160/Fabrication 5.12 Welding Environment 5.12.1 Maximum Wind Velocity. GMAW, GTAW, EGW, or FCAW-G shall not be done in a draft or wind unless the Weld is protected by a shelter. Such shelter shall be of material and shape appropriate to reduce wind velocity in the vicinity ofthe weld to » maximum of five ries per hour (eight kilometers per hour) 5.12.2 Minimum Ambient Temperature, Welding shall not be done (Q)_when the ambient temperature is lower than O°F 18°C) (@) when surfaces are wet or exposed to rain, snow, oF G) high wind velocities. or (4) when welding personnel are exposed to inclement conditions. Note: Zero*F does not mean the ambient environmental teraperature, but the temperature in the immediate vicin- ity of the weld. The ambient environmental temperature may be below O°F, but a heated structure or shelter ‘around the area being welded could maintain the tem- ‘perature adjacent 0 the weldment at O°F or higher. 5.13 Compliance with Design ‘The sizes and lengths of welds shall be no less than those specified by design requirements and detail draw- ings, except as permitted in Table 6.1. The location of ‘welds shall not be changed without approval of the Engineer. 5.14 Minimum Fillet Weld Sizes ‘The minimum fillet weld size, except for filet weld: used fo reinforce groove welds, shall be as shown it ‘Table 5.8. In both cases the minimum size applies if itis sufficient to satisfy design requirements. 5.15 Preparation of Base Metal Surfaces on which weld metal is to be deposited shal bbe smooth, uniform, and free from fins, ters, cracks, anc other discontinuities which would adversely affect the ‘quality or strength of the weld. Surfaces to be welded. and surfaces adjacent to & weld, shall also be free from loose or thick scale, slag, rust, moisture, grease, and ‘other foreign materiel that would prevent proper welding cot produce objectionable fumes. Mill scale that can with: stand vigorous wire brushing, » thin nist-inhibitive coat- ing, or antispatter compound may remain with the following exception: for girders in cyclically loaded structures, all mill scale shall be removed from the sur- faces on which flange-to-web welds are to be made by SAW or by SMAW with low-nydrogen electrodes. 5.15.1 Mill Induced Discontinulties, The limits of ac- ‘ceptability and the repair of visually observed cut surface ‘discontinuities shall be in accordance with Table 5.4, in which the length of discontinuity is the visible long di- ‘mension on the cut surface of material and the depth is the distance that the discontinuity extends into the mate- rial from the cut surface. All welded repairs shall be in accordance with this code, Removal ofthe discontinuity Table 5.4 Limits on Acceptability and Repair of Mill induced Laminar Discontinuities in Cut Surfaces (see 5.15.1) Description of Discontinsity Repair Required ‘Any discontinuity 1 in. (25 mm) in length or less None, need not be explored ‘Any discontinuity over 1 in. (25 man) in length and 1/8 in. 3 mim) maximum depth __ None, but the depth shouldbe explored. ‘Any discontinuity over | in (25 mm) in length with depth over 1/8 in. 3 ram) but ot greater than 174 in (6 mn) ‘Any discontinuity over | in, (25 mma) in length with depth over 1/8 in (6 mm) but ‘ot greater than 1 i ‘Any discontinity over 1 in. (25 run in length with depth greater than 1 in Remove, need not weld Completely emove and weld See $15.11 A spt check of 10% af he diecomtnities onthe ext surface in queution sal be explored by pnding to determine depth Whe depth fay one ofthe dacomtouien explored excseds 1 h(t) ten ll of he discontines over 1a-(25 min length remaining on hacer srface sal be ‘xpored by grinding a dtermine dept. I noe of te discontnuisesexpared i the 10% op check have a ep exceeding 7 a (3 me), then the ‘emainer ofthe isconnies on ta ut surface ned ot be exploremay be done from either surface of the bese metal. The aggregate length of welding shall not exceed 20% of the length ofthe plate surface being repaired except with ap- proval ofthe Engineer. S.15.1.1 Acceptance Criteria, For discontinuities ‘eater than | in, (25mm) in length and depth discovered ‘on cut surfaces, the following procedures shall be observed. (1) Where discontinuities such as W, X, or Y in Fig- wre 5.1 are observed prior to completing the. size and shape of the discontinuity shall be determined by ultrasonic testing. The erea of the discontinuity shall bbe determined as the area of total loss of back reflection, + when tested in accordance with the procedure of ASTM ‘A435, Specification for Straight Beam Ultrasonic Exam- ination of Steet Plates! (@) For acceptance of W. X, or ¥ discontinuities, the area ofthe discontinuity (or the aggregate area of multi- ple discontinuities) shall not exceed 4% of the cut mate- I area (length times width) with the following exception: if the length of the discontinuity, or the agere- gate width of discontinuities on any transverse section, 45 measured perpendicular to the cut materiel length, ex- ceeds 20% ofthe cut material width, the 4% cut material area shall be reduced by the