Copyright

by

Erik lvaan Moorhead

1996

Brooke Army Medical Center: A Case Study of Field Welding and Welding Inspection
Practices on Structural Steel Moment Connections

by

Erik lvaan Moorhead, B.S., B.A.

Report

Presented to the Faculty of the Graduate School

of The University of Texas at Austin
in Partial Fulfillment
of the Requirements
for the Degree of

Master of Science in Engineering

The University of Texas at Austin

May 1996

Brooke Army Medical Center: A Case Study of Field Welding and Welding Inspection
Practices on Structural Steel Moment Connections

APPROVED

BY

SUPERVISING

COMMITTEE:

Michael D. Engelhardt

Karl H. Frank

ACKNOWLEDGMENTS

The author wishes to acknowledge the kind cooperation and assistance of Mr. Ronald W.
Rowland, Mr. Michael W. May and Mr. Robert A. Rowe, without which this study would not
have been possible. The author also wishes to acknowledge the generous cooperation of
Dr. Michael Engelhardt and Dr. Karl Frank.

Submitted: 4 January 1996

iv

ABSTRACT

Brooke Army Medical Center: A Case Study of Field Welding and Welding Inspection
Practices on Structural Steel Moment Connections
by
Erik lvaan Moorhead, M.S.E.
The University of Texas at Austin, 1996
SUPERVISOR: Michael D. Engelhardt

With the failures of field welds on moment connections of several structural steel
moment frames observed during the 1994 Northridge earthquake, an interest has developed
in examining the ability of present codes, welding practices and welding quality control
practices to insure installation of field welds of a quality commensurate with the assumptions
made in the structural design of the moment connections. This report is a case study of
field welding and welding quality control practices on moment connections on a large
medical facility constructed in San Antonio, Texas, under a contract administered by the
U.S. Army Corps of Engineers. The paper will include 1) a general description of the
project; (2) a description of the project participants and their contractual relationships with
regard to weld installation and welding quality control; (3) a description of field welded
moment connection details and the role of these connections in the structural system; (4)
a review of contract requirements for the welding and inspection of moment connections;
(5) an evaluation of the compliance with contract requirements for the field welding and
welding inspection; (6) an analysis of data collected from the weld inspection reports and
other submittals; (7) a discussion of observed problems and successes in the quality control
of project field welding; and (8) a discussion of suggested practices to help mitigate the
observed problems and reinforce the observed successes. The written records and data
which this case study used are from the U.S Army Corps of Engineers' project files which
were made available to the author. The author also draws on his personal observations
from his involvement with the project and on interviews with project participants and other
professionals in the steel erection/welding inspection industry.

TABLE OF CONTENTS

List of Tables
List of Figures
lntroduction
Section 1: Project Description
Section 2: Contractual Relationships and Project Players
Overview of Contractual Organization of a Corps of Engineers' Project.
Project Participants
Section 3: Moment Connection Details and Their Role in the Structural System
Section 4: Review of Contract Requirements
Contract Requirements for Field Welding of Moment Connections
Contract Requirements for Inspection of Field Welded Moment Connections
Section 5: Evaluation of Compliance with Contract Requirements
Compliance With Contract Requirements for Field Welding of Moment
Connections
Compliance With Contract Requirements for Inspection of Field Welded
Connections
Section 6: Analysis of Data From Weld Reports
Overall Quality of Welders
Overall Quality of Welding
Visual and Ultrasonic Rejectable Defects
Welding Inspector Rejection Rates
Section 7: Observed Problems and Successes in Field Welding Quality Control.
Section 8: Suggested Practices to Mitigate Observed Problems and
Reinforce Observed Successes
Options to increase the probability of getting good verification inspectors
Options to increase the probability of getting properly qualified welders
Options for increasing the probability of having a competent QA
Inspector/Owner's Representative for structural welding
Options for insuring good tracking of the status of welding
Providing for independent verification inspection
Providing a safety net with full nondestructive inspection
Options for QA/Owner control of information without confusion about
approval responsibility
Options to help eliminate problems regarding inspector access
Appendix A: Tabularized Summary of Moment Connection Weld Inspection Reports
Appendix B: Tables
Appendix C: Welding Procedure Specifications
Appendix D: Typical Weld Inspection Report
Appendix E: Contract Specifications
Section 05055 -Welding, Structural
Section 05061 - Ultrasonic Inspection ofWeldments
Section 05120 - Structural Steel..
Structural Steel General Notes
Bibliography
Vita

vi

vii
viii

1
3

5
6
8
12
12
16
21
21
25
33

33
34
34
35
37

.41
41
.43
.44
.45
..45

.45
.46
.46
.47
97
113
115
121
122
128
141
149
150
151

LIST OF TABLES

Table A 1: Summary of Visual and Ultrasonic Weld Inspection Reports for Field
Welded Moment Connections

.48

Table 81: Summary of Weld Inspection Results

98

Table 82: Summary of Rejected Welds with No Record of Repair

99

Table 83: Summary of Welds Having No Record of Any lnspection

100

Table 84: Summary of Welds Having No Record of Ultrasonic Inspection

101

Table 85: Summary of Visually Rejected Welds

102

Table 86: Summary of Ultrasonically Rejected Welds

104

Table 87: Number of Inspections Performed and Rejection Rates for Each
Welding Inspector

107

Table BB: Inspection Timeliness - Time Difference in Days Between Visual

and Ultrasonic lnspections

108

Table 89: Summary of Inspector Exposure to Each Welder

109

Table 810: Summary of Moment Connection Field Welder Qualifications on Record

110

Table 811: Total Welds Performed and Reject Rates for Each Field Welder

111

Table 812: Overall and Per Welder Visual Inspection Rejectable Defect
Frequency Distribution

112

vii

LIST OF FIGURES

Figure 1.1: Descriptive Plan of Project.

.4

Figure 3.1: Typical Field-Welded Moment Connection Details

10

Figure 3.2: Moment Connection Details From Contractor's Shop Drawings

11

viii

INTRODUCTION

With the failures of field welds on moment connections of several structural steel
moment frames observed during the 1994 Northridge earthquake, an interest has developed
in examining the ability of present codes, welding practices and welding quality control
practices to insure installation of field welds of a quality commensurate with the assumptions
made in the structural design of the moment connections. This report is a case study of
welding and welding inspection practices observed during the field welding of moment
connections in the construction of Brooke Army Medical Center, a large medical facility at
Fort Sam Houston, in San Antonio, Texas.
This project was constructed under a contract administered on behalf of the Army
by the U.S. Army Corps of Engineers, Fort Worth District.

The Corps maintained a

dedicated field office, known as the Brooke Resident Office, at the site to monitor
construction which began in 1992. With approximately two months of structural steel
erection work remaining, the author joined the Brooke Resident Office as Lead Quality
Assurance (QA) Civil Engineer.

His responsibilities included overseeing the Corps of

Engineers' monitoring of contract civil, structural, and architectural work. He served as the
leader of a team of QA Inspectors, including the QA Inspector assigned to monitor structural
steel work and the field welding of moment connections. The Brooke Resident Office
project files relating to field welding of structural steel, including contract drawings and
specifications, visual and ultrasonic weld inspection reports, submitted field welder and
inspector qualifications, and other contractor submittals, generously have been made
available to the author. This information along with the author's first hand observations and
the author's interviews with an erector, two welding inspectors, the project structural
Engineer of Record, and the American Welding Society's Director of Certification provide
the data on which this study is based.
The statistical information contained in this report is derived from analysis of the
data contained in the project weld inspection reports. Selected information for each field
welded moment connection joint, including inspector, welder, and dates and results of visual
and ultrasonic inspection, was transcribed by the author from the original welding inspection
reports and organized in a master summary table. This master summary table is included
in its entirety in Table A1, Appendix A.

This report is divided into eight sections.

project.

The second is a description

The first is a general description of the

of the project participants

and their contractual

relationships. The third is a description of field welded moment connection details and the
role of these connections
requirements

in the structural system.

The fourth is a review of contract

for the welding and inspection of moment connections.

evaluation of the compliance with contract requirements

inspection.

The fifth is an

of the field welding and welding

The sixth is an analysis of data from the weld inspection reports. The seventh

is a discussion of observed problems and successes in the quality control of project field
welding.

The eighth is a discussion of suggested practices to help mitigate the observed

problems and reinforce the observed successes.

SECTION 1: PROJECT DESCRIPTION

The project is a replacement hospital for the existing Brooke Army Medical Center
located on Fort Sam Houston in San Antonio, Texas, constructed under a contract
administered by the U.S. Army Corps of Engineers, Fort Worth District. The building and
structure were designed by Harwood K. Smith and Partners, of Dallas, Texas, a wellestablished, nationally recognized Architectural/Engineering(A/E) firm under a separte A/E
design contract also administered by the Corps of Engineers. The General Contractor, steel
Fabricator and steel Erector were all companies with a nationwide presence, experienced
in large building construction, and were among the largest U.S. contractors in their
respective categories. Approximately 1.4 million square feet of total floorspace was
provided for a contract price of $234 million. Approximately 10,000 tons of structural steel
and 75,600 cubic yards of concrete were used . The value of the structural steel contract
was approximately $17 million. 918 field welded moment connections were used in the
structural steel framing. The General Contractor planned to complete the project using a
very aggressive 38 month schedule, 10 months less than the time alotted by the Corps of
Engineers.
The contract included construction of the main facility, which consisted of three
distinct functional and structural elements separated by 2" wide expansion joints (See Figure
1.1 ): a three-story outpatient clinic of rectangular plan, a five-story ancillary building of
rectangular plan, and a seven-story nursing tower of V-shaped "open arms" plan. It also
included construction of two detached structures, a two-story research building of U-shaped
plan and a one-story ambulance garage of rectangular plan. The interstory height was 19
feet in order to accomodate a 7-foot high interstitial floor above each occupied floor. The
interstital floor system was hung from the structural steel framing the floor above. The
interstitial floors were provided to allow for easier installation of the vast amount of
mechanical and electrical distribution equipment, for ease of retrofit, and to provide the
opportunity to conduct maintenance and repair operations without disruption to hospital
operations.

Figure 1.1: Descriptive Plan of Project

SECTION 2: CONTRACTUAL

RELATIONSHIPS

AND PROJECT PLAYERS

Overview of Contractual Organization of a Corps of Engineers' Project

This section begins by providing a brief background on how a typical building project
involving the U.S. Army Corps of Engineers works. On behalf of a client agency who
identifies the need for a particular project and provides funding for design and construction,
the Corps of Engineers first develops a scope of work, solicits proposals for and selects an
A/E firm for production of design, specifications and drawings. The selection of the A/E firm
is competitive, based solely on the evaluated merits of the firms and their proposals. The
Corps negotiates terms with the selected A/E firm and administers the design contract.
Upon receipt of final plans and specifications, the Corps assembles a contract around the
plans and specs and puts the job out for bid. Unlike many private sector contracts, the A/E
has no say over which Contractor is awarded the job and the selection is solely on the basis
of the lowest submitted bid which is verified as being responsive to all contract
requirements. Again unlike private sector construction, the Corps of Engineers, not the A/E,
administers the contract. In fact, after submission of final plans and specs, the A/E has no
further active involvement in the project unless the Corps of Engineers has contracted with
them for what are called Title II Services. These services include providing technical
support and periodic site inspection and are typically included for large projects.
To insure that the General Contractor fulfills its responsibility to produce work
conforming to the contract requirements the Corps of Engineers requires the General
Contractor to develop and execute an adequate Quality Control (QC) Plan. This includes
maintaining an adequate QC Staff, independent of the production side of the operation, the
sole purpose of which is to insure on a daily basis that all work, including that done by
subcontractors, is in accordance with requirements. To insure that its interests are
protected and to give the General Contractor a tangible reason to maintain a good faith QC
effort, the Corps of Engineers maintains a parallel Quality Assurance (QA) staff. The role
of the QA staff is to monitor the work for compliance and insure that the QC Staff corrects
any discovered nonconforming work. The intent is that the presence of government QA
Inspectors creates the situation where the General Contractor will suffer a financial penalty
in the form of tear-out and rework should he allow deficient work to be constructed. This
presumably encourages the General Contractor to maintain an effective QC program and
minimize deficient work. This system breaks down, of course, if the QA and QC inspection

is lax or if the QA inspector is not knowledgeable

enough about contract requirements to

know whether the Contractor is complying or not.

ProjectParticipants
To monitor the construction of Brooke Army Medical Center the Corps of Engineers
set up a dedicated field office, called the Brooke Resident Office, at the project site whose
function was to provide QA inspection, to receive, review, and respond to contractor
submittals and queries, to make progress payments, and to negotiate and execute contract
modifications. At Brooke one Corps of Engineers QA inspector and one General Contractor
QC inspector were assigned to monitor the structural steel work. For the remainder of this
paper the Brooke Resident Office will be referred to as the Corps of Engineers.
For the Brooke Army Medical Center project a joint venture of two large, wellestablished General Contractors submitted the low bid and received the contract.
Henceforth they shall be referred to as the General Contractor. The General Contractor in
turn subcontracted all structural steel work to a large, well-established fabricator who shall
henceforth be referred to as the Fabricator. The Fabricator in turn subcontracted the
erection of the structural steel, including field welding, to a large, well-established erection
company who shall henceforth be referred to as the Erector. To fulfill their contractual
obligations for independent verification weld inspection, the General Contractor
subcontracted with a large, well-established testing company who shall henceforth be
referred to as the Testing Lab. The Testing Lab in turn subcontracted the actual inspection
work to a small company who supplied three inspectors, all of whom were AWS Certified
Welding Inspectors qualified to conduct visual inspection of welds and two of whom were
ASNT Level II Ultrasonic Inspectors qualified to conduct ultrasonic inspection of welds. The
two inspectors qualified for both visual and ultrasonic inspection will be referred to as
Inspector #1 and Inspector #2 and the inspector qualified only for visual inspection will be
referred to as Inspector #3. Inspector #1 served as the lead inspector, Inspector #2 served
as a supplementary inspector, and Inspector #3 served as the primary visual inspector. This
company shall be referred to henceforth as the Inspection Company. When referring to the
Inspection Company in its specific role of providing visual inspection of welds the term VT
Inspector may be used. When referring to the Inspection Company in its specific role of
providing ultrasonic inspection of welds the term UT Inspector may be used. The Corps of
Engineers had a contractual relationship only with the General Contractor and had no direct

moment-resisting

frames were not the primary lateral force resisting system used in the

project, this study is still relevant to the question of quality of moment connections
seismic applications since the large number of moment connections

for

used in this project

were subject to the same details, codes, construction practices, and level of inspection as
would be expected for moment connections in a moment frame constructed in a higher-risk
seismic zone.
All field welded moment connections
connection
connections.

details

shown

in Figure

used the basic field-welded,

3.1, for

beam-to-column

and

field-bolted

beam-to-beam

These details are in accordance with American Institute of Steel Construction

(AISC) standard field-welded,

field-bolted moment connections

(AISC, 1989, Manual of

Steel Construction, 4-106, 4-127 and 4-129). For all flange welds a full penetration single
bevel groove weld with backing was specified. The typical field welded moment connection
details in the Fabricator's shop drawings, shown in Figure 3.2, indicate that AISC/AWS
prequalified joint details B-U4a, for butt joints at flange connections in beam-to-beam
moment connections and beam-to-column-web moment connections, and TC-U4a, for Tjoints at flange-to-web connections in beam-to-beam moment connections and flange
connections in beam-to-column-flangemoment connections, were used (AWS, 1992, AWS
01.1, Fig. 2.4). These prequalifiedjoints use full penetration single bevel groove welds with
backing. Weld access holes are cut at the top and bottom flanges of the beam to be welded
so that backing can be placed under the flange joints and welding can be done from a
position with the welder directly over the joint. This position is the easiest to weld from and
is called the flat, or 1G, position (AWS, 1992, AWS 01.1, Fig. 5.3). The details in Figure 3.2
indicate that butt joints will be welded using a B-U4a-GF procedure specification and T-joints
will be welded using a TC-U4a-GF procedure specification. A review of the Fabricator's
welding procedure submittals from the Brooke Project Files shows that these procedures
each use the Flux Cored Arc Welding (FCAW) process.

fi~.J

Sll.DlnJ

(a) Typical Beam-to-Beam Moment Connection

JI.

llUI IUI[ Ill' i11a 1111.I

llllRl 111111 11. SIK II IOI' AD IOI.

II a111 11. IU. llJCIXSI
'
Wll nm II ICI IUI.

(b) Typical Beam-to-Column Moment Connection

1/1" CSI. llClll Pl

nr, Sll.11&111

-----

r-r

.:i;:-nI

I"

:=:::=====;;;;:~i:..:;;:;;::t::::=======:J

~CQ;~::.______Jr
llJl[lfl

C:IN[CllQll

l!i. SJl.01/0l !TIP.J

., .;.
ur

z-11r smruu u,

(Q91

I sm
rte,

srot

11.
Pl TO II S.11(
1S 1znm fl.J)I;(

llCl(JI ctllll(CllCI ----'

au.

Sll.1"11 llTP.I

(c) Typical Type 3 Application Detail at Expansion Joint

Figure 3.1: Typical Field-Welded Moment Connection Details

10

'TC U'4a GrF

.>-....-~
lo"

(TY?)
,r-..-"='30::.:--<..
& U4a GF

e...::.:o.JG ~

(T'IP)

4c:G..;.'2)..i !!'

.. DETAIL@
(MOMENT CONN:10 COLfll~.)

Figure 3.2: Moment Connection Details From Contractor's Shop Drawings

11

SECTION 4: REVIEW OF CONTRACT REQUIREMENTS

The contract requirements for field welding and inspection of field welding were
included in the specifications, the codes incorporated within those specifications, and the
drawings. Provisons for field welding were enumerated in contract specification sections
"05120 - Structural Steel" and "05055 - Structural Welding" and in the General Structural
Notes appearing at the beginning of the structural contract drawings.

Provisons for

inspection of field welding were enumerated in contract specification sections "05055 Structural Welding" and "05061 - Ultrasonic Inspection of Weldments" and in the General
Structural Notes. Henceforth , "05055 - Structural Welding" will be referenced as Spec
05055, "05061 - Ultrasonic Inspection of Weldments" will be referenced as Spec 05061,
"05120 - Structural Steel" will be referenced as Spec 05120, and the General Structural
Notes will be referenced as the General Notes. Copies of these three specification sections
and the portion of the General Notes applicable to field welding and inspection of field
welding are included in their entirety in Appendix E.
Contract Requirements for Field Welding of Moment Connections
The nine critical requirements applicable to field welding of moment connections are
as indicated below.
1. General Requirements - Erection of the structural steel shall be in accordance
with all applicable provisions of the American Institute of Steel Construction's (AISC)
Specification for Structural Steel Buildings: Allowable Stress Design and Plastic Design with
Commentary (AISC-02) and the welding will be in accordance with all applicable provisions

of the American Welding Society's (AWS) AWS D 1. 1 - 88: Structural Welding Code - Steel
(Spec 05120, para. 3.2 and para. 1.2). The General Notes also reference AWS D1.1 as
controlling all welded construction. Thus AWS D1.1 is wholly incorporated within the
contract. It is interesting to note that AISC-02 also incorporates Sections 3, Workmanship,
and 4, Technique, (and all referenced Sections therein) of AWS D1.1 so that even if the
specifier had failed to specifically incorporate AWS D1.1 it would still have been a contract
requirement by virtue of its inclusion in AISC-02, albeit a less obvious one (AISC, 1989,
AISC-02, sec. M2.4).

