AWS D1.

5 Code Changes -2020 Edition

NESMEA
Mr. Allen W. Sindel – TRC
Presented by: Mr. Robert Horwhat - TRC
AWS D1.5 2020 Pending Changes – Introduction.
– INTRODUCTION
• The purpose of this slide presentation is to inform the
attendees at this conference of the pending changes to
the AASHTO/AWS D1.5 – 2020 Edition.
• The pending changes have been approved by the AWS
D1 Main Committee, and AWS D1J Subcommittee on
Bridge Welding.
• These changes are still pending approval by AASHTO,
AWS Technical Activities Committee (TAC), and AWS
Standards Council (SC).
• Additional changes may also occur at the AWS D1
Meeting schedule in October 2018.
• The current schedule for publication is the 2nd Quarter of
2020.
AWS D1.5 2020 – Our AWS Team members

– TRC has 3 members on the AWS D1 committees in

various positions, :
• Allen W. Sindel, AWS D1 Chairman and TAC Member.
• James Merrill, AWS D1.8 Structural Welding Seismic
and D1 Main Committee Member.
• Mr. John Kinsey, Task Group Vice Chairman,
Inspection.
AWS D1.5 2020 Pending Changes – Disclaimer

DISCLAIMER
The information presented in this presentation represents the
personal opinion of the author, Mr. Allen W. Sindel, and not that of
the American Welding Society, American Welding Society Technical
Activities Committee (TAC), or American Welding Society D1
Structural Welding Committees.
The pending AWS D1.5 for the 2020 edition that are contained in
this presentation are subject to modifications or deletions due to the
subsequent balloting process of AASHTO, AWS TAC, and AWS
Subcommittees (SC).
Users of the information contained herein are reminded, these
pending changes or any subsequent modifications will not be
effective until after publication of this Code.
AWS D1.5 2020 Pending Changes – Code Outline
• Table of Contents – Clauses
– 1. General Provisions
– 2. Design of Welded Connections
– 3. Workmanship
– 4. Technique
– 5. Qualification
– 6. Inspection
– 7. Stud Welding
– 8. Statically Loaded Structures
– 9. Welded Steel Bridges
– 10. Tubular Structures
– 11. Strengthening and Repairing Existing Structures
– 12. Fracture Control Plan for Nonredundant Members
….Getting into the details

• Over 120 revisions to over 50

pages of the code have been
made.
• Only a portion of these
are being presented here
AWS D1.5 2020 Pending Changes – List

Note: Red-Deletions, Blue- Words Added (Other than Cause or Commentary Section and Titles, bold for
emphasis only in this presentation – not part of the proposed code revision) , C-X.X.X- Commentary –
Highlighted – focus areas (RDH)
2.1 Drawings (Design)
– C-2.1.2(2) The Engineer may consider whether minor weld discontinuities or base metal imperfections can be
left unrepaired without jeopardizing the structural integrity, as gouging and repair welding will add additional
cycles of weld shrinkage to the connection, and may result in the extension of existing flaws discontinuities or
the generation of new flaws discontinuities by lamellar tearing.
– Rationale: Flaws may be considered as rejectable where-as discontinuities must be evaluated to an acceptance
criteria:.