percentage amount of the Width exceeding 20%. For example, if discontinuity is : N x Figure 5.1—Edge Discontinuities in Cut Material (see 5.15.1.1) 1. ASTM, 100 Bare Harbor Drive, West Conshohocken, PA. __ 19428-2089. Fabrication/161 30% of the cut material width, the area of discontini cannot exceed 3,6% of the cut material area.) The dis- continuity on the cut surface ofthe cut material shall be removed toa depth of { in, (25 ram) beyond its intersee- tion with the surface by chipping, gouging, or grinding, and blocked off by welding with « low-hydrogen process in layers not exceeding 1/8 in. (3 mm) in thickness for at least the fist four layers. (8) Ifa discontinuity Z, not exceeding the allowable area in 5.15.1.1(2), is discovered after the joint has been completed and is determined to be 1 in, (25 mm) or more away from the face ofthe weld, as measured on the cut bbase-metal surface, no repair of the discontinuity is re- quired. Ifthe discontinuity Z.is less than | in, away from the face ofthe weld, it shall be removed (oa distance of 1 in. from the fusion zone of the weld by chipping, goug- ing. or grinding. It shall then be blocked off by welding. with a low- hydrogen process in layers not exceeding. 118 in, (3 mm) in thickness for at least the first four layers. (4) Ifthe area ofthe discontinuity W. X. Y, or Z ex~ ceeds the allowable in 5.15.1.1 (2), the eut material or subcomponent shall be rejected and replaced, or repaired. atthe discretion of the Engineer 5.1.1.2. Repair, In the repair and determination of limits of mill induced discontinuities visually observed on cut surfaces, the amount of metal removed shall be the minimum necessary to remove the discontinuity of to determine that the limits of Table 5.4 are not exceeded. However, if weld repair is required, sufficient base metal shall be emoved to provide access for welding. Cut sur- faces may exist at any angle with respect to the rolling direction. All welded tepairs of discontinuities shall be made by: (1) Suitably preparing the epai area (@) Welding with an approved low-hydrogen process ‘and observing the applicable provisions of this code (3) Grinding the completed weld smooth and flush (see $.24.4.1) with the adjacent surface to produce a workmanlike finish, Note: The requirements of 5.15.1.2 may not be adequate in cases of tensile load applied through the thickness of the material 5.18.2 Joint Preparation. Machining, thermal eutting, ‘gouging, chipping, or grinding may be used for joint preparation, or the removal of unacceptable work or metal, except that oxygen gouging shall not be used on steels that are ordered as quenched and tempered or normalized ‘5.18.3 Material Trimming. For cyclically loaded struc- tures, material thicker than specified in the following shall be trimmed if and as required 10 produce a satisfac-162Rabrication tory welding edge wherever a weld is to cary caleuleted stress: (1) Sheared materia thicker than 12 in (12.7 mm) (Q) Rolled edges of plates (other than universal mill plates) thier than 3/8 n.(9.5 mm) (3) Toes of angles or roled shapes (ther than wide ‘ange sections) thicker than 58 in. (15.9 mm) (4) Universal mil plats or edges of anges of wide flange sections thicker than | in. (25.4 mim) (6) The preparation for butt joints shall conform to the requirements of the detail drawings 5.18.4 Thermal Cutting Processes. Electric arc cutting and gouging processes and oxyfucl gas cutting processes are recognized under this code for use in preparing, eut- ‘ing, or tcimming materials. The use of these processes shall conform to the applicable requirements of section 5. 5.15.4.1 Other Processes, Other thermal cutting ‘processes may be used under this code, provided the Contractor demonstrates to the Engineer an ability to successfully use the process. $.1542 Profile Accuracy. Stee! and weld metal may be thermally cut, provided a smooth and regular surface free from cracks and notches is secured, and provided that an accurate profile is secured by the use of a me~ ‘chanical guide, Por eycically loaded structure, freehand thermal cutting shall be done only where approved by the Engineer.. $.18.43 Roughness Requirements. In thermal cut- ting, the eqdipment shall be so adjusted and manipulated fs to avoid cutting beyond (inside) the prescribed lines. ‘The roughness of all thermal cut surfaces shall be no greater than that defined by the American National Stan- dards Institute surface roughness value of 1000 win. (2S ym) for material up to 4 in. (102 mm) thick and 2000 win, (50 jm) for material 4 in. to 8 in, (203 mm) thick, with the following exception: the ends of members ‘not subject to calculated stress at the ends shall not ex: coed a surface roughness value of 2000 pin. ANSI 'B46.1, Surface Texture is the reference standard. AWS ‘Surface Roughness Guide for Oxygen Cutting (AWS, C4.1-77) may be used as a guide for evaluating surface roughness of these edges. For malerials up to and includ- ing 4 in, (102 mm) thick, use Sample No. 3, and for ‘materials over 4 in. up to 8 in, 203 ram) thick, use Sam- ple No. 2. 