2. Submission of Certification of Welder Qualifications - The General

Contractor is required to submit to the Corps of Engineers certification that each welder is
12

qualified in accordance with the requirements of AWS 01.1 (Spec 05120, para. 1.3). The

information on which the General Contractor may base this certification would come from
the Erector but it is the General Contractor who must assume responsibility for the
certification. The certification shall state the name of each welder, process and welding
positions for which the welder is qualified, the code and welding procedure under which the
welder is qualified, the date of qualification, and the names of the firm and person certifying
the qualification tests (Spec 05055, para. 1.6.2). It is the responsibility of the Erector to
properly qualify all welders in its employ and this requirement was intended to gain written
assurance that the General Contractor had made sure the Erector had accepted and fulfilled
this responsibility (AWS, 1992, sec. 5.1.1).
Given the welding procedure specification that was used for field welded moment
connections (Ref. Appendix C), an appropriately qualified welder would need at a minimum
to have been qualified in the FCAW process, using a test plate or test pipe for groove welds
welded in any position, and using E70T-X or E71T-X electrodes. Qualification on a test
plate under 1" thick would result in the welder being limited in the thickness of materials he
could weld.
3. Submission of Welding Procedure Specifications and Welder Qualification
Records Prior to Start of Welding - Prior to the start of field welding all welding procedures

and welders must have been qualified

and copies of the procedure specifications,

procedure qualification test records (unless a prequalified procedure}, and welder

qualification test records must have been submitted to the Corps of Engineers (Spec 05055,
para. 1.3 and 1.4).

This was intended to help insure that only proven, successful

procedures and welders would be used and that the Erector has demonstrated a
commitment to employ good practices in accordance with AWS requirements.
For this contract a prequalified procedure would be one that conformed in all
aspects of joint design, workmanship, and welding technique to AWS 01.1, Sections 2,
Design of Welded Connections, 3, Workmanship, 4, Technique and, since the structure was
considered statically loaded, 8, Statically Loaded Structures (AWS, 1992, sec. 5.1.1). An
adequate prequalified welding procedure specification for groove welded moment
connection joints should address the joint configuration and preparation, surface preparation
of base metal, alignment and fit-up tolerances, allowable ambient temperatures and other
conditions, peening if it is contemplated, inprocess and completed weld cleaning
13

procedures,

groove weld backing, welding process to be used, filler metal type and size

requirements, preheat and interpass temperature requirements,

if applicable, weld layer thicknesses,

shielding gas requirements

welding current, welding voltage, welding speed of

travel, and welding positions to be used (AWS, 1992, App. H).

4. Requirementfor Welder QualificationWithin Past 6 Months - Each welder

shall be or shall have been qualified by testing in accordance with applicable requirements
of AWS 01.1. Welders who were qualified by test within the previous 6 months may be
accepted without requalification if (1) copies of the welding procedure specifications and
welder qualification test records have been submitted as elsewhere required, (2) the testing
was performed by an approved testing agency, and (3) the procedure used in the
qualification test conforms to the procedure specification used on this project (Spec 05055,
para. 1.6).

What constitutes an approved testing agency is not made clear in the

specification since there was no specific requirement to submit a testing agency for approval
or any guidance as to what authority may grant approval. By the language used it appears
that the intent is to require requalification prior to beginning work on this project of any
welder whose most recent qualification test is more than 6 months old.

This is more

stringent than AWS 01.1 requirements wherein a welder's qualification remains in effect
indefinitely unless the welder is not engaged in welding using the process for which he is
qualified for a six month or longer period or if there is some specific reason to question the
welder's ability (AWS, 1992, sec. 5.30). The intent of this provision was to lessen the risk
to the Corps of Engineers of getting welders who were qualified before that date and who
may not be well-practiced.
5. SituationsRequiringWelder Requalification- Requalification of welders by
test will be required if (1) it has been more than six months since the welder has used the
process for which he was qualified, (2) there is some specific reason to question the
welder's ability to make sound welds, or (3) the welder was qualified by an employer other
than the Erector for this project and his most recent qualification test is more than 12
months old (Spec 05055, para. 1.6.3).

Reasons (1) and (2) are identical to AWS 01.1

requirements but reason (3) is a more stringent additional requirement of this contract. The
intent here is to make it less expensive to qualify, and thus encourage the use of, welders
for this project who have been previously qualified and have stayed with the same employer
for an extended period. The assumption is that these welders present fewer unknowns,

14

more stability, and less risk. Continuity records are required to be submitted to the Corps
of Engineers for any welder falling into this category.
a problem because the contract specifications

This provision presents something of

also seem to indicate that requalification

would be required for any welder whose test is more than 6 months old.

Thus these two

provisions appear to be in conflict unless the assumption is made that paragraph 1.6.3 is
intended to apply only after the welder has been accepted (with a qualification within the
previous 6 months) and worked for a time on this contract. Thus a welder who was qualified
3 months before beginning work on this contract by someone other than the Erector could
be accepted but would have to requalify after 9 months while a similar welder qualified by
the Erector would not need requalification for the duration of his work on this contract.

6. Drawings to Reference Applicable Welding Procedure SpecificationsWelding procedure specifications were to be individually identified and referenced on the
shop detail and erection drawings (Spec 05055, para. 1.5). The intent here is to make it
very clear to reviewers, erection foremen and production welders what procedure is to be
used for each field welded joint so that any question about the suitablilty of the procedure
for a given joint may be addressed up front during submittal review and to insure that the
joints are welded using proper procedures.
7. Equipment and Materials - The contract specifications indicate that all welding
equipment, electrodes, welding wire, and fluxes shall conform to all applicable requirements
of AWS 01.1 (Spec 05055, para. 2.1 ). They also indicate that all welding electrodes shall
conform to A WS AS. 1-81: Specification for Covered Carbon Steel Arc Welding Electrodes
and AWS AS. 5-81: Specification for Low Alloy Steel Covered Arc Welding Electrodes (Spec
05120, para. 3.2.3).

This is intended to insure that only satisfactory equipment and

materials capable of producing sound welds will be used.

This specification provision

perhaps makes a poor choice of words since this could be construed as limiting all welding
to the Shielded Metal Arc Weding (SMAW) process since only SMAW electrodes are
specified in AWS AS.1-81 and AWS AS.5-81 (AWS, 1992, sec. 4.5.1). The General Notes
further this conception by specifically echoing the AWS requirement that only low-hydrogen
electrodes (peculiar to the SMAW process) be used for welding of ASTM A572 Grade 50
steel (AWS, 1992, Table 4.1).

It is doubtful that so limiting a contractor is what was

intended, particularly since Flux Cored Arc Welding (FCAW) is a successful and very widely
used process in field welding of moment connections. The use of the term welding wire, as

15

distinguished from welding electrode, in the contract specifications seems to indicate that
the specifier is using the term electrode in the specific sense of it being a SMAW electrode
and that thus other processes

using welding wire in lieu of an "electrode,"

FCAW for

instance, would also be acceptable.

8. Identification of Welds - Welds shall be identified by either written records

indicating the location and welder for each weld or by the marking of an identification symbol
unique to each welder at the weld (Spec 05055, para. 3.1.2). This is intended to provide
traceability and to enable the Corps of Engineers and the Inspection Company to identify
both problem and stellar welders and more easily verify that the welders actually working
agree with the list of accepted welders.
9. Completion of Connections Before Load is Applied - Field welded
connections must be completed before load is applied (Spec 05120, para. 3.2.3). This
means that no concrete floor slab or any other permanent load shall be applied until the
welding is completed. The Corps of Engineers interpreted complete to mean fully welded
as detailed, inspected, repaired if necessary and reinspected, and accepted by the
Inspection Company.
Contract Requirements for Inspection of Field Welded Moment Connections
The eleven critical requirements applicable to the inspection of field welded
moment connections are as indicated below.
1. Extent of Required Inspection - All moment connection field welds shall be
visually inspected and ultrasonically inspected (Spec 05055, para. 3.3, and General Notes).
It is interesting to note that while 100% visual inspection is the default, there is no minimum
default level for ultrasonic or other nondestructive testing. If the specifier does not indicate
a required level of nondestructive testing, none would be required to be performed (AWS,
1992, sec. 8.15.1 and 6. 7). The project Engineer of Record indicated to the author that for
field-welded moment connections involving beams he typically requires 100% ultrasonic
inspection, as he did on this project. It should be noted that the Uniform Building Code
requires 100% ultrasonic inspection of all full penetration welds in lateral force resisting
framing in seismic zones 2 through 4 (ICBO, 1991, sec. 2710 (k)).

16

2. Visual Inspector Qualifications - The visual inspection of welds is to be

performed by inspectors holding current certification as AWS Certified Welding Inspectors

(CWI) in accordance with the provisions of AWS QC-1-88: Standard and Guide for
Certificationand Qualification of Welding Inspectors. Inspectors may be supported by AWS
Certified Assistant Welding Inspectors (CAWI) who may perform specific tasks under the
supervision of the CWI (AWS, 1992, sec. 6.1.3).

The inspector qualification paragraph

in Spec 05055 is somewhat confusing in that it refers to the necessary qualifications for
ultrasonic inspectors but erroneously implies that those are also the required qualifications
of the visual inspectors.

This is a problem because qualified ultrasonic or other

nondestructive testing personnel need not have any AWS certification and thus may not
have the training, experience, or knowledge of welding technology that would make them
competent to monitor welding practices and judge the visual adequacy of welds. Luckily this
problem is eliminated by the incorporation of AISC-02 into the contract.

AISC-02

incorporates AWS 01.1, Chapter 6, Inspection, and thus restores the visual inspector
qualification requirements.
3. Ultrasonic Inspector Qualifications - The ultrasonic inspection is to be
performed by nondestructive testing personnel qualified at Level II in accordance with The
American Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT-TC1A: Personnel Qualification and Certification in Nondestructive Testing. Level II Inspectors
may be supported by qualified Level I Operators who may perform specific tasks under the
supervision of the Level II Inspector (Spec 05061, para. 2.1 ). This requirement is in
accordance with AWS 01.1.
4.

Requirement for Independent Testing Lab for Welding Inspection - All

acceptance inspection is to be performed by an independent, established testing lab or

consultant, i.e. not by General Contractor, Fabricator, or Erector personnel (Spec 05055,
para. 3.2).

This means that the inspection referred to in the contract specifications is

verification inspection, above and beyond what would be required of the Erector, since the
inspectors represent the interests of the General Contractor who is the "owner" until the
Corps of Engineers accepts the building. The interests of the Corps of Engineers are also
represented by virtue of the fact that the Testing Lab must be an established entity separate
from the General Contractor. It should be noted, however, that the Testing Lab is paid by
the General Contractor, not by the corps of Engineers. The Erector is required to maintain

17

a quality control program adequate, as determined by the Erector, to insure that all their
work is in accordance with contract requirements (AISC, 1989, AISC-01, sec. 8.1.2).

5. Ultrasonic Testing Procedures - The requirements for reference standards,

equipment qualification, equipment calibration, preparation of materials for inspection, and
inspection prodedures for ultrasonic inspection are contained in Spec 05061, Appendix E,
and will not be duplicated here. The Engineer of Record indicated to the author that this
specification is derived from an older Military Standard and Navy Publication and is
essentially independent of AWS 01.1. He said that typically he would specify ultrasonic
testing to be in accordance with AWS 01.1, Section 6, Part C, but that for this project the
U.S. Army Corps of Engineers, Fort Worth District, required that the older specifications be
used. These older specifications are part of the established Corps of Engineers guide
specifications which is why their use was required. Because of the bureaucratic difficulties
encountered in changing Corps guide specs, many older specs which are different from
industry standards are still used. The Testing Lab was required to submit through the
General Contractor a detailed plan outlining ultrasonic testing procedures to be used to the
Corps of Engineers (Spec 05061, para. 1.3).
6. Acceptance Criteria for Visual Inspection - Acceptance criteria for visual
inspection shall be as stated in AWS 01.1, section 8.15.1 (General Notes). Welds shall
have no cracks; there shall be full fusion between all layers of weld metal and between weld
metal and base metal; there shall be no underfill; weld profiles shall exhibit no reinforcement
more than 1/8", no overlap, no excessive convexity, and no undercut greater than 1/32"
(except 1/16" allowed for up to 2 inches in any 12 lineal inches of weld for welds under 1"
thick); and there shall be no porosity or inclusions (AWS, 1992, sec. 8.15.1 and 3.6).
7. Acceptance Criteria for Ultrasonic Inspection - Acceptance criteria for
ultrasonic inspection shall be as stated in AWS 01.1-92, section 8.15.4 and Table 8.2
(General Notes). It should be noted that the General Notes refer to AWS 01.1-88, section
8.15.3. The author contacted Mr. Hardy Campbell, AWS Technical Director, who explained
that after the 1988 version of AWS 01.1, under which this project was designed, the
acceptance criteria for ultrasonic inspection of welds was moved from section 8.15.3 to
8.15.4.

18

Welds having any indication of a Class A discontinuity, regardless of length, shall

be rejected. Welds having any indication of a Class 8 discontinuity of length greater than
3/4" shall be rejected.
greater

Welds having any indication of a Class C discontinuity of length

than 2" shall be rejected.

acceptable

if the discontinuities

Welds with Class 8 or C discontinuities

are each less than the prescribed

may be

maximum allowable

length and they are separated by at least 2 times the length of the longer discontinuity or if
the total length of the discontinuities and their separation distance is less than the prescribed
maximum allowable length.

For moment connections welds having Class 8 or Class C

discontinuities within a distance of twice the length of the discontinuity from the ends of the
weld shall be rejected. Welds having any indication of a Class D discontinuity shall not be
rejected unless they also contain some other rejectable defect (AWS, 1992, Table 8.2). The
ultrasonic

acceptance

criteria specified in the General Notes are different from those

specified in Spec 05061 (Spec 05061, para. 3.4). It should be noted that the UT Inspector
used the criteria from the General Notes. Since these criteria were in accordance with A WS

01.1 and the Engineer of Record's wishes, their use could be considered acceptable.
8. Weld InspectionReports - The independent testing lab is to submit certified
reports of all visual and ultrasonic inspections (Spec 05055, para. 1.4 and Spec 05061,
para. 1.3). Ultrasonic test reports are to include the identification and location of each
inspected weld, sufficient detail of the methods of inspection to allow later duplication,
locations and details of rejectable defects, and a record of repaired welds (Spec 05061,
para. 3.5). Copies of all reports should be provided to the Erector and, in this case, the
Fabricator since the Erector was the Fabricator's subcontractor (AWS, 1992, sec. 6.1.1 ).

9. Access, Timeliness of Inspection, and Furnishingof Complete Documents

to Inspectors- In order to satisfactorily conduct verification field weld inspection, the
Inspection Company, General Contractor, and Erector incur certain obligations relative to
the inspection. The Inspection Company is required to complete its inspections in a timely
manner so as not to unduly disrupt progress of the work and the Erector is required to
provide the Inspection Company a minimum of 24 hours notice that inspectable work will be
going on and to provide the inspectors with safe access to the work (AISC, 1989, AISC-01,
sec. 8.5). The VT and UT Inspectors are to be provided with complete detailed drawings
of all welds and with the parts of the contract documents that describe material and quality
requirements (AWS, 1992, sec. 6.1.5

and 6.8.4). In this case this would be the General

19

Contractor's responsibility.

The Inspection Company should be provided with all updated

or changed drawings as such changes occur.

10. Repair of Rejected Welds - All rejected welds must be repaired in accordance

with AWS 01.1, Section 3.7, Repairs, and be visually and ultrasonically reinspected as if
they were new welds (Spec 05055, para. 3.5).
11. Responsibilitiesof Visual Inspector- It is the responsibility of the field
welding VT Inspector to ascertain that all field welding is performed in accordance with the
requirements of the contract documents.

This would include, in addition to visual

examination of completed welds, verifying that correct materials are used, reviewing all
welding procedure specifications to be used and verifying that they conform to code,
verifying that all welding equipment is set in accordance with the procedure specifications
and is in proper working order, verifying that all welders are properly qualified and requesting
requalification or dismissal of those who are not, verifying that the welding is done in
accordance with the welding procedure specifications, verifying that joint preparation and
fit-up are in conformance with code, and identifying with a clear mark all parts that have
been inspected (AWS, 1992, sec. 6.1, 6.2, 6.3, 6.4, and 6.5).

20

SECTION 5: EVALUATION OF COMPLIANCE WITH CONTRACT REQUIREMENTS

The Brooke Resident Office project files relating to field welding of structural steel
were generously made available to the author by the Corps of Engineers. Information in
these files includes contract and shop drawings, contract specifications, submitted visual
and ultrasonic weld inspection reports, submitted field welder and inspector qualifications,
submitted welding procedure specifications, submitted work and quality control plans, and
other contractor submittals and miscellaneous correspondence. This information, the
author's first hand observations during his involvement with this project, and interviews with
Inspector #1, the lead inspector for the Testing Lab, provide the data upon which this review
is based.
The author collected all weld inspection reports submitted by the Inspection
Company and transcribed selected information about each field welded moment connection
into a spreadsheet so that the information from the weld inspection reports could be better
analyzed. The information transcribed included connection identifier, location, welder, visual
inspector, visual inspection date, report number for visual inspection, visual inspection
result, visual defects noted, ultrasonic inspector, ultrasonic inspection date, report number
for ultrasonic inspection, result of ultrasonic inspection, and ultrasonic rejectable indications
noted for each field welded moment connection. This information, with the exception of
location, is contained in Table A 1: Summary of Visual and Ultrasonic Weld Inspection
Reports for Field Welded Moment Connections, Appendix A

The vast majority of the

statistical information contained in this report and all of the tables in Appendix B are derived
in whole or in part from analysis of the data contained in the project weld inspection reports
and Table A1.
Compliance With Contract Requirements for Field Welding of Moment Connections
1. Submissionof Certificationof Welder Qualifications- All of the 18 welder
qualification test records submitted were certified as having been conducted under the
requirements of AWS 01.1. In some cases the certification was by the employer, in some
by the testing lab administering the test. All the submitted welder qualifications indicate the
welder's name, process and positions qualified, information about the welding procedure
used, the date of qualification, and the names of the firm and person certifying the
qualification tests. However, there is an additional requirement that, beyond providing

21

certified qualification

test records, the General Contractor

must provide a certification

statement that all welders are qualified as specified and that certification
current for the duration of the contract.

must be kept

It would seem that the intent here was for the

General Contractor to provide a certified summary of all welders, including the specified
information

for each welder, to be kept by the General Contractor and modified as new

welders came on board or as information changed.

There is no record in the project files

of any submittals on field welder qualifications other than the test records.

Since so many

of the welder qualifications were not in accordance with contract requirements,

with regard to age, and since many qualifications

particularly

were not received by the Corps of

Engineers until after welding was complete, the General Contractor clearly did not meet its
obligations in this area.

2. Submission of Welding Procedure Specifications and Welder Qualification

Records Prior to Start of Welding - The welding procedure specifications for field welding

of moment connections were submitted and approved prior to the start of field welding. The
procedure was prequalified so procedure qualification tests were not necessary. A review
of the information provided in the submitted welding procedure specification indicates that
it addressed and complied with all applicable code provisions for joint design, workmanship
and technique.
A review of Table 810, Appendix 8, a summary of the moment connection field
welder qualification data in the Corps of Engineers' files, shows that of the 19 different
welders identified who did work on moment connections, 10 had qualifications which were
not submitted until 16 months after welding operations were completed. Two of those had
qualification dates after welding was completed, and one never had welding qualifications
submitted at all. Six of the 18 welders for whom qualification tests were provided were not
qualified in the FCAW process. Of those six, one also was not qualified to weld groove
welds and one welded materials outside the thickness range he was qualified for in the
process in which he was qualified. Of the 18 qualifications submitted, 10 were not
acknowledged by the Corps of Engineers as being acceptable. 10 of the 18 qualificatons
received were older than 6 months when received, with ages ranging from 8 months to 11
years. Of the 7 qualifications acknowledged by the Corps of Engineers as being acceptable
for FCAW welding when submitted, 6 were more than 6 months old by the time those

22

welders began welding.