– C-2.1.6 2nd paragraph

– In most cases, E70 or E80 weld metal classified with minimum specified tensile strength of 70 or 80 ksi will be
used for undermatching applications. 70-ksi weld metal E70 is generally preferable, but 80-ksi weld metal E80
is often required used for unpainted weathering applications. because, when atmospheric corrosion
resistance is required for weathering steels, the added alloys result in E80 strength class weld metal.
– Rationale: Guidance for undermatch and overmatched weld metal based on strength versus the use of AWS
filler metal classification (minimums but maybe more).
AWS D1.5 2020 Pending Changes – List (Cont.)
3.2 Preparation of Base Metal (Workmanship)
– C-3.2.1 General. For quality welds, base metal cleanliness is important. However, it is neither
required nor necessary for base metal to be perfectly clean before welds are made. It is difficult
both to establish quantifiable limits of cleanliness and to measure to those limits therefore, this
provision uses the practical standard of the resultant weld quality. If the base metal is
sufficiently clean so as to facilitate a weld to be made that meets the requirements of this code,
it is clean enough. If the resultant welds do not meet the weld quality requirements of this
code, cleaner base metal may be required.
– Rationale: Guidance on base metal cleanliness when the resultant weld meets the quality
requirements, then the base metal cleanliness is sufficient.
– 3.2.2 Mill-Induced Surface Defects. Welds shall not be placed on surfaces that contain fins,
tears, cracks, slag, or other base metal defects as defined in the base metal specifications.
– Rationale: ASTM product specifications many times have acceptance limits for base metal
defects. However, this provisions addresses welding over them.
 AWS D1.5 2020 Pending Changes – List (Cont.)
– C-3.2.2 Mill-Induced Surface Defects. The base metal to which
3.2 Preparation of Base Metal welds are attached must be sufficiently sound so as to not
affect the strength of the connection. Base metal defects may
(Workmanship) be repaired prior to the deposition of the prescribed weld. This
subclause does not limit base metal repairs by welding.
– Rationale: Same reason as before but also address guidance
for base metal repairs by welding.
– 3.2.3 Scale and Rust. Loose scale, thick scale, and thick rust
shall be removed from the surfaces to be welded and within 25
mm [1 in] of the weld. Welds may be made on surfaces that
contain thin mill scale and rust if:
•
(1)the mill scale and rust can withstand vigorous
hand wire brushing; and
(2)if the applicable weld quality requirements of this
code can be met.
All mill scale shall be removed from the following:
(1) web-to-flange connections
(2) joint boundary of groove welds subject to calculated tensile stress
AWS D1.5 2020 Pending Changes – List (Cont.)
3.2 Preparation of Base Metal (Workmanship)
•C-3.2.3 Scale and Rust. Excessive rust or scale can negatively affect weld quality. The code
permits welding on surfaces that contain mill scale, providing both: a) the mill scale remains
intact after wire brushing and b) the resultant weld quality is not adversely affected.