5.15.44 Gouge or Notch Limitations. Roughness exceeding these values and notches or gouges not more than 3/16 in, (5 mm) deep on other wise satisfactory sur- faces shall be removed by machining or grinding. Notches of gouges exceeding 3/16 in. deep may be fe- ppaiced by grinding if the nominal cross-sectional area is, ‘not reduced by more than 2%. Ground or machined suc- faces shall be fared to the original surface with a slope, rot exceeding one in ten. Cut surfeces and adjacent edges shall be left free of slag. In thermal-cut surfaces, ‘ecasional notches or gouges may, with approval of the Engineer, be repaired by welding. 5.16 Reentrant Corners Reentrant comers of cut material shall be formed to provide « gradual transition with a radius of not less than 1 in, (25 mm). Adjacent surfaces shall meet without off- set or cutting past the point of tangency, The reentcant comers may be formed by thermal cutting, fotlowed by grinding, if necessary, to meet the surface requirements of 5.1543. 5.17 Beam Copes and Weld Access Holes Radi of beam copes and weld access holes shall pro- vide a smooth transition free of notches or cutting past the points of tangeney between adjacent surfaces und shall meet the surface requirements of 5.15.4.3. SATA Weld Access Hole Dimensions. All weld access holes required to facilitate welding operations shall have a length from the toe of the weld preparation not less than 1-1/2 times the thickness of the material in which the hole is made. The height of the access hole shall be adequate for deposition of sound weld metal in the edja- ‘cent plates and provide clearance for wetd tabs for the weld in the material in which the hole is made, but not less than the thickness of the material, [n hot rolled shapes and built-up shapes, all beam copes and weld access holes shall be shaped free of notches or sharp re~ entrant corners except that when fillet web-to-flange ‘welds are used in built-up shapes, access holes are per- mitted to terminate perpendicular to the flange. Fillet welds shall not be returned through weld access holes. See Figure 52. 5.17.2 Group 4 and $ Shapes. For ASTM A6 Group 4 land 5 shapes and built-up shapes with web materia! thickness greater than 1-1/2 in, (38.1 mm), the thermally ‘ut surfaces of beam copes and weld access holes shall ‘be ground to bright metal and inspected by either mag- netic particle or dye penetrant methods. If the curved ‘transition ponion of weld access holes and beam copes ate formed by predrilled or sawed holes, that portion of the access hole of cope need not be ground. Weld access holes and beam copes in ather shapes need aot be ground nor dye penetrant or magnetic-partile inspected.BACKING IF USED BACKING IF USED ale vein LPL E SA FOULED SHAPE OA ‘GROOVE WELDED SHAPE'? Fabrication/t63, RADIUS PREOUT BY OFILLOR HOLE SAW 215, NEED NOT BE TANGENT NOTCHES PROMBITED SEE FIG. C32 ‘OPTIONAL METHOD FOR MAKING CORNER RADIUS. FILLET WELDED SHAPE'* Notes: 1 Por ASTM AS Group 4 and 5 shapes and wekiod bultup shapes wih web rickness more than 1-172 I, (38.1 mn), prabeat to 150" {66°C} prior to thermal euttng. gin and Fepecttermaty cut edges of aocess hole using magnate partici or dye penetration met ‘0d prior 19 making web and fange epic groove wold ‘Acooes opering mace afer wai wab fo fange. paon Faclua chal provide smooth note-Wea traniion: P28 in. (@ mm) (Typical V2 in. (19 ran ‘Reseed opening made betere weling wed to fange. Weld rot returned trough oponing. “These are typical deta for omnis wet from one sid agains sloal backing. Ateriauv jl designs should be considered. Figure 5.2—Weld Access Hole Geometry (see 5.17.1) 5.18 Temporary and Tack Welds 5.18.1 Temporary Welds. Temporary welds shall be subject to the same welding procedure cequirements as the final welds. These shall be removed, when required by the Engineer. When they are removed, the surface shall be made flush with the original surface. For cyclically loaded nontubuler connections, there ‘shall be no temporary welds in tensien zones of members made of quenched and tempered steel except at locations ‘more than 1/6 of the depth of the web from tension flanges of beams or girders; temporary welds at other locations shall be shown on shop drawings. 5.18.2 General Requirements for Tack Welds. Tack ‘welds shall be subject to the same quality requirements as the final welds, with the following exceptions: (1) Preheat is not mandatory for single-pass tack welds which are remelted and incorporated into continu fous submerged arc welds. @) Discontinuities, such as undercut, unfilled eraters, and porosity need nat be removed before the final sub- merged are welding $.18.2.1 Incorporated Tack Welds. Teck welds which are incorporated into the final weld shall be made ‘with electrodes meeting the requirements of the final welds and shall be cleaned thoroughly. Multiple-pass tack welds shall have cascaded ends. 5,182.2 Nonincorporated Tack Welds, Tack welds rot incorporated into final welds shall be removed, ex cept that, for statically loaded strvetures, they need not bbe removed unless required by the Engineer.