No evidence that those welders had had no breaks in employment

as welders using the FCAW process longer than 6 months was ever requested or furnished.
In summary,
qualification

none of the 19 identified welders was qualified and had submitted

records in full accordance with the contract requirements.

The Erector and

General Contractor QC Inspector were clearly somewhat less than diligent in assuring that
only qualified welders were used. It appears that the Corps of Engineers' QA Inspector did
not monitor welder qualifications at all, for there is no record of the Corps having raised any
objection about improperly qualified welders or missing welder qualifications until 1995, long
after welding operations had been completed.

For their part, the Inspection Company did

not detect this problem either, although it did not have access to the welder qualification
records.
3. Requirement for Welder Qualification Within Past 6 Months - Review of

Table 810, Appendix B, shows that only 7 of the 18 welder qualifications submitted have a
date within six months of when they were submitted. All others would have been required
to requalify. There is no record in the project files of any of those welders having been
requalified. Of the seven whose qualification date was within six months of submittal of
cerdentials, only one actually began welding on the project within 6 months of qualification.
There is no record in the project files that additional information indicating that the other six
welders' qualifications had not lapsed was ever requested or submitted. For all of those
seven welder qualifications the procedure used in the testing closely follows that of the
submitted procedure specification. Review of the submitted qualification test records shows
that all seven of those welders were qualified by a union local using the same testing lab
which, by the specifications, must be an "approved" lab. What constitutes an "approved"
testing lab or technical consultant for the purpose of conducting welder qualification tests
is not made clear in the specifications. The contract, then, conceivably could be construed
to mean anything from a sole-proprietorship run by a newly certified CWI, as appears was
perhaps the case with welders qualified through the union local, to a large, well-established
testing lab.

Therefore, 11 of the 18 welders who had qualifications submitted, had

qualifications which unquestionablydid not meet this contract requirement. Because of the
gap between when their qualifications were submitted and when they began welding, the
qualifications of six others are in some doubt of having met this contract requirement.

23

4. Situations Requiring Welder Requalification - There is no record in the project

files of any welder having been requalified during the course of the project. As mentioned
above, after acknowledgement of acceptable qualifications by the Corps of Engineers, there
were six welders who did not begin welding until more than six months after their
qualification dates. No information indicating they had during that time been using the
welding procedure for which they were qualified was provided. Thus, they technically should
have been requalified. One welder, 17F, whose qualifications were not submitted to the
Corps of Engineers until after welding operations were complete and were never
acknowledged, was requested to be requalified by Inspector #3 in weld report #162, dated
7/16/93, for exhibiting a consistent pattern of rejectable defects. There is no record of this
welder having been requalified and a review of Table A1, Appendix A, indicates that he
continued welding for a short time after that report. There were two situations where a
welder with accepted qualifications, who was qualified by someone other than the Erector,
was welding on the project more than 12 months after his qualification date without having
been requalified. Those two cases, where the time interval was 12 months and 10 days, are
hardly worth considering.
5. Drawings to Reference Applicable Welding Procedure Specifications - The
moment connection details in the Fabricator's shop drawings referenced procedure
specification B-U4a-GFfor butt joint connections and TC-U4a-GF for T-joint connections.
Procedure B-U4a-GF used the AWS/AISC prequalified joint configuration B-U4a, single
bevel butt joint with backing, and procedure TC-U4a-GF used the AWS/AISC prequalified
joint configuration TC-U4a, single bevel corner joint with backing. Both procedures used the
FCAW process with welding in the flat (1G) position. Both procedure specifications had
been submitted and approved prior to the start of field welding. Thus, this contract
requirement was unquestionably met.
6. Equipment and Materials - There is no record in the weld inspection reports of
there having been equipment or materials used in the welding of moment connections which
did not meet contract requirements. There is also no record of the Corps of Engineers' QA
Inspector or of the General Contractor's QC Inspector having reviewed electrodes, electrode
storage, or welding equipment for compliance.
7. Identification of Welds -A review of Table 811, Appendix B, shows that 357 of
the 2057 attributable welds (17%) had no welder ID stencil. Thus this contract requirement
24

was not fully met. An interesting observation is that, while one might assume these welds
as being ones no one wanted to claim, the overall reject rate for this group was in fact lower
than for eight of the moment connection field welders.
8. Completion of Connections Before Load is Applied - Since some welds have

no record of inspection and some have no record of repair, load would have been applied
to some connections before they were complete by the Corps of Engineers' definition. Also,
since an arrangement had been made between the Erector, Inspection Company and
General Contractor whereby ultrasonic inspection would be done from below after the
interstitial floor was placed, it is likely that the concrete floor slab was placed over several
connections before their inspection was complete.
Compliance With ContractRequirements for Inspectionof Field Welded Moment
Connections
1. Extent of Required Inspection - Table 81, Appendix 8, indicates that all field
welded moment connections were completely visually inspected except for two which had
no record of any visual or ultrasonic inspection (a total of four welds). Table 81 also shows
that 7 connections, including the two mentioned above, had no ultrasonic inspection at all
(15 welds total) and 3 connections had ultrasonic inspection on only one weld. This means
2060 of2064 welds (99.8%) were visually inspected, 1972of1990 ultrasonicallyinspectable
welds (99.1%), i.e. those not failing visual inspection, were ultrasonically inspected, 916 of
918 moment connections (99.8%) received complete visual inspection, and 908 of 918
moment connections (99.1%) received complete ultrasonic inspection. The Engineer of
Record for the project indicated he was pleased with that amount of coverage. Inspector
#1 indicated that those numbers seemed in line with what he remembered and explained
that the missed inspections were due to access problems. He indicated that he had notified
the General Contractor of the missed inspections. There is no record of the General
Contractor having notified the Corps of Engineers of the possibility of having field welded
moment connections with missed inspections. It should be noted that in the Quality Control
Work Plan submitted by the Testing Lab it was indicated that a marked-up set of plans
indicating the status of all welded connections would be kept. This was not done. When
asked about this Inspector #1 said that item had not been in their subcontract with the
Testing Lab. Having such a set of plans would have made it much easier to track the status

25

of welded connections and conceivably would have eliminated the missed inspections and
missed repairs, or at least made their presence known to the Corps of Engineers.
The fact that a weld was not inspected is certainly no indication that a defect exists.
However, let us review the uninspected welds to see if there is good reason for heightened
concern in any of the cases. Table 83, Appendix B, shows probable welder and moment
connection application type for the two completely uninspected connections.

The probable

welder was determined by reviewing the weld inspection reports for which welders were
welding in the area adjacent to the connection in question.
welders

had comparatively

In each case the probable

low reject rates (See Table 811,

connections were the less critical application type 2. Consequently,

reason for worry there.

Appendix

8) and the

there seems to be little

Table 84, Appendix 8, shows welder and moment connection

application type for the eight connections with missing ultrasonic inspections.

Given the

critical nature of the moment connections MC496, MC518, and MC519 (application types
3 and 4) and the high ultrasonic reject rate of welder 19F shown in Table 811,

some

concern about these connections might be justified.

2. Visual InspectorQualifications- Numbered certificates endorsed by AWS

indicating that the inspector had satisfied all AWS requirements for registration as a
Certified Welding Inspector (CWI) and resumes indicating extensive experience with
welding technology and the visual inspection welds were submitted for Inspectors #1, #2,
and #3. The certificates alone satisfy the contract requirement for qualification. Since all
three inspectors held CWI certification, each was qualified to conduct visual inspection
without supervision. A review of Table A 1, Appendix A, indicates that only these three
inspectors performed visual inspection. Therefore, all visual inspection was done by
qualified individuals. As further corroboration of the competence of the visual inspectors,
the project files indicate that on four occasions the Corps of Engineers brought in another
testing company to review work previously visually inspected by the Inspection Company.
In all cases the VT Inspector's work was verified.
3. Ultrasonic InspectorQualifications- For both Inspector #1 and Inspector #2,
certifications by an officer of the Inspection Company that each inspector was qualified at
Ultrasonic Level II in accordance with ASNT No. SNT-TC-1A were provided. Certifications
by an ASNT NOE Level Ill that each inspector had completed the necessary academic and
practical requirements for Ultrasonic Level II certification as required by AWS (AWS, 1992,

26

sec. 6.7.8.2), and resumes indicating extensive experience in nondestructive

testing of

moment connections were provided. Thus the two inspectors appeared to be well qualified
and their submitted qualifications were in accordance with all requirements.

A review of

Table A 1, Appendix A, indicates that only Inspectors #1 and #2 performed ultrasonic testing.
Consequently,
personnel.

the records indicate that all ultrasonic testing was performed by qualified

As further corroboration

of the competence

of the ultrasonic

inspectors, the

project files indicate that on four occasions the Corps of Engineers brought in another
testing company
Company.

to review work previously

for Independent

Testing Lab was a well-established

contract.

inspected

by the Inspection

Lab for Welding

Inspection - The

In all cases the UT Inspector's work was verified.

4. Requirement

Contractor,

ultrasonically

Testing

firm which, although a subcontractor

was an entity independent

of all other parties performing

The Inspection Company was also an independent entity.

requirement was unquestionably

5. Ultrasonic

of the General
work under the

Thus this contract

met.

Testing Procedures

- The Fabricator submitted a detailed ultrasonic

testing procedure which was in strict accordance

with the requirements

of AWS 01.1,

Section 6C. There is no record of the Testing Lab having submitted an ultrasonic testing
procedure other than in their Quality Control Work Plan in which they said ultrasonic testing
would be done in accordance with Spec 05061 and AWS 01.1-88, paragraph 8.15.3. It
appears from the welding reports, however, that ultrasonic testing by the UT Inspector was
completed wholly under the provisions of AWS 01.1-92.

While this is in technical violation

of the contract specifications, such ultrasonic testing procedures are generally recognized
as sound practice.
6. Acceptance Criteria for Visual Inspection -About all that can be said regarding
adherence to acceptance criteria for visual inspection is that a review of Table 85, Appendix
B, a summary of visually rejected welds, shows welds being rejected for reasons in
accordance with criteria.
7. Acceptance Criteria for Ultrasonic Inspection - A review of Table A1,
Appendix A, shows that all noted discontinuities were Class A, except one which was Class
D. In accordance with AWS criteria, the Class D discontinuity was accepted and all welds

27

with Class A discontinuities

were rejected.

A summary of ultrasonically

rejected welds

appears in Table 86, Appendix B.

8. Weld InspectionReports - The weld inspection reports appeared to meet

contract requirements quite well. Reports were written and submitted on a daily basis and
each report was certified in that it was signed and dated by the qualified inspector who did
the inspection. Both visual and ultrasonic inspection reports include the identification and
location of each inspected weld, the welder identification observed, the inspection results,
and descriptive details for both visual and ultrasonic inspections. The ultrasonic inspection
reports all contain information about the equipment used and calibration and testing
parameters in sufficient detail to recreate the test. Reinspections of repaired welds are
clearly identified on the reports. Copies of all reports were routed to the Erector and
Fabricator as required. A copy of a typical inspection report is contained in Appendix D.

9. Access, Timelinessof Inspection, and Furnishingof Complete Documents

to Inspectors- Access to inspect work was a problem according to Inspector #1. He
indicated that the Erector was initially quite cooperative until the Inspection Company began
finding larger numbers of rejectable welds. After that point the relationship soured and,
according to Inspector #1, the Erector actually limited access for the Inspection Company
by such methods as removing ladders or scaffolding as soon as welding operations were
complete and placing metal deck soon after an area was welded. Inspector #1 indicated
that, while it is not uncommon for erectors and inspectors to find themselves at odds over
rejected work and provision of access, the Erector was much less cooperative than is
typical. Another contributing factor was the pressure of the construction schedule on the
Erector. The General Contractor was working on a highly accelerated schedule and the
Erector was under tremendous pressure to put as much steel up in as short a time as was
possible, particularly between June and October of 1993. Inspector #1 reports that the
Erector felt it just didn't have time to wait for the inspectors. The Inspection Company was
able to solve its access problem in a rather ingenious way, however. Inspector #1 said that
in exchange for many cases of beer over the course of the job, the electrical contractor
allowed them to use their ladders and scissor lifts after hours and on weekends. Whatever
access problems were encountered, the final result was quite good. Table 81, Appendix
B shows that of 918 total field welded moment connections, only 10, or about 1.1 %,
received less than full visual and ultrasonic inspection.

28

The welding reports indicate only the dates of visual and ultrasonic inspections; not
the date the welds were actually completed.

Without

knowing when the welds were

completed it was difficult to judge for certain whether inspection was timely or not. However,
since the Erector was moving so quickly, it would be a reasonable course to assume that
visual inspection

probably took place very soon after welding was finished.

Thus a

measure of inspection timeliness would be to consider the time difference between visual
and ultrasonic inspection for each weld. The author consulted Mr. James L. Willson, Vice
President of L. R. Willson and Sons, a steel erector from Gambrills, Maryland, Mr. Hilton
Holcomb, Metals Department Manager for SM&E, of Raleigh, North Carolina, a testing lab
who performs extensive welding inspection, and Inspector #1 as to what time intervals they
felt would constitute timely, marginally timely, late, very late and incredibly late inspection.
Their answers were fairly close, with general agreement that 3 days would be the outer limit
of timely, that 7 days would constitute the outer limit of marginally timely, and that beyond
10 working

days the ability to control and maintain any kind of schedule

compromised.

is severely

With this informaton the timeliness categories used in Table 88, Appendix

8, were developed.
Table 88 indicates

that 72.2%

of the welds were visually and ultrasonically

inspected the same day, 78.9% fall within the timely range, and 21.1 % fall within the late
range. A rather curious result was that of that 21.1 %, 19% fell in the incredibly late category.
After looking more closely at the inspection date data it became apparent that in this group
the time interval was typically in the 40 to 90 day range.

Also, a large number of these

incredibly late inspections occurred between June and October, 1993. When asked about
this Inspector #1 explained that in order to move faster the Erector had asked if the UT
Inspector would be willing to do the ultrasonic testing from underneath, after the interstitial
floor had been placed. The Inspection Company agreed to this on condition that the Erector
acknowledged
inconvenient.

that any discovered

defects would have to be repaired, no matter how

The Erector indicated to Inspector #1 that it felt if the top flange weld passed

visual inspection, any ultrasonically rejectable indication would almost certainly be in the
weld root area which could be repaired from underneath by removing the backing bar,
gouging, and rewelding.
objection.

The General Contractor was apprised of this and raised no

This explanation seems credible, given the Erector's preoccupation with speed,

given that the period from June to October, 1993, was one where the General Contractor
put great pressure on the Erector to step up production and make the schedule date for
29

topping out the main facility, and given that the 40 to 90 day range was in in line with how
far installation of the interstital floor would typically follow behind the main steel erection.
Thus, considering the inspections other than in the incredibly late category, it appears that
the Inspection Company adequately fulfilled its obligations for timely inspection.
Inspector #1 indicated that getting current drawings from the General Contractor
was a problem. He said that the Inspection Company would have to request drawings well
in advance of the beginning of welding in an area or it would often not receive them in time.
When this occurred the inspectors would have to refer to the Erector's field drawings which
they could not, of course, carry with them.

Inspector #1 also indicated that often the

drawings they did receive were outdated, which they would discover when discrepancies
occurred between what they were seeing and what was on the drawings.

He also indicated

that, although requested to do so by the Inspection Company, the General Contractor did
not provide a copy of the welding procedure specifications.

From this information it appears

that the General Contractor was lax in its responsibility to provide the Inspection Company
with complete information about the welding to be inspected and thus made it more difficult
to achieve adequate inspection.
10. Repair of Rejected Welds - Review of Table 81, Appendix 8, indicates that

there were 185 rejected welds on 141 different moment connections. Review of Table 82,
Appendix 8, indicates that there were four rejected welds, one each on four different
connections, which had no record that could be found in the weld inspection reports of
having been repaired and reinspected. Three of these four welds are top flange welds and
would always be in tension. The fourth is a bottom flange weld in a moment frame
connection which could also be in tension. The possibly missing weld in connection MC286-T is of greatest concern since without a weld there the connection could not function
as intended. It is somewhat unlikely, although certainly possible, that an inspector would
have checked the bottom flange connection, which was also rejected in the same initial
report and reinspected several days later, and not noticed a missing weld at the top flange.
When asked about this Inspector #1 indicated that he remebered "one or two" rejected
welds which they were unable to reinspect because of access problems, that he had notified
the General Contractor of this, and that the General Contractor had responded that that was
to be expected on a job of this size. Inspector #1 also indicated that he could not remember
any missing welds and that it was possible a few reinspections of repaired welds did not get

30

noted

in the reports

because

there were some days devoted

reinspection, where the inspectors were accompanied

very hectic.

exclusively

to such

by Erector personnel, which were

Only one of the four welds noted in Table 82 should have presented any

access problems and the other three conceivably could still be checked from the interstital
level with a minimum amount of tear out.
connections

In terms of gross numbers, to have four of 918

(about 0.4%) of the connections with missed repairs may not be too bad but

one would certainly be concerned

about having a defective weld in a moment frame

connection or a missing weld in any moment connection.

There is no record in the Corps

of Engineers' project files of the General Contractor having notified the Corps of Engineers
of the possibility of a small number of unrepaired rejected welds or of a missing weld.
11. Responsibilities
of VisualInspector- Inspector #1 indicated the Inspection

Company was able to conduct fit-up inspections on about 40% of the moment connection
welds. The author observed in the field that inspected connections were being clearly
marked by the Inspection Company. There is no record in the welding reports of noted
deiciencies in equipment or materials used for welding moment connections so one may
conclude that either the VT Inspector did not look closely at these items or that these items
were generally in compliance with requirements. Given the level of diligence displayed by
the VT Inspector, the latter seems more likely. The Inspection Company appears to have
fulfilled its obligations in these areas.
There is some question, however, as to how well the Inspection Company fulfilled
its obligations in the areas of verification of welder qualifications and verification of welding
procedure specifications. Inspector #1 indicated that although the Inspection Company had
requested the General Contractor to provide it with copies of the welder qualifications and
welding procedure specifications, the General Contractor had declined to do so on the
grounds that the Corps of Engineers had already approved them and that, therefore, the
Inspection Company did not need to review them.

While the welding procedure

specifications were in good order and had been approved by the Corps of Engineers, that
did not relieve the VT Inspector of the code-mandated responsibility to verify that the
procedure specification was in full conformance with all code requirements, nor did it relieve
the General Contractor of its responsibility to provide the VT Inspector with the necessary
information to make that verification.

31

With regard to welder qualifications,

it seems clear that some unqualified welders

were assigned to field weld moment connections on this project. A review of the project
submittal register indicates that welder qualifications were to be submitted "For Information
Only" to the Corps of Engineers, meaning that while the Corps could acknowledge apparent
acceptability or raise objections, the full responsibility for approval of welder qualifications
lay with the General Contractor.

Thus the General Contractor's premise behind declining

to provide the Inspection Company with copies of the welder qualifications was in error on
two counts. First, no qualifications had actually been approved by the Corps of Engineers
and second,

not all welder qualifications

had even been submitted

to the Corps of

Engineers. Again, whether the Corps of Engineers approves a welding qualification or not,
there is still a code-mandated responsibility for the VT Inspector to verify that all welders are
properly

qualified and the General Contractor

should be obligated to provide the VT

Inspector the necessary information to make such a verification.

It is far less probable that unqualified welders would have been permitted to begin
welding on the project had the VT Inspector been allowed to review welder qualifications.
The question arises as to how far the Inspection Company's responsibility goes when it
requests but is not provided with information
responsibilities.

necessary to carry out its code-mandated

In this case the Inspection Company was in a difficult position because the

only way for it to get information officially was through the General Contractor.
Inspection

Company

had at this point an obligation to somehow

unofficially

or to notify the Corps of Engineers is not for this study to answer.

Whether the

get that information

To the VT

Inspector's credit, requalification of welder 17F was requested because, in the professional
opinion of the VT Inspector, the welder's skills were questionable.

