11 WELDING
11-1 General
11-1.01 General
Section 11 -1 includes general specifications for welding where welding is specified to comply with an AWS welding code. Do not perform welding using flux -cored welding electrodes that comply with AWS A5.20, E6XT -4 or E7XT -4. Wherever reference is made to the following AWS welding codes in the Contrac t, the year of adoption for these codes is as shown in the following table: AWS code Year of adoption D1.1 2020 D1.3 2018 D1.4 2018 D1.5 2020 D1.6 2017 D1.8 2016
11-1.02 Definitions
continuous inspection: QC Inspector must be within close proximity of all welders or welding operators such that inspections by the QC Inspector of each welding activity at each welding location do not lapse for a period exceeding 30 minutes. gross nonconformance: Rejectable in dications are present in more than 20 percent of the tested weld length.
11-1.03 Quality Control Inspector
Replace clause 8.1.3 of AWS D1.1, the 1st paragraph of clause 9.1.2 of AWS D1.4, and clause 8.1.2 of AWS D1.5 with: The QC Inspector must be the duly assigned person who acts for and on your behalf for inspection, testing, and quality related matters for all welding. The QA Inspector is the authorized representative who acts for and on behalf of the Engineer. The QC Inspector must be responsible for QC acceptance or rejection of materials and workmanship. Where the term Inspector is used without further qualification, it refers to the QC Inspector. The QC Inspector must document inspection and approval of:
1.All jo int preparations, assembly practices, joint fit -ups, and welding techniques
2.Performance of each welder, welding operator, and tack welder on a daily basis for each day welding is performed For each inspection, including fit -up, WPS verification, and fi nal weld inspection, the QC Inspector must confirm and document compliance with the specifications, AWS welding codes and any referenced drawings.
11-1.04 Personnel Qualifications and Certifications
The Engineer has the authority to verify the qualificati ons or certifications of any welder, QC Inspector, or NDT personnel to specified levels by retests or other means determined by the Engineer. If welding will be performed without gas shielding, then qualification must also include welding without gas shiel ding. Replace clause 8.14.6.1 of AWS D1.1, clause 9.8.1 of AWS D1.4, and clause 8.1.3.4 of AWS D1.5 with: Personnel performing NDT must be qualified and certified under American Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT -TC-1A and the written practice of the NDT firm. The written practice of the NDT firm must comply with or exceed the guidelines of the ASNT SECTION 1 1 WELDING Recommended Practice No. SNT -TC-1A. Individuals who perform NDT, review the results, and prepare the written reports must b e one of the following:
1.Certified NDT Level II technicians
2.Level III technicians certified to perform the work of Level II technicians
11-1.05 Weld Joint Details
Replace the first sentence of clause 7.21.1.1 of AWS D1.1 with the following: The se paration between surfaces of plug and slot welds, and of joints landing on a backing, shall not exceed 1/16 in [2 mm]. Replace clause 5.3.1.1 of AWS D1.5 with the following: The separation between surfaces of plug and slot welds, and of joints landing on a backing, shall not exceed 2 mm [1/16 in]. If weld joint details proposed for use in the work are not prequalified under clause 5 of AWS D1.1 or figure 4.4 or 4.5 of AWS D1.5, submit the proposed WPS and the intended weld joint locations. Upon authoriza tion of the proposed joint detail locations and qualification of the proposed joint details, welders and welding operators using these details must weld an additional qualification test plate using the WPS variables and the weld joint detail to be used in production. The test plate must:
1.Have the maximum thickness to be used in production and a minimum length of 18 inches.
2.Be mechanically and radiographically tested. Mechanical and radiographic testing and acceptance criteria must comply with the applicable AWS codes. The type of mechanical testing must be authorized. If a nonprequalified weld joint configuration is proposed using a combination of WPSs for work welded under AWS D1.1, you may conduct a single test combining the WPSs to be used in p roduction, if the essential variables, including weld bead placement, of each process are limited to those established in table 6.5 of AWS D1. 1.
