Welding Procedure for Steel Structure Welding at Penthouse Engineers (Pvt) Ltd

Parent Material Designation: S255Jo

Material Thickness (mm):10mm /30mm
Method of preparation & Cleaning: Flame cutting & grinding
Welding Process: GMAW (MAG)
Joint type & weld type: Single groove weld with full penetration / Fillet
Welding Position: 1G/2G/3G
Mode of metal transfer: Short Circuit Transfer
Filler material designation, make & Classification: CHW-50C6SM, AWS A5.18 ER70S-6
Electrode Diameter: 1.2mm
Any special Backing or Drying: N/A
Shielding Gas: - CO2 100% Gas flow Rate: 15-20 l/min
Details of Back gouging/Backing: Back gouging: Yes (Grinding) Backing: No
0
Preheat Temperature: Ambient Temperature for 10mm / 110 C for 30mm
Inter-pass Temperature: 2000C Max.
Welding Technique (Weave/Stringer bead): Both
Maximum allowed weaving: Three times of the electrode Diameter
Special Precautions to be followed:
 To avoid rust, the wire must be kept in dry condition.
 To prevent welding defects, the shield gas should be pure particularly no moisture in it.
 The surfaces to be welded must be cleaned away impurities of oil contamination, rust, moisture and so
on.
 Mechanical properties, crack resistance and compactness of the weld metal are affected by heat input in
welding so should pay more attention to it.

1. Welding 10mm thick Web of H-beam

Joint Design Welding Sequences

Welding Parameters (Welding Position 3G):

Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-220 26-29 DC+ve 120-200
Capping 1.2mm 160-220 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Capping 1.2mm 160-220 26-29 DC+ve 140-200

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2. Full Penetration Welding of 30mm thick flange

Joint Design Welding Sequences

30 30 30 30
mm mm mm mm

3-4 mm

Welding Parameters (Welding Position 1G):

Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-240 26-29 DC+ve 120-200
Capping 1.2mm 160-240 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Capping 1.2mm 160-240 26-29 DC+ve 140-200

3. Fillet Welding of 30mm Doubler Plate to 30mm Flange

Joint Design Welding Sequences

30 mm
Doubler
L=14mm
Plate
(Leg
Length)
30 mm
Flange

Welding Parameters (Welding Position 1G/2G/3G):

Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-240 26-29 DC+ve 120-200
Capping 1.2mm 160-240 26-29 DC+ve 140-200

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4. Full Penetration Welding of 30mm Base Plate to 30mm Flange

Joint Design Welding Sequences

L=8mm

Welding Parameters (Welding position – 2G/1F)

Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-240 26-29 DC+ve 120-200
Capping 1.2mm 160-240 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Capping 1.2mm 160-240 26-29 DC+ve 140-200

5. Full Penetration Welding of 40mm flange (Beam to Beam Welding)

Joint Design Welding Sequences

40 40
40 40
mm mm
mm mm

R= 2-4mm

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Welding Parameters (Welding Position 1G/4G):
Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-240 26-29 DC+ve 120-200
Capping 1.2mm 160-240 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Capping 1.2mm 160-240 26-29 DC+ve 140-200

6. Full Penetration Welding of 20mm Web (Beam to Beam Welding)

Joint Design Welding Sequences

L=10mm

20 mm 20mm

Welding Parameters (Welding Position: 3G/3F)

Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-220 26-29 DC+ve 120-200
Capping 1.2mm 160-220 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Filling 1.2mm 160-220 26-29 DC+ve 120-200
Capping 1.2mm 160-220 26-29 DC+ve 140-200

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7. 30mm flange full penetration welding (Column to Beam Welding)

Joint Design Welding Sequences

R= 2-4mm 300+-50 L=12mm

L= 6mm
F=2-3 mm

Welding Parameters (Welding Position 1G/1F/4F):

Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-240 26-29 DC+ve 120-200
Capping 1.2mm 160-240 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Filling 1.2mm 160-240 26-29 DC+ve 120-200
Capping 1.2mm 160-240 26-29 DC+ve 140-200

8. 15mm Web full penetration welding (Column to Beam Welding)

Joint Design Welding Sequences

7mm

15mm
15mm

30mm 30mm

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Welding Parameters (Welding Position 3G/3F):
Pass/Layer Size of filler Current Voltage Current Polarity Travel speed
material (A) (V) (mm/min)
Root 1.2mm 140-180 25-28 DC+ve 80-120
Filling 1.2mm 160-220 26-29 DC+ve 120-200
Capping 1.2mm 160-220 26-29 DC+ve 140-200
Back gouge from other side up to the sound metal & then complete the capping.
Filling 1.2mm 160-220 26-29 DC+ve 120-200
Capping 1.2mm 160-220 26-29 DC+ve 140-200

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