This request was based

solely on observing the welder's work because the Inspection Company had no way of
knowing that this welder's qualifications were in the wrong process and were over 9 years
old (Ref. Table 810, Appendix B).

32

SECTION 6: ANALYSIS OF DATA FROM WELD REPORTS

Overall Quality of Welders

The author consulted Mr. Hilton Holcomb, Mr. James L. Willson, and Inspector #1
and asked each of them what reject rate they might expect for someone who would be
considered a "good," "average," "marginal," and "poor" welder. Mr. Willson indicated that
he felt a good welder would have a reject rate of up to 2%, an average welder of 3% to 4%,
and a marginal welder of 5%. He indicated that if So/o or more of a welder's work has to be
torn out and redone, there is a severe cost penalty to the erector. Mr. Holcomb felt that less
than S% rejects would be indicative of a good welder, So/o to 7% of an average welder, and
8% to 10% of a marginal welder. Inspector #1 felt that 3% or less rejects would be .
indicative of a good welder, 4% to 7% of an average welder, and 8 to 10% of a marginal
welder. Taking average values from the three sources gives a range of up to 3% for a good
welder, up to 6% for an average welder, and up to 8% for a marginal welder.
From Table 811, Appendix 8, it is seen that the overall reject rate for all welders
was 8.8S% which puts the overall welder performance just into the "poor" category.
Welders SF, 7F, 9F, 12F, 13F, 17F, 19F, and 28F had particularly bad reject rates, ranging
from 16.67% to 31.2S%. Table 810, Appendix 8, indicates that welders SF, 7F, 9F, and 17F
were not qualified in the FCAW process used to field weld moment connections and had
outdated qualifications. It is no great surprise that they would perform poorly. Welders 12F,
13F, 19F, and 28F were all qualified in the FCAW process but when they began welding on
the project their qualifications were all more than 6 months old. No information that they had
remained active in FCAW since their qualification was ever provided. The other item these
four welders have in common is that they all were qualified by the same union local using
the same testing lab. This testing lab was mentioned earlier as being operated by a CWI
who had been so certified for less than 16 months when the qualifications were performed.
This, of course, may mean nothing, particularly since welders 18F and 20F, who were two
of the best welders, also were qualified by that testing lab, but it is a common thread. The
reason this point is mentioned is to illustrate that it is important when evaluating welder
qualifications to

also consider the credentials of the testing agency conducting and

interpreting the qualification test.

33

Table 811 shows that of the 19 identified welders, 9 were in the "poor" category, 2
were in the "marginal" category, 3 were in the "average" category, and 5 were in the "good"
category.

Given that none of the eighteen welder qualifications

accordance with the specifictions,

submitted were in full

it is not surprising that the overall welder performance

was not good.

Overall Qualityof Welding

Judging by the finished product, the overall quality of field welded moment
connections on this project would probably have to be considered good. As shown in Table
81, Appendix 8, 99.8% of the welds made in 99.8% of the moment connections were
visually inspected, 99.1 % of the ultrasonically inspectable welds in 98.9% of the connections
were ultrasonically inspected. Only 4 welds (0.19% of total welds) in 4 connections (0.44%
of total moment connections) were not certified to be satisfactorily repaired and only 18
welds (0.87% of total welds) in 10 connections (1.1% of total moment connections) were not
completely inspected. Thus there is a certainty that 904 of the 918 connections are in
accordance with requirements and there is relative certainty (applying the average failure
rate of 8.85% to the 10 not fully inspected connections) that 913 of the 918 moment
connections are acceptable. That is due more than anything else to a contract which
required extensive independent verification inspection of the field welding and to the
diligence of the Inspection Company.
This is a very interesting result, given that a number of the welders were apparently
unqualified and that the overall performance of the welders was considered to be poor.
Thus, it appears that even when those doing the welding are subpar as a group, as long as
some competent welders are present and as long as there is thorough, good, independent
verification inspection, an acceptable final product can still be achieved. This underscores
the central importance of verification inspection to getting satisfactory field welded moment
connections.
Visual and UltrasonicRejectable Defects
Tables 85 and 86, Appendix 8, provide a summary of visually and ultrasonically
rejected welds, respectively. There were a total of 74 visually rejected welds in 62 different
connections (6.8% of total moment connections) and 111 ultrasonically rejected welds in 80
different connections (8.7% of total moment connections). It is not surprising that there
34

would be more ultrasonic rejects because visual inspection only allows a view of the weld
surface while ultrasonic inspection allows inspection of the entire weld volume.

Of the 7 4

visually rejected welds, there were an equal number of top and bottom flange welds. Of the
111 ultrasonically rejected welds, 46 were top flange and 65 were bottom flange.

Because

of the increased difficulty in making bottom flange welds, due to interference from the beam
webs, one would expect there to be a greater number of bottom flange welds rejected.

The

even split between top and bottom flange welds visually rejected is somewhat of a surprise.
Perhaps the differences

in difficulty between top and bottom flange welding are less

pronounced for face passes or perhaps this is simply a function of poor welders having
problems everywhere.
Table 812, Appendix 8, gives a frequency distribution for visual defects.
not completely

Underfill,

filling the joint with weld, was far and away the most common defect,

occurring in 50 of the 74 rejected welds and occurring ten times as frequently as any other
defect.

Of the 60 defects attributable to a known welder, 22 (37%)

are attributable to

welder 17F alone and 41 (68%) are attributable to the welders not qualified in the FCAW
process.

Table 86, Appendix 8, indicates that all ultrasonically rejected welds had Class

A indications.

The weld reports did not include comment on the type of defect those

indications represented.

Welding InspectorRejection Rates

Table 87, Appendix 8, shows rejection rates for each welding inspector. The
overall reject rates for the three inspectors are within 1.5% of each other, which suggests
that there was no inspector bias, i.e. one inspector interpreting requirements differently and
finding significantly more or significantly less to reject than the others. Inspector #1 had a
higher ultrasonic rejection rate than Inspector #2 and a lower visual rejection rate than
Inspectors #2 and #3 who had similar visual rejection rates. Tables 811 and 85, Appendix
8, may help explain this. These tables indicate that Inspector #1 had much less visual
inspection exposure to welders 7F, 9F, and 17F (high visual reject rate welders) than did
the other inspectors and in the one high reject group that Inspector #1 had much more
exposure to, the "No Stencil" group (i.e. the group of welds where no welder ID stencil was
recorded), Inspector #1 only had half of the group's rejected welds. These tables also show
that lnspector#1 had much higher ultrasonic inspection exposure to welders 1F, 10F, 16F,

35

17F, and the "No Stencil" group (contributors of larger numbers of UT rejects) than did
Inspector #2.

36

SECTION 7: OBSERVED PROBLEMS AND SUCCESSES IN PROJECT FIELD WELDING

QUALITY CONTROL

There were five problems on this project with regard to quality control of field welded
moment connections which seem to stand out :

1. Unqualified welders were assigned to and allowed to weld moment

connections. This happened for several reasons. First, the General Contractor did not
provide welder qualification test records for a number of welders, as was required before
beginning welding, to the Corps of Engineers for review until after welding was completed.
A number of these qualification records turned out to be in violation of contract and, in some
cases, code requirements.

It is unclear whether or not the General Contractor had

possession of this information earlier or not. Second, the VT Inspector was not given
access to the welder qualification records by the General Contractor so he could not verify
whether the welders were qualified or not. Third, while the weld inspection reports clearly
indicate the welder identification stencils for each moment connection weld, the General
Contractor QC Staff and the Corps of Engineers QA Inspector apparently did not properly
monitor these reports and check the noted weld stencils against qualifications on file. If they
had, the fact that many of the welders had no qualifications on file, or that they were not
properly qualified for the welding procedure used for moment connection welds should have
been easily detected and corrected.
The data from the welding reports shows that, not surprisingly, these unqualified
welders had very high reject rates indicative of poor welding. This should not have
happened with proper execution and enforcement of the contract provisions, which were
clear and rather stringent with respect to welder qualification requirements. In this case the
contract specifications and codes appeared able to provide for the use of properly qualified
welders, but those provisions were not followed or adequately enforced by the General
Contractor and Corps of Engineers.
2. Overall welder performance was poor. The use of unqualified welders
obviously was the primary contributor to this result. Some doubts were also raised
concerning the experience level of the testing lab which conducted welder qualification
testing for the union local on several welders whose qualifications were acknowledged by
the Corps of Engineers. By the time several of the union local qualified welders began

37

welding on the project their qualifications

may have been lapsed.

Inspector #1 also

indicated that the welding procedure specifications were not made available to the welders
and that several of the welders had little idea what the proper welding procedure was
supposed to be. If welders are unfamiliar with the procedure specifications

or choose not

to follow them, a principal goal of the welding code - to assure the use of procedures which
have previously been shown to produce good welds - is defeated.

This can have a quite

detrimental effect on final wled quality.

3. There were "misunderstandings"
aboutcontractobligations.The General

Contractor was under the mistaken impression that the Corps of Engineers had approved
welding procedure specifications and welder qualifications, thus making it unnecessary for
the Inspection Company to verify them. Consequently, the General Contractor declined to
provide that information to the Inspection Company which prevented it from fulfilling its
responsibility to verify that all procedure specifications are in accordance with requirements
and that all welders are properly qualified.

Had the Inspection Company been in

possession of this information, it is less likely that unqualified welders would have been
allowed to weld and more likely that the proper welding prodedures would have been
followed.
In the Quality Control Work Plan submitted by the Testing Lab it was indicated that
a set of status plans would be kept (presumably by the Inspection Company) that would
show the completion and inspection status of all field welded moment connections. This
apparently got lost in the cracks and did not make it into the Inspection Company's
subcontract with the Testing Lab so the status plans were never kept. Had these plans
been kept up it is less likely that repairs and inspections would have been missed, since
there would have existed a clear graphic picture of where inspection stood at any time. This
information in this form, rather than being parceled across several weld inspection reports,
would have made the status of welding completion and inspection more readily apparent to
everyone, including the Corps of Engineeers' QA Inspectors.

4. The Erectorwas not cooperativein providingaccess for the inspectors.

The Erector apparently became uncooperative in providing the Inspection Company access
to inspect the welding. The Inspection Company informed the General Contractor who was
not helpful in resolving this problem. The Inspection Company successfully took it upon
itself to solve the access problem and was thus able to complete thorough inspections. Had

38

the Inspection Company not been so resourceful and aggressive, it is possible that a great
deal of the specified inspection might not have been completed.

5. There was ineffectiveGeneral Contractorand Corps of Engineers QC/QA

oversight. With the number of contract requirements that were not met and the lack of
objection raised during the course of work, it suggests that both the QC and QA Inspectors
were somewhat lax in monitoring the work.

Required submittals were not received,

unqualified welders were welding, several welders had excessively high rejection rates, the
General Contractor failed to supply the Inspection Company with current drawings and
necessary information about welding procedures and welder qualifications , some rejected
welds were unrepaired, and the Erector was not complying with its responsibility to provide
the inspectors with access to the work. The Quality Control Staff is in theory not supposed
to allow any of this to happen and the Quality Assurance inspector is supposed to note and
demand correction where contract requirements are not being met.
In the case of the Corps of Engineers QA inspector, the person assigned to monitor
structural steel erection did not have a background in structures and had had little or no prior
experience with structural steel. The inspector did not carry drawings in the field, did not
have copies of the applicable AWS or AISC codes, did not keep a list of submitted qualified
welder names and stencils, did not keep a checklist of submittals, and did not until late in
the job begin to keep a list of rejected welds to be repaired. It is quite possible that the QA
Inspector had very little idea what the contract requirements were with respect to the field
welding of moment connections and was thus in no position to enforce them.
There were two successes which seem to stand out:
1. Despite pooroverall welderperformance, good overall weldingqualitywas
achieved. The final state of the field welded moment connections would have to be
described as good. Thorough and diligent independent inspection identified the many
defective welds and verified that repairs had been made. The data from the weld reports
indicates that 99% of the moment connections were fully inspected and verified as being
in compliance with contract requirements. This level of inspection was acheived despite
difficulties in getting access to the work and in getting complete information.
2. The contract was written with good provisionsfor level of inspection,
inspectorqualifications,
and submittalrequirements
. The contract specified extensive
39

inspection requirements - 100% visual and ultrasonic inspection of all moment connection
welds.

This compensated

independent

scrutiny of the finished product.

ASNT certification
competent

for the problems with welder quality by allowing for complete,

The contract provisions requiring AWS and

of visual and ultrasonic inspectors, respectively,

inspectors

were looking at the welds.

The contract

helped assure that

requirement

for an

independent testing agency to conduct acceptance inspection got that critical role away from
the possibly conflicting
requirements

interests of the Erector and General Contractor.

for identification

The contract

of welds and for detailed daily reporting of inspections

provided for the recording of a great deal of useful information

about each weld.

The

requirements to submit work plans, certifications, and procedure specificatons, to the extent
that they were followed, forced the Erector to lay out how it planned to execute and control
the work before starting.

This would normally allow the QC/QA Inspectors a chance to

prepare better for inspecting the work and to have a written plan to which the Erector could
be held during the course of work.

40

SECTION 8: SUGGESTED
REINFORCE OBSERVED

PRACTICES TO MITIGATE OBSERVED PROBLEMS AND

SUCCESSES

Options to increase the probabilty of getting good verification inspectors

The experience of this project has shown that to get good quality it is absolutely
necessary to have a good verification inspector. As a minimum, the contract should specify
AWS Certified Welding Inspector certification for all visual inspectors and ASNT Level II
certification for all ultrasonic inspectors. However, as will be discussed below, these
certifications are not necessarily unqualified assurance that the inspector is sufficiently
knowledgeable and experienced to provide thorough, high-quality inspection. While AWS
and ASNT inspector certification programs have been successful at producing competent
weld inspectors, for certain types of projects requiring a high level of confidence in welding
quality owners might wish to consider augmenting the AWS and ASNT inspector
qualification requirements in their specifications in order to increase their confidence of
getting top-flight weld inspectors. Such projects might include critical facilities such as
hospitals or energy-producing facilities, multi-story buildings in zones of high seismic risk
where welded connections are critical parts of the lateral force resisting system, or buildings
housing commercial operations whose disruption would result in severe economic loss.
Large Corps of Engineers' projects such as Brooke Army Medical Center would fall into this
category. Three areas of possible concern are the use of "apprentice" inspectors, AWS
visual inspector certification criteria, and ASNT ultrasonic inspector certification criteria.
While the importance of apprenticeship of inspectors cannot be denied, it is
recommended that for quality critical projects owners consider tighter restriction or even
deletion of the code allowance for AWS Certified Associate Welding Inspectors (CAWI)
working under the "supervision" of a CWI and for ASNT Level I operators working under the
"supervision" of a Level II inspector.

This will eliminate the possibility of the word

"supervision" being stretched so that the lesser qualified personnel are effectively working
independently.

If the allownace is not deleted altogether it is recommended that the

specifications require the Inspection Company to submit a detailed plan outlining the exact
duties a CAWI or Level I operator will perform and the exact nature, extent, and frequency
of their supervison.

41

Also, there could be some concern that AWS CWI certification may not necessarily
be a categorical indication of competence.
file an education

and experience

To qualify to take the CWI exam one needs to

affidavit,

signed only by one's present

supervisor,

indicating the proper education level and length of experience in a welding related field. Mr.
Jeff Huffsey, Director of Certification for AWS, confirmed to the author that, due to the great
volume of applications

and due to the limitations of available staff, the experience affidavits

are seldom checked unless there is a glaring incongruity in them.

Having submitted the

experience listing and having passed an eye examination, one may sit for the CWI exam.
The exam consists of three parts: (1) Fundamentals,
welding technology,

which tests general knowledge

(2) Practical, which tests facility with actual inspection

of

tools and

practices, and (3) Code, which tests facility with the welding code. One passes and receives
the CWI certification

if they score 71 % or above on each of the three parts.

If someone

scores in the 50% to 70% range on any or all of the three parts, they qualify as a CAWI
(AWS, 1988, AWS QC-1-88, sec. 6.1). Mr. Huffsey also indicated the passing rate is about

75% of examinees. It is not so difficult to envison someone with some stretched experience
scoring straight seventy-two's and thus becoming a CWI. This arguably does not constitute
an confidence-inspiring command of welding technology. Such a person would be have
been as qualified to be a visual inspector on the Brooke Army Medical Center project as
would have an inspector who scored perfectly on all parts. Inspector #1 volunteered to the
author that his scores were in the 90's on all three parts of the most recent CWI exam he
took.
Again, for quality-critical projects it may be worth considering some methods to gain
higher assurance that the visual inspector is truly knowledgeable. One possible tactic is to
require that the visual inspector also submit his CWI exam test grades and that minimum
acceptable grades on each part would be something well above 71 %, perhaps 85% on
Fundamentals and 90% on Code and Practical. This could provide more confidence that
the inspector is in good command of the subject. Another possibility is to require that the
visual inspector be approved subject to the satisfactory results of an interview with the
Engineer of Record, or some other suitable authority, where the inspector's knowledge of
the AWS Code and of welding technology could be verified. A third option is to require that,
in addition to having AWS CWI certification, the inspector will have passed the welding
inspector's test administered by the International Conference of Building Officials (ICBO).

42

Inspector #1, who has taken and passed this test, indicates that it is much more difficult and
much more comprehensive

than the AWS CWI exam.

There is also a concern that certification as an ASNT Level II Ultrasonic inspector

alone may not be sufficient guarantee that the inspector has the necessary skill level to give
each weld a thorough inspection.

Depending on a candidate's education level, the ASNT

recommended training for Level II Ultrasonic certification ranges from 64 to 120 hours and
the level of recommended

experience is 12 months.

Of that 12 months, it is possible that

as little as 25% of it may be spent actually doing ultrasonic inspection and some lesser part
of that 25% may be actual scope time (ASNT, 1984, Table 6.3.1 ). Inspector #1 indicated
that he felt it took about a year of using the ultrasonic testing equipment full-time before one
really becomes familiar enough with the nuances of it and with how to approach different
joint configurations

to be able to consistently get a good look at the whole weld. With this

in mind it may be a good idea to consider specifying that the ultrasonic inspector should
have a minimum of one year of full-time experience at the ASNT Level II certification prior
to beginning work on the project and be able to demonstrate that he has logged a sufficient
number of hours of scope time, perhaps 750 to 1000, prior to beginning work on the project.
Inspector #1 estimated that he had logged approximately 1500 hours of scope time prior to
beginning work on the Brooke Army Medical Center project.

Optionsto increasethe probabilityof gettingproperlygualifiedwelders

While it has been shown on this project that with good inspection quality welding
can still be achieved, even if the welders are not so good, the odds of getting quality welding
dramatically increase if the welders used are also good. The AWS code requirements for
qualifying welders are well-established and well-tested. If followed properly, the welder
qualification procedures should produce competent welders. This project showed that the
code requirements are always in danger of not being followed properly.

Welder

certifications may not be reviewed properly, contractors may hire welders who have
qualifications which are lapsed, and the VT Inspector may not be given copies of the
qualification test records to review. Given this it would seem prudent to take as much of the
uncertainty as possible out of qualifying welders, particularly for large, complex jobs. It is
recommended that all welders simply be required to pass a qualification test, either
administered by or witnessed by the verification VT Inspector for the project, within 10 days
prior to beginning welding on the project. The only exception would be for welders who have
43

been last qualified by the welding contractor and have remained in the welding contractor's
employ as a welder for at least two years. They could be accepted provided a copy of a
certified qualification test record and records certified by an officer of the welding contractor
showing that the welder has been continuously engaged in the type of welding for which
qualified since the date of qualification are submitted.
To help make sure that the qualified welders are familiar with the procedures to be
used it is also recommended

that it be specified that copies of all welding procedure

specifications be kept by each welding crew foreman and be made readily available to the
welders. To make it easier to verify that only properly qualified welders are being used it is
recommended

that it be specified that the welding contractor is to submit a report on a

weekly basis indicating the names and stencils of all welders who welded during that week,
the type of connections they worked on, and the procedure specifications

they used.

