DESCRIPTION AND APPLICATION GUIDELINES

Roxtec welding guidelines

Prepared for: Roxtec International AB

Date: 2016-06-07
Author: Jens Bohlin, Anders Hansson
Roxtec Group, Box 540, Karlskrona, Sweden
Abstract
This guideline is a help for the welding responsible to produce a welding procedure specification (WPS).
This can be unique for every site due to local requirements and regulations.

Personnel competence recommendations

For reliable and high quality results, welders are recommended to be qualified according to the latest
editions of AWS D1.1, ISO 9606-1 2013, ISO 9606-2 2004 or other authorized system.

Welding methods described in the guideline

Shielded metal arc welding (SMAW)
Flux core arc welding (FCAW)
Gas tungsten arc welding (GTAW)

Welding consumables
Welding consumables are to be chosen depending on the materials that shall be welded together. Shall
be handled and treated according to instructions from manufacturer of consumables.

Welding quality levels for imperfections of the frame

Roxtec frames manufactured in mild steel and stainless steel are welded according to EN-ISO 5817 Min
Class C. Aluminum frames are welded according to EN-ISO 10042 Min Class C.

Requirements after welding

The Roxtec system is certified for pressure up to 6 bar. Therefore we recommend undestructive testing
of the welds such as liquid penetrant, ultrasonic testing and magnetic particle testing. The dimensions
should be according to the table on page 9 to obtain optimal performance of the transit.

Legend
Location of various welds between structure and sleeve/frame.

Front side of sleeve/frame

Fixing weld
Fillet weld

Structure

Tack weld
Optional seal weld

Back side of sleeve/frame

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Contents

1. Aperture and buttering ............................................................................. 4

1.1 For frames without flange ................................................... 4
1.2 For frames with flange ........................................................ 4
2. Positioning and fixing ............................................................................... 5
2.1 Positioning .......................................................................... 5
2.2 Fixing .................................................................................. 5
3. Tack weld................................................................................................. 6
4. Fillet weld ................................................................................................ 7
4.1 Weld passes – Frames/sleeves without flange ................... 8
4.2 Weld passes – Frames/sleeves with flange ........................ 8
5. Measuring................................................................................................ 9
6. SO (openable weld frame) ..................................................................... 10
6.1 SO frames ........................................................................ 10
6.2 Dimensions ...................................................................... 10
7. SFO (openable weld frame with flange) .................................................. 11
7.1 SFO frames ...................................................................... 11
7.2 Dimensions ...................................................................... 11
7.3 Procedure – single frame .................................................. 12
7.4 Procedure – combination frame ........................................ 13
8. Caution! ............................................................................................... 14
8.1 Intermettent welds ............................................................ 14
8.2 Exceeding the recommended weld size............................. 14
8.3 Weld pass ........................................................................ 14

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1. Aperture and buttering

1.1 For frames without flange

Make the aperture as close to the frame outer dimension as possible to avoid large root gaps.
Max allowed total root gap before welding is 2 mm. Larger gaps must be buttered to avoid deformation of
the frame. The buttering shall not be made on the frame.

max 2 mm

max 2 mm

Measure the aperture using Maximum total root gap for Buttering of aperture shall be
the frame. fillet weld. performed on the structure.

1.2 For frames with flange

Make the aperture considering the minimum clearance of 15 mm. The edge of the aperture should be
placed at the center of the flange of the frame.

15 mm
(min clearance)

Position of frame with flange into an

aperture.

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2. Positioning and fixing
The frame or sleeve can be centered or fixed in a corner of the aperture at any depth or angle. It is
important not to exceed the maximum allowed root gap also when welding the frame in an angle. Frames
and sleeves with flange must cover the aperture in full.
Check fire certification with regard to allowed positioning.

2.1 Positioning

15 mm (min clearance)

For flanged frames/sleeves a 15 mm clearance is required.

2.2 Fixing
The frame can be centered or fixed in a corner of the aperture at any depth. The maximum allowed root
gap is 2 mm to prevent heat deflection.

max 2 mm

max 2 mm max 2 mm

Fixing of rectangular frame Fixing of sleeve

without flange. without flange.

Fixing of sleeve with flange. Fixing of rectangular frame

with flange.

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3. Tack weld
Apply tack welds with a length of 15-20 mm on the back side at the corners and in the center of every
opening of the flange. Use an appropriate tool to clamp the frame in tolerance during the whole welding
process to avoid heat deflection. Do not remove the tool until the frame has a temperature below 50˚C.
Clamping is only required at the side openings and in the center of a x3 combination frame.
Note: If the fillet weld is applied on only one side the tacking must be made on the opposite side.

15-20
mm

Clamp tool applied on a rectangular Tack weld of a rectangular Tack weld of a rectangular
frame without flange. combination frame without flange. combination frame with flange.

Tack welded rectangular frame Tack weld of a sleeve without flange. Tack weld of a sleeve with flange.
without flange.

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4. Fillet and seal weld
■ Apply the fillet weld on the front side with an interpass temperature below 150˚C for stainless steel
and below 250˚C for mild steel or aluminum. The weld runs shall not exceed 150 mm/weld pass.
■ Grind off the tack welds on the back side before applying the optional seal weld.

Weld pass front side

a
T1
T2

(z)
Seal weld back side if
required by design
Frame/sleeve with flange.

T1
Weld pass front

Note: The optional seal weld is for T2

a
corrosion protection only and not

(z)
mandatory unless specified by
Seal weld back side
the design. if required by design
Frame/sleeve without flange.

Weld sizes Max heat input (kJ/mm)

Frame thickness Structure thickness Fillet weld size Seal weld size Mild steel Stainless steel Aluminum
T1 T2 (max) (max)

5-6 3<T2<12 a3 (z4) a3 (z4) 1.5 1.1 2.5

10-12 ≤6 a4 (z5) a3 (z4) 1.5 1.1 2.5
10-12 >6 a5 (z7) a3 (z4) 1.5 1.1 2.5

Q = Heat input [KJ/mm]

U = Voltage [V]
Q= k x U x I x 60
I = Current [A]
v x 1000 v = Welding speed [mm/min]
k = Thermal efficiency [dimensionless]

Welding method Thermal

efficiency

SMAW (shielded metal arc) 1.0

GMAW (gas metal arc) 0.8
GTAW (gas tungsten arc) 0.6

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 4.1 Weld passes – Frames/sleeves without flange

12 8
1 4

Weld Weld 1 Weld

3 pass
pass pass
5 10
1
9 6
4 2

3 2 2
7 11

4.2 Weld passes – Frames/sleeves with flange

4 6

3
Weld Weld Weld
pass 8 2 pass pass

1
1 2

1 7

4 2
5 3

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5. Measuring
Measure 10 mm into the frame depth on the front and back side in accordance with the table.
The measurements are to be made with a frame or sleeve temperature below 50˚C.

W +1 +B
-0.5 ØD -C

H ±1

Frame dimensions Sleeve dimensions Sleeve dimensions

Size H W Size B C Size B C
(mm) (mm) ØD (mm) (mm) ØD (mm) (mm)
1 101 60 23 1 0 200 3 0
2 101 120 25 1 0 225 3 0
3 159.5 60 31 1 0 250 3 0
4 159.5 120 43 2 0 300 3 0
5 218 60 50 2 0 350 3 0
6 218 120 68 2 0 400 3 0
7 278 60 70 2 0 450 3 0
8 278 120 75 2 0 500 3 0
100 2 0 550 3 0
125 2 0 600 3 0
150 2 0 644 3 0
175 2 0

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 6. SO, Openable frames
Openable frames intended for retrofit are recommended to be installed by welders qualified according to the
latest edition of AWS D1.1, ISO 9606-1 2013, ISO 9606-2 2004 or other authorized system. It is important
to achieve a gas-tight weld and secure that the burn through is well controlled preferably by backing.

6.1 SO frames
Weld the frame parts together before fixing it to the structure. Make sure to keep the geometrical
tolerances. After assembly the SO frame is welded following the normal routine for a rectangular frame
without flange with fixing, buttering and fillet weld. See table on page 7 for appropriate heat input.

Grind off the fixing welds. Remove frame part. Protect cables during welding.

6.2 Dimensions after welding

Note 1

SO frame opening
Size H1 W1
H ±1

(mm) (mm)
1x1 101 60
(10)

2x1 101 120

W1 +1
(10) -0.5
3x1 159.5 60
4x1 159.5 120

Note 1
5x1 218 60
Note 1 6x1 218 120
7x1 278 60
8x1 278 120
H ±1
(10)

(10) W1 +1
-0.5 (10)

Note 1: Min 20% burn through of total weld length. Max R1 on all inner corners.

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7. SFO, Openable frames with flange
Openable frames intended for retrofit are recommended to be installed by welders qualified according to the
latest edition of AWS D1.1, ISO 9606-1 2013, ISO 9606-2 2004 or other authorized system. It is important
to achieve a gas-tight weld and secure that the burn through is well controlled preferably by backing.

7.1 SFO frames

Weld the frame parts together before fixing it to the structure. Make sure to keep the geometrical
tolerances. After assembly the SFO frame is welded following the normal routine for a rectangular frame
with flange with fixing, buttering and fillet weld. See table on page 7 for appropriate heat input.

Grind off the fixing welds. Remove frame parts. Protect cables during welding.

7.2 Dimensions after welding

(60)
A (3)
SFO frame opening
Size H1 W1
(mm) (mm)
1x1 101 60
Note 1 2x1 101 120
H ±1

3x1 159.5 60
4x1 159.5 120
5x1 218 60
6x1 218 120
A 7x1 278 60
8x1 278 120
W1 +1
-0.5

Note 1: Min 20% burn through of total weld length. Max R1 on all inner corners.

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7.3 Procedure – single frame

Note 1

(2x)

Note 1: Min 20% burn through of total weld length. Max R1 on all inner corners.

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7.4 Procedure – combination frame

Note 1
GTAW

Note 1

Note 1: Min 20% burn through of total weld length. Max R1 on all inner corners.

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8. Caution!
Even though the guideline is an help to make safe welds it is important to be aware of potential errors
that can lead to system failure. Below sections are examples of errors that can occur during welding.

8.1 Intermittent welds

Make sure to overlap weld seams.

8.2 Exceeding the recommended weld size

Excessive welding or too large heat input can cause the frame to deflect and thereby increase the
packing space, lowering the compression in the sealing system.

8.3 Weld pass

Start a new weld seam from an end point of a previous weld.

End point of
previous weld

Weld
direction

Start point for

new weld

Start point of
previous weld

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 PDF2016000301
DISCLAIMER
”The Roxtec cable entry sealing system (”the Roxtec system”) is a modular- The product information provided by Roxtec does not release the purchaser
based system of sealing products consisting of different components. Each of the Roxtec system, or part thereof, from the obligation to independently
and every one of the components is necessary for the best performance determine the suitability of the products for the intended process, instal-

ver_1.0/EN/1604/stsan
of the Roxtec system. The Roxtec system has been certified to resist a lation and/or use. Roxtec gives no guarantee for the Roxtec system or
number of different hazards. Any such certification, and the ability of the any part thereof and assumes no liability for any loss or damage whatso-
Roxtec system to resist such hazards, is dependent on all components ever, whether direct, indirect, consequential, loss of profit or otherwise,
that are installed as a part of the Roxtec system. Thus, the certification occurred or caused by the Roxtec systems or installations containing
is not valid and does not apply unless all components installed as part components not manufactured by an authorized manufacturer and/or
of the Roxtec system are manufactured by or under license from Roxtec occurred or caused by the use of the Roxtec system in a manner or for
(“authorized manufacturer”). Roxtec gives no performance guarantee with an application other than for which the Roxtec system was designed or
respect to the Roxtec system, unless (I) all components installed as part intended. Roxtec expressly excludes any implied warranties of merchan-
of the Roxtec system are manufactured by an authorized manufacturer tability and fitness for a particular purpose and all other express or implied
and (II) the purchaser is in compliance with (a), and (b), below. representations and warranties provided by statute or common law. User
determines suitability of the Roxtec system for intended use and assumes
(a) During storage, the Roxtec system or part thereof, shall be kept indoors
all risk and liability in connection therewith. In no event shall Roxtec be
in its original packaging at room temperature.
liable for indirect, consequential, punitive, special, exemplary or incidental
(b) Installation shall be carried out in accordance with Roxtec installation damages or losses.”
instructions in effect from time to time.

Roxtec ® and Multidiameter ® are registered trademarks of Roxtec in Sweden and/or other countries.

Roxtec International AB
Box 540, 371 23 Karlskrona, SWEDEN
PHONE +46 455 36 67 00, FAX +46 455 820 12
EMAIL [email protected], www.roxtec.com

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