance with AWS D1.1.

1. Qualify welders in accordance with AWS D1.1 for each process, position, and joint
configuration.
2. WPSs for each joint type shall indicate proper AWS qualification and be available where
welding is performed.

PART 2 PRODUCTS

2.01 SHOP CONNECTIONS (Field similar)

A. Welded connections: Comply with AWS D1.1.

1. Weld only in accordance with approved WPSs, which are to be available to welders and
inspectors during the production process.

PART 3 EXECUTION

3.01 SOURCE QUALITY CONTROL (Field similar)

A. The Owner’s Testing Agency will inspect shop welding for conformance with AWS D1.1
requirements and will verify that welds are made in accordance with approved WPSs.