Options for increasing the probabilityof having a competentQA Inspector/Owner's

Representative for structuralwelding
The ability to achieve good quality field welding suffers greatly when the QA
Inspector or, for a private sector job, the Owner's Representative is not familiar enough with
the contract requirements to enforce them. It is recommended that anyone who will be
directly monitoring the contractor's field welding performance, particularly on a large project,
be provided with the AWS week-long CWI training. This course is generally provided as a
review for taking the CWI exam but, even for someone not qualified to sit for the exam, it
is a valuable course providing excellent coverage of basic welding technology, the A WS
01.1 code, and visual inspection tools and techniques. Someone who has gone through
this training may not necessarily be a competent welding inspector, but they will have an
understanding of the importance of and details of welding procedure specifications and
welder qualifications, welding processes, welding positions, joint types, inspector
qualifications, and inspector responsibilities. With this knowledge and understanding the
QA Inspector/Owner's Representative is in a better position to confidently monitor the
welding work and to vigorously enforce contract requirements. Should the QA inspector
happen to obtain the CWI certification, the added advantage of having increased technical
authority when dealing with the contractor and the verification inspector can be gained.

44

Options for insuring good tracking of the status of welding

It was evidenced on this project that no one other than the Inspection Company
appeared to be keeping track of the status of inspections and no one was keeping track of
welder qualifications. This exhibits the possibility that unless a tracking or reporting practice
is specifically mentioned in the contract specifications it may not get done. Consequently,
it is recommended that it be specified that a marked-up set of plans showing the status of
all welded connections be maintained and kept current by someone, preferably the
independent verification inspector, and be made available to the QA Inspector/Owner's
Representative on demand. This will provide a well-organized, graphic, easily monitored
means of tracking the status of welds and should reduce the possibility of missed
inspections, unrepaired welds, and placing concrete over incomplete areas. It should also
be specified that the independent verification inspector maintain a list of all qualified welders
and of all rejected welds.
Providingfor independentverificationinspection
Contractors get paid for putting it up, not necessarily for putting it up right.
Particularlywhen schedules and budgets are tight, the contractor will be less concerned with
providing adequate inspection of their own work. The independent verification inspector is
the lynchpin of field welding quality control.

The independent inspector is the only

knowledgeable party whose interests are unaffected by schedule, cost of production, or

expediency concerns in the pursuit of welding in conformance with the contract
requirements. Acceptance inspection responsibility should always be assigned to an
independent inspector. Any reliance by the contracting entity on contractor personnel
inspection for acceptance of welded moment connections is risky and may not result in
satisfactory quality.
Providinga safety net with full nondestructiveinspection
Because of the potential for a breakdown in one or more areas of the QC/QA
system, as was evidenced in this project, it is recommended that the inspection coverage
be as wide as possible to compensate for that possibility. Consequently, for all beam fullpenetration welds in moment connections, whether in moment frames or not, it is
recommended that 100% nondestructive testing by ultrasound be specified.

45

Options for QA/Owner

control of information without confusion about approval

responsibility

Because the more information the QA Inspector/Owner's Representative has, the

stronger his position will be, and the better he will be able to monitor compliance, it is
recommended that the specifications require the contractor to submit

all pertinent

information, including quality control work plans, welding procedure specifications, welder
qualification test records, qualified welder lists with assigned stencils, welding detail
drawings, inspector qualifications, inspection procedures, inspection reports, and repair lists.
So that there will not be any confusion on the General Contractor's part about approval
responsibilities, it is recommended that all submittals be specified to be "For Information
Only." This leaves the General Contractor with full responsibility for approval of submittals
but gives the QA staff the opportunity to point out noncomforming items which the General
Contractor is still obligated to correct.
Options to help eliminate problems regarding inspectoraccess
It is recommended that the mutual obligations for the Inspector to provide timely
inspection and the Erector to provide the independent inspector with access to the
inspectable work be specifically mentioned in the contract specifications. This will get that
important point into the record. Also, it is recommended that the independent inspector's
work plan be required to include a section on how timely inspection will be accomplished
and that the Erector's work plan be required to include a section on how access will be
provided for the independent inspector. This will force each party to formulate a written
plan to which they can be held.

46

APPENDIX A ~ Tabularized Summary of Moment Connection Weld Inspection

Reports

Key Notes to Table A1:

Connection Notes: Characters to the left of the hyphen are sequential identifiers. An "R"
to the left of the hyphen indicates the connection was in the Research Building. To the right
of the hyphen T and B indicate top and bottom flanges. Type 3 moment connections had
a middle joint which is indicated by M. An "R#" to the right of the hyphen indicates a
repaired weld and the number of the repair attempt.

Visual Remarks Notes: Abbreviations were used for visual rejects as noted below.
UC = Undercut
S =Slag Inclusion
UF = Underfill
FG = Flange Gouge
ER = Excessive Reinforcement
FM = Flange Misalignment
INC= Incomplete/Missing Weld
P =Porosity
UP = Unacceptable Profile
CL= Cold Lap
EWB = Excessive Weld Bead
IRO =Insufficient Root Opening
LOF = Lack of Fusion
UltrasonicResult Notes: NRI indicates No Rejectable Indications

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APPENDIX

97

B - Tables

TABLE 81: SUMMARY

OF WELD INSPECTION

RESULTS

Total Number of Field Welded Moment Connections: 918

Total Number of Welded Moment Connection Joints: 1883
Total Number of Moment Connection Welds Made (Includes Repairs): 2064
Total Number of Rejected Welds: 185
Total Number of Visually Rejected Welds: 74
Total Number of Ultrasonically Rejected Welds: 111
Number of Rejected Welds Repaired 1st Time: 159
Number of Rejected Welds Requiring 2nd Repair: 20
Number of Rejected Welds Requiring 3rd Repair: 2
Number of Rejected Welds with No Record of Repair: 4
Rejected Welds as a % of Total Welds Made: 8.96%
Rejected Welds as a % of Total Joints: 9.82%
Number of Moment Connections with Rejected Welds: 141 (15.4%)
Number of Moment Connections with Visually Rejected Welds: 62 (6.8%)
Number of Moment Connections with Ultrasonically Rejected Welds: 80 (8.7%)
Number of Moment Connections with Unrepaired Rejected Welds: 4 (0.44%)
Number of Moment Connection Welds Not Visually Inspected: 4 (0.29%)
Number of Moment Connection Welds Not Ultrasonically Inspected: 18 (0.90%)
Number of Moment Connection Welds With No Record of Any Inspection: 4 (0.19%)
Number of Moment Connections Having Deficient Inspection: 10 (1.1%)
Number of Moment Connections Having Some Welds Not Visually Inspected: O (0.0%)
Number of Moment Connections Having No Record of Any Visual Inspection: 2 (0.22%)
Number of Moment Connections Having One Weld Not Ultrasonically Inspected: 3 (0.33%)
Number of Moment Connections Having No Record of Any Ultrasonic Inspection: 7 (0.76%)
Number of Moment Connections Having One Weld Completely Uninspected: 0 (0.0%)
Number of Moment Connections Completely Uninspected: 2 (0.22%)

Note: Numbers in parenthesis are % of total category

e.g. - number of moment connections with rejected welds: 141 (141of918 = 15.4%)

98

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99

TABLE 83: SUMMARY

Connection
MC24-T

OF WELDS HAVING NO RECORD OF ANY INSPECTION

Probable Location
D/23-2

Probable Welder ID

Remarks

1F

T~Qe & Size

2-W16x31

At False Pilaster - Accessible

MC24-B

D/23-2

1F

2- W16x31

At False Pilaster - Accessible

MC70-T

C.9/19-3N

1For10F

2-W27x84

At Mall Deck - Accessible

MC70-B

C.9/19-3N

1F or 10F

2-W27x84

At Mall Deck - Accessible

Connection Notes: T or B indicates top or bottom flange

Location Notes: Location ID is column line/column line - floor (side, if applicable)
Type and Size Notes: Type is type of moment connection; Size is size of the beam being moment welded
2 torsion counterbalance (beam-to-beam)

100

TABLE 84: SUMMARY OF WELDS HAVING NO RECORD OF ULTRASONIC INSPECTION

Connection

Location

Welder ID

T~11e & Size

MC248-TR1

B/8.9-1

1F

2-W21x44

At Loading Dock - Accessible

Remarks

MC314-TR1

SS/DD.5-2

NS

2-W16x31

At False Pilaster - Accessible

MC314-BR1

SS/DD.5-2

NS

2 -W16x31

At False Pilaster - Accessible

MC393-BR1

J.6/11-3S

18F

2-W27x84

At Exp Joint - Accessible

MC437-BR1

T/10.5-4

NS

2-W16x26

At False Pilaster - Accessible

MC473X-T

M/13.5-4

17F

2-W16x26

At False Pilaster - Accessible

MC473X-B

M/13.5-4

SF

2-W16x26

At False Pilaster - Accessible

MC496-T

J/11-5E

1F

3-W36x160

At Exp Joint Haunch - Accessible

MC496-M

J/11-5E

19F

3-W36x160

At Exp Joint Haunch - Accessible

MC496-B

J/11-5E

19F

3-W24x68

At Exp Joint Haunch - Accessible

MC518-T

H.8/9-5E

19F

4-W30x99

In Shaft - Inaccessible

MC518-B

H.8/9-5E

19F

4-W3Dx99

In Shaft - Inaccessible

MC519-T

H.8/9-5W

19F

3-W30x99

In Shaft - Inaccessible

MC519-B

H.8/9-5W

19F

3-W30x99

In Shaft - Inaccessible

Note: These welds all passed visual inspection

Connection Notes: T or B indicates top or bottom flange; R# indicates the number of the repair attempt
Location Notes: Location ID is column line/column line - floor (side, if applicable)
Type and Size Notes: Type is type of moment connection; Size is size of the beam being moment welded
2

= torsion counterbalance

(beam-to-beam)

= cantilever balance (beam-to-column)

= cantilever connection

(beam-to-column)

101

TABLE 85: SUMMARY

OF VISUALLY

REJECTED

WELDS

Connection

Welder ID

VT lnsp

Result

Remarks

MC3-TR1
MC68-BR1

1F
1F

uc,s

Fail
Fail

MC74-B

NS

Fail

UF

MC82-T

7F

Fail

UF

MC82-B

7F

Fail

UF

UC = Undercut

MC83-T
MC83-B
MC84-B
MC86-B
MC87-T

7F

2
2
2
2

Fail
Fail

UF

S = Slag Inclusion

UF = Underfill
UC = Undercut
FG = Flange Gouge
ER = Excessive Reinforcement

MC87-B

7F

Fail
Fail

UF
UF
UF
UF
UF

FM = Flange Misalignment

MC88-B

7F

Fail

UF

INC = Incomplete/Missing Weld

MC119-T
MC140-T

NS
10F

Fail

Fail

FG
FG

P =Porosity
UP= Unacceptable Profile

MC142-B
MC143-B

NS

Fail
Fail

UF

NS

2
2

CL= Cold Lap

EWB = Excessive Weld Bead

MC162-B

NS

Fail

UF

IRO =Insufficient Root Opening

LOF = Lack of Fusion

7F
7F
7F
7F

UF

Fail
Fail

UF

Fail

2
2
2
3

Fail
Fail
Fail
Fail

MC414-T

1F
NS
NS
18F
10F
10F

Fail

ER
FM
FM
INC
UF
UF

MC423-T

17F

Fail

UF

MC426-B

17F

3
3

Fail

UF

MC428-T

17F

Fail

ER

MC430-T

17F

Fail

UF

MC437-B

17F

Fail

UF

MC248-T
MC314-T
MC314-B
MC393-B
MC413-B

MC439-B

9F

Fail

UF

MC441-T

13F

MC448-T

13F
NS
9F
17F

Fail
Fail
Fail
Fail

UF

MC442-T
MC444-T
MC445-M

3
3
3

UF
p

Fail

UC
p

MC450-T

17F

Fail

UF,CL,UP

MC450-B

17F

Fail

UF,UP

MC451-T

17F

Fail

UF,UP

9F
9F

3
3

Fail

EWB

Fail

UF

MC471-B

9F

Fail

UF

MC473-T

17F

Fail

UF

MC474-T

17F

Fail

IRO

MC474-B
MC475-B
MC476-T

17F
17F
17F

3
3
3

Fail
Fail
Fail

IRO
UF
UF

MC451-B
MC469-B

102

Notes on Remarks:

TABLE 85 (CONT'D): SUMMARY OF VISUALLY

Connection
MC476X-B
MC477-T
MC477-B
MC478-B
MC481-T
MC502B-B

Welder ID

VT lnsp

Result

Remarks

1F

3
3

Fail

UF
UF

MC516-T

17F
17F
17F
17F
NS
19F

MC592-B

SF

SF
24F

Fail
Fail

UF

MC593-B
MC619-B

Fail

UF

MC635-B

NS

Fail

INC

MC704-T

NS

Fail

UF

MC705-T

NS

Fail

UF

MC705-B
MC705-BR1
MC706-T
MC707-T
MC710-T

NS

Fail

UF

NS
NS
NS

Fail
Fail
Fail

CL,S
UF
UF

Fail

UF

MCR2-B
MCR3-T
MCR3-B
MCR4-T
MCR4-B

REJECTED WELDS

3
3
3

Fail
Fail
Fail
Fail

2
3

Fail
Fail

NS
28F
28F
28F
28F
28F

3
3

UF
UF
UF
UC
UF
UF

UF

Fail
Fail

UF,S
UF

3
3

Fail
Fail

Fail

UF

MCR67-T

NS

Fail

LOF,UP,S

MCR144-T

24F

Fail

ER

MCR146-T
MCR147-T
MCR152-T

24F

Fail

24F

Fail
Fail

ER
ER
FM

1F

103

TABLE 86: SUMMARY

Connection
MC3-T
MC3-M

OF ULTRASONICALLY

Welder ID

UT lnsp

Result

1F
1F

Reject
Reject

REJECTED WELDS
Remarks
Class A
Class A

MC3-B
MC3-BR1

1F
1F

Reject
Reject

Class A

MC4-TE

Reject

MC4-TER1

1F
1F

Reject

Class A
Class A

MC4-TW

1F

Reject

Class A

1F
10F

Reject

Class A
Class A

MC4-TWR1
MC67-B
MC68-B
MC104-B
MC133-B
MC225-B
MC229-T

1F
3F
NS

Reject
1
2

Reject
Reject

16F
1F
1F

Reject
Reject
Reject

Class A

Class A
Class A
Class A
Class A
Class A
Class A

2
2

Reject
Reject

Reject

MC230-T

1F
1F

Reject

Class A
Class A

MC230-M
MC231-T

1F

Reject

Class A

1F

Reject

Class A

Reject
Reject
Reject
Reject

Class A
Class A
Class A
Class A
Class A

MC229-TR1
MC229-M
MC229-B

1F

Class A

1F
1F
16F
16F
1F

1F

MC255-TR2

1F

Class A

MC255-B

1F

Reject
Reject

MC261-B

1F

Reject

Class A

MC264-T

1F

Reject

Class A

MC272-M

1F

Reject

Class A

MC286-B

1F

Reject

Class A
Class A

MC233-T
MC233-M
MC236-T
MC242-T
MC255-T
MC255-TR1

Reject
Reject

Class A
Class A

MC299-T

16F

Reject

MC299-TR1
MC303-T
MC369-B

16F
16F

Reject
Reject
Reject

Class A
Class A
Class A

MC369-BR1

16F

Reject

MC375-B

3F

Reject

Class A
Class A

MC384-B

16F

Reject

Class A

MC384-BR1

16F

Reject

MC402-B

10F

Reject

Class A
Class A

MC416-B

10F

Reject

Class A

MC417-B

10F

Reject

Class A

MC422-B

17F

Class A

MC423-B

17F

Reject
Reject

16F

104

Class A

TABLE 86 (CONT'D):
Connection
MC427-B
MC428-B
MC436-B
MC442-B
MC442-BR1

SUMMARY

OF ULTRASONICALLY

Welder ID

UT lnsp

Result

17F
17F
17F
9F
24F

Reject

Remarks
Class A

Reject
Reject
Reject

Class A
Class A
Class A

Reject
Reject

Class A
Class A

MC460-B

17F

MC462-B

17F

Reject

Class A

MC462-BR1

17F

Reject

Class A

MC462-BR2

24F

Class A

MC474X-B

16F

Reject
Reject

MC475X-T

18F

Reject

Class A

MC477X-T

NS
NS

Reject

Class A

Reject
Reject
Reject
Reject
Reject

Class A
Class A
Class A
Class A
Class A
Class A
Class A
Class A

MC478X-T
MC478X-TR1
MC490-T
MC490-M
MC491-M

Class A

MC498-M

24F
1F
1F
1F
19F

MC498-B
MC500-B

19F

Reject
Reject

20F

Reject

MC521-T

20F

MC524-B

10F

Reject

Class A

MC525-B

10F

Reject

Class A

MC526-B
MC548-B

10F
20F
SF
SF

Reject
Reject

Class A
Class A
ClassA
Class A
Class A

Reject

Class A

1F
1F

Reject
Reject
Reject
Reject

MC634-T

1F

Reject

Class A

MC635-T
MC636-T

NS

Class A

19F

Reject
Reject

MC636-B

19F

MC639-B

12F

MC640-B

12F

1
1
1
1
1
1
1
1
1
1
1
1
1

MC583-B
MC593-BR1
MC632-T
MC633-T

MC657-T

1F

MC658-T

1F

MC672-T
MC672-B
MC673-T

NS
NS
NS
NS
NS
NS
NS
NS

MC673-B
MC674-T
MC674-TR1
MC681B-T
MC704-B

Class A

Reject

Class A
Class A

Reject

Class A

Reject

Class A

Reject

Class A

Reject

Class A
Class A

Reject
Reject
Reject
Reject

Class A
Class A
Class A

Reject

Class A

Reject

Class A

Reject

Class A

Reject

Class A

105

REJECTED

WELDS

TABLE 86 (CONT'D):

SUMMARY OF ULTRASONICALLY

Connection

Welder ID

UT lnsp

Result

Remarks

MC706-TR1

NS
NS
NS
NS
NS
NS

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1

Reject

Class A

MC706-B
MC707-TR1
MC707-B
MC709-B
MC711-B
MCR11-B

1F

MCR24-T

28F

MCR24-B

28F

MCR25-T

1F

MCR25-TR1
MCR44-B

1F
28F

MCR45-T

28F

MCR69-B

28F

MCR71-B
MCR71-BR1

28F
24F
28F

MCR72-T
MCR91-B
MCR100-T

1F
1F

MCR112-B

KS

MCR125-T

1F

Reject

Class A

Reject
Reject
Reject
Reject
Reject
Reject

Class A
Class A
Class A
Class A
Class A

Reject
Reject
Reject

Class A
Class A
Class A

Reject

Class A
Class A

Reject

Class A

Reject

Class A

Reject
Reject

Class A

Reject
Reject
Reject

Class A
Class A
Class A
Class A

Reject

Class A

Reject

Class A

106

REJECTED

WELDS

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107

TABLE BS: INSPECTION TIMELINESS -TIME DIFFERENCE IN DAYS BETWEEN

VISUAL AND ULTRASONIC INSPECTIONS
Timeliness Category

Days Bet VT & UT

very timely
timely
marginally timely

Same Day
1 to 3
4to7

late
very late

7 to 10
11 to 21

incredibly late

22 & Above

Inspections in Category
1424
96
36
6
35
375

108

% of Welds Inspected
72.21
4.87
1.83
0.30
1.77
19.02

TABLE 89: SUMMARY OF INSPECTOR EXPOSURE TO EACH WELDER

Visual Inseection

Welder ID
1F
3F
SF
7F
BF
9F
10F
12F
13F
16F
17F
18F
19F
20F
22F
24F
28F
KS
Albert
No Stencil

lnsp #1
265
6
3
0
0
9
21
2
0
37
6
10
0
17
0
160
29
2
0
246

lnsp #2
152
32
0
23
8
0
11
0
0
13
0
23
0
0
0
10
12
31
0
44

UT lnseection

lnsp#3
243
16
17
24
6
27
89
8
7
98
82
47
16
101
2
16
17
0
2
67

109

lnsp#1
432
11
18
14
0
30
104
10
5
91
58
26
9
88
0
172
33
2
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280

lnsp #2
219
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0
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14
0
14
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11
53
0
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20
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59

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1~

u,

APPENDIX C - Welding Procedure Specifications for Moment Connections

113

TITLE:

Prequalified Welding Procedure No: B-U4a-GF & TC-U4a-GF

This procedure may vary due 10 Iabricaunn sequence, Iii-up, P";'S size, etc., within the limiLation.s of variables given in 48,
C. or D and DS.1.2 of A WS m.i.
Sec matching filler mei.al tables this specifieauon

Material Specification: AWS Dl.l-90TABLE

Welding
Process:
Manual or
Machine_:__ FCAW
S_E_M_I A_UT_O_M_A_TI_C

4.1 GROUP I,II

_

Position of Weld:
FLAT AND HORIZONTAL
Filler Metal:
E7Ul"-l &. E71T- l Aws A5.20
Flux:
N/A
Sheilding Gas:
C02 40CFM DEW POINT -40"
Welding Current: ,,
DCEP
Root Treatment:
BACKING BAR
Preheat and lnterpass Temperature: AWS Dl.l-90TABLE

-----------------------~
----,,,,...---------------------~
43 GROUP A,B

Sec preheat tables this specification

Joint Geometry

Joint Geometry
Tl & T2 UNLIMITED THICKNESS

Tl= UNLIMITED THICKNESS

R

= 3/16 a= 3-0"

R ~ 3/16 a = 30"

,.._,

_j

T1

B-U4a-GF

Pass.
Na:
ALL
ALL

.. Weld
. Type
FCAW
FCAW

..;.