Web-to-flange welds are frequently minimum size fillet welds deposited at relatively high
speeds; therefore these welds could exhibit piping porosity if welded over the heavy mill scale
often found on thick flange plates. Therefore, web-to-flange welds in girders have the
mandatory requirement to completely remove all mill scale. Similarly, welds subject to tensile
stress at the weld root are more sensitive to internal discontinuities, so scale is also prohibited
See C-3.2.1
Rationale: Clarify guidance on excessive rust or scale that could affect the quality of the weld;
may be permitted with provisions of a) and b). However, must be removed as described in the
second paragraph above.
AWS D1.5 2020 Pending Changes – List (Cont.)
3.2 Preparation of Base Metal (Workmanship)
– C-3.2.4 Foreign materials. This subclause prohibits volumetric (three dimensional)
quantities of contaminants from being left in place on the surface to be welded and
adjacent areas. Surfaces contaminated by the materials listed in 3.2.4.1 must be cleaned,
such as by wiping prior to welding. Special consideration should be given to the removal
of surface contaminants containing hydrocarbons or condensed moisture, as the
hydrogen released into the molten weld pool can cause serious weld imperfections, e.g.,
cracking. The cleaning operations, which may involve just wiping, need not remove all
foreign contaminants nor do they require the use of solvents; welding through thin
layers of remaining contaminants is acceptable, unless they degrade the weld quality
requirements of this code resulting in unacceptable welds.
– 3.2.4.1 Surfaces to be welded, and surfaces adjacent to the weld, shall be cleaned to
remove evident quantities of the following:
• Water
• Oil
• Grease
• Other hydrocarbon based materials
Welding on surfaces containing residual amounts of foreign materials is permitted
providing the weld quality requirements of this code can be met.
AWS D1.5 2020 Pending Changes – List (Cont.)
3.2 Preparation of Base Metal (Workmanship)
– 3.2.4.2 Welds are permitted to be made on surfaces with anti- spatter compounds or
protective coatings applied providing the weld quality requirements of this code can be met.
Protective coatings are not permitted on web-to-flange connections or joints subject to
calculated tensile stress.
– Rationale: To better clarify foreign materials, methods of cleaning when necessary, welding
is permitted on surfaces with anti-spatter compounds provided the weld quality to the
Code is maintain.
• Note: Many of the clauses shown in this presentation and previous slides concerning cleanliness
are being revised or clarified back to 2010 criteria. Maybe not exactly but close to be clearer and
more specific.
– C-3.2.6 Changes are once again changing the word “indications” to “discontinuities”.
– Rationale: Indications is broad term which can mean any relevant or non relevant
indication. Discontinuity generally means the indication is relevant and is evaluated with
respect to Acceptable or Rejectable.
– 3.3.7.1 All tack welds shall be subject to the same quality requirements as the final welds,
with the following exceptions: except as exempted in 3.3.7.3. Tack welding shall be
performed in accordance with a WPS meeting the requirements of Clause 3 unless
exempted by 3.3.7.3. Tack welds shall be cleaned and visually inspected before subsequent
welding.
 AWS D1.5 2020 Pending Changes – List
(Cont.)
3.3 Assembly (Workmanship)
(1) Preheat is not mandatory for single-pass tack welds that are remelted and incorporated into
continuous SAW, ESW, or EGW welds.
(2) Discontinuities such as undercut, unfilled craters, and porosity need not be removed before the
final SAW, ESW, or EGW that remelts the tack weld (see 3.3.8)
– C-3.3.7.1 This subclause requires that tack welds meet the same requirements as final welds,
with a few exceptions as listed in 3.3.7.3. The exceptions deal with tack welds that are
remelted. Tack welds that are not consumed in a final weld and are left in the structure require
remelted become part of the final weld and therefore normal quality practices such as the
removal of visible slag and/or cracks to ensure that they are sound prior to subsequent weld
passes.
– Reason. Provides guidance and requirements for tack welds left in place with the intent the
final weld will meet the requirements of the Code.
– C-3.3.7.2 Cascading the ends of multipass tack welds reduces the potential for incomplete
fusion between the final weld and the ends of the tack welds. Incomplete fusion would create
stress concentrations at the ends of the tack welds. Cascaded ends of multiple pass tack welds
provide a smooth transition for the final welding.
AWS D1.5 2020 Pending Changes – List (Cont.)
3.3 Assembly (Workmanship)
3.3.7.3 Remelted Tack Welds. Tack Welds made in accordance with 3.3.7.3(1) and
3.3.7.3(2) shall be considered fully remelted and incorporated into the final weld and
shall be exempt from the following requirements:

(a)Minimum preheat requirements shall not apply.

(b)WPSs for tack welding shall not require qualification testing in
accordance with Clause 5.
(1) Exemption Requirements. The following conditions shall be met for the exemptions of
3.3.7.3 to apply:
(a) The tack welds shall be made in a single pass
(b) The filler metal for tack welding is listed in Table 4.1
(c) (c) No other welding process may be used to weld over a FCAW-S tack weld unless
qualified by 5.7.7.1.
AWS D1.5 2020 Pending Changes – List (Cont.)
3.3 Assembly (Workmanship)
(2) Remelting Conditions. To ensure that tack welds are fully remelted the following
shall apply:

(a) The remelting capability of the subsequent welding process and procedure is
verified by macroetch in accordance with Clause 5.18.2 and 5.19.3.

(b) The maximum tack weld size used in production shall not exceed the tack
weld size used in the qualification testing.

