WELDING OPERATIONS MANUAL
Welding Operations Manual
Control Number
Welding Operations Manual Controlled Copy Issued to each welder and identified by Welder ID Welder ID
Issued To:
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 2
Weld Manual Table of Contents Subject
Work Instruction
Pages
Qualified Welding Personnel Welder ID Stamps Production Welding Procedures Weld Standards Visual Acceptance Criteria Welding Procedure Specifications
PR-4000 PR-4001 PR-4002
3 4 5 6 16-18 19-71
REVISION HISTORY Revision 1 April 15, 2010 Revision 2 May 20, 2010
Revision 3 Revision 4
Revision 5
Revision 5.1 Revision 5.2 Revision 5.3 Revision 5.4 Revision 5.5
Revised typographical errors made in first printing Added Controlled Distribution List. Made clarifications noted from self-audit Added number of electrodes to all welding procedures per essential variables list from AWS D1.1 June 3, 2010 Distribution List Control Number corrected. December 16, 2010 Removed controlled distribution list from Welding Operations Manual and placed it in Quality Records File. Removed WPS 3F and WPS 4F. Added 2F and 3F tack weld WPS. February 8, 2011 Revise Weld Standards to add crane tie back weld. Added WPS BTC-P4-G for crane tie back. Made other corrections to Weld Standards May 24, 2011 Revised WPS D1.3-11P-G, WPS 1.3-12P-G and WPS 1.3-13P-G to include PQR’s and include ASTM A1039 material. June 23, 2011 Revised WPS Fillet-G and R1-Fillet-G to match fillet weld strength to material tensile strength. June 27, 2011 Clarified Fillet-G welding requirements January 16, 2012 General Revision January 16, 2013 Removed Weld Standard Drawings
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
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Qualified Welding Personnel PR-4000 (IAS AC472, 5.1.3, 5.1.3.1) All production welds and tack by ACI Building Systems will be made by properly qualified welders, welder operators and tack welders in compliance with this procedure. 1. Welder, Welder Operator and Tack Welder tests as provided in the ACI Building Systems Welder Qualification Manual Procedure PR-4003 will be administered by the ACI Building Systems in-house CWI. 2. The test coupons will be visually inspected to meet AWS D1.1 and D1.3 visual acceptance criteria. The test coupons will undergo bend tests as prescribed by AWS D1.1 or D1.3 by an independent AWS Certified Welding Inspector (CWI). Visual Acceptance of all weld coupons will be determined by both the ACI Building Systems In-House CWI and the Independent CWI. The Independent CWI will be present and witness all bend tests. AWS D1.1 assemblies will be tested on ACI Guided Bend Test Jig which is in conformance with AWS D1.1. AWS D1.3 assemblies will be tested bend tests or torsion test prescribed by AWS D1.3 3. The in-house CWI will prepare proper Welder, Welder Operator or Tack Welder Qualification Test Reports after the test coupon results are received. 4. The in-house CWI will prepare the Welder Qualification Test Record (ACI Form WQT). 5. Welder Qualification Test Records shall be maintained by Quality Assurance Supervisor while the welder is employed by ACI Building Systems and for a period of 2 years after separation. 6. No welder, welder operator or tack welder shall be allowed to do any production welding or tack welding until they have been properly qualified. 7. The Quality Assurance Supervisor shall be responsible for maintaining the Welder Continuity Log (ACI Form WCL).
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Effective Date 01/16/2012
Revision Number: 5.5
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Use of Welder Identification Stamps PR-4001 (IAS AC472 5.1.3.2) All production welders shall have and use appropriate welder identification stamps. 1. The Quality Assurance Supervisor shall maintain a Welder Identification Stamp Log. 2. Welder Identification Stamps may be re-issued as personnel changes occur. Identification of any individual weld shall be by the Identification Stamp and the weld was made. 3. Welders, Welder Operators and Tack Welders shall stamp all weldments as indicated. A. Flange Line B. C. D. E.
Web Line Pull-Through Fit-Up Hand Welding
Approved by: Dennis Johnson
Stamp adjacent to weld (away from the center of the flange) Stamp adjacent to weld Stamp End of Web Near Flange Stamp End of Flange Stamp End of Flange
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Production Welding Procedures PR-4002 Typical Welds All production welding at ACI Building Systems is to be performed according to the Weld Standards and Welding Procedure Specifications contained in the Welding Operations Manual.
Welds Show on Shop Drawings 1. If welds are shown on shop drawings they will take precedence over the Weld Standards. 2. The welds shown on shop drawings must indicate the location of the weld and the weld type and size.
Complete Joint Penetration Groove Welds on Shop Drawing or Weld Standard If Complete Joint Penetration groove welds are indicated on the shop drawing the welder must select the appropriate welding procedure for that the joint location and material thickness.
Welds not on Weld Standards Any weld that cannot be made using the Weld Standards and Welding Procedure Specifications must be brought to the attention of the in-house CWI prior to making the weld.
Do not weld over rust. Rust may be removed by wire brush or grinding. ALL VISIBLE RUST MUST BE REMOVED.
Cold Conditions For material ¾” thick and less, do not weld if the ambient temperature of the shop is less than 32°. If shop temperature falls below 32°, the steel must be brought to 70°F for a minimum of 3” in all directions adjacent to the weld before welding operations may begin. For material 1” to 1-1/2” thick, do not weld if the ambient temperature of the shop is less than 50°F. If the shop temperature is falls to below 50°F, the steel must be brought to 50°F for a minimum of 3” in all
directions of the weld before welding operations may begin. Thickness 1/8” to 3/4” 1” to 1-1/2” Maximum
Minimum Temperature 32°F 50°F 500° Interpass Temperature
Pre-Heat When pre-heat is required it shall be applied by use of a propylene or oxygen acetylene hand held torch applied to the immediate area of the weld until the weld area is warm to the touch through a gloved hand. Do not over heat the area. If the area is too warm to touch comfortably with a gloved hand it has been over heated. Allow the area to cool until it can be touched with a gloved hand.
Outside Storage If material is stored outside when the outside air temperature is less than 32°, the material must be brought inside for a minimum of one hour to insure the steel has warmed to the minimum preheat temperature.
Do not weld over paint, galvanizing or water Only pre-painted and galvanized cold-formed members may be welded without removing paint or galvanizing. All material must be dry prior to welding.
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Visual Acceptance Criteria (Hot Rolled and Built-Up Members) Table 1 Visual Acceptance Criteria for Built-up and Hot Rolled Members and Connections Discontinuity Category and Inspection Criteria Crane Beams, Pipe and Standard Crane Brackets Tube Important Note: Table 1 has been adapted from Table 6.1 Connections and Crane Connections of AWS D1.1-2008. Some Visual Acceptance Criteria Tiebacks language has been modified and somewhat more restrictive criteria are listed for use by ACI Building Systems. Rather (Cyclically Loaded (Tubular than rejecting a production weld the original source Nontubular Connections-All (Statically document (Table 6.1 of AWS D1.1-2008) may be used as Connections) Loads) Loaded an alternate criteria to accept or reject a weld. Only a Nontubular Certified Welding Inspector may use the original Connections) source document determine weld acceptability. (1) Crack Prohibition Any crack shall be unacceptable regardless of size or location.
(2) Weld/Base Metal Fusion Thorough fusion shall exist between adjacent layers of weld metal and between weld metal and base metal.
(3) Crater Cross Section All craters shall be filled to provide the specified weld size, except at the ends of intermittent fillet welds outside of their effective length.
(4) Weld Profiles Weld profiles shall be in conformance with Weld Profiles shown in Figure 1 of this Work Instruction.