'

w}j
.

A-~\,
~~"

Electrode

T2

i:;n~

NOTEJ

NOTE V

TC-U4a-GF

Welding Current
1--------'1'----------1
Volts
.Amperes.

~.20 sxrr -1 5/64

~.20E7Ul"-1 .052

28
26

350
260

..... Travel
Speed
NIA
NIA

Comments
1.

nfE MEMBER ORIENTATION

MAY BE CHANGED PROVIDED THE ROOT OPENING, GROOVE ANGLE AND TiiE DESIGN

WELD SIZE IS MAINrAINED.

NOTE J IFFillET WELDS ARE USED TO REINFORCE GROOVE WELDS IN CORNER AND TEE JOINTS,
THEY SHAU.. BE EQUAL TO 1/4 Tl, BUT NEED NOT EXCEED 3/8 IN.

114

APPENDIX D - Typical Weld Inspection Report

115

..
,.

-------=~

FIELD REPORT
~'

11009 Osg004.l,S.ln /\nlunio, T cui 7!!2JJ

PROJECT:

CATE:

LOCATION:

Center

Brooke Army Medical

San Antonio,

3-1993

Texas

;...o..

G/3Nl3R41- c.oNrRA~r~

CONSTRUCTION:

Ft40/.

CONTRACTOR

uuues. A]!!;!t/i:_T,Qf/SO//tc

~t!.{d.Ci.S - U1/GI.. 1
Ptt./WYI,:

C:l2"Ull:ll..!

'{ '1!

l'h" (512) "55951; !'AX: (!;121 55-9519

JOB NO.:

CUENT:

r-.:;;, ..

Ti;;~r1.tl(2

Reoort

"F .1110Mf;;.7tJT cott!Afe:t/fio/f/S

#.7'1..

WEATHER:

Cc.orJtN
WITH:

REPORTED TO:

Phil

Hyman/Manhattan

Broom

COMMENTS:

C(X (/M ,fl

srcrccs

/YI/(' 81tfJ.

u/,

7Ht:.'l e

Mont

~t1EC(c;'!)

/,(/ rife

./i,r/l)
J,/t;tl

Approved: ----------!

Date:

d/!

/j./(.fl/a/(/(

J-19- 91

/99J

'(":!t

avr

tlAtlG

7?/t:rc

/}. ,e. alti/_?4

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trll/'I CaJtI .AlIJe.

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CotlJtJE.C 7iol).s

By:

19.

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rUtmC COT. C'OCI

cOlf/;f/l!,tftcJ#;. "171110lt!7J/9-Ac

Regular Hour~:
Overtime Hours:
Total Hours:

116

i/t&v&L TUT/If),{

VtJtlll/...

ARD VlTli./?-.Sottl1c

l{~ter

TH5

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esee::.roP:..

Mileage:

cc:

Miles

FAe?F<iMT'oFZ-

VISUAL
~
-~-IC

INSPECTION

REPORT

FORM

MC - MomentConnection
- Imbed Connection

WELD CONDITIOi
_&_AS
WELDE!
SMOOTH

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We. the undersigned
. certify lhat me statements in this record are corie~tand that the welds were prepared and tested in accordance
with lhe requirementsof section 6, Pan C of ANSl/AWS 01.1, (
1'112) Slructursl Welding Code-Sleel.
year

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Dale-----------------

119

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REPORT OF ULTRASONIC TESTING OF WELDS

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We. the undersigned. certify that me statements in this record are corre;;t and that the welds were prepared and tested in accordance
with the requirements of section 6. Part C of ANSl/AWS 01.1, (
/'l'I Z..
) Structural Welding Code-Steel.
year
Test date
Inspected by~~

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Manufacturer or contractor ----------

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Authorized by------------Dote

120

APPENDIX E - Contract Specifications

121

SECTION 05055 - WELDING. STRUCTURAL

PART 1 - GENERAL

1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The
publications are referred to in the text by basic designation only.
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)
AISC S326 (Nov. 1, 1978) Specification for the Design, Fabrication and Erection of
Structural Steel for Buildings (with Commentary).
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)
ANSI Z49.1 (1983) Safety in Welding and Cutting.
AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)
ASNT No. SNT-TC (Aug. 1984; Rev. 1A) Personnel Qualification and Certification in
Nondestructive Testing.
AMERICAN WELDING SOCIETY (AWS)
AWS A2.4 (1986) Symbols for Welding and Nondestructive Testing.
AWS A3.0 (1985) Welding Terms and Definitions.
AWS D1 .1 (1988) Structural Welding Code - Steel.
AWS D1 .3 Specification for Welding Sheet Steel.
AWS D1 .4 Structural Welding Code - Reinforcing Steel.
1.2 DEFINITIONS
Definitions of welding terms shall be in accordance with AWS A3.0.
1.3 GENERAL REQUIREMENTS
The design of welded connections shall conform to AISC S 326 unless otherwise indicated
or specified. Material with welds will not be accepted unless the welding is specified or
indicated on the drawings or otherwise approved. Welding shall be as specified in this
section, except where additional requirements are shown on the drawings or are specified
in other sections. Welding shall not be started until welding procedures, welders, welding
operators, and tackers have been qualified and the submittals furnished to the Contracting
Officer. Qualification testing shall be performed at or near the work site. Each Contractor
122

performing welding shall maintain records of the test results obtained in welding procedure,
welder, welding operator, and tacker performance qualifications.

1.4 SUBMITTALS
The following shall be submitted in accordance with SECTION 01300 - SUBMITTALS:
SD-31, Detail Drawings
Detail drawings consisting of fabrication and assembly drawings for all parts of the work in
sufficient detail to enable the Government to check conformity with the requirements of the
contract documents.
SD-39, Qualifications
Qualifications of welding inspector.
SD-64, Quality Assurance Plan
Detailed procedures defining methods to ensure compliance to contract drawings and
specifications by drawing control, inspection and procurement records, system and material
testing, and certification records.
SD-70, Test Reports
An independent testing agency's certified reports of inspections and laboratory tests,
including analysis and interpretation of test results. Each report shall be properly identified.
Test methods used and compliance with recognized test standards shall be described.
SD-74, Welding Procedures and Qualifications
Copies of the welding procedure specifications, the procedure qualification test records, and
the welder, welding operator, or tacker qualification test records shall be submitted.
SD-91, Records
Letters of record expressing Contractor and Contracting Officer communication and records
of historical field data.
1.5 WELDING PROCEDURE QUALIFICATION
Except for prequalified (per AWS 01 .1) and previously qualified procedures, each
Contractor performing welding shall record in detail and shall qualify the welding procedure
specification for any welding procedure followed in the fabrication of weldments.
Qualification of welding procedures shall conform to AWS 01 .1 and to the specifications in
this section. Copies of the welding procedure specification and the results of the procedure
qualification test for each type of welding which requires procedure qualification shall be
submitted. Approval of any procedure, however, will not relieve the Contractor of the sole
responsibility for producing a finished structure meeting all the requirements of these
specifications. This information shall be submitted on the forms in Appendix E of AWS
123

01 .1. Welding procedure specifications shall be individually identified and shall be

referenced on the detail drawings and erection drawings, or shall be suitably keyed to the
contract drawings.
In case of conflict between this specification and AWS 01 .1, this
specification governs.
1.5.1
Previous Qualifications:
Welding procedures previously qualified by test may be
accepted for this contract without requalification if the following conditions are met:
a. Testing was performed by an approved testing laboratory, technical consultant, or the
Contractor's approved quality control organization.
b. The qualified welding procedure conforms to the requirements of this specification and
is applicable to welding conditions encountered under this contract.
c. The welder, welding operator, and tacker qualification tests conform to the requirements
of this specification and are applicable to welding conditions encountered under this
contract.
1.5.2 Prequalified Procedures: Welding procedures which are considered prequalified as
specified in AWS 01 .1 will be accepted without further qualification. The Contractor shall
submit a listing or an annotated drawing to indicate the joints not prequalified. Procedure
qualification shall be required for these joints.
1.5.3 Retests: If welding procedure fails to meet the requirements of AWS 01 .1, the
procedure specification shall be revised and requalified, or at the Contractor's option,
welding procedure may be retested in accordance with AWS 01 .1. If the welding procedure
is qualified through retesting, all test results, including those of test welds that failed to meet
the requirements, shall be submitted with the welding procedure.

1.6 WELDER, WELDING OPERATOR, AND TACKER QUALIFICATION

Each welder, welding operator, and tacker assigned to work on this contract shall be
qualified in accordance with the applicable requirements of AWS 01 .1 and as specified in
this section. Welders, welding operators, and tackers who make acceptable procedure
qualification test welds will be considered qualified for the welding procedure used.
1.6.1 Previous Qualifications: At the discretion of the Contracting Officer, welders, welding
operators, and tackers qualified by test within the previous 6 months may be accepted for
this contract without requalification if all the following conditions are met:

a. Copies of the welding procedure specifications, the procedure qualification test records,
and the welder, welding operator, and tacker qualification test records are submitted in
accordance with the requirements for detail drawings.
b. Testing was performed by an approved testing laboratory, technical consultant, or the
Contractor's approved quality control organization.
c. The previously qualified welding procedure conforms to the requirements of this
specification and is applicable to welding conditions encountered under this contract.

124

d. The welder, welding operator, and tacker qualification tests conform to the requirements
of this specification and are applicable to welding conditions encountered under this
contract.
1.6.2 Certificates: Before assigning any welder, welding operator, or tacker to work under
this contract, the Contractor shall submit the names of the welders, welding operators, and
tackers to be employed, and certification that each individual is qualified as specified. The
certification shall state the type of welding and positions for which the welder, welding
operator, or tacker is qualified, the code and procedure under which the individual is
qualified, the date qualified, and the name of the firm and person certifying the qualification
tests.
The certification shall be kept on file, and 3 copies shall be furnished.
The
certification shall be kept current for the duration of the contract.
1.6.3 Renewal of Qualification:
Requalification
required under any of the following conditions:

of a welder or welding operator shall be

a. It has been more than 6 months since the welder or welding operator has used the
specific welding process for which he is qualified.
b. There is specific reason to question the welder or welding
welds that meet the requirements of these specifications.

operator's ability to make

c. The welder or welding operator was qualified by an employer other than those firms
performing work under this contract, and a qualification test has not been taken within the
past 12 months. Records showing periods of employment, name of employer where welder,
or welding operator, was last employed, and the process for which qualified shall be
submitted as evidence of conformance.
d. A tacker who passes the qualification test shall be considered eligible to perform tack
welding indefinitely in the positions and with the processes for which he is qualified, unless
there is some specific reason to question the tacker's ability. In such a case, the tacker
shall be required to pass the prescribed tack welding test.

1.7 INSPECTOR QUALIFICATION

The inspector will be an independent, established commercial consultant or employed by
an independent testing laboratory. Inspection and nondestructive testing personnel shall
be qualified in accordance with the requirements of ASNT No. SNT-TC for Levels I or II in
the applicable nondestructivetesting method. The inspector may be supported by assistant
welding inspectors who are not qualified to ASNT No. SNT-TC, and assistant inspectors
may perform specific inspection functions under the supervision of the qualified inspector.
1.8 SYMBOLS
Symbols shall be in accordance with AWS A2.4, unless otherwise indicated.
1.9 SAFETY
Safety precautions during welding shall conform to ANSI Z49.1.

125

PART 2 - PRODUCTS

2.1 WELDING EQUIPMENT AND MATERIALS

All welding equipment, electrodes, welding wire, and fluxes shall be capable of producing
satisfactory welds when used by a qualified welder or welding operator performing qualified
welding procedures. All welding equipment and materials shall comply with the applicable
requirements of AWS D1 .1, AWS D1 .3 and AWS D1 .4.
PART 3 - EXECUTION
3.1 WELDING OPERATIONS
3.1.1 Requirements: Workmanship and techniques for welded construction shall conform
to the requirements of AWS D1 .1 and AISC S 326. When AWS D1 .1 and the AISC S 326
specification conflict, the requirements of AWS D1 .1 shall govern.
3.1.2 Identification: Welds shall be identified in one of the following ways:
a. Written records shall be submitted to indicate the location of welds made by each welder,
welding operator, or tacker.
b. Each welder, welding operator, or tacker shall be assigned a number, letter, or symbol
to identify welds made by that individual. Each welder, welding operator and tacker shall
apply their symbol next to the weld by means of rubber stamp, felt-tipped marker with
waterproof ink, or other methods that do not cause an indentation in the metal. For seam
welds, the identification mark shall be adjacent to the weld at 3-foot intervals. Identification
with die stamps or electric etchers shall not be allowed.

3.2 QUALITY CONTROL

Testing shall be done by an independent, approved inspection or testing laboratory or
technical consultant, and shall be within the Contractor's contract. Visual and ultrasonic
inspection shall be performed to determine conformance with paragraph "STANDARDS OF
ACCEPTANCE." Procedures and techniques for inspection shall be in accordance with
applicable requirements of AWS D1 .1.

3.3 STANDARDS OF ACCEPTANCE

Dimensional tolerances for welded construction, details of welds, and quality of welds shall
be in accordance with the applicable requirements of AWS D1 .1 and the contract drawings.
Nondestructive testing shall be by visual inspection and ultrasonic methods. The minimum
extent of nondestructive testing shall be as indicated on the drawings.
3.3.1 Nondestructive Examination: The welding shall be subject to inspection and tests in
the mill, shop, and field. Inspection and tests in the mill or shop will not relieve the
Contractor of the responsibilityto furnish weldments of satisfactory quality. When materials
or workmanship do not conform to the specification requirements, the Government reserves
126

the right to reject material or workmanship or both at any time before final acceptance of the
structure containing the weldment.
3.3.2 Destructive Tests: When metallographic specimens are required to be removed from
any part of a structure, the Contractor shall make repairs. The Contractor shall employ
qualified welders or welding operators, and shall use the proper joints and welding
procedures, including peening or heat treatment if required, to develop the full strength of
the members and joints cut and to relieve residual stress.

3.4 GOVERNMENT INSPECTION AND TESTING

In addition to the inspection and tests performed by the Contractor's independent testing
laboratory or technical consultant for quality control, the Government will perform inspection
and testing for acceptance to the extent determined by the Contracting Officer. The costs
of such inspection and testing will be borne by the Contractor if unsatisfactory welds are
discovered, or by the Government if the welds are satisfactory. The work may be performed
by the Government's own forces or under a separate contract for supplemental inspection
and testing. The Government reserves the right to perform supplemental nondestructive
and destructive tests to determine compliance with paragraph "STANDARDS OF
ACCEPTANCE."

3.5 CORRECTIONS AND REPAIRS

When inspection or testing indicates defects in the weld joints, the welds shall be repaired
using a qualified welder or welding operator as applicable. Corrections shall be in
accordance with the requirements of AWS D1 .1 and the specifications. Defects shall be
repaired in accordance with the approved procedures. Defects discovered between passes
shall be repaired before additional weld material is deposited. Wherever a defect is
removed and repair by welding is not required, the affected area shall be blended into the
surrounding surface to eliminate sharp notches, crevices, or corners. After a defect is
thought to have been removed, and before rewelding, the area shall be examined by
suitable methods to insure that the defect has been eliminated. Repair welds shall meet the
inspection requirements for the original welds. Any indication of a defect shall be regarded
as a defect, unless reevaluation by nondestructive methods or by surface conditioning
shows that no unacceptable defect is present.

--oOo--

127

SECTION 05061 - ULTRASONIC INSPECTION OF WELDMENTS

PART 1 - GENERAL
1.1 REFERENCES
The publications listed below form a part of this specification to the extent referenced. The
publications are referred to in the text by basic designation only.
MILITARY STANDARDS (MIL. STD.):
MIL-STD-271 E Nondestructive Testing Requirements & Notice 1for Metals
MIL-STD-410D Nondestructive Testing Personnel & Notices 1, 2Qualification and
Certification (Eddy Current, Liquid Penetrant, Magnetic Particle, Radiographic and Ultrasonic)
DEPARTMENT OF THE NAVY, NAVAL SEA SYSTEMS COMMAND (NAVSHIPS)
PUBLICATION:
0900-006-3010 Ultrasonic Inspection Procedure and Acceptance Standards for Hull Structure
Production and Repair Welds (January 1966)
AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT) RECOMMENDED
PRACTICE:
SNT-TC-1A Personnel Qualification and Certification in Nondestructive Testing (August
1984)
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) PUBLICATIONS:
E 165-80 (R. 1983) Liquid Penetrant Inspection Method
E 709-80 (R. 1985) Magnetic Particle Examination
AMERICAN WELDING SOCIETY (AWS) PUBLICATION:
D1 .1-86 Structural Welding Code - Steel

1.2 GENERAL REQUIREMENTS

The procedures, methods, standards, and description of equipment specified herein that shall
be used for inspection ofweldments specified. Ultrasonic inspections shall be made to detect
the following defects:
a. Cracks or crack-like faults.
b. Root defects, including lack of penetration and fusion.