(c)The heat input of the pass used to remelt the tack in production shall not be
less than that used in the qualification testing.
- C-3.3.7.3 Remelted tack welds are exempt from some code requirements because the
remelting process eliminates the tack weld. The tack weld metal becomes part of the
final weld metal. The code requirement to use Table 4.1 electrodes for tack welding is
sufficient to ensure the quality of final welds that incorporate remelted tack welds.

Preheat is not required for remelted tack welds since the remelting process is expected
to eliminate any potentially deleterious effects of welding on unpreheated steel,
namely potentially hardened HAZs. However, even though preheat is not mandated for
such tack welds, the tack welds must be crack-free in accordance with 3.3.7.5.
AWS D1.5 2020 Pending Changes – List (Cont.)
3.3 Assembly (Workmanship)
Given the restraint that tack welds resist, when tack welds do crack, the cracking is typically readily
apparent. Visible inspection is generally sufficient assurance that no cracked tack welds are present
before final welding. Cracked tack welds should not be confused with broken tack welds (see 3.3.7.5).

High heat input processes such as SAW and ESW typically remelt small, single pass tack welds. Other
welding processes and procedures can also remelt small tack welds. However, processes that utilize
lower levels of heat input, including some SAW procedures, may not remelt tack welds. The code
provides a qualification method to ensure that the final welding process and procedure being used will
effectively remelt the tack weld.
- 3.3.7.4 Unincorporated Tack Welds.
(1) Removal. Tack welds that are not incorporated into the final weld shall be removed in such a manner
that the base metal is not damaged. Base metal damaged during tack weld removal may be repaired
when approved by the Engineer. If the repair involves welding, it shall be done in conformance with
3.7.1.

(2) Cracked Base Metal. The removal of tack welds may expose cracked base metal. When cracked base
metal is discovered after tack welds are removed, all other tack weld removal locations in the tension
regions on the member shall be tested by MT to assure that no cracks are present. If the MT testing
reveals cracks, hardness testing of the HAZ shall be required. Hardness values shall not exceed Rockwell
C30 in the HAZ. These excessively hard HAZs shall be removed by shallow grinding.
AWS D1.5 2020 Pending Changes – List (Cont.)
3.3 Assembly (Workmanship)
- C-3.3.7.4 Unincorporated tack welds are usually avoidable, but when they are
necessary, they are removed after welding to avoid local stress risers and to reflect
sound workmanship. They can simply be ground away.

Depending upon the constraint conditions and size of the components being tacked, it is
possible for cracking to occur; when such cracking is observed, the code requires that
additional testing be conducted. However, the MT testing and hardness testing prescribed
by the code are only required when cracking is observed; these tests are not required for
tack weld removal sites that reveal no cracks.
Rationale: The above clauses both Code and Commentary, provide guidance on Tack
welds being remelted and unincorporated. Addition Code changes address Broken Tack
Welds (which are not cracked welds) and Tack Welding to Backing. The main intent is to
differentiate between tack welds that are left in place that could affect the quality of the
final weld and tack welds that will be removed which should not affect the quality of the
weld.
AWS D1.5 2020 Pending Changes – List (Cont.)

3.4 Control of Distortion and Shrinkage

– 3.4.8 When straightening is necessary, membersMembers distorted by welding shall be
straightened by mechanical means (with or with out the application of heat) or by heat
straightening (“heat shrink”) method s. If heat is applied , the minimum temperature during
mechanical straightening or bending shall be 370 C [700 F].and/or by carefully supervised
application of a limited amount of localized heat. The maximum temperature of the heated
areas as measured by approved methods shall not exceed 600 C [1100 F] for M 270M/M
270 (A709/A709M) Grades HPS 485W [HPS 70W] and HPS 690W [HPS 100W] steels or 650 C
[1200 F] for other steels. The part to be heated for straightening shall be substantially free of
stress from external forces, except stresses resulting from the mechanical straightening
methods used in conjunction with the application of the heat.
– Rationale: The Code is specifying the requirements for straightening and the associated
Commentary is providing guidance concerning overheating, maximum temperature near the
transformation temperature, and awareness when the material quenched and tempered.
AWS D1.5 2020 Pending Changes – List (Cont.)
4. Technique (4.2 Electrodes and Fluxes for SAW)