(5) Time of Inspection Visual inspection of welds in all steels may begin immediately after the completed welds have cooled to ambient temperature.
(6) Undersized Welds The size of a fillet weld in any continuous weld may be less than the specified nominal size (L) without correction by the following amounts (U). L (inches) U (inches) allowable decrease in L Specified nominal weld size 5/16” In all cases, the undersized portion of the weld shall not exceed 10% of the weld length. On web-to-flange welds on girders, under run shall prohibited at the ends for a length equal to twice the width of the flange.
(7) Undercut (A). For material less than I inch thick, undercut shall not exceed 1/32”, with the following exception: undercut shall not exceed 1/16” for any accumulated length up to 2” in any 12”. For material equal to or greater than 1” thick, undercut shall not exceed 1/16” for any length of weld. (B) No undercut is permitted for crane beams to cap channel welds, crane brackets to column flanges and crane tie-back welds.
(8) Porosity (A) All CJP Groove Welds shall be free from piping porosity. (B) The frequency of piping porosity in fillet welds shall not exceed one in each 4 inches of weld length and the maximum diameter shall not exceed 3/32”. (C) All CJP Groove Welds shall be free from piping porosity.
Approved by: Dennis Johnson
Effective Date 01/16/2012
X X
X X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Welding Operations Manual
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C
Figure 1 (Adapted from Figure 5.24 of AWS D1.1-2008)
SIZE
a)
C
(N
ot e
a)
SIZE
(N C ot e
SIZE
Size
SIZE
(N C ot e a)
SIZE
W
SIZE
W
SIZE
W
W
SIZE
(B) Acceptable Fillet Weld Profiles
(A) Desireable Fillet Weld Profiles
aConvexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table:
___________________________
WIDTH OF WELD FACE OR INDIVIDUAL SURFACE BEAD, W
MAX. CONVEXITY, C
___________________________ 1/16 in 1/8 in 3/16 in
W < 5/16 in. W > 5/16 in to W < 1 in W > 1 in
SIZE
SIZE
UNDERSIZE WELD
EXCESSIVE CONVEXITY
SIZE
SIZE EXCESSIVE UNDERCUT
OVERLAP
SIZE
SIZE
INCOMPLETE FUSION
UNDERSIZE WELD
(C) UNACCEPTABLE WELD PROFILES T1 R R (Note b) (Note b)
R ) te b
(no
BUT JOINT EQUAL THICKNESS PLATE b Reinforcement R shall not exceed 1/8 in
BUT JOINT EQUAL THICKNESS PLATE
(D) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT
EXCESSIVE WELD REINFORCEMENT
UNDERFILL
EXCESSIVE UNDERCUT
OVERLAP
(E) UNACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINTS
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
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Visual Acceptance Criteria for Cold-Formed on Cold-Formed Members Discontinuity Category and Inspection Criteria Important Note: Table 1 has been adapted from Section 6.1 of AWS D1.3-2008. . Rather than rejecting a production weld the original source document (Section 6.1 of AWS D1.3-2008) may be used as an alternate criteria to accept or reject a weld. Only a Certified Welding Inspector may use the original source document determine weld acceptability. (1) Crack Prohibition Any crack shall be unacceptable regardless of size or location.
(2) Weld/Base Metal Fusion There shall be no evidence of lack of fusion at the toes of weld passes.
(3) Minimum Reinforcement Square Groove Welds Welds shall have a minimum reinforcement of 1/32” for all square groove welds.
(4) Undercut The cumulative length of undercut shall be no longer than L/8, where L is the specified length of the weld. Depth of undercut is not a subject of inspection and need not be measured. Melt through that results in a hole is not acceptable
(5) Fillet Welds The faces of fillet welds shall be flat or slightly convex
Approved by: Dennis Johnson
Effective Date 01/16/2012
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Welding Procedure Specifications (WPS) AWS D1.1 Structural Welding Procedures B-L1a-G Prequalified B-L1b-G Prequalified B-U2-G Prequalified B-U4b-G Prequalified TC-L1-G Prequalified TC-U4b-G Prequalified TC-U5-G Prequalified Fillet-G Prequalified SAW/GMAW-1 Qualified by PQR SAW-1 Qualified by PQR SAW-2 Qualified by PQR B-L1-S Prequalified B-L1a-S Prequalified B-L2a-S Prequalified B-U4b-S Prequalified Fillet-S Prequalified R1-B-L1a-G Prequalified R1-Fillet-G Prequalified Tack Prequalified BTC-P4-G Prequalified
Page 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58
AWS D1.3 Cold-Formed Welding Procedures D1.3-11P-G Qualified D1.3-11G-G Qualified D1.3-12P-G Qualified D1.3-12G-G Qualified D1.3-13P-G Qualified D1.3-13G-G Qualified
Page 60 62 64 66 68 70
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ACI Building Systems Welding Procedure Specification (WPS) B-L1a-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1a-G Dave Williams GMAW SPRAY
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 YES N/A
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: ASTM A109 Joint Welded from: One Side X Both Sides
T1
Base Metal Material Speciation Type and Grade: AWS D1.1-08 Group I or II Thickness Range: 0.188” to 0.332” Diameter Range: 4-1/2” O.D through 8-5/8” O.D. Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression: Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size:
A5.18 ER70S-6 Single 1G(Rotated) N/A
R B-L1a-G
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = T1
+1/4, -1/16
N/A Notes: Argon/CO2 90/10 (Welding Grade) 36-50 CFH 6/00
Flux Type Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade)
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ACI Building Systems Welding Procedure Specification (WPS) B-L1a-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1a-G Dave Williams GMAW SPRAY
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 YES N/A
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.188 to 0.258
1
1
0.045
270-330
27-31
405-495
14-22
1G
0.280 to 0.322
1 1
1 2
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
14-22 14-22
1G 1G
Notes 1. Pass Number 2 shall not exceed ¼” in thickness in accordance with Table 3.7 of AWS D1.1-2008. Split Ring Installation Procedure 1. Fit the backing ring into one side of the pipe to be spliced making sure there is no more than 1/16” gap between the backing ring and the inside diameter of the pipe at any point. 2. Tack the splice and remove the backing ring. 3. Weld the splice in the backing ring using WPS B-L1b-G. This must be a full penetration weld which requires backgouging to sound metal and weld both sides. Weld tabs may be needed to completely fill the crater on the ends and prevent undercut. 4. Grind weld flush on the outside diameter of the ring and fit both sides of the pipe splice in accordance with Number 1 above.
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ACI Building Systems Welding Procedure Specification (WPS) B-L1b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1b-G Dave Williams GMAW SPRAY
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side Both Sides
Rev: 4 Prequalified: Supporting PQR:
Date: 05/20/2010 YES N/A
X T1
Base Metal Material Speciation Type and Grade: AWS D1.1-08 Group I or II Thickness Range: 1/8” to 3/8” Diameter Range: N/A
R
Filler Metal AWS Specification: A5.18 AWS Classification: ER70S-6 Number of Electrodes: Single
Root Opening Root Face Groove Angle
Tolerances As Fit-up
Positions Metal Position of Groove: Position of Fillet:
1G N/A
R = 0 to 1/8” F = T1 a=0
+1/16, -1/8
Progression:
N/A
Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size:
Argon/CO2 90/10 (Welding Grade) 36-50 CFH 6/00
Flux Type:
N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Notes:
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ACI Building Systems Welding Procedure Specification (WPS) B-L1b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1b-G Dave Williams GMAW SPRAY
Rev: 4 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1/8”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
15-25 15-25
1G 1G
10 ga (0.1345”)
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
15-25 15-25
1G 1G
3/16”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
14-22 14-22
1G 1G
¼”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
12-20 12-20
1G 1G
5/16”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
11-17 11-17
1G 1G
3/8”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
9-15 9-15
1G 1G
Notes 1. When welding base metals of different thicknesses, the parameters of the thinner material shall be used.
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ACI Building Systems Welding Procedure Specification (WPS) B-U2-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-U2-G Dave Williams GMAW SPRAY
Rev: 6 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: ASTM A572 Joint Welded from: One Side Both Sides
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – Unlimited Diameter Range: N/A Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
A5.18 ER70S-6 Single 1G N/A
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 0 to 1/8” F = 0 to 1/8” a = 60
+1/16 -1/8 Not Limited +10, -5
N/A Notes:
Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size:
Argon/CO2 90/10 (Welding Grade) 40 CFH (-10% +25%) 6/00
Flux Type:
N/A
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ACI Building Systems Welding Procedure Specification (WPS) B-U2-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-U2-G Dave Williams GMAW SPRAY Technique
Thickness
Side
Pass Number
5/16”
1 2 1 1 2 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2
1 1 1 2 1 1 2 1 1 2 3 4 5 1 1 2 3 4 5 6 1 1 2 3 4 5 6 1 1 2 3 4 5 6 7 8 1
3/8” 7/16” 1/2”
5/8”
3/4”
1”
Approved by: Dennis Johnson
Filler Metal Size 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045
Rev: 6 Prequalified: Supporting PQR:
Amps
Volts
270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31
Effective Date 01/16/2012
Date: 05/20/2010 Yes N/A
Wire Speed (IPM) 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495
Travel Speed (IPM) 12-20 12-20 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 9-15 9-15 9-15 9-15 9-15
Position
Revision Number: 5.5
1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G 1G
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ACI Building Systems Welding Procedure Specification (WPS) B-U4b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-U4b-G Dave Williams GMAW SPRAY
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side Both Sides
Rev: 6 Prequalified: Supporting PQR:
Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet:
Flat N/A
Progression:
N/A
T1
f Side 2
A5.18 ER70S-6 Single
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 40 CFH-10% +25%) Cup Size: 6/00 Flux Type:
Side 1
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – 1” Diameter Range: N/A
Date: 05/20/2010 Yes N/A
R
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 0 - 1/8 F = 0 - 1/8 a = 45
+1/16”, -1/8” Not limited +10, -5
Notes: 1. Backgouge to sound metal before welding second side.
N/A
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Effective Date 01/16/2012
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ACI Building Systems Welding Procedure Specification (WPS) B-U4b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-U4b-G Dave Williams GMAW SPRAY
Rev: 6 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique 1/8”
1
1
0.045
270-330
27-31
405-495
15-25
1G
3/16”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
14-22 14-22
1G 1G
1/4”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
12-20 12-20
1G 1G
5/16”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
12-20 12-20
1G 1G
3/8”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
12-20 9-15
1G 1G
½”
1 1 2
1 1 1
0.045 0.045 0.045
270-330 270-330 270-330
27-31 27-31 27-31
405-495 405-495 405-495
9-15 9-15 9-15
1G 1G 1G
5/8”
1 1 1 2
1 2 3 1
0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495
9-15 9-15 9-15 9-15
1G 1G 1G 1G
¾”
1 1 1 1 1 2
1 2 3 4 5 1
0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495
8-14 8-14 8-14 8-14 8-14 8-14
1G 1G 1G 1G 1G 1G
1”
1 1 1 1 1 1 1 1 1 2
1 2 3 4 5 6 7 8 9 1
0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495
8-14 8-14 8-14 8-14 8-14 8-14 8-14 8-14 8-14 8-14
1G 1G 1G 1G 1G 1G 1G 1G 1G 1G
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 28
ACI Building Systems Welding Procedure Specification (WPS) TC-L1-G TC-L1-G Dave Williams GMAW SPRAY
Weld Joint Weld Type: Tee, Corner Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side Both Sides
Rev: 5 Prequalified: Supporting PQR:
Side 2
X
Side 1
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – 3/8” Max. Diameter Range: N/A Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
R
A5.18 ER70S-6 Single
Root Opening Root Face Groove Angle
Tolerances As Fit-up
2G N/A N/A
R = 0 - 1/8
+1/16”, -1/8
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 40 CFH-10% +25%) Cup Size: 6/00 Flux Type:
Date: 05/20/2010 Yes N/A
T1
WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
Notes: 1.
2.
N/A
Approved by: Dennis Johnson
3.
Effective Date 01/16/2012
This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. Reinforcing fillet welds shall be made in accordance with WPS Fillet-G. Reinforcing fillet welds shall be detailed for size on fabrication drawing when required by Engineering.
Revision Number: 5.5
Welding Operations Manual
Page 29
ACI Building Systems Welding Procedure Specification (WPS) TC-L1-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
TC-L1-G Dave Williams GMAW SPRAY
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1/8”
1 2 1 2
1 1 1 1
0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495
15-25 15-25 15-25 15-25
2G 2G 2G 2G
1 2 1 2 1 2 1 2
1 1 1 1 1 1 1 1
0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495
14-22 14-22 12-20 12-20 11-17 11-17 9-15 9-15
2G 2G 2G 2G 2G 2G 2G 2G
10 Ga (.1345”) 3/16 ¼ 5/16 3/8
Notes When welding base metals of different thicknesses, the parameters of the thinner material shall be used.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 30
ACI Building Systems Welding Procedure Specification (WPS) TC-U4b-G TC-U4b-G Dave Williams GMAW SPRAY
Weld Joint Weld Type: Tee, Corner Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side Both Sides
Progression:
Date: 05/20/2010 Yes N/A
a
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – 1” Diameter Range: N/A Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet:
Rev: 6 Prequalified: Supporting PQR:
T1
WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
R
.
A5.18 ER70S-6 Single 2G N/A
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 0 - 1/8 f = 0 - 1/8 a = 45
+1/16”, -1/8 Not Limited + 10,-5
N/A
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Notes:
Effective Date 01/16/2012
1.
2.
3.
This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. Reinforcing fillet welds shall be made in accordance with WPS Fillet-G. Reinforcing fillet welds shall be detailed for size on fabrication drawing when required by Engineering.
Revision Number: 5.5
Welding Operations Manual
Page 31
ACI Building Systems Welding Procedure Specification (WPS) TC-U4b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
TC-U4b-G Dave Williams GMAW SPRAY
Rev: 6 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1/8”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
14-22 14-22
2G 2G
3/16”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
14-22 14-22
2G 2G
5/16”
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
14-22 14-22
2G 2G
3/8”
1 2 2
1 1 2
0.045 0.045 0.045
270-330 270-330 270-330
27-31 27-31 27-31
405-495 405-495 405-495
14-22 14-22 12-20
2G 2G 2G
½”
1 2 2 2 2 1 2 2 2 2 1 2 2 2 2 2 2 1 2 2 2 2 2 2 2 2
1 1 2 3 4 1 1 2 3 4 1 1 2 3 4 5 6 1 1 2 3 4 5 6 7 8
0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495
12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20 12-20
2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G 2G
5/8”
¾”
1”
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 32
ACI Building Systems Welding Procedure Specification (WPS) TC-U5-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
TC-U5-G Dave Williams GMAW SPRAY
Weld Joint Weld Type: Tee, Corner Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side Both Sides
Rev: 6 Prequalified: Supporting PQR:
X
a
Progression:
T1
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 7/16” – 1” Diameter Range: Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet:
R a
A5.18 ER70S-6 Single 2G N/A N/A
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 0 - 1/8 f = 0 - 1/8 a = 45
+1/16”, -1/8 Not Limited + 10,-5
Notes: 1.
2.
3.
Approved by: Dennis Johnson
Date: 05/20/2010 Yes N/A
Effective Date 01/16/2012
This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. Reinforcing fillet welds shall be made in accordance with WPS Fillet-G. Reinforcing fillet welds shall be detailed for size on fabrication drawing when required by Engineering.
Revision Number: 5.5
Welding Operations Manual
Page 33
ACI Building Systems Welding Procedure Specification (WPS) TC-U5-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
TC-U5-G Dave Williams GMAW SPRAY
Rev: 6 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique 7/16”
1 1 2 2
1 2 1 2
0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495
12-20 12-20 12-20 14-22
2G 2G 2G 2G
1/2”
1 1 2 2 2
1 2 1 2 3
0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495
12-20 12-20 12-20 14-22 12-20
2G 2G 2G 2G 2G
5/8”
1 1 1 2 2 2 2
1 2 3 1 2 3 4
0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495
12-20 12-20 12-20 14-22 14-22 14-22 14-22
2G 2G 2G 2G 2G 2G 2G
3/4”
1 1 1 1 2 2 2
1 2 3 4 1 2 3
0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495
12-20 12-20 12-20 14-22 14-22 14-22 14-22
2G 2G 2G 2G 2G 2G 2G
1”
1 1 1 1 2 2 2 2 2 2
1 2 3 4 1 2 3 4 5 6
0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495 405-495
14-20 14-20 14-20 14-20 14-22 14-22 14-22 14-22 14-22 14-22
2G 2G 2G 2G 2G 2G 2G 2G 2G 2G
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 34
ACI Building Systems Welding Procedure Specification (WPS) FILLET-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
FILLET-G Dave Williams GMAW SPRAY
Rev: 10 Prequalified: Supporting PQR:
Date: 06/27/2011 Yes N/A
Weld Joint Weld Type: Tee, Corner, Lap Backing: (yes) X (no) Backing Material Type: N/A Joint Welded from: One Side X Both Sides X Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – Unlimited Diameter Range: Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet:
NA 2F
Progression:
N/A
Root Opening Root Face Groove Angle
A5.18 ER70S-6 Single
Notes: 1.
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Tolerances As Fit-up
Effective Date 01/16/2012
2.
Fillet welds must meet the requirements of paragraph 3.9 of AWS D1.1-98. Size of weld to be in accordance with Appendix B of ACI D1.1 Weld Specification, unless otherwise specified by the Engineer.
3. Welding from one side or both sides to be specified by the Engineer 4. This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. Note: Drawing changed to show fillet welds on a crane runway beam.
Revision Number: 5.5
Welding Operations Manual
Page 35
ACI Building Systems Welding Procedure Specification (WPS) FILLET-G WPS Number: Fillet-G Prepared By: Dave Williams Welding Process: GMAW Mode of Transfer for GMAW: SPRAY
Material Thickness
Rev: 10 Prequalified: Supporting PQR:
Date: 06/27/2011 Yes N/A
Weld Size
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
3/16” 1/4”
3/16”
1
1
0.045
270-330
27-31
405-495
17-27
2F
5/16”
1/4”
1
1
0.045
270-330
27-31
405-495
15-25
2F
3/8”
5/16”
1
1
0.045
270-330
27-31
405-495
15-25
2F
1/2”
7/16”
1 1 1
1 2 3
0.045 0.045 0.045
270-330 270-330 270-330
27-31 27-31 27-31
405-495 405-495 405-495
14-22 15-25 12-20
2F 2F 2F
5/8”
9/16”
1 1 1 1
1 2 3 4
0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495
12-20 15-25 12-20 12-20
2F 2F 2F 2F
Technique
Notes Per this procedure the max. pass fillet shall be 5/16”
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 36
ACI Building Systems Welding Procedure Specification (WPS) SAW-GMAW-1 WPS Number: SAW-GMAW-1 Prepared By: Dave Williams Welding Process: SAW/GMAW-1 Mode of Transfer for GMAW: SPRAY
Rev: 6 Date: 05/20/2010 Prequalified: NO Supporting PQR: Saw/Gmaw-1
Weld Joint
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 5/16”-1 Diameter Range: Filler Metal AWS Specification: A5.17/ A5.18 AWS Classification: EM12K (Lincoln L 61)/ER70S-6 Wire Flux Combination:F7A2-EM12K Number of Electrodes: Single Positions Metal Position of Groove: Flat (1G) Position of Fillet: N/A Progression:
N/A
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% +25%) Cup Size: 6/00 Flux
Type:
Approved by: Dennis Johnson
Side 1 Copper and Flux Backing
1/4"
Weld Type: Butt Backing: (yes) X (no) Backing Material Type: SAW-Copper & Flux / GMAW-Weld Metal Joint Welded from: One Side Both Sides X
1/16"
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 1/16” F=T
(0- +1/16 F=T
Notes: 1.This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. 2. After welding first side with SAW, backgouge to sound metal and weld second side with GMAW.
Lincoln 780
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 37
ACI Building Systems Welding Procedure Specification (WPS) SAW-GMAW-1 WPS Number: SAW-GMAW-1 Prepared By: Dave Williams Welding Process: SAW/GMAW Mode of Transfer for GMAW: SPRAY
Rev: 6 Date: 05/20/2010 Prequalified: NO Supporting PQR: Saw/Gmaw-1
Technique Per this procedure no pass shall exceed ¼” in thickness and no pass will exceed 5/8” in width. Thickness
5/16” Saw Gmaw 3/8” Saw Gmaw ½” Saw Gmaw Gmaw 5/8” Saw Gmaw Gmaw Gmaw ¾ Saw Gmaw Gmaw Gmaw Gmaw 1” Saw Gmaw Gmaw Gmaw Gmaw Gmaw
Side/ Pass
R
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1/1 2/1
1/16”
1/8” 0.045
N/A 300
29 29
155 450
35 9-11
1G 1G
1/1 2/1
1/16” N/A
1/8” 0.045
N/A 300
29 29
155 450
35 9-11
1G 1G
1/1 2/1 2/2
1/16” N/A N/A
1/8” 0.045 0.045
N/A 300 300
29 29 29
155 450 450
30 10-12 10-12
1G 1G 1G
1/1 2/1 2/2 2/3
1/16” N/A N/A N/A
1/8” 0.045 0.045 0.045
N/A 300 300 300
29 29 29 29
155 450 450 450
28 11-13 11-13 11-13
1G 1G 1G 1G
1/1 2/1 2/2 2/3 2/4
1/16” N/A N/A N/A N/A
1/8” 0.045 0.045 0.045 0.045
N/A 300 300 300 300
29 29 29 29 29
155 450 450 450 450
26 11-13 11-13 11-13 11-13
1G 1G 1G 1G 1G
1/1 2/1 2/2 2/3 2/4 2/5
1/16” N/A N/A N/A N/A N/A
1/8” 0.045 0.045 0.045 0.045 0.045
N/A 300 300 300 300 300
29 29 29 29 29 29
155 450 450 450 450 450
25 9-11 9-11 9-11 9-11 9-11
1G 1G 1G 1G 1G 1G
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 38
ACI Building Systems Welding Procedure Specification (WPS) SAW-1 WPS Number: SAW-1 Prepared By: Dave Williams Welding Process: SAW Mode of Transfer for GMAW:
Rev: 4 Date: 05/20/2010 Prequalified: NO Supporting PQR: Saw-1
Weld Joint
Joint Welded from: One Side X
Copper and Flux Backing 1/16"
Both Sides
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – ¼” Diameter Range: Filler Metal AWS Specification: A5.17 AWS Classification: EM12K (Lincoln L 61) Wire Flux Combination:F7A2-EM12K Number of Electrodes: Single Positions Metal Position of Groove: Flat (1G) Position of Fillet: N/A Progression:
Side 1 1/4"
Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Copper & Flux
N/A
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% +25%) Cup Size: 6/00 Flux Type: Lincoln 780
Approved by: Dennis Johnson
Effective Date 01/16/2012
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = See Table on Page 2 For R
+1/16, -0
Notes: 1. This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification.
Revision Number: 5.5
Welding Operations Manual
Page 39
ACI Building Systems Welding Procedure Specification (WPS) SAW-1 WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
SAW-1 Dave Williams GMAW SPRAY
Rev: 4 Date: 05/20/2010 Prequalified: NO Supporting PQR: Saw-1
Technique Thickness
Side/ Pass
R
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1/8”(.125)
1/1
0
1/8”
N/A
28
108
40
1G
10GA (.135)
1/1
0
1/8”
N/A
28
108
40
1G
3/16”
1/1
1/16”
1/8”
N/A
28
120
35
1G
¼”
1/1
1/16”
1/8”
N/A
29
125
30
1G
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 40
ACI Building Systems Welding Procedure Specification (WPS) SAW-2 WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
SAW-2 Dave Williams SAW
Rev: 1 Prequalified: Supporting PQR:
Date: 05/20/2010 No A572-55-1
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Flux Joint Welded from: One Side Both Sides
X
Base Metal Material Speciation Type and Grade: AWS D1.1-08 Group I or II Thickness Range: 1” Diameter Range: N/A Filler Metal AWS Specification: A5.17 AWS Classification: EM12K Number of Electrodes: Single Positions Metal Position of Groove: Position of Fillet:
1G N/A
Progression:
N/A
Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size:
N/A N/A N/A N/A
Flux Type:
F7A2
Approved by: Dennis Johnson
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R=0 F = 3/16 a = 40
+1/4, -1/16 +/- 1/16 +10, -5
Notes: Weld Side 1 Back Gouge Side 2 to Sound Metal Weld Side 2
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 41
ACI Building Systems Welding Procedure Specification (WPS) SAW-2 WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
SAW-2 Mac Aguilar SAW N/A
Rev: 1 Prequalified: Supporting PQR:
Date: 05/20/2010 No A572-55-1
Technique Thickness
Side
Pass Number
1”
1 1 1 1 2 2
1 2 3 4 1 2
Approved by: Dennis Johnson
Filler Metal Size 5/64” 5/64” 5/64” 5/64” 5/64” 5/64”
Amps
Volts
N/A N/A N/A N/A N/A N/A
28-32 28-32 28-32 29-33 28-32 29-33
Effective Date 01/16/2012
Wire Speed (IPM) 159-193 175-213 175-213 175-213 175-213 175-213
Travel Speed (IPM) 17-23 17-23 13-17 11-13 13-17 13-17
Position
Revision Number: 5.5
1G 1G 1G 1G 1G 1G
Welding Operations Manual
Page 42
ACI Building Systems Welding Procedure Specification (WPS) B-L1-S WPS Number: B-L1-S Prepared By: Welding Process: SAW Mode of Transfer for GMAW:
Dave Williams
Rev: 4 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Joint Welded from: One Side
Both Sides
X
T1
Weld Joint Weld Type: ACI Building Systems, Inc. Backing: (yes) X (no) Backing Material Type: Weld Metal
R=0
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 10 gage – 3/8”MAX Diameter Range: Filler Metal AWS Specification: A5.17 AWS Classification: EM12K Wire Flux Combination:F7A2-EM12K Number of Electrodes: Single Positions Metal Position of Groove: (1G) Position of Fillet: N/A Progression: Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size: Flux
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R=0
(+1/16) -0
N/A Notes: 1. Remove copper backup bar and weld second side with SAW.
N/A N/A
Type:
Approved by: Dennis Johnson
Lincoln 780
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 43
ACI Building Systems Welding Procedure Specification (WPS) B-L1-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1-S Dave Williams SAW
Rev: 4 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Per this procedure on pass shall exceed ¼” in thickness and no pass shall exceed 5/8” in width. Plate Thk,
Side
Pass
Filler Metal Size (Each Wire)
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
10Gage
1
1
1/8”
N/A
27-31
54-66
46-63
1G
3/16”
1
1
1/8”
N/A
27-31
54-66
46-63
1G
¼”
1
1
1/8”
N/A
27-31
59-72
42-57
1G
5/16”
1 2
1 1
1/8” 1/8”
N/A N/A
27-31 27-31
59-72 59-72
42-57 42-57
1G 1G
3/8”
1 2
1 1
1/8” 1/8”
N/A N/A
27-31 27-31
59-72 59-72
38-51 38-51
1G 1G
Notes 1. Remove copper backup bar and weld second side.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 44
ACI Building Systems Welding Procedure Specification (WPS) B-L1a-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1a-S Dave Williams SAW
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side
Backgouge
Both Sides
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 10 ga. – 5/8”MAX Diameter Range:
Filler Metal AWS Specification: A5.17 AWS Classification: EM12K Wire Flux Combination:F7A2-EM12K Number of Electrodes: Single Positions Metal Position of Groove: (1G) Position of Fillet: N/A Progression: Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size: Flux
Type:
T=5/8" MAX
N/A
R
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R=0
+1/16, -0
Notes: 1. Remove flux backing, backgouge to sound metal and weld second side.
N/A N/A Lincoln 780
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 45
ACI Building Systems Welding Procedure Specification (WPS) B-L1a-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L1a-S Dave Williams SAW
Rev: Prequalified: Supporting PQR:
Yes N/A
Technique Per this procedure on pass shall exceed ¼” in thickness and no pass shall exceed 5/8” in width. Plate Thk,
Side
Pass
Filler Metal Size (Each Wire)
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
10Gage
1
1
5/64”
N/A
28-33
110-134
48-65
1G
3/16”
1
1
5/64”
N/A
28-33
110-134
48-65
1G
¼”
1
1
5/64”
N/A
28-33
157-192
47-64
1G
5/16”
1 2
1 1
5/64” 5/64”
N/A N/A
29-34 29-34
188-230 188-230
47-64 47-64
1G 1G
3/8”
1 2
1 1
5/64” 5/64”
N/A N/A
29-34 29-34
203-248 203-248
43-60 43-60
1G 1G
½”
1 2
1 1
5/64” 5/64”
N/A N/A
29-34 29-34
215-260 215-260
40-56 40-56
1G 1G
5/8”
1 2
1 2
5/64” 5/64”
N/A N/A
29-34 29-34
215-260 215-260
40-56 40-56
1G 1G
Notes 1. Remove flux backing, backgouge the second side to sound metal before welding. 2. Number of passes may vary as long as the welding parameters are within the ranges given on the WPS.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 46
ACI Building Systems Welding Procedure Specification (WPS) B-L2a-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L2a-S Dave Williams SAW
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Weld Joint Backgouge
Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Weld Metal
a 30°
Side 2
Joint Welded from: One Side
Both Sides
Filler Metal AWS Specification: A5.17 AWS Classification: EM12K (Lincoln L61) Wire Flux Combination:F7A2-EM12K Number of Electrodes: Single (1G) N/A
Progression:
N/A
Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size: Flux Type:
N/A N/A Lincoln 780
Approved by: Dennis Johnson
R=1/4"
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 5/16” thru 1” Diameter Range:
Positions Metal Position of Groove: Position of Fillet:
1/2"
T1
Side 1
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 1/4 f =0 a = 30
(+1/4”)(-1/16”) NA (+10)(-5)
Notes: 1. The number of passes may vary as long as the welding parameter are within the ranges given Remove Copper backup bar, Backgouge to sound metal Weld second side.
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 47
ACI Building Systems Welding Procedure Specification (WPS) B-L2a-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-L 2a-S Dave Williams SAW
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Per this procedure on pass shall exceed ¼” in thickness and no pass shall exceed 5/8” in width. Plate Thk,
Side
Pass
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1-2 1
Filler Metal Size (Each Wire) 1/8” 1/8”
5/16”
1 2
N/A N/A
27-31 27-31
59-72 59-72
30-40 30-40
1G 1G
3/8”
1 2
1-2 1
1/8” 1/8”
N/A N/A
27-31 27-31
59-72 59-72
30-40 30-40
1G 1G
½”
1 2
1-2 1
1/8” 1/8”
N/A N/A
27-31 27-31
81-99 81-99
27-36 27-36
1G 1G
5/8”
1 2
1-5 1
1/8” 1/8”
N/A N/A
27-31 27-31
81-99 81-99
25-34 25-34
1G 1G
¾”
1 2
1-6 1
1/8” 1/8”
N/A N/A
27-31 27-31
83-109 83-109
23-31 23-31
1G 1G
1”
1 2
1-7 1
1/8” 1/8”
N/A N/A
27-31 27-31
83-109 83-109
23-31 23-31
1G 1G
Notes 1. Fill passes shall not exceed ¼” in thickness in accordance with Table 3.7 of AWS D1.1-98.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 48
ACI Building Systems Welding Procedure Specification (WPS) B-U4b-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-U4b-S Dave Williams SAW
Rev: 4 Prequalified: Supporting PQR:
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side
Side 1
Both Sides
Filler Metal AWS Specification: A5.17 AWS Classification: EM12K Wire Flux Combination:F7A2-EM12K Number of Electrodes: Single Positions Metal Position of Groove: (1G) Position of Fillet: N/A
Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size: Flux Type:
N/A
T1
f
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1” Diameter Range:
Progression:
Date: 05/20/2010 Yes N/A
R
Side 2
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 0” f = 1/4” max a = 60
+1/4, -0 +/- 1/16 +10, -5
Notes: 1. Remove copper bar and backgouge to sound metal before welding second side.
N/A N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 49
ACI Building Systems Welding Procedure Specification (WPS) B-U4b-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
B-U4b-S Dave Williams SAW
Rev: 4 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Per this procedure on pass shall exceed ¼” in thickness and no pass shall exceed 5/8” in width. Plate Thk,
Side
Pass
Filler Metal Size (Each Wire)
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1”
1 2
1 8
1/8” 1/8”
na na
27-31 27-31
83-100 83-100
28-37 28-37
1G 1G
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 50
ACI Building Systems Welding Procedure Specification (WPS) FILLET-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
FILLET-S Dave Williams SAW
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Weld Joint Weld Type: Tee Backing: (yes) NA (no) Backing Material Type: Weld Metal Joint Welded from: One Side
X
Both Sides
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1” Diameter Range: Filler Metal AWS Specification: A5.17 AWS Classification: EM12K Wire Flux Combination:F7A2-EM12K Number of Electrodes: Two per head Positions Metal Position of Groove: N/A Position of Fillet: 2F Progression: Shielding Gas Shielding Gas: AWS Classification: Flow Rate: Cup Size: Flux Type:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R=
R=0
Notes:
N/A N/A N/A Lincoln 780
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 51
ACI Building Systems Welding Procedure Specification (WPS) FILLET-S WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
FILLET-S Dave Williams SAW
Rev: 5 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Size of Fillet Weld
Web Thick ness
Pass
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1
Filler Metal Size (Each Wire) 1/16
3/16”
10 Gage
N/A
27-31
189-231
59-80
2F
3/16”
3/16
1
1/16
N/A
27-31
211-258
55-74
2F
3/16”
1/4“
1
1/16
N/A
27-31
211-258
55-74
2F
¼
5/16”
1
1/16
N/A
27-31
225-275
51-69
2F
5/16”
3/8”
1
1/16
N/A
27-31
225-275
38-52
2F
SEE SHOP DRAWING (MUST BE SIZED BY ENGINEERING)
1/2“
Notes 1. Fillet welds must meet the requirements of paragraph 3.9 of AWS D1.1-98. 2. Size of weld to be in accordance with Appendix B of ACI D1.1 Weld Specification, unless otherwise specified by the Engineer. 3. Welding from one side or both sides to be specified by the Engineer. 4. This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. 5. If burn through occurs, grind opposite side and weld using WPS FILLET-G. If pinholes occur, remove by grinding and weld using WPS FILLET-G. If undercut occurs, prepare area by grinding and weld using WPS FILLET-G. 6. The maximum pass fillet weld size is 5/16” per Table 3.7 of AWS D1.1-98.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 52
ACI Building Systems Welding Procedure Specification (WPS) R1-B-L1b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
R1-B-L1b-G Dave Williams GMAW Spray
Rev: 3 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Weld Joint Weld Type: Butt Backing: (yes) X (no) Backing Material Type: Ceramic Both Sides
X
T1
Joint Welded from: One Side
R
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – 3/8 Max Diameter Range: Filler Metal AWS Specification: A5.18 AWS Classification: ER70S-6 Number of Electrodes: Single Positions Metal Position of Groove: 1G Position of Fillet: N/A Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R = 0 -1/8
+1/16,-1/8
N/A
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% +25%) Cup Size: 6/00 Flux Type: NA
Approved by: Dennis Johnson
Effective Date 01/16/2012
Notes:
Revision Number: 5.5
Welding Operations Manual
Page 53
ACI Building Systems Welding Procedure Specification (WPS) R1-B-L1b-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
R1-B-L1b-G Dave Williams GMAW SPRAY
Rev: 3 Prequalified: Supporting PQR:
Date: 05/20/2010 Yes N/A
Technique Size of Fillet Weld
Web Thick ness
Pass
1/8”
1 2 1 2 1 2 1 2 1 2 1
10Gauge (.1345”) 3/16 1/4 5/16 3/8
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1 1 1 1
Filler Metal Size (Each Wire) 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495
15-25 15-25 15-25 15-25
1G 1G 1G 1G
1 1 1 1 1 1 1
0.045 0.045 0.045 0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495 405-495 405-495 405-495
14-22 14-22 12-20 12-20 11-17 11-17 9-15
1G 1G 1G 1G 1G 1G 1G
Notes 1. This procedure is for the repair or replacement of weld metal due to under fill or discontinuities in flange or weld seams. 2. Underfill shall be welded so as insure the full cross of weld at each transverse seam. Meets the requirements of AWS D1.1 3. Remove discontinuities to sound metal 1: either side of the discontinuities by either grinding or air arc gouging. 4. Reweld above area with sufficient weld metal to meet engineering requirements excessive reinforcement shall be remove by grinding. 5. When welding base metals of different thicknesses, the parameters for the thinner material shall be used.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 54
ACI Building Systems Welding Procedure Specification (WPS) R1-FILLET-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
R1-FILLET-G Dave Williams GMAW Spray
Rev: 4 Prequalified: Supporting PQR:
Date: 06/272011 Yes N/A
Weld Joint Weld Type: Tee,Corner,Lap Backing: (yes) X (no) Backing Material Type: Weld Metal Joint Welded from: One Side X
Both Sides
X
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – Unlimited Diameter Range: Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet:
N/A 2F
Progression:
N/A
A5.18 ER70S-6 Single
Root Opening Root Face Groove Angle
Tolerances As Fit-up
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% +25%) Cup Size: 6/00 Flux Type: NA
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 55
ACI Building Systems Welding Procedure Specification (WPS) R1-FILLET-G WPS Number: R1-FILLET-G Prepared By: Welding Process: Mode of Transfer for GMAW:
Rev: 4 Prequalified: Supporting PQR:
Dave Williams GMAW Spray
Date: 06/27/2011 Yes N/A
Technique Material Thickness
Weld Size
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
3/16
1/4
1
1
0.045
270-330
27-31
405-495
17-27
2F
1/4
5/16
1
1
0.045
270-330
27-31
405-495
15-25
2F
5/16”
3/8
1
1
0.045
270-330
27-31
405-495
14-22
2F
3/8”
7/16
1 1 1
1 2 3
0.045 0.045 0.045
270-330 270-330 270-330
27-31 27-31 27-31
405-495 405-495 405-495
12-20 15-25 12-20
2F 2F 2F
1/2
9/16
1 1 1 1
1 2 3 4
0.045 0.045 0.045 0.045
270-330 270-330 270-330 270-330
27-31 27-31 27-31 27-31
405-495 405-495 405-495 405-495
12-20 12-20 12-20 12-20
2F 2F 2F 2F
Notes 1. This procedure is for the repair or replacement of weld metal due to discontinuities in production fillet welds. 2. Remove discontinuities to sound weld metal 1” either side of the discontinuities by either grinding or air arc gouging, care must be taken not to remove excessive base metal. 3. Reweld above area with sufficient weld material to meet the engineering requirements (care shall be taken to tie the repair weld to the existing weld on either side with a minimum of reinforcement.) Excessive reinforcement shall be removed by grinding. 4. Fillet welds must meet the requirements of paragraph 3.9 of AWS D1.1-98.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 56
ACI Building Systems Welding Procedure Specification (WPS) TACK WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
TACK Dennis Johnson GMAW SPRAY
Rev: 0 Prequalified: Supporting PQR:
Date: 12/16/2010 Yes N/A
Weld Joint Weld Type: Tee, Corner, Lap Backing: (yes) X (no) Backing Material Type: N/A Joint Welded from: One Side X Both Sides X Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 1/8” – Unlimited Diameter Range: Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
A5.18 ER70S-6 Single
Tolerances As Fit-up
NA 2F or 3F Notes:
N/A
6.
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
7.
Fillet welds must meet the requirements of paragraph 3.9 of AWS D1.1-98. Size of weld to be in accordance with Appendix B of ACI D1.1 Weld Specification, unless otherwise specified by the Engineer.
8. Welding from one side or both sides to be specified by the Engineer 9. This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification. Note: Drawing changed to show fillet welds on a crane runway beam.
Revision Number: 5.5
Welding Operations Manual
Page 57
ACI Building Systems Welding Procedure Specification (WPS) TACK WPS Number: Tack Prepared By: Welding Process: Mode of Transfer for GMAW:
Thinner Material 1/8” to Unlimited
Rev: 0 Prequalified: Supporting PQR:
Dennis Johnson GMAW SPRAY
Date: 12/16/2010 Yes N/A
Weld Size
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
1/8” min.
1
1
0.045
270-330
27-31
405-495
17-27
2F or 3F Down
Technique
Notes Welders must be qualified separately for horizontal tack and for vertical tack down.
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 58
ACI Building Systems Welding Procedure Specification (WPS) BTC-P4-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
BTC-P4-G Dennis Johnson GMAW SPRAY
Weld Joint Weld Type: Butt, Tee, Corner Backing: (yes) (no) Backing Material Type: l Joint Welded from: One Side Both Sides
Rev: 0 Prequalified: Supporting PQR:
X 1/4
X
3/16(3/16) Side2
Base Metal Material Speciation Type and Grade: AWS D1.1-98 Group I or II Thickness Range: 3/8” Diameter Range: N/A Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
T1 Side1 R
A5.18 ER70S-6 Single 2G 2F N/A
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 40 CFH-10% +25%) Cup Size:
Date: 02/08/2011 Yes N/A
Root Opening Root Face Groove Angle
Tolerances As Fit-up
R=0 F = 1/8 min. α = 45°
+3/16, -0 +U, -0 +10, -5
6/00 Notes:
Flux Type:
1.
N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
This procedure is used as indicated on ACI Buildings, Inc. Standard Weld Schematic. See Appendix B of ACI D1.1 Weld Specification.
Revision Number: 5.5
Welding Operations Manual
Page 59
ACI Building Systems Welding Procedure Specification (WPS) BTC-P4-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
BTC-P4-G Dennis Johnson GMAW SPRAY
Rev: 0 Prequalified: Supporting PQR:
Date: 02/08/2011 Yes N/A
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
3/8
1 2
1 1
0.045 0.045
270-330 270-330
27-31 27-31
405-495 405-495
9-15 9-15
2F 2G
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 60
ACI Building Systems Welding Procedure Specification (WPS) D1.3-11P-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-11P-G Dave Williams GMAW Globular
Rev: 8 Prequalified: Supporting PQR:
Date: 05/25/2011 No 1P & 5P
Weld Joint Weld Type: Tee, Corner, Lap Backing: (yes) (no) X Backing Material Type: N/A Joint Welded from: One Side Both Sides X Base Metal Material Speciation Type and Grade: ASTM A1011 SS or HSLAS Grade 55 ASTM A1039 SS or HSLAS Grade 55 Thickness Range: 0.0598” (16 gage) to 0.1875” Diameter Range: N/A Coating Type: Painted or Bare Coating Thickness: 0.5 mil per side Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
A5.18 ER70S-6 Single N/A 2F N/A
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 61
ACI Building Systems Welding Procedure Specification (WPS) D1.3-11P-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-11P-G Dave Williams GMAW Globular
Rev: 8 Prequalified: Supporting PQR:
Date: 05/25/2011 No 1P & 5P
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.0598” (16 Gage)
1
1
0.045
211-258
17-19
351-429
18-22
2F
0.0673” (15 Gage)
1
1
0.045
211-258
17-19
351-429
18-22
2F
0.0747” (14 Gage)
1
1
0.045
211-258
17-19
351-429
18-22
2F
0.0897” (13 Gage)
1
1
0.045
211-258
17-19
351-429
18-22
2F
0.1049” (12 gage)
1
1
0.045
211-258
17-19
351-429
18-22
2F
0.1196” (11 gage)
1
1
.045
211-258
17-19
351-429
18-22
2F
0.1345” (10 gage)
1
1
.045
211-258
17-19
351-429
18-22
2F
0.1875” (3/16”)
1
1
.045
211-258
17-19
351-429
18-22
2F
Notes
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 62
ACI Building Systems Welding Procedure Specification (WPS) D1.3-11G-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-11G-G Dave Williams GMAW Globular
Rev: 7 Prequalified: Supporting PQR:
Date: 05/20/2010 No 1G
Weld Joint Weld Type: Tee, Corner, Lap Backing: (yes) (no) X Backing Material Type: N/A Joint Welded from: One Side Both Sides X Base Metal Material Speciation Type and Grade: ASTM A1653 SS or HSLAS Grade 55 Thickness Range: 0.0598” (16 gage) to 0.1875” Diameter Range: N/A Coating Type: Galvanized Coating Thickness: G90 Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
A5.18 ER70S-6 Single N/A 2F N/A
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 63
ACI Building Systems Welding Procedure Specification (WPS) D1.3-11G-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-11G-G Dave Williams GMAW Globular
Rev: 7 Prequalified: Supporting PQR:
Date: 05/20/2010 No 1G
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.0598” (16 Gage)
1
1
0.045
211-258
18-22
351-429
18-22
2F
0.0673” (15 Gage)
1
1
0.045
211-258
18-22
351-429
18-22
2F
0.0747” (14 Gage)
1
1
0.045
211-258
18-22
351-429
18-22
2F
0.0897” (13 Gage)
1
1
0.045
211-258
18-22
351-429
18-22
2F
0.1049” (12 gage)
1
1
0.045
211-258
18-22
351-429
18-22
2F
0.1196” (11 gage)
1
1
.045
211-258
18-22
351-429
18-22
2F
0.1345” (10 gage)
1
1
.045
211-258
18-22
351-429
18-22
2F
0.1875” (3/16”)
1
1
.045
211-258
18-22
351-429
18-22
2F
Notes
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 64
ACI Building Systems Welding Procedure Specification (WPS) D1.3-12P-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-12P-G Dave Williams GMAW Globular
Rev: 6 Prequalified: Supporting PQR:
Date: 05/25/2011 No 3P & 6P
Weld Joint Weld Type: Butt Backing: (yes) (no) X Backing Material Type: N/A Joint Welded from: One Side X Both Sides Base Metal Material Speciation Type and Grade: ASTM A1011 SS or HSLAS Grade 55 ASTM A1039 SS or HSLAS Grade 55 Thickness Range: 0.0598” (16 gage) to 0.1875” Diameter Range: N/A Coating Type: Painted or Bare Coating Thickness: 0.5 mil per side Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
A5.18 ER70S-6 Single 1G (Flat) N/A N/A
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 65
ACI Building Systems Welding Procedure Specification (WPS) D1.3-12P-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-12P-G Dave Williams GMAW Globular
Rev: 6 Prequalified: Supporting PQR:
Date: 05/25/2011 No 3P & 6P
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.0598” (16 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.0673” (15 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.0747” (14 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.0897” (13 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.1049” (12 gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.1196” (11 gage)
1
1
.045
198-242
18-22
342-418
18-22
1G
0.1345” (10 gage)
1
1
.045
198-242
18-22
342-418
18-22
1G
0.1875” (3/16”)
1
1
.045
198-242
18-22
342-418
18-22
1G
Notes
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 66
ACI Building Systems Welding Procedure Specification (WPS) D1.3-12G-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-12G-G Dave Williams GMAW Globular
Rev: 8 Prequalified: Supporting PQR:
Date: 05/20/2010 No 4G
Weld Joint Weld Type: Butt Backing: (yes) (no) X Backing Material Type: N/A Joint Welded from: One Side X Both Sides Base Metal Material Speciation Type and Grade: ASTM A653 SS or HSLAS Grade 55 Thickness Range: 0.0598” (16 gage) to 0.1875” Diameter Range: N/A Coating Type: Galvanized Coating Thickness: G90 Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
A5.18 ER70S-6 Single 1G (Flat) N/A N/A
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 67
ACI Building Systems Welding Procedure Specification (WPS) D1.3-12G-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-12G-G Dave Williams GMAW Globular
Rev: 8 Prequalified: Supporting PQR:
Date: 05/20/2010 No 4P
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.0598” (16 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.0673” (15 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.0747” (14 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.0897” (13 Gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.1049” (12 gage)
1
1
0.045
198-242
18-22
342-418
18-22
1G
0.1196” (11 gage)
1
1
.045
198-242
18-22
342-418
18-22
1G
0.1345” (10 gage)
1
1
.045
198-242
18-22
342-418
18-22
1G
0.1875” (3/16”)
1
1
.045
198-242
18-22
342-418
18-22
1G
Notes
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 68
ACI Building Systems Welding Procedure Specification (WPS) D1.3-13P-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-13P-G Dave Williams GMAW Globular
Rev: 3 Prequalified: Supporting PQR:
Date: 05/25/2011 No 13P-G & 7P
Weld Joint Weld Type: Plug Backing: (yes) (no) X Backing Material Type: N/A Joint Welded from: One Side X Both Sides Base Metal Material Speciation Type and Grade: ASTM A1011 SS or HSLAS Grade 55 ASTM A1039 SS or HSLAS Grade 55 Thickness Range: 0.0598” (16 gage) to 0.1875” Diameter Range: N/A Coating Type: Painted or Bare Coating Thickness: 0.5 mil per side Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
A5.18 ER70S-6 Single 1G (Flat) N/A N/A
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 69
ACI Building Systems Welding Procedure Specification (WPS) D1.3-13P-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-13P-G Dave Williams GMAW Globular
Rev: 3 Prequalified: Supporting PQR:
Date: 05/25/2011 No 13P-G & 7P
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.0598” (16 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.0673” (15 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.0747” (14 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.0897” (13 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.1049” (12 gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.1196” (11 gage)
1
1
.045
216-264
18-22
324-396
18-22
1G
0.1345” (10 gage)
1
1
.045
216-264
18-22
324-396
18-22
1G
0.1875” (3/16”)
1
1
.045
216-264
18-22
324-396
18-22
1G
Notes
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 70
ACI Building Systems Welding Procedure Specification (WPS) D1.3-13G-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-13G-G Dave Williams GMAW Globular
Rev: 2 Prequalified: Supporting PQR:
Date: 05/20/2010 No 13G-G
Weld Joint Weld Type: Plug Backing: (yes) (no) X Backing Material Type: N/A Joint Welded from: One Side X Both Sides Base Metal Material Speciation Type and Grade: ASTM A653 SS or HSLAS Grade 55 Thickness Range: 0.0598” (16 gage) to 0.1875” Diameter Range: N/A Coating Type: Galvanized Coating Thickness: G90 Filler Metal AWS Specification: AWS Classification: Number of Electrodes: Positions Metal Position of Groove: Position of Fillet: Progression:
Root Opening Root Face Groove Angle
Tolerances As Fit-up
A5.18 ER70S-6 Single 1G (Flat) N/A N/A
Notes:
Shielding Gas Shielding Gas: Argon/CO2 AWS Classification: 90/10 (Welding Grade) Flow Rate: 36-50 CFH(40 CFH-10% + 25%) Cup Size: 6/00 Flux Type: N/A
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5
Welding Operations Manual
Page 71
ACI Building Systems Welding Procedure Specification (WPS) D1.3-13G-G WPS Number: Prepared By: Welding Process: Mode of Transfer for GMAW:
D1.3-13G-G Dave Williams GMAW Globular
Rev: 2 Prequalified: Supporting PQR:
Date: 05/20/2010 No 13G-G
Technique Thickness
Side
Pass Number
Filler Metal Size
Amps
Volts
Wire Feed Speed (IPM)
Travel Speed (IPM)
Position
0.0598” (16 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.0673” (15 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.0747” (14 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.0897” (13 Gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.1049” (12 gage)
1
1
0.045
216-264
18-22
324-396
18-22
1G
0.1196” (11 gage)
1
1
.045
216-264
18-22
324-396
18-22
1G
0.1345” (10 gage)
1
1
.045
216-264
18-22
324-396
18-22
1G
0.1875” (3/16”)
1
1
.045
216-264
18-22
324-396
18-22
1G
Notes
Approved by: Dennis Johnson
Effective Date 01/16/2012
Revision Number: 5.5