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c. Lack of fusion between passes on the sidewall.

d. Porosity or inclusions and excessive undercutting.
1.2.1 Ultrasonic Equipment: The ultrasonic equipment shall conform to the requirements
listed in AWS D1 .1 section inspection, subsection Ultrasonic Equipment, with the following
exceptions:
1.2.1.1 The ultrasonic test instruments shall be able to generate, receive, and present pulses
in the frequency range from 1 to 10 megahertz (MHz).
1.2.1.2 The horizontal linearity of the ultrasonic instrument shall be measured in accordance
with paragraph EQUIPMENT QUALIFICATION REQUIREMENTS.
1.2.1.3 In addition to the resolution test specified in AWS D1 .1, subsection Ultrasonic
Equipment, both near- and far-surface resolution tests shall be conducted in accordance with
the tests specified for these characteristics in the paragraph EQUIPMENT QUALIFICATION
REQUIREMENTS.
1.2.2 Procedures and Methods: The pulse echo contact method with an A scan presentation
shall be used for the ultrasonic inspection of welded joints except that immersion techniques
may be used for some applications when approved by the Contracting Officer.
The
Contractor shall provide a standard reference block and working standards as described in
paragraphs REFERENCE STANDARDS FOR EQUIPMENT, QUALIFICATIONS,
AND
CALIBRATION.
The procedures to be used for personnel and equipment qualification,
equipment calibration and inspection shall be submitted to the Contracting Officer for
approval at least 30 days prior to their intended use. Approval by the Government will in no
way affect the obligation of the Contractor to employ qualified personnel, equipment, and
procedures, and to perform the inspection as specified. The procedure description shall
include the following:
a. Couplant.
b. Search unit characteristics
designation.

including

angle, size, shape, nominal frequency,

type

c. Method and type of wave.

d. Equipment and accessories including manufacturer, model number, date of manufacture,
last date of calibration and the manufacturer's electrical, physical and performance
specifications.
e. Decibel (dB) compensation

system for distance-amplitude

correction.

1.2.3 Test Frequency: The test frequency for ferrous materials shall be as specified in AWS
D1 .1 section Inspection, subsection Ultrasonic Equipment, except for thicknesses below
1/2-inch, frequencies between 2.25 and 5 MHz may be used to obtain increased sensitivity.
For materials that are difficult to penetrate, any frequency within the operating range of the
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equipment may be used. The effective depth of penetration and sound beam divergency
shall be demonstrated to the Contracting Officer.
1.2.4 Wave Types: The types of waves and the conditions under which they shall be used
are specified below:
1.2.4.1 Shear waves shall be used unless conditions prohibit their use. A longitudinal wave
procedure may be used instead, if approved by the Contracting Officer. Refracted waves
between 40 degrees and 70 degrees shall be used except where different angles are
indicated in approved procedures, such as for materials less than 1/2-inch thick, for materials
with sound velocities greater than in steel, when the weldments are not readily accessible,
or when existing backing rings or backing strips are not removed.
For inspection of
weldments containing backing rings or backing strips, the instrument shall be adjusted and
the refracted angles shall be selected in a way to separate the weldment and the backing ring
reflections. The search unit angle and the resulting shear wave angle in the material to be
inspected shall be established by the Contractor for each application and this information
shall be included in the procedure submitted for approval.
1.2.4.2 Longitudinal waves may be used when conditions prohibit the use of shear waves.
The procedure shall be specially developed to suit the application and shall have the prior
approval of the Contracting Officer.
1.2.5 Changes in Procedure: Should application of an approved procedure not provide for
good resolution or adequate ultrasonic penetration in the items to be inspected (see
paragraph EQUIPMENT QUALIFICATION REQUIREMENTS), changes in procedure or
equipment such as frequency, pulse repetition rate, angle of search unit, couplant, or
oscilloscope shall be made by the Contractor. Adequacy of the new procedure shall be
demonstrated to the Contracting Officer. The Government reserves the right to require a
change in test equipment during these tests if any of the following test system characteristics
fall below the levels listed in paragraph EQUIPMENT QUALIFICATION REQUIREMENTS:
sensitivity, amplitude and distance linearity, signal-to-noise ratio, entry and back surface
resolution and penetration.

1.3 SUBMITTALS
The following shall be submitted in accordance with SECTION 01300 - SUBMITTALS:
SD-39, Qualifications of Inspectors
Provide names of persons to perform ultrasonic inspection of weldments along with
certification that each person meets the minimum qualifications specified under paragraph
2.1.
SD-62, Work Plan
Provide detailed procedures to be employee for the ultrasonic inspection of weldments
required by the contract documents.

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SD-91, Records of Identification and Inspection of Weldments

Identify all welds requiring ultrasonic inspection in accordance with the requirements of
"Non-Destructive Welding Notes" in structural document S1 series. Provide appropriate
record of all ultrasonic inspections performed indicating acceptance/non-acceptance.
Provide appropriate record of repair for all unacceptable areas. Reports and records shall
conform to the requirements of paragraph 3.5 REPORTS AND RECORDS.

PART 2 - PRODUCTS
2.1 PERSONNEL CLASSIFICATION AND REQUIREMENTS
2.1.1 Personnel Classification: The three levels of responsibility associated with ultrasonic
inspection are defined in MIL-STD-410 as follows:
2.1.1.1 Level I - Special ultrasonic operator for inspecting specific products.
2.1.1.2 Level II - Ultrasonic inspector.
2.1.1.3 Level Ill - Ultrasonic supervisor.
2.1.2 Personnel Qualification: For qualification to perform ultrasonic inspection, personnel
shall show evidence of having satisfactorily worked in accordance with MIL-STD-271, or shall
be certified under NAVSHIPS 0900-006- 3010, or under ASNT SNT-TC-1A, Supplement C
for ultrasonic inspection, within a period of 1 year before the date of contract. Other
qualification or certification may be accepted at the Contracting Officer's discretion.
Personnel with only an operator or inspector trainee certification will not be considered
qualified to pass judgement on the acceptability of inspected items, but may work under the
direct supervision of a qualified ultrasonic inspector. Qualified ultrasonic inspectors shall be
able to judge the acceptability of the item in accordance with paragraph
ACCEPTANCE/REJECTION LIMITS.
2.1.3 Personnel Certification: Personnel not qualified as noted in paragraph PERSONNEL
CLASSIFICATION AND REQUIREMENTS may be certified by meeting the requirements of
MIL-STD-410 for the particular level at which they are to operate in fulfilling the terms of the
contract.
2.1.4 Examinations: If the Contracting Officer doubts an individual's ability as an operator,
inspector, or supervisor, the individual shall be recertified in accordance with MIL-STD-410.
At the option of the Government, the Contracting Officer may participate in administering the
examination and in evaluating of the results.
2.2
REFERENCE STANDARDS FOR EQUIPMENT, QUALIFICATIONS,
CALIBRATION

AND

Reference standards shall be used to calibrate the inspection equipment, test its operating
conditions and record the sensitivity or response of the equipment during the inspection in
accordance with paragraph EQUIPMENT QUALIFICATION REQUIREMENTS. The
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standards shall comprise a standard reference block and reference specimens as noted
below.
2.2.1 Standard Reference Block: The standard reference block or primary standard shall
be provided by the Contractor and shall consist of the llW block in AWS D1 .1, section
Inspection, subsection Reference Standards. The standard reference block also shall be
used in any reinspection on the same basis as the original inspection, even though the
reinspection is to be performed by other ultrasonic instruments and accessories.
2.2.2 Working Standards: The Contractor may use other recognized working standards
detailed with the llW block in AWS D1 .1 such as the Sensitivity Calibration (SC) block.
However, such blocks must be referenced to the llW block as noted in paragraph
SENSITIVITY CALIBRATION OF LONGITUDINAL AND ANGLE WAVE SYSTEMS. Details
of their use must be included in the procedure description submitted to the Contracting
Officer. These blocks are the secondary standards. They shall be of acoustically similar
material to the welds to be inspected. The secondary standards shall be suited for the
applicable tests specified in paragraph EQUIPMENT QUALIFICATION REQUIREMENTS
and shall be used as follows, except where the llW block is specifically required:
a. To assure adequate penetration of the base material.
b. To provide a secondary field standard.
c. To calibrate the equipment and establish the standard reference level.
2.2.3
Resolution Test Block: The Contractor shall furnish a resolution test block in
accordance with the details shown in AWS D1 .1 section Inspection, subsection Ultrasonic
Equipment.

2.3 EQUIPMENT QUALIFICATION REQUIREMENTS

The ultrasonic instrument and accessories shall be evaluated on their arrival at the shop
and/or jobsite just before the start of inspection. They shall be evaluated using the
Contractor's furnished primary standard and shall meet or exceed the requirements listed in
paragraph EQUIPMENT QUALIFICATION REQUIREMENTS. Equipment that does not meet
these requirements shall not be used in the inspection.
2.3.1 Requalifications: The equipment shall be requalified after normal use at intervals not
to exceed 40 hours except as noted. The equipment also shall be requalified immediately
after maintenance or repair or when the Contracting Officer considers its operation
questionable.
2.3.2 Longitudinal Wave System:
2.3.2.1 Vertical Amplitude Linearity: Two adjacent reflections of different amplitudes
obtained through the thickness of the primary or secondary standard shall vary in the same
proportion as the amplitude of the first reflection is increased in descrete 2~dB increments
between 20 percent and 80 percent to full screen height. For each gain setting, the amplitude
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of each reflection shall vary by the same factor within plus or minus 5 percent.
Requalification is required monthly or as otherwise stated in paragraph EQUIPMENT
QUALIFICATION REQUIREMENTS.
2.3.2.2
Horizontal Linearity: The first three multiple reflections obtained through the
thickness of the primary or secondary standard shall be equally spaced within plus or minus
5 percent when spread over 90 percent of the sweep length. Requalification is required
monthly
or as otherwise
stated
in paragraph
EQUIPMENT
QUALIFICATION
REQUIREMENTS.
2.3.2.3 Near-Surface Resolution: Excessive ringing that appears on the CRT to the right of
the sound entry point is not to exceed a 1/2-inch equivalent distance in steel with the search
unit placed on the 4-inch edge of the llW (primary) block and positioned for maximum
amplitude reflection from the .06- inch reference hole of the primary standard. The reference
reflector shall be set to mid-screen and the gain shall be increased 20 dB. The reference
hole located at least 1/2-inch from one edge of the AW DSC or SC secondary standard shall
be used similarly. Acceptability shall be on the same basis as in the primary standard.
2.3.2.4 Far-Surface Resolution: This property of the equipment will be verified by the method
detailed in AWS D1 .1 section Inspection, subsection Calibration of the Ultrasonic Unit with
the llW or Other Approved Calibration Blocks. In addition, the trailing edge of the third
reflection shall return to the sweep line and be clearly discernible.
2.3.3

Angle Wave System:

2.3.3.1
Vertical (Amplitude) Linearity: Two adjacent multiple reflections from the .06-inch
reference hole in the primary standard shall vary in the same proportion as the amplitude of
the first reflection in discrete 2-dB increments between 20 percent and 80 percent of full
screen height. For each gain setting, the amplitude of each adjacent reflection shall vary
within plus or minus 5 percent. For testing with the AWS SC or DSC secondary standard,
the same criteria shall apply. For the SC block, the transducer shall be placed on the
longitudinal surface contiguous with the sound entry point lines whereas the 4-inch
longitudinal surface of the DSC block shall be used for the same purpose. Requalification
is required monthly or as otherwise stated in paragraph EQUIPMENT QUALIFICATION
REQUIREMENTS.
2.3.3.2
Horizontal Linearity: The first three multiple echoes obtained from the .06-inch
reference hole of the primary standard or from the reference hole in a secondary standard
with the transducer positioned at a minimum of 1-inch sound path distance shall be equally
spaced plus or minus 5 percent when spread over 90 percent of the sweep length. The gain
shall be adjusted to give a mid-screen height first reflection. Requalification is required
monthly
or as otherwise
stated in paragraph
EQUIPMENT
QUALIFICATION
REQUIREMENTS.
2.3.3.3
Near-Surface Resolution:
The search unit shall be positioned for maximum
amplitude using the primary or secondary standard as in the horizontal linearity test. The gain
shall be adjusted to give a mid-screen height first reflection and then shall be increased 20

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dB. Excessive ringing that appears on the CRT to the right of the sound entry point is not to
exceed 1/2-inch equivalent distance in steel.
2.3.3.4 Far-Surface Resolution: The equipment shall delineate the three resolution holes in
the resolution block appropriate for the angle of the transducer to be used in the inspection.
2.3.3.5 Signal-to-Noise Ratio: With the search unit located as in the horizontal linearity test,
the gain shall be set to obtain an 80 percent full screen height first reflection. The reference
reflection-to-noise-amplitude
ratio shall not be less than 10 to 1.
2.3.3.6 Exit Point: The search unit shall be placed on the graduated scale on the 12-inch
edge of the primary standard and the ultrasound shall be beamed toward the curved edge
of the block. The gain shall be set for a mid-screen first reflection. The search unit shall be
moved back and forth until the first reflection is maximized. The index line on the side of the
search unit shall be within 1/16-inch of the mid-point of the graduated scale in either direction.
Requalification is required after 40 hours or as otherwise stated in paragraph EQUIPMENT
QUALIFICATION REQUIREMENTS.
2.3.3.7 Transducer Angle: The established exit point of the probe shall be set over the
applicable angle index line scribed on the 8-inch or 12-inch edge, as appropriate, of the
primary standard. The gain shall be set to obtain a mid-screen first reflection from the 50 mm
plexiglass-lined hole for search units up to 70 percent with the search unit placed on the
8-inch edge. Search units of large angles that have been approved specifically by the
Contracting Officer shall be tested from the 12-inch edge using the .06-inch reference hole.
The search unit shall be moved back and forth to maximize the first reflection. When the
material to be inspected is not acoustically similar to the primary standard, the inspection
angle shall be within plus or minus 2 degrees of the angle specified in the approved
procedure. Requalification is required after 40 hours or as otherwise stated in paragraph
EQUIPMENT QUALIFICATION REQUIREMENTS.

2.4 SENSITIVITY CALIBRATION OF LONGITUDINAL AND ANGLE WAVE SYSTEMS

Sensitivity calibration shall be done immediately after a change of operators and at least
every 30 minutes thereafter as testing proceeds. Recalibration shall also be required after
any power interruption, including a change of source, when the equipment is suspected of
being in error, or after relocation of the jobsite. The 30-minute and relocation calibrations
may coincide. Before calibration, the instrument shall be allowed to warm up before
calibration is attempted. The instrument range and delay controls shall be adjusted to display
signals from the reference hole in the primary (llW block) or secondary standard (DSC or SC
block or both) on the viewing screen for the range of distances to be inspected.
2.4.1 Calibration Procedure: The test instrument shall be calibrated as described below.
2.4.1.1 Longitudinal Wave System: In calibrating with the primary standard, the transducer
shall be positioned on the 4-inch edge for maximum reflection from the .06-inch reference
hole. The gain shall be adjusted so that the first reflection is at 50 percent full scale. The top
of that indication shall be marked on the CRT with a wax pencil or by other means. This
establishes the standard reference level. A point at 80 percent of the standard reference
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level shall be calculated and marked. This locates the reject/repair line. If a secondary
standard is to be used in the inspection, the reject/repair line will be established similarly. For
the DSC block, the transducer shall be positioned on the 4-inch long surface and with the SC
degrees sound entry point lines. Adjustment for loss of signal due to distance shall be
compensated for as noted in paragraph SENSITIVITY CALIBRATION OF LONGITUDINAL
AND ANGLE WAVE SYSTEMS.
2.4.1.2 Angle Wave System: In calibrating with either the primary or secondary standard,
the transducer shall be positioned on the same surfaces as in the case of the longitudinal
wave system but over the sound entry point lines appropriate for the angle of the transducer
to be used in the inspection. The gain shall be adjusted to give a first reflection that is 50
percent of full-scale response. The top of that indication shall be marked with a wax pencil
or by other means. This establishes the standard reference level. A point at 80 percent of
the standard reference level shall be calculated and marked. This locates the reject/repair
line.
Loss of signal shall be compensated as noted in paragraph SENSITIVITY
CALIBRATION OF LONGITUDINAL AND ANGLE WAVE SYSTEM.
2.4.2 Calibration of the Secondary Standards: After adjusting the first reflection from the
reference hole in the secondary standard to 50 percent full-scale response for a sheer or
longitudinal wave inspection, a maximized reflection from the .06-inch reference hole in the
primary standard shall be obtained without changing the gain setting. Then this gain setting
shall be readjusted to obtain a 50 percent full-scale reflection and the readjusted setting shall
be recorded as required by paragraph REPORTS AND RECORDS to provide a basis for
recalibration when the secondary standard is unavailable.
2.4.3 Equipment With a Calibrated Gain Control (Attenuator): When a calibrated gain control
attenuator is used, the transducer shall be positioned for a maximum reflection from the
reference hole in the secondary standard representing approximately 1/2 the longest
inspection distance. This reflection shall be adjusted to mid-scale by varying the gain control
accordingly. The difference in decibels between this amplitude and the signal obtained from
the first, second, and longest distance reflection obtainable on the secondary standard shall
be measured. The differences shall be recorded and plotted on a curve to determine the
necessary correction to the amplitude at the various inspection distances. A level (80 percent
of the primary level) obtained from the corrected signal heights is equivalent to the
reject/repair line.
2.4.4 Equipment With Electronic Distance Compensation Circuitry: If the difference in
amplitude between the first reflection and the reflection obtained from the maximum
inspection distance is 1 dB or less, the instrument may be used as is. If not, the procedure
used for equipment with a calibrated decibel control must be used to determine the necessary
correction to the reflections obtained at the various inspection distances. This characteristic
of the equipment must be reexamined on a monthly basis or as otherwise stated in paragraph
REQUALIFICATION, and correction factors must be modified accordingly.
2.4.5 Longitudinal Wave Distance-Amplitude Correction Curve: A distance- amplitude
correction curve may be used instead of the calibrated gain control or the electronic circuitry
for either the shear or longitudinal wave system as described below.

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2.4.5.1 A shear wave distance-amplitude correction curve shall be constructed and drawn
on the face of the cathode ray tube (CRT) for inspection of weldments in excess of 1-1/2 inch
thick when the design of the test equipment permits. The reference hole in the secondary
standard [SC] [or DSC] shall be used to construct the distance-amplitude correction curve
for a minimum of three node points, 1, 2, and 3. The sensitivity of the instrument shall be
adjusted to produce 50 percent full-scale response for the maximized primary reflection and
the reject/repair line shall be constructed at 80 percent of the established distance-amplitude
curve.
2.4.5.2 A longitudinal wave distance-amplitude correction curve shall be constructed and
drawn on the face of the CRT when longitudinal waves are to be used in the inspection for
material thicknesses exceeding 1 inch, if design of the test equipment permits.
The
reference hole in the secondary standard shall be used. Instrument sensitivity shall be
adjusted to 50 percent full- scale of the maximized response from the reference hole at
1/2-maximum inspection distance. A reject/repair line shall be constructed at 80 percent of
the established distance-amplitude curve. The reflection amplitudes to define this curve shall
be taken from the faces of the secondary sensitivity standards which are 1-inch, 2-inch and
1/2-maximum inspection distance, and the longest distance obtainable from the secondary
standard, respectively, from the reference hole. When a correction curve cannot be drawn
on the face of the CRT, one of the distance-amplitude correction methods noted above and
submitted under the procedure description in accordance with paragraph GENERAL
REQUIREMENTS shall be applied.
2.4.6 Longitudinal Wave Inspections Using Immersion Technique: The reference hole in a
secondary standard shall be used for each different inspection distance. Repair/reject limits
shall be established by immersing both the search unit and secondary standard in the liquid
bath in which the inspection is to be conducted. The procedure noted below shall be used.
2.4.6.1 The longitudinal waves from the search unit shall be directed toward the face of the
secondary standard closest to the reference hole.
2.4.6.2
The search unit shall be positioned for maximum response. The amplitude of
reflection shall be adjusted to 50 percent full-scale. The top of that indication shall be marked
on the CRT with a wax pencil or by other means. This establishes the standard reference
level. A point at 80 percent of the standard reference level shall be calculated and marked.
This locates the reject/repair point. The above shall be repeated for each different
surface-to-hole distance to establish the reject/repair point. The above shall be repeated for
each different surface-to-hole distance to establish the reject/repair line.
2.4.6.3 With the gain at the same setting and the primary standard and search unit in air, a
maximized reflection shall be obtained from the .06-inch reference hole in the primary
standard (llW). Then, this gain setting shall be readjusted to obtain a 50 percent full-scale
reflection. The readjusted setting shall be recorded as required by paragraph REPORTS
AND RECORDS to provide a basis for recalibration when the secondary standard is
unavailable.

PART 3 - EXECUTION

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3.1 PREPARATION

OF MATERIALS FOR INSPECTION

Surfaces shall be free from the following:

3.1.1 Weld Spatter: Spattering or any roughness that interferes with free movement of the
search unit or impairs transmission of the ultrasonic vibrations.
3.1.2 Irregularities: Those which could mask or be confused with defect indications.
3.1.3 Weld Backing Strips: Strips that are not to remain in place shall be removed and all
sharp edges and valleys shall be eliminated by grinding or other mechanical means.
3.1.4 Dirt: All loose scale, rust, paint, and dirt shall be removed from the coupling surface.
3.2 INSPECTION PROCEDURE
When possible, all welds shall be examined from both sides of the weld and from one
surface. If complete inspection cannot be accomplished from one surface, inspection shall
be made from another surface that is part of the same joint. Preliminary scanning techniques
using an increased instrument gain shall be used to locate possible defects. When possible,
gain shall be increased to a minimum of twice (6 dB) the reference level setting. Final
acceptance or rejection shall be evaluated with the equipment properly calibrated and the
gain control set at the reference level. The reject/repair line shall be used to evaluate quality
of the weld. If a periodic calibration check shows that the equipment is not operating properly
or that the system's sensitivity has decreased more than 20 percent (2 dB) from the
established sensitivity level, all welds inspected since the prior calibration shall be
reexamined. If penetration of the shear waves is questionable, the angle search unit shall
be placed in position on one side of the weldment with the waves directed through the
weldment. A disconnected angle search unit, plastic or metal wedge or disk, or any good
reflector shall be placed in the wave path of the search unit on the far side of the weld to
reflect the sound. When good reflections cannot be obtained by either shear or longitudinal
waves, the Contractor shall modify the procedures in accordance with paragraph GENERAL
REQUIREMENTS.
3.2.1 Couplants: The choice of couplant is optional with the Contractor except as follows:
3.2.1.1 The couplant shall be the same as that used for equipment qualification and
calibration.
3.2.1.2 Couplants that may corrode the reference standards and material being tested or
leave objectionable residues shall not be used.
3.2.1.3 Couplants shall be of the proper viscosity to give good coupling for the surface
roughness.
3.2.2 Shear Wave Inspection: Shear wave inspection shall be performed as follows:

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3.2.2.1 The search unit shall be placed on the contact surface at a distance from the weld
equal to that used when calibrating the equipment.
3.2.2.2 To detect longitudinal flaws, the search unit shall be slowly moved toward and away
from the weld far enough to cover its entire cross section, approximately 90 degrees to the
weld centerline. The search unit shall be radially oscillated to the left and right, covering an
angle of approximately 30 degrees. During the foregoing movement, the search unit shall
be continually advanced parallel to the weld centerline. The rate of movement shall depend
on the operator's ability to clearly see and identify all reflections. The amount of movement
shall be calculated to insure that the inspection distance will be great enough to traverse the
weld. [For plate thicknesses 2 inches and greater with an unmachined stainless steel overlay
covering the welded joint, the inspection distance shall range from a minimum of one
thickness (T) or the first node back from the near fusion line to a distance exceeding T plus
2/3, the maximum width of the weld deposit at the surface. The inspection shall be repeated
from the other side of the weld on the same surface if accessible or if not, from another
surface that is part of the same joint as indicated above. The surface of the weld metal in the
joint shall be ground smooth and blended with the base metal.
3.2.2.3 To detect transverse flaws when the welded surface is ground flush, the search unit
shall be moved along the weld surface in each direction parallel to the centerline of the weld
metal with the wave radiating parallel to the weld centerline. To detect transverse flaws when
the welded surface is not ground flush, the search unit shall be moved parallel to the weld in
each direction, on the adjacent base metal at the top of the weld, with the wave directed at
an angle of 30 degrees to the weld centerline.
3.2.3 Longitudinal Wave Inspection: This inspection shall be made as follows:
3.2.3.1 The search unit shall be placed on the contact surface with the wave directed in a
straight line through any intervening base metal and through the weldment.
3.2.3.2 The search unit shall then be moved slowly in a direction parallel to the weld
centerline and zigzagged across an area equivalent to the welded thickness to make sure
that waves penetrate the entire welded cross section.
3.2.3.3 The rate of movement shall be dependent on the operator's ability to clearly see and
identify all reflections.

3.3 GENERAL ACCEPTANCE/REJECTION REQUIREMENTS

Discontinuities shall be evaluated only when the ultrasonic equipment is calibrated properly.
If discontinuities are detected, the sound beam shall be directed to maximize the signal
amplitude. To determine the length of a discontinuity, the search unit shall be moved parallel
to the discontinuity axis in both directions from the position of maximum signal amplitude.
One- half the amplitude or a 6-dB increase in sensitivity from a point at which the discontinuity
signal drops rapidly to the baseline shall be defined as the extremity of the discontinuity. At
this point, the scanning surface shall be marked at the position indicated by the center of the
transducer. This shall be repeated to determine the other extremity. The length of the
discontinuity shall be defined as the distance between these two marks. For discontinuities
with signal amplitudes exceeding full screen height, 50 percent of full screen shall be
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considered half-peak amplitude. At this point, the scanning surface shall be marked at the
position indicated by the center of the transducer. This shall be repeated to determine the
other extremity. The length of the discontinuity shall be defined as the distance between
these two marks. The maximum signal amplitude, length, depth, and position within the
inspection zone shall be determined and reported as indicated in paragraph REPORTS AND
RECORDS for discontinuities yielding a signal amplitude equal to or exceeding the
reject/repair line. The minimum recordable length of a discontinuity shall be 1/8-inch. When
evaluating welds joining two members with different thicknesses at the weld, the thickness
T shall be the lesser of the two thicknesses. The criteria for acceptance or rejection based
on ultrasonic inspection will supplement a visual inspection. The sizes and surface conditions
of the welds shall conform to the requirements indicated on the applicable plans and
drawings and other sections of the specification.
3.3.1 Inspection of Repairs: All repairs shall undergo the same inspection procedure that
originally revealed the discontinuities. Before acceptance, the welds shall meet the standards
required for the original weld.

3.4 ACCEPTANCE/REJECTION LIMITS

Welds shall be accepted or rejected by ultrasonic indication in accordance with the following:
3.4.1 Partial or full Penetration Butt Welds and/or Groove Welds:
3.4.1.1

Class Ill: Welds shall be rejected on the basis of the following:

3.4.1.1.1 Any discontinuity with a reflection exceeding the established reject/repair line and
with a length exceeding 1/2-inch. Adjacent discontinuities separated by sound metal with a
dimension less than twice the length of the longest discontinuity shall be considered a single
discontinuity.
3.4.1.1.2 Any discontinuity with a reflection equal to or exceeding 50 percent of the
reject/repair line or with the level 8 dB more than the reject/repair line or with the level 8 dB
more than the reject/repair line and with a length (L) exceeding 2 inches or LT, whichever is
greater.
3.4.1.1.3 If the total cumulative length of discontinuities in any 12 inches of weld length
exceeds 3 inches or 2 T, whichever is greater, that weld length shall be rejected.
3.5 REPORTS AND RECORDS
Reports containing the following information shall be submitted to the Contracting Officer:
3.5.1 Identification and Location of Inspected Item: Name and place of the inspected item,
the person performing the inspection, and the date of inspection.
3.5.2
Detail of Inspections: Details of methods, types of waves used, search units,
frequencies, inspection equipment identification,and calibration data with enough information
to permit duplication of the inspection at a later date.
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3.5.3 Response in Calibration: The response from the DSC or SC block used in calibration
and for acceptance/rejection in terms of the response from the .06-inch reference hole in the
standard llW block (primary standard).
3.5.4 Identification of Unacceptable Areas: Locations, dimensions, types, and area of
unacceptable defects and discontinuities giving reflections over 50 percent of the reject/repair
line. These may be noted on a sketch or marked-up drawing.
3.5.5 Record of Repair Areas:
results for the repaired areas.

A record of repaired areas shall be furnished as well as test

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SECTION 05120 - STRUCTURAL STEEL

PART 1 - GENERAL

1.1 REFERENCES
The publications listed below form a part of this specification to the extentreferenced. The
publications are referred to in the text by basic designation only.
AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC) PUBLICATIONS:
AISC-01(Sep. 1, 1986, with Commentary) Code of Standard Practice for Steel Buildings and
Bridges.
AISC-02(Jun. 1, 1989, with Commentary) Specification for the Design, Fabrication and
Erection of Structural Steel for Buildings.
AISC-03(Nov. 13, 1985) Specification for Structural Joints Using ASTM A 325 or A 490 Bolts.
AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI):
ANSI B18.22.1(1965; R 1981) Plain Washers.
ANSI B46.1(1985) Surface Texture (Surface Roughness, Waviness and Lay).
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) PUBLICATIONS:
ASTM A 6(1989) General Requirements for Rolled Steel Plates, Shapes, Sheet Piling, and
Bars for Structural Use.
ASTM A 36(1989) Structural Steel.
ASTM A 53(1989a) Pipe, Steel, Black and Hot-Dipped, Zinc-Coated Welded and Seamless.
ASTM A 123(1989a) Zinc (Hot Galvanized) Coatings on Products.
ASTM A 153(1982; Revised 1987) Zinc Coating (Hot-Dip) on Iron and Steel.
ASTM A 307(1989) Carbon Steel Bolts and Studs, 60,000 psi, Tensile Strength.
ASTM A 325(1989) High-Strength Bolts for Structural Steel Joints.
ASTM A 490(1989) Heat Treated Steel Structural Bolts,
150 ksi Minimum Tensile Strength

141

ASTM A 500(1989) Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in
Rounds and Shapes.
ASTM A 501(1989) Hot-Formed Welded and Seamless Carbon Steel Structural Tubing.
ASTM A 108(1989) Steel Bars (Shear-Connectors
Standard Quality.
ASTM A 563(1989a) Carbon and Alloy Steel Nuts.
ASTM A 572(1988b)
Quality.

High-Strength

and Headed Studs), Cold Finished,

Low-Alloy Columbium-Vanadium

Steels of Structural

ASTM F 436(1989) Specification for Hardened Steel Washers.

ASTM F 959(1989a) Compressible-Washer-Type
Structural Fasteners.

Direct Tension Indicators For Use with

AMERICAN WELDING SOCIETY (AWS) PUBLICATION:

AWS A5.1 (1981) Specification
Adopted.

for Covered Carbon Steel Arc Welding

Electrodes;

DOD

AWS A5.5(1981) Specification for Low Alloy Steel Covered Arc Welding Electrodes; DOD
Adopted.
AWS D1.1(1988) Structural Welding Code -Steel.
FEDERAL SPECIFICATIONS
FS TT-P-86d(Rev.

H) Paint, Red-Lead-Base,

STEEL STRUCTURES
SSPC-SP3(1982)

(FS):
Ready-Mixed.

PAINTING COUNCIL (SSPC):

Power Tool Cleaning

1.2 GENERAL REQUIREMENTS

The AISC-02 shall govern the work. Welding shall be in accordance with AWS D1 .1.
High-strength bolting shall be in accordance with the AISC-03. Paragraph 4.2.1 of AISC-01
is hereby modified by deletion of the following sentence: "This approval constitutes the
Owner's acceptance of all responsibility for the design adequacy of any detail configuration
of connections .... ".

1.3 SUBMITTALS
The following shall be submitted in accordance with SECTION 01300 - SUBMITTALS:
SD-10, Design Analysis and Calculations
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All members and non-standard connections for any portion of the structure not shown on the
Contract Drawings shall be designed by the Fabricator and the calculations shall be
submitted with the Shop Drawings. Non-standard connections are those connections that
require analysis and are not readily
selected from AISC Tables or other applicable publications.
Examples are moment
connections, connections with axial and/or horizontal shear loads, and connections with "X"
bracing. Calculations shall be sealed by a professional engineer, registered in the state of
Texas.
SD-31, Detail Drawings
Detail drawings shall include all shop and erection details. Members and connections for any
portion of the structure not shown on the contract drawings shall be detailed by the fabricator
and indicated on the detail
drawings. All welds shall be indicated by standard welding symbols of the AWS D1 .1. Shear
connector diagrams and arrangements shall be detailed by the fabricator and indicated on
the detail drawings. Reproduction of the Contract Documents in any manner for use as detail
drawings will not be allowed.
SD-62, Work Plan
Prior to erection, an erection plan of the structural steel framing is required. This erection
plan shall conform to the requirements of the AISC-01. The erection plan shall describe all
necessary temporary supports, including the sequence of installation and removal. Work
plan shall include a section covering provisions to be taken to address steel erection safety
and accident prevention provisions to be employed in the work. This work plan shall be
submitted a minimum of 60 days prior to start of steel erection.
SD-70, Test Reports/Certificates
Certified copies of mill test reports for structural steel and other related structural steel items
are required. Test certificates shall be furnished for bolts, nuts, washers, and direct tension
indicators with each and every lot supplied. Certificates shall show tensile strength and
hardness for bolts, hardness and proof load test for nuts, and hardness test for washers. For
direct tension indicators, a minimum of eight tests per lot shipped to either fabricator or
jobsite shall be performed by an independent commercial testing laboratory to demonstrate
proper load measuring characteristics per ASTM F959. When directed by the Contracting
Officer random chemical and physical tests shall be made on the bolts, nuts, washers, and
direct tension indicators in accordance with ASTM procedures.
SD-76, Certificates of Compliance
Certification that each welder is qualified in accordance with AWS 01 .1
Certification that shop primer paint meets or exceeds this specification
The fabricator of the structural steel shall be currently certified under
Certification Program, Category II. A copy of the AISC Certification shall
to fabrication.

143

shall be provided.
shall be provided.
the AISC Quality
be submitted prior

SD-91, Records
Letters of record expressing Contractor and Contracting Officer communications and records
of steel elevations prior to and after the completion of concreting operations.

1.4 STORAGE
Material shall be stored out of contact with the ground in such manner and location as will
minimize deterioration.
1.5 RESPONSIBILITY FOR ERRORS
The Contractor shall be responsible for all errors of detailing, fabricating, and for the correct
fitting of the structural members.

PART 2 - PRODUCTS
2.1 STRUCTURAL STEEL
2.1.1 Carbon Grade Steel: Carbon grade steel shall conform to ASTM A 36.
2.1.2 High-Strength Low-Alloy Steel: High-strength low-alloy steel shall conform to ASTM
A 572, Grade 50.
2.2 STRUCTURAL TUBING
Structural tubing shall conform to ASTM A 500, Grade 8.

2.3 STEEL PIPE

Steel pipe shall conform to ASTM A 501 or A53, Type E or S.
2.4 WELDING ELECTRODES
Welding electrodes shall conform to AWS A5.1 and AWS A5.5.

2.5 HIGH-STRENGTH BOLTS

High-strength bolts shall typically conform to ASTM A 325 Type 1 and shall be domestically
manufactured. Use bearing type bolts at standard shear connections and friction type bolts
at all slip critical connections indicated in the drawings. High-strength bolts conforming to
ASTM A490 are acceptable at connections where their use will improve joint detailing.
2.6 CARBON STEEL BOLTS
Carbon steel bolts at base plate connections shall conform to ASTM A 307, Grade A
144

2.7 CARBON STEEL NUTS

Carbon steel nuts shall conform to ASTM A 563, Grade A, Heavy Hex Style, and shall
indicate manufacturer's mark and the relevant nut type symbol.

2.8 WASHERS
Washers shall conform to ASTM F 436 and shall indicate manufacturer's mark.
2.9 PAINT - (SHOP PRIMER)
Paint shall conform to FS TT-P-86d, Type I or II. Paint shall be tested and certified to
produce no significant difference in strength of welds in accordance with allowable design
loads from the American Welding Society's Structural Welding Code 01 .1-88. Surface
preparation shall conform to SSPC-SP3 power tool cleaning. The following product is
referenced to establish quality and type. Products of other manufacturers may be submitted
with supporting test data showing performance characteristics which meet or exceed the
standards herein:
10-1009 Tnemec Primer (One Coat, Gray) (Solids by volume= 55+ 2%) (Dry film thickness
= 2.5 - 3.5 mils)
2.10 DIRECT TENSION INDICATORS
Direct tension indicators shall meet the requirements of ASTM F959 and shall be
domestically manufactured. Provide DTl's at all slip critical connections indicated in the
drawings.
2.11 SHEAR CONNECTORS
Studs shall be of suitable design for arc welding to steel members with the use of
automatically timed stud welding equipment. Type and size as indicated in the drawings,
consisting of cold drawn bar stock conforming to the requirements of ASTM A 108 and AWS
01.1.
2.12 GALVANIZED BEAMS
Shall be in accordance with ASTM A 123.
PART 3 - EXECUTION
3.1 FABRICATION
Fabrication shall be in accordance with the applicable provisions of the AISC-02. Fabrication
and assembly shall be done in the shop to the greatest extent possible. Compression joints
depending on contact bearing shall have a surface roughness not in excess of 500 micro
inches as determined by ANSI 846.1, and ends shall be square within the tolerance for milled
145

ends specified in ASTM A6. Structural steelwork, except surfaces to be fireproofed, top
flanges of beams to receive shear connectors, surfaces to be field welded, surfaces to
receive metal deck welded attachment, and contact surfaces of friction-type high-strength
bolted connections shall be prepared for painting and primed with the specified paint. All
surfaces to be fireproofed shall receive surface preparation same as required for painted
steelwork, whether required to be painted or not.

3.1.1 Fabrication Camber Recording: Measure and record the camber of all primary beams
and girders in a manner which will allow that information to be compared to the as-erected
condition of beams and girders. Attach this list of recorded cambers to the Shop Inspection
Reports.

3.2 ERECTION
Erection of structural steel shall be in accordance with the applicable provisions of the
AISC-02.
3.2.1 Base Plate Connections: Anchor bolts and other connections between the structural
steel and foundations shall be provided and shall be properly located and built into connecting
work. Use ASTM A307 bolts.
3.2.2 Base Plates and Connection Plates to Concrete: Column base plates for columns and
connection plates for beams, girders, and similar members shall be provided. Base plates
shall be provided with full bearing after the supported members have been plumbed and
properly positioned, but prior to placing superimposed loads. Separate setting plates under
column base plates will not be permitted. Tolerance on elevation of column base plates
relative to design grade shall be 1/8 inch. The area under the plate shall be grouted solidly
with non-shrink grout. Grout shall be as specified in SECTION 03300 - CONCRETE FOR
BUILDING CONSTRUCTION.
3.2.3 Field Welded Connections: Field welded structural connections shall be completed
before load is applied.
3.2.4 Beam to Beam and Beam to Column Connections: Standard shear connections shall
utilize bearing-type bolts with threads allowed across the shear plane (Type N). Moment
connections and torsional restraint connections shall be as indicated in the structural
drawings.
3.2.5 Bearing-Type Bolt Tightening: Standard shear connections utilizing bearing-type bolts
need only be tightened to the snug tight condition. This is the tightness that exists when all
the plies in a joint are in firm contact, generally achieved by a few impacts of an impact
wrench or the full effort of a man using an ordinary spud wrench.
3.2.6 Slip-Critical Connections: All connections specifically noted in the drawings as
slip-critical shall utilize friction-type bolts (Type F) with Direct Tension Indicators. All bolts
used in moment connections shall be considered as slip-critical fasteners and shall receive
Direct Tension Indicators.
146

3.2. 7 Shear Connector Welding: All areas to which studs are to be attached must be free
of all foreign material, such as rust, oil, grease, paint, etc. When the mill scale is sufficiently
thick to cