Professional Documents
Culture Documents
BS EN Welding Book
BS EN Welding Book
Procedure
Specifications for
Structural Steelwork
Typical Welding
Procedure
Specifications for
Structural Steelwork
Acknowledgements
This publication has been produced with the special assistance of:
Mr Jeff Garner - BCSA
Mr Johann Krancioch - Severfield-Rowen plc
Mr Richard Thomas - Rowecord Engineering Ltd
Dr David Moore - BCSA
Mr David Brown - SCI
Contents
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Typical Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Basis of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Qualification of Welding Procedure Specifications to BS EN ISO 15614-1 . . . . . . . . . . . . . . . . . . . . .
3.4 How to use this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
7
25
25
25
25
26
1 Foreword
This publication has been prepared with the aim of simplifying and
standardising welding procedures used in structural steelwork.
The need for such a document was first identified some years ago
by a group of welding engineers, steelworks contractors,
metallurgists and industry experts and a draft document was
produced outlining how this might be achieved and the range of
variables which typically needed to be considered. This publication
draws on the wealth of experience, knowledge and work put in to
the early document and has been updated to reflect current welding
practice, standards and specifications.
This document contains 14 preliminary Welding Procedure
Specifications (pWPS) as defined in BS EN ISO 15614-1, and 40
partially completed Welding Procedure Specifications (WPS), called
typical WPS in this document. The pWPS have been identified as
those required to support the necessary welding procedure tests on
the route to qualifying the typical WPS. The typical WPS have been
chosen to cover the majority of WPS required for the welding of
structural steelwork for buildings and bridges. They cover weld types
ranging from simple fillet welds to the more difficult butt welds made
from one side, with backing.
To assist the user the weld types are placed in five categories where,
in general terms, the skill level required by the welder increases the
higher the category number. The categories are as follows:
Category 1: Fillet welds only (PA, PB positions)
Category 2: Fillet welds only (PA, PB and PF positions)
Category 3: Fillet welds (PA, PB positions); butt welds made from
two sides in the PA position
Category 4: Fillet welds (PA, PB and PF positions); butt welds made
from two sides in the PA position
Category 5: Fillet welds (PA, PB and PF positions); butt welds made
from two sides or with permanent backing in the PA, PC
and PF positions
Depending on contract requirement and welder competence,
a steelwork contractor may select the appropriate range of weld
types to be approved and the associated pWPS. More details on the
choice of pWPS are given in Section 3.3 How to use this document.
The five categories are recommendations; a steelwork contractor is
at liberty to choose a different selection of pWPS resulting in a
different range of approved WPS.
2 Scope
This document is intended for use by steelwork contractors, welding
engineers and inspectors, and those actively involved in welding and
welding technology. Familiarity with BS EN ISO 15614, BS EN 287,
and the welding principles contained in BS EN 1011 is required.
Structural capacity checking and weld inspection are not addressed
in this document.
This document contains 14 preliminary Welding Procedure
Specifications (pWPS) written in accordance with the requirements
of BS EN ISO 15609-1. They cover the welding of plate and rolled
sections up to 25mm thick in carbon manganese structural steels to
BS EN 10025, with a maximum carbon equivalent value (CEV) of
0.45 (1) (see BS EN 1011-2 Clause C.2.1). The maximum combined
thickness is limited to 75mm.
The welding process is solid wire partly mechanised Metal-arc Active
Gas (MAG), process 135 in BS EN ISO 4063. It is assumed that
preparation, control and use of a suitable consumable will achieve a
hydrogen content of 5ml/100g or below in the deposited weld metal
i.e. Scale D in BS EN 1011-2, Table C.2. In order to achieve the
required hydrogen content, the steelwork contractor should ensure
that consumables are stored and used in accordance with
manufacturers' recommendations - i.e. they should be kept clean,
dry and free from contamination.
The welding parameters proposed in the pWPS are designed to
produce welds which meet the mechanical requirements of BS EN
10025 steel grades up to and including S355J2; with a minimum
Charpy impact value of 27J at -20C.
(1)
The WPS in this document are based on using steel with a CEV of 0.45, since this is the maximum allowable in BS EN 10025 for grade S355 steels < 30mm thick.
However, reputable steel makers typically supply products with CEV's lower than the specified maximum. In light of this, when developing WPS outside the scope
of this document, a steelwork contractor may wish to consider purchasing steel with a CEV lower than the maximum to accommodate a greater thickness range
without the requirement for preheating. Specifying a maximum CEV of 0.43 may not be unreasonable for S275 and S355 grade steels.
Introduction
3.2
(1)
Develop a preliminary
welding procedure
specification (pWPS)
The welding details have been developed for the standard grades of
structural steels, S275 and S355 up to and including sub-grade J2,
using the Metal-arc Active Gas (MAG) process. Joint configurations
and welding positions have been chosen to meet the majority of
practical requirements.
(2)
Complete a welding
procedure test
(3)
Complete a welding
procedure qualification
record (WPQR)
Example WPQR
given in
Appendix C
(4)
Prepare Welding Procedure
Specifications (WPS)
based on the (WPQR)
Typical completed
WPS given in
Section 6
3.3
3.4
Category pWPS
1
Qualification Range
Fillet welds only in PA and PB
positions
PF positions
09p, 10p
positions
09p, 10p
positions
09p, 10p
pWPS sheets
ensure that all fusion faces are clean and free from oil, grease,
scale and other contaminants which may be detrimental to the
welding process.
For consistency and ease of use, the format of the pWPS, and
subsequent WPS, is based on the example given in Annex A of BS
EN ISO 15609-1. Section 4 contains 14 preliminary Welding
Procedure Specifications (pWPS). Table 3.1 in Section 3 shows the
selection of pWPS which, when completed, tested, examined and
qualified, allow the completion and provide qualification of the WPS
contained in Section 6. The pWPS are placed in categories based
upon level of complexity and, as such, the steelwork contractor may
elect to qualify whichever category it considers most appropriate for
its product range.
The details given on the pWPS are described in the following sections.
Location
Stating 'Workshop' or 'Site' will generally suffice unless the steelwork
contractor operates from a number of different workshop / site
locations then the site reference should be specified.
WPS number
Procedures are presented in numerical order followed by the letter
(p) to signify that they are preliminary and require qualification.
WPQR
The WPQR number is not applicable since the welding procedure is
only at the preliminary stage and, as such, is unqualified.
Manufacturer
The procedures state 'to be confirmed'. When a manufacturer
chooses to qualify a particular pWPS then the manufacturer's own
name, address etc. should be entered here.
Material thickness
The material thickness specified is the actual thickness to be used
during qualification of the pWPS.
Outside diameter
Each pWPS states 'not applicable' since they are all designed for use
on plate.
Welding position
Welding positions are described by the BS EN ISO 6947
designation. The correspondence between these and the American
Welding Society (AWS) designations is shown in Table 4.1. The
pWPS in Section 4 cover welding in the PA, PB, PC and PF positions.
Welder's name
Each of the pWPS states 'to be confirmed'. Whilst there is typically no
requirement to specify the welder's name on a WPS, it may be
prudent to do so on a pWPS since the welder who satisfactorily
undertakes the welding procedure qualification test is automatically
qualified within the range of qualification given in BS EN 287.
Welding process
On each pWPS the welding process is given its numeric reference
number according to BS EN ISO 4063 along with its standard
abbreviation (i.e. 135 - MAG)
Joint type
Each pWPS specifies the type of joint and whether it is to be welded
single or double sided, with or without backing etc.
Fillet
Designation
BS EN
AWS
Flat
Horizontal
Vertical downwards
Vertical upwards
PA
PC
PG
PF
1G
2G
3G
3G
Overhead
PE
4G
Flat
Horizontal vertical
Vertical downwards
Vertical upwards
Horizontal overhead
PA
PB
PG
PF
PD
1F
2F
3F
3F
4F
Figure 4.1 Illustrates the designated positions for plates and open
sections
Butt Welds:
Joint design
A sketch of the joint preparation is given on each pWPS. This
typically includes such items as the material dimensions, root gap,
root face, included angle etc. The preparations indicated generally
conform to the requirements of BS EN ISO 9692-1: 2003.
Welding Sequence
PA Flat
PC Horizontal
Run
Each weld run is given a number that is linked to the welding
sequence sketch.
Process
The MAG process is identified as process 135 in BS EN ISO 4063.
PE Overhead
PF Vertical Upwards
Welding parameters
Fillet Welds:
PA Flat
PB Horizontal Vertical
The welding parameters, travel speeds, wire feed rates etc. given on
the pWPS are taken from previously qualified welding procedures
and are thus considered appropriate for the joint configurations and
material thicknesses they are assigned to. The specified heat inputs
are calculated using the formula given in BS EN 1011-1. It is
recognised however, that alternative welding parameters and
conditions could be used to achieve successful welding. In view of
this, when carrying out welding procedure qualification tests, the
steelwork contractor should not be precluded from selecting
alternative parameters and welding conditions to suit working
practices that are already established. The welding procedure
qualification test should be based on a revised pWPS.
PD Horizontal Overhead
PF Vertical Upwards
10
Each pWPS states not applicable since this relates to the control of
parameters for the post-weld heat treatment.
Preheat temperature
The welding procedures within this document are limited to a
maximum material thickness of 25mm (75mm maximum combined
thickness) to eliminate the requirements for preheating. It should be
noted, however, that this is based on the following assumptions:
Interpass temperature
For certain types of steel too high an interpass temperature may
have an undesirable affect on notch toughness in the heat affected
zone, or may cause an alteration of properties produced by a
previous heat treatment of the steel.
The maximum interpass temperature stated on the pWPS (250C) is
based on recommended good practice for Group 1 type steels.
However, in accordance with BS EN ISO 15614-1, the upper limit of
approval is the nominal maximum interpass temperature reached
during the welding procedure test.
11
Other information
For manufacturer
Each pWPS states 'RWC's Signature'. When a steelwork contractor
chooses to qualify a WPS, the Responsible Welding Coordinator
(RWC) is required to sign and date the pWPS so as to verify that the
proposed welding parameters are considered suitable and that the
subsequent range of qualification will be adequate for the intended
future application.
Joint Design
Welding Sequence
10 mm
z6
< 1mm
10 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
320 - 340
1.1 - 1.3
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
N/A
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
12
Joint Design
Welding Sequence
25mm
z6
< 1mm
25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
290 - 310
29 - 31
DC +ve
8.3 - 9.0
300 - 330
1.2 - 1.5
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
N/A
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
13
Joint Design
Welding Sequence
10mm
z 10
< 1mm
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
320 - 340
1.1 - 1.3
2-3
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
340 - 380
0.9 - 1.3
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
14
Joint Design
Welding Sequence
25mm
z 10
< 1mm
25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
290 - 310
29 - 31
DC +ve
8.3 - 9.0
300 - 330
1.3 - 1.5
2-3
135 (MAG)
1.2
290 - 310
29 - 31
DC +ve
8.3 - 9.0
310 - 330
1.2 - 1.5
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
15
Joint Design
< 1mm
Welding Sequence
10mm
z6
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
160 - 180
19 - 21
DC +ve
4.6 - 5.3
120 - 140
1.0 - 1.5
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
N/A
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
16
Joint Design
< 1mm
Welding Sequence
25mm
z6
25mm
Dimension z = Fillet weld leg length in mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
190 - 200
19 - 21
DC +ve
5.1 - 5.5
120 - 140
1.3 - 1.6
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
N/A
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
17
Joint Design
Welding Sequence
10mm
< 1mm
2
z 10
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
160 - 180
19 - 21
DC +ve
4.6 - 5.3
120 - 140
1.0 - 1.5
2-3
135 (MAG)
1.2
160 - 180
19 - 21
DC +ve
4.6 - 5.3
140 - 160
0.9 - 1.3
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
18
Joint Design
Welding Sequence
25mm
< 1mm
z 10
25mm
Dimension z = Fillet weld leg length in mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
190 - 200
19 - 21
DC +ve
5.1 - 5.5
120 - 140
1.3 - 1.6
2-3
135 (MAG)
1.2
190 - 200
19 - 21
DC +ve
5.1 - 5.5
110 - 130
1.3 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
19
Welding Sequence
50 - 0 / +10
10mm
Side 1
3
2
1
4
Side 2
0 - 2mm
0 - 3mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-4
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
20
Welding Sequence
50 - 0 / +10
15mm
Side 1
0 - 2mm
5
3
2
1
6
Side 2
2 - 3mm
Grind back Side 2 to sound metal and MPI
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-6
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
21
Backing material
25 x 6 mm
n
Welding Sequence
0 - 1mm
30 - 0 / +5
6
2 4
1 3 5
6 - 8mm
15 - 0 / +5
1mm
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-5
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.2 - 1.4
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
22
Backing material
25 x 6 mm
Welding Sequence
6 - 8mm
10mm
< 1mm
0 - 1mm
2
3
40 - 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
120 - 140
1.1 - 1.6
2-3
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
100 - 120
1.2 - 1.9
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
23
Backing material
25 x 6 mm
Welding Sequence
0 - 1mm
30 - 0 / +5
2 4
1 3
6 - 8mm
15 - 0 / +5
7
6
5
< 1mm
15mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-6
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.2 - 1.4
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
24
Backing material
25 x 6 mm
Welding Sequence
6 - 8mm
15mm
< 1mm
1
2
3
4
0 - 1mm
40 - 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
120 - 140
1.1 - 1.6
2-4
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
100 - 120
1.2 - 1.9
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
250C Maximum
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
25
Introduction
Welding position
In accordance with the welding position and process specific
requirements of BS EN ISO 15614-1 (Sections 8.4.2 and 8.5.2), this
document recommends separate tests (pWPS 05p, 06p, 07p and
08p) to cover the PF positions.
Table 5.1 indicates the pWPS and consequent range of approval
based strictly on BS EN ISO 15614-1. It should be noted, however,
that achieving the 9mm maximum allowable leg length for single run
fillets may be impractical.
pWPS
01p
02p
03p
04p
05p
06p
07p
08p
5.2
Fillet welds
5.3
Butt welds
In similar fashion to the fillet welds, the pWPS for butt welds have
been chosen to achieve approval over a range of material thickness,
and for a variety of weld types and positions. The pWPS for butt
welds are arranged as shown in Table 5.2, and the range of approval
described in the following sub-sections.
Material thickness
The material thicknesses of 10 and 25mm cover thickness ranges of
5 to 12mm and 12.5 to 30mm respectively.
Material
Position Thickness
(mm)
09p
PA
10
10p
PA
15
The 6mm fillet covers single run fillets with leg lengths of 4.5 to 9mm.
11p
PC
10
The 10mm fillet covers multi-run fillets with no restriction on leg length.
12p
PC
15
13p
PF
10
14p
PF
15
Weld size
Table 5.2
26
Material thickness
The material thicknesses of 10 and 15mm cover thickness ranges of
3 to 12mm and 7.5 to 30mm respectively.
Welding position
BS EN ISO 15614-1 indicates that where neither impact nor
hardness requirements are specified, welding in any one position
qualifies for welding in all positions. In almost all instances, impact
requirements will have been specified by the choice of steel subgrade made by the structural designer. When either impact or
hardness requirements must be satisfied, the range of positions
approved is determined by the positions in which the weld
procedure test pieces were carried out and is related to the heat
input during welding. The range of positions approved are those with
heat inputs between the highest and lowest heat inputs tested.
pWPS 09p and 10p reflect the most straightforward type of butt
welding in the PA position and approval is limited to PA positions only.
To achieve a wider range of qualified positions, pWPS 11p to 14p are
completed in the PF and PC positions. PF is generally the highest
heat input position and PC the lowest, approving PA, PC and PF.
Joint type
Clause 8.4.3 of BS EN ISO 15614-1 specifies the range of
qualification for joint types. All the butt welds in this document are inline butt welds on plate. PWPS 09p and 10p are used to qualify the
butt welds covered in the Category 3 and 4 WPS (See Table 6.1).
These pWPS are welded from both sides with back gouging and / or
grinding and, as such, only qualify butt welds made from both sides
with back gouging and / or grinding. Single sided welds and those
with backing are not qualified.
Some of the butt welds in the Category 5 WPS (See Table 6.1) are
qualified by single sided butt welds made with permanent backing
(pWPS 11p to 14p). In accordance with BS EN ISO 15614-1, butt
welds with backing also qualify butt welds welded from both sides.
However, this document also recommends qualification of pWPS
09p and 10p when qualifying the Category 5 WPS so as to
demonstrate full positional capability.
In-line butt welds on plate also qualify T butt welds on plate.
However, it should be noted that T butt welds are generally
considered difficult to form and it may be advisable to carry out weld
procedure tests for T butt welds.
Welder approval
The procedure qualification tests in this document have been
chosen primarily to qualify the procedures, not the welders.
However, Clause 5 of BS EN ISO 15614-1 states that the welder who
undertakes the welding procedure test satisfactorily is qualified
within the range of qualification given in BS EN 287.
Material
It is recommended that the test material is BS EN 10025 - S355J2,
as successful tests in this material will also cover steels of lower yield
strength and those with lesser impact properties.
27
5.4
NDT
Weld finish
Interpass temperature
A suffix (a, b or c) differentiates minor changes to essentially the
same procedure due to slight differences in preparation or welding
from one / both sides.
Weld preparation
The joint design sketches on the partial penetration butt weld WPS
in this document use the term 'design throat' as a means of
specifying the depth of preparation required. Whilst responsibility for
specifying the design throat thickness rests with the structural
designer, the steelwork contractor is responsible for selecting the
appropriate depth of preparation to ensure the required design
throat thickness (i.e. depth of penetration) is achieved.
Run
Where a weld can be completed within the same range of welding
parameters the term 'All' is used to show that there is no distinction
between passes. For those welds requiring the use of a broad range
of welding parameters, the welding runs are described as 'root' (the
first weld pass), 'fill' (all intermediate passes) and 'cap' (the final pass).
Welding details
The welding parameters, travel speeds, wire feed rates etc. shown
on the WPS are based on those used in the welding procedure test.
Each parameter will normally be quoted as a range (as specified in
BS EN ISO 15614-1), the mid-point being the nominal value
recorded during the test. The ranges shown on the partially
completed WPS indicate typical values, and will need to be replaced
with ranges based on the actual values recorded during the tests.
Tack welds
Tack welds (to maintain fit-up, or to attach backing strips) should be
made using the same parameters as for the first run of the main
welds. The length of the tack should be the lesser of 4 times the
thickness of the thicker part joined, or 50mm, unless demonstrated
in the WPQR that shorter lengths can be deposited without detriment
to the properties of the material and finished weld. Tack welds
28
6.1
Category
Approved Procedures
pWPS to
Procedure
be qualified
Joint Type
Preparation
Access
Page No
01-PA
10p
single bevel
one side
29
01-PC
12p
single bevel
one side
30
01-PF
14p
single bevel
one side
31
02-PA
single bevel
both sides
32
02-PC
12p
single bevel
both sides
33
02-PF
14p
single bevel
both sides
34
03-PA
double bevel
one side
35
03-PF
14p
double bevel
one side
36
04-PA
double bevel
both sides
37
04-PF
14p
double bevel
both sides
38
05-PA
single bevel
one side
39
05-PC
single bevel
one side
40
05-PF
single bevel
one side
41
06-PA
double bevel
one side
42
06-PF
double bevel
one side
43
07-PB(a)
6, 8mm fillet
one side
44
07-PB(b)
one side
45
07-PF(a)
6, 8mm fillet
one side
46
07-PF(b)
one side
47
08-PA
10p
single bevel
one side
48
08-PC
single bevel
one side
49
08-PF
single bevel
one side
50
09-PA
single bevel
both sides
51
09-PC
single bevel
both sides
52
9-PF
single bevel
both sides
53
10-PA
single bevel
both sides
54
10-PC
single bevel
both sides
55
10-PF
single bevel
both sides
56
Table 6.1
29
11-PC(a)
single bevel
one side
57
11-PC(b)
single bevel
both sides
58
11-PC(c)
single bevel
both sides
59
11-PF(a)
single bevel
one side
60
11-PF(b)
single bevel
both sides
61
11-PF(c)
single bevel
both sides
67
12-PA(a)
double bevel
both sides
63
12-PA(b)
double bevel
both sides
64
12-PC(a)
double bevel
both sides
65
12-PC(b)
double bevel
both sides
66
12-PF(a)
double bevel
both sides
67
12-PF(b)
double bevel
both sides
68
Joint Design
Welding Sequence
40 0 / +10
See Note 3
8 25 mm
0 3mm
See Note 2
D = Design Throa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
30
Joint Design
Welding Sequence
8 25 mm
D
See Note 3
40 0 / +10
0 3 mm
See Note 2
D = Design Throa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
31
Joint Design
Welding Sequence
D = Design Th roa t
0 3mm
See Note 2
See Note 3
8 25m m
40 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
32
Joint Design
Welding Sequence
40 0 / +10
Side 1
See Note 3
See Note 2
5 25 mm
Cut back
Side 2
0 1 mm
0 3 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.0
300 - 360
0.75 - 1.0
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
33
Joint Design
Welding Sequence
5 25 mm
Side 1
0 1mm
40 0 / +10
Side 2
Cut back
See Note 2
0 3mm
See Note 3
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.0
300 - 360
0.75 - 1.0
Fill
(Note 4)
135
1.2
270 - 290
28 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
240 - 260
26 - 28
DC +ve
8.5 - 9.0
280 - 300
1.0 - 1.25
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
34
Joint Design
0 3mm
Welding Sequence
Side 2
0 1mm
Cut back
See Note 3
See Note 2
5 25 mm
Side 1
40 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
35
Joint Design
Welding Sequence
50 0 / +10
See Note 3
8 25 mm
0 3mm
See Note 2
D = Design Throa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
36
Joint Design
Welding Sequence
D = Design Throa t
0 3 mm
See Note 2
8 25 mm
See Note 3
50 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
37
Joint Design
Welding Sequence
50 0 / +10
Side 1
See No te 2
See No te 3
5 25m m
Cut bac k
Side 2
0 1mm
0 3mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.0
300 - 360
0.75 - 1.0
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
38
Joint Design
0 3mm
Welding Sequence
Side 2
0 1mm
Cut bac k
See No te 3
5 25m m
See No te 2
Side 1
50 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
39
Joint Design
Welding Sequence
30 + / 5
6mm min.
See Note 4
5 25mm
0 1mm
0 1mm
See Note 2
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
40
Joint Design
Welding Sequence
5 25m m
See No te 4
0 1mm
30 + / 5
6mm min.
0 1mm
See Note 2
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
41
Joint Design
Welding Sequence
See No te 2
0 1mm
0 1mm
See No te 4
5 25m m
6mm min.
30 + / 5
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 210
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
42
Joint Design
Welding Sequence
40 0 / +10
6mm min.
See Note 4
5 25 mm
0 1mm
0 1mm
See Note 2
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
43
Joint Design
Welding Sequence
0 1mm
0 1mm
See Note 4
5 25 mm
6mm min.
40 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
44
Joint Design
Welding Sequence
6 - 25mm
z68
< 1mm
6 - 25mm
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.0
320 - 340
1.1 - 1.3
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
45
Joint Design
Welding Sequence
6 - 25mm
z 10 12
3
< 1.5mm
6 - 25mm
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
2-3
135 (MAG)
1.2
250 - 270
26 - 28
DC +ve
6.0 - 6.5
260 - 280
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
46
Joint Design
<1mm
Welding Sequence
6 - 25mm
z68
6 - 25mm
Dimension z = Fillet weld leg length in mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
47
Joint Design
Welding Sequence
10 - 25mm
<1.5mm
See Notes 2 & 3
1
3
z 10 12
10 - 25mm
Dimension z = Fillet weld leg length in mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
1-3
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
48
Joint Design
Welding Sequence
45 0 / +10
See Note 3
D
8 25m m
0 3mm
See Note 4
See Note 2
8 25mm
D = Design Th roa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
49
Joint Design
Welding Sequence
D = Design Throa t
8 25mm
D
See Note 3
45 0 / +10
See Note 4
0 3mm
See Note 2
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
50
Joint Design
Welding Sequence
8 25mm
See Note 4
0 3mm
See Note 2
8 25mm
D
See Note 3
45 0 / +10
D = Design Th roa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
3.5 - 4.0
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
51
Joint Design
Welding Sequence
8 25mm
Side 1
45 0 / +10
See Note 3
See Note 2
8 25mm
0 1 mm
Side 2
0 3 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
52
Joint Design
Welding Sequence
8 25mm
See Note 2
0 1mm
Side 2
45 0 / +10
0 3mm
Side 1
See Note 3
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
53
Joint Design
Welding Sequence
0 1 mm
Side 2
0 3 mm
Cut back
See Note 2
8 25mm
See Note 3
45 0 / +10
Side 1
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
54
Joint Design
Welding Sequence
8 25 mm
Side 1
45 0 / +10
See Note 3
See No te 2
8 25 mm
0 1mm
Side 2
0 3mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
55
Joint Design
Welding Sequence
8 25mm
See Note 2
0 1 mm
45 0/ +10
0 3 mm
Side 2
Side 1
See Note 3
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
56
Joint Design
Welding Sequence
0 1 mm
0 3 mm
See Note 2
8 25 mm
See Note 3
45 0 / +10
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
57
Joint Design
Welding Sequence
8 25 mm
See Note 2
45 0/ +10
0 3 mm
See Note 3
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
58
Joint Design
Welding Sequence
8 25 mm
See Note 2
45 0/ +10
0 3 mm
See Note 3
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
59
Joint Design
Welding Sequence
8 25mm
See No te 3
Cut back
45 0/ +10
Side 1
0 3 mm
Side 2
See Note 2
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
60
Joint Design
8 25 mm
Welding Sequence
0 3mm
See Note 3
45 0/ +10
See Note 2
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
61
Joint Design
8 25 mm
Welding Sequence
0 3mm
See Note 3
45 0 / +10
See Note 2
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
62
Joint Design
8 25 mm
Welding Sequence
0 3 mm
See Note 2
Side 1
Side 2
45 0 / +10
Cut back
See Note 3
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
63
Joint Design
Welding Sequence
0 3 mm
See Note 2
=
8 25mm
See Notes
4&5
=
45 0 / +10 Typical
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
64
Joint Design
Welding Sequence
0 3mm
Side 1
=
8 25 mm
See Notes
2&3
0 2mm
Cut back
Side 2
45 0 / +10 Typical
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
For Manufacturer:
RWCs Signature
65
Joint Design
Welding Sequence
8 25mm
0 3 mm
45 0 / +10 Typical
See Note 2
See Notes
4&5
8 25mm
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
66
Joint Design
Welding Sequence
8 25 mm
=
Side 1
0 3mm
Cut back
Side 2
45 0 / +10 Typical
See Notes
2&3
8 25 mm
0 2mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
67
Joint Design
Welding Sequence
8 25 mm
0 3 mm
See Note 2
45 0 / +10 Typical
See Notes
4&5
8 25 mm
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
68
Joint Design
0 2 mm
0 3 mm
Welding Sequence
See Notes
2&3
8 25 mm
45 0 / +10 Typical
Side 1
Side 2
Cut back
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
15 - 18 L/min
N/A
Preheat Temperature
Interpass Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
69
7 References
BSI Publications:
BS EN ISO 15614-1: Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 1: Arc and gas
welding of steels and arc welding of nickel and nickel alloys
BS EN 287-1:
BS EN 1011-1:
Welding - Recommendations for welding of metallic materials - Part 1: General guidance for arc welding
BS EN 1011-2:
Welding - Recommendations for welding of metallic materials - Part 2: Arc welding of ferritic steels
BS EN ISO 15609-1: Specification and qualification of welding procedures for metallic materials - Welding procedure specification - Part 1:
Arc welding
BS EN 10025-1:
Hot rolled products of structural steels - Part 1: General technical delivery conditions
BS EN 10025-2:
Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy structural steels
BS EN ISO 3690:
Welding and allied processes - Determination of hydrogen content in ferritic steel arc weld metal
BS EN ISO 6947:
BS EN ISO 9692:
Welding and allied processes - Recommendations for joint preparation - Part 1: Manual metal-arc welding, gas-shielded
metal-arc welding, gas welding, TIG welding and beam welding of steels
BS EN ISO 4063:
BS EN ISO 14341:
Welding consumables - Wire electrodes and deposits for gas shielded metal arc welding of non alloy and fine grain steels
- Classification
BS 2901:
Filler rods and wires for gas-shielded arc welding - Part 1: Ferritic steels
BS EN ISO 14175:
BS EN ISO 15607:
Specification and qualification of welding procedures for metallic materials - General rules
BCSA Publications:
National Structural Steelwork Specification - 5th Edition
National Structural Steelwork Specification - CE Marking Edition
70
180
160
140
125
100
Minimum preheating
temperature, C
50 0
75 20
120
100
80
60
40
20
0
0,0
0,5
1,0
d1
d2 (= d1)
2,5
3,0
0,34
0,39
0,41
0,46
0,48
All rust, paint, grease and moisture should be removed from the
workpiece if hydrogen scale D is to be achieved. Should any of
these contaminants be present, the hydrogen scale would have
to be increased to scale B; which requires the use of Figure C.2
e) of BS EN 1011-2 (Figure A4). Using the same key parameters
(i.e. CEV, combined thickness and a 1.1 kJ/mm heat input)
preheating to a minimum of 125C is required. Procedures
requiring preheat are outside the scope of this publication.
200
Minimum preheating temperature, C
180
160
2,0
1,5
175
150
125
100
75
50
20
140
120
100
80
60
40
20
0
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
Hydrogen Scale
To be used for carbon
equivalent not exceeding
0,43
0,45
0,47
0,53
0,55
71
4,5
The dip transfer or short circuiting arc mode is appropriate for welding
in all positions. Low current and voltage settings produce a short
circuiting arc to achieve controlled transfer of metal droplets.
This mode is associated with low heat input. Precise control of the
parameter settings is required to attain stable operating conditions and
to avoid lack of fusion defects. For a solid wire of 1.2mm diameter, a
current range of 80-200A and a voltage range of 15-23V can be used.
In addition, it may be necessary to set the inductance or choke level of
the equipment. This slows down the surge in current when short
circuiting takes place and reduces spatter.
Useful generalisations in setting up and operating solid wire
semi-automatic equipment are set out below (see Figure B.1):
1. Constant voltage (flat characteristic power curve) DC power
source is preferred;
2. Two or four roll feeders can be used but care should be taken to
ensure that their alignment is accurate;
3. For spray transfer mode, an electrode extension of 15-20mm is
typical, with the contact tip retracted 3mm within the gas nozzle;
4. For dip transfer mode, an electrode extension of 6-12mm is typical,
with the contact tip extended 3mm outside the gas nozzle;
5. A gas nozzle of 16mm diameter is generally used;
6. The preferred torch angles depend on welding position being
used. The suggested ranges and directions are as follows:
Transfer
Mode
Welding
Postion
Angle of torch in
and direction
Spray
PA, PB, PC
Dip
PF
0 - 5 Trailing
Dip
All except PF
15 - 20 Leading or Trailing
10-20
(1)
Leading
Trail
angle
Nozzle
Completed weld
Direction of travel
Contact tip
Completed weld
Direction of travel
PA Position
PF Position
72
73
74
75