- 4.20 Condition of Flux

Flux shall conform to all of the following requirements:
(1) Flux shall be neutral fused flux., dry
(2) and fFlux shall be dry and free of contamination from dirt, grease,
mill scale, or other foreign material.
(3) Flux shall be received in moisture-resistant packaging that can be
stored under normal conditions for at least six months without such storage
affecting its welding characteristics or weld properties.
(4) Flux shall be conditioned at 120 C [250 F] for at least two hours
prior to welding, or as recommended by the manufacturer, and stored at
the same temperature until dispensed for use.
(5) Flux that has been dispensed for use shall be discarded after 8 hours.
(6) Flux from packages damaged in transit or in handling shall be
discarded.
(7) Wet Fflux that has been wet shall not be used.
- Rationale: The Code clarified “Neutral” flux, i.e. maybe fused or
bonded, shall be dry, packaging and storage which will not affect the
welding properties, when dispensed for after 8 hours be discarded,
and wet flux shall not be used.
AWS D1.5 2020 Pending Changes – List (Cont.)
5. Qualification (Weld Procedure Qualifications)

– 5.5.1 WPS Requirements for Consumables.

If the name of a manufacturer changes (e.g., merger or acquisition) or if the brand name or type of
a consumable is revised without reformulation or other physical changes, such changes shall not
constitute a change that requires WPS requalification. New WPSs may use the new identity based
upon a PQR retaining the old information. Existing WPSs shall be revised to list the new identity
while based upon a PQR retaining the old information. Documentation from the manufacturer
explaining the change shall be filed with the PQR.
Rationale: This addresses the issue where by a merger or acquisition or brand name or type of
consumable is revised but the formulation (generally chemistry or physical changes) has not
changed, then a new WPS qualification is not required. Likewise, new WPS’s and PQR can be
revised to list the new identity but the old PQR must be retained; document the explanation of the
change in the revised PQR.

- Table 5.6 PQR Essential Variables requiring WPS Requalification for ESW
(11) A change in type of current (AC or DC) or polarity.

Rationale: Changes in type of current or polarity may affect the heat input.
AWS D1.5 2020 Pending Changes – List (Cont.)
…into 6. Inspection

– 5.23.3 Tack Welder Qualification was revised.

– Rationale: Position was added and added if a welder is qualified by Options 1,2,3 in
5.23.1 or by the test in 5.23.1.1, the welder is also qualified to tack weld in the positions
permitted by 5.22. As position is an essential variable and allows welders that were
qualified by the other referenced paragraphs are equally qualified to tack weld.
– 6.7 Nondestructive Testing (NDT)
The contractor shall perform NDT on welds to primary components of main members
using the methods and frequencies required in Table 6.X. Subclauses 6.7.1 through 6.7.3
contain additional requirements. Where Table 6.X requires only partial testing, the
inspector shall select the inspection locations, after welding is complete. The choice of
the lot basis or per-joint basis of partial testing, where both options are given, shall be at
the Contractor’s option. (See Table 6.X next Page).

Rationale: To address when NDT is required, what types of joints, and to address in a
New Table the NDT Methods and Frequency by the types of joints/Member Design
Stress.
AWS D1.5 2020 Pending Changes – List (Cont.)
AWS D1.5 2020 Pending Changes – List (Cont.)
12. Fracture Control Plan for Non-Redundant Members

- 12.2.2 Fracture Critical Member (FCM). The AASHTO LRFD Bridge Design Specifications
define an FCM as a steel primary member or portion thereof subject to tension whose
failure would probably cause a portion of or the entire bridge to collapse.
– Rationale: This Clause was revised to reference AASHTO LFRD Bridge Design
Specifications for the definition and other clauses that follow in this section are already
defined in this specification or in ASTM specifications, e.g. Fine Grain Practice, Specifying
CVN testing which generally in the ASTM specification is a supplementary requirement
S-X.
– 12.6.1.31 Electrode Optional Supplemental Diffusible Hydrogen Moisture-Resistant
Designator Requirements for Welding. Electrodes and electrode/flux SMAW electrodes
used to weld base metal with a minimum specified yield strength of 345 MPa [50 ksi] or
less shall conform to the diffusible hydrogen requirements of the AWS filler metal
specifications optional supplemental designator H4, H8, or H16. All SMAW electrodes
and electrode/flux combinations used to weld base metal with a minimum specified
yield strength greater than 345 MPa [50 ksi] shall conform to the diffusible hydrogen
requirements of the AWS filler metal specification optional supplemental designator H4
or H8. This requirement does not apply to GMAW with solid electrodes approved per
12.5.2 for use on FCMs.
AWS D1.5 2020 Pending Changes – List (Cont.)
12. Fracture Control Plan for Non-Redundant Members

– C-12.6.31 Electrode Optional Supplemental Diffusible Hydrogen Moisture-Resistant

Designator Requirements for Welding. The “H” designator indicates the maximum
average diffusible hydrogen content in milliliters per 100 grams (mL/100 g) of deposited
weld metal. H4 means a maximum of 4 mL/100 g and H16 means a level of 16 mL/100 g.
Higher strength steels have a higher risk of hydrogen-induced cracking, therefore higher
strength weld metal requires lower diffusible hydrogen levels for this Fracture Control
Plan. Solid electrodes for GMAW are typically not tested for diffusible hydrogen because
the electrodes have no flux to absorb moisture. Solid GMAW electrodes are assumed to
be capable of meeting the requirements for diffusible hydrogen designator H4.
– Rationale: Filler metal classifications with “H” designators are to indicate the average
diffusible hydrogen content in mL/100g. However, indicating filler metal is “Moisture
Resistant” was probably not the actual intent. Likewise, solid wire electrodes do not
have a coating (flux to absorb moisture) and therefore not tested for diffusible
hydrogen.

Hey, There’s no coating on GMAW wire

AWS D1.5 2020 Pending Changes- Summary

– Overall Summary
• The changes listed in this presentation are to provide information on the more
significant proposals to the AWS D1.5-2020 Code, but due to a limited time not all
are included. Many changes not included probably have the same technical intent,
but are either reworded for clarity or to prevent inconsistencies between
AASHHTO, AISC, ASTM, or other specifications/standards.
• As previous mentioned, these changes have been balloted through AWS Task
Groups, Bridge Subcommittee, and the Main Committee. The remaining balloting
process outstanding is AASHTO, AWS Technical Activities Committee, and AWS
Standards Council. As such, through the remaining balloting process, the wording is
subject to modifications in order to resolve either technical or editorial comments.
• With respect the Tubular Section in the Bridge Code, the balloting process is
ongoing at the time of this presentation. The AWS D1 Code meeting(s) will be in
the middle of October 2018 and the work will continue. If the resolution to
comments can be addressed and finalized at these meetings then we are optimistic
a Tubular Section should be in the AWS D1.5 – 2020 Code, publication scheduled
for the 2nd Quarter 2020. If not then the committee leadership will be exploring
other mechanizms to issue the Tubular Section prior to 2025.
AWS D1.5 – 2020 Pending Code Changes

Questions?

Picture to the right Xisha Bridge

From HighestBridges,com.
Lianghezhen, Chongquing, China
711 Feet High and 620 feet span
Completed 2010.
http://www.highestbridges.com/wi
ki/index.php?title=Xisha_Bridge