11-1.06 Procedure Qualification Tests
All procedure qualification tests for WPSs that were not previously auth orized by the Department must be witnessed by the Engineer . Submit an inspection request form to METS at least 7 days before performing any procedure qualification tests. Notify the Engineer of your submittal. Witnessing of qualification tests by the Engineer does not constitute authorization of the intended joint locations, welding parameters, or essential variables.
11-1.07 Nondestructive Testing
Replace item 3 of clause 8.26.3.2 of AWS D1.5 with:
3.If indications that exhibit these planar characte ristics are present at scanning sensitivity, or other evidence exists to suggest the presence of transverse cracks, a more detailed evaluation of the discontinuity by other means must be performed (e.g., alternate UT techniques, RT, grinding, or gouging fo r visual inspection or MT of the excavated areas.) Replace the scanning angle in clause 8.24.2.2 of AWS D1.5 with: e = 45 max Clause 8.6.5 of AWS D1.1, clause 9.6.5 of AWS D1.4, and clause 8.6.5 of AWS D1.5 do not apply. The Engineer may order you to pe rform NDT that is in addition to the visual inspection or NDT specified in the specifications or AWS welding code. The additional NDT and associated repair work is change order work. If the NDT discloses an attempt to defraud or reveals a gross nonconforma nce, the Department does not pay for the costs associated with the repair of the deficient area, the NDT of the weld and of the repair, or any delays caused by the repair. SECTION 1 1 WELDING If less than 100 percent of NDT is specified for any weld, the entire length of weld must comply with the specified acceptance criteria. If any welding deficiencies are discovered by additional NDT ordered or performed by the Engineer that uses the same NDT method as that originally specified, the Department does not pay for the costs ass ociated with the repair of the deficient area, including NDT of the weld and of the weld repair, or any delays caused by the repair. If any welding deficiencies are discovered by visual inspection ordered or performed by the Engineer, the Department does n ot pay for the costs associated with the repair of a deficient area or any delays caused by the repair.
11-2 Welding Quality Control
11-2.01 General
Section 11 -2 applies to (1) work welded under sections 49, 52, 55, and 60 -4.09, and (2) work in section 99 that must comply with an AWS welding code. All welding requires inspection by the Engineer. You must provide continuous inspection when any weldi ng is being performed.
11-2.02 Welding Quality Control Manager
Assign a welding QC manager. The welding QC manager must be registered as a civil engineer in the State or currently certified as a CWI.
11-2.03 Submittals
11-2.03A General
If welding is performed at the job site, submit an inspection request form at least 3 business da ys before performing welding at the job site. Notify the Engineer of your submittal.
11-2.03B Welding Quality Control Plan
Before submitting a welding QC plan, hold a prewelding meeting to discuss the requirements for the welding QC plan. The meeting attendees must include the Engineer, your welding QC manager, and a representative from each entity performing welding or inspection for the Contract. For the contents, format, and organization required for a welding QC plan, go to the Department's Division of Engineering Services website . Submit 2 copies of a welding QC plan for each subcontractor or supplier for each item of work for which welding is performed. Submit an amended welding QC plan or an addendum to the welding QC plan fo r any changes to:
1.WPSs
2.NDT firms
3.QC personnel or procedures
4.NDT personnel or procedures
5.Systems for tracking and identifying welds
6.Welding personnel Allow 15 days for the Engineer's review of an amended welding QC plan or an addendum to the welding QC plan. Submit 7 copies of each authorized QC plan and any authorized addendums. Make 1 copy available at each location where work is performed.
11-2.03C Welding Report
Submit a welding report within 7 days following the performance of any we lding. The welding report must include:
1.Daily production log for welding for each day that welding is performed SECTION 1 1 WELDING
2.Reports of all visual weld inspections and NDT performed, whether specified, additional, or informational
3.Radiographs and radiographic reports, and other required NDT reports
4.Summary of welding and NDT activities that occurred during the reporting period
5.Reports of each application of heat straightening
6.Summarized log listing the rejected lengths of weld by welder, position, proc ess, joint configuration, and piece number
7.Documentation that you have: 7.1. Evaluated all radiographs and radiograph reports and NDT and NDT reports 7.2. Corrected all rejectable deficiencies and that all repaired welds have been reexamined using the required NDT and found acceptable
8.Reports or chart recordings of each application of any stress relieving used
9.Reports and chart recordings for any electroslag welding used The daily production log must include:
1.Locations of all welding
2.For each location, the welders' names, quantity of welding performed, any problems or deficiencies discovered, and any testing or repair work performed
3.Daily report from each QC Inspector Clearly write the following information on the outside of radiogra phic film envelopes:
1.Name of the QC manager
2.Name of the NDT firm
3.Name of the radiographer
4.Date
5.Contract number
6.Complete part description
7.All included weld numbers, report numbers, and station markers or views as detailed in the welding QC plan Clearly write on all interleaves the part description and all included weld numbers and station markers or views as detailed in the welding QC plan. Use a maximum of 2 pieces of film for each interleave. The QC Inspector or certified technician m ust sign all visual inspection and NDT reports and submit them daily to the welding QC manager for review and signature before submittal to the Engineer. Corresponding names must be cle arly printed or typewritten adjacent to all signatures. The Engineer re views the welding report to determine whether you are complying with the welding QC plan and the Contract. Except for field welded steel pipe piling and field welded bar reinforcement in CIP concrete piling:
1.Allow the Engineer 15 days to review the repo rt.
2.You may encase in concrete or cover welds for which the welding report has been submitted before receiving authorization of the welding report. If you choose this option, you will not be relieved of the responsibility for incorporating material in t he work that complies with the Contract. Material not complying with the Contract is subject to rejection. For field welded steel pipe piling and field welded bar reinforcement in CIP concrete piling:
1.Allow the Engineer 2 business days to review the we lding report
2.Do not install the steel pipe piling or encase the reinforcement in concrete until the Engineer has authorized the welding report
11-2.03D Certificates of Compliance
Submit a certificate of compliance for each item of work for which welding is performed. The certificate must be signed by the welding QC manager. The certificate must state that all of the materials and workmanship incorporated in the work, and all requir ed tests and inspections of this work, have been performed in compliance with the Contract. SECTION 1 1 WELDING
11-2.04 Personnel Qualifications and Certifications
Clauses 8.1.4.2 and 8.1.4.4 of AWS D1.1, the 2nd paragraph of clause 9.1.2 of AWS D1.4, clauses 8.1.3.1 through 8.1.3.3 of AWS D1.5, and clause 7.2.3 of AWS D1.8 are replaced with: The QC Inspector must be currently certified as an AWS Certified Welding Inspector under AWS QC1. The QC Inspector may be assisted by an Assistant QC Inspector provided that this indiv idual is currently certified as an AWS Certified Associate Welding Inspector under AWS QC1. The Assistant QC Inspector may perform inspection under the direct supervision of the QC Inspector provided the assistant is always within visible and audible range of the QC Inspector. The QC Inspector must be responsible for signing all reports and for determining if welded materials comply with the workmanship and acceptance criteria. The ratio of QC A ssistants to QC Inspectors must not exceed 5 to 1. Welding ins pection personnel or NDT firms to be used in the work must not be employed or compensated by any subcontractor or by other persons or entities hired by subcontractors who will provide other services or materials for the Contract, unless one of the followin g conditions is met:
1.Work is welded at a permanent fabrication or manufacturing plant that is certified under the AISC Certification Program for Steel Bridge Fabricators, Intermediate Bridges, and Fracture -Critical Member endorsement if required.
2.Structural steel for building construction work is performed at a permanent fabrication or manufacturing plant that is certified under the AISC Quality Certification Program, Category BU, Fabricators of Steel Buildings. Except for the exempt facilities ident ified above, an authorized independent third party must witness the qualification tests for welders or welding operators. The independent third party must be currently certified as a CWI and must not be an employee of the Contractor performing the welding. Allow 15 days for the Engineer to review the qualifications and copy of the current certification of the independent third party.
11-2.05 Welding Inspection
Replace clause 8.5.4 of AWS D1.5 with: The QC Inspector must inspect and approve each joint prep aration, assembly practice, welding technique, joint fit -up, and the performance of each welder, welding operator, and tack welder to make certain that the applicable requirements of this code and the qualified WPS are met. The QC Inspector must examine th e work to make certain that it complies with clauses 3 and 6.26. The size and contour of all welds must be measured using suitable ga uges. Visual inspection for cracks in welds and base metal, and for other discontinuities must be aided by strong light, ma gnifiers, or other devices as necessary. You may use acceptance criteria different from those specified in this code if authorized.
11-2.06 Welding Procedures Qualification
Welding procedures qualification for work welded under AWS D1.5 must comply with clause 7.12 or 7.12.4 of AWS D1.5 and the following:
1.Macroetch tests are required for all WPS qualification tests, and acceptance must comply with clause 7.19.2 of AWS D1.5.
2.If a nonstandard weld joint is to be made using a combination of WPSs, you m ay conduct a test under figure 7.3, combining the qualified or prequalified WPSs to be used in production, if the essential variables, including weld bead placement, of each process are limited to those established in table 7.6 of AWS D1.5.
3.Before prepa ring mechanical test specimens, inspect the PQR welds by visual and radiographic tests. The backing bar must be 3 inches in width and must remain in place during NDT. Results of the visual and radiographic tests must comply with clause 8.26.2 of AWS D1.5 e xcluding clause 8.26.2.2. All other requirements for clause 7.17 are applicable. When electric resistance welding is used for work welded under AWS D1.1, the welding procedure must be qualified under Clause 6 of AWS D1.1. Welding procedures must be qualif ied for the thickness and the SECTION 1 1 WELDING pole diameter tested. Test samples for tapered poles must be obtained from three locations, each end and the middle of the tapered pole, to qualify for the diameter range tested.
11-2.07 Repair Work
Notify the Engineer immedi ately if you discover welding problems, deficiencies, base metal repairs, or any other type of repairs not included in the welding QC plan. Submit the proposed repair procedures to correct them. Allow the Engineer 7 days to review the repair procedures. You must receive authorization before performing:
1.3rd-time excavations of welds or base metal to repair unacceptable discontinuities, regardless of NDT method
2.Repairs of cracks
3.Repairs not included in the welding QC plan Requests to perform 3rd -time excavations, repairs of cracks, or repairs not included in the welding QC plan must include an engineering evaluation. At a minimum, the engineering evaluation must address:
1.Cause of each defect
2.Why the repair will not degrade the material proper ties
3.What steps are being taken to prevent similar defects from happening again
11-3 Welding for Overhead Sign Structures, Standards, and Poles
11-3.01 General
Fabricate overhead sign structures, standards, and poles at a pl ant on the Authorized Facility Audit List.
11-3.02 Welding Inspection
Welding inspection personnel or NDT firms to be used in the work must not be employed or compensated by any subcontractor or by other persons or entities hired by subcontractors who pro vide other services or materials for the Contract except for welding performed at a permanent fabrication or manufacturing plant that is certified under the AISC Quality Certification Program. The AISC Certification category for overhead sign structures is Bridge and Highway Metal Component (CPT) or Simple Steel Bridge Structures (SBR). The AISC Certification category for pole structures is Bridge and Highway Metal Component (CPT) or Standard for Steel Building Structures (BU).
11-3.03 Submittals
Submit a welding report under section 11 -2.03C except submit the welding report 2 business days before submitting the certificate of compliance.
11-4 11-9 Reserved
Source: California Standard Specifications, 2024 Edition. Pages 153–158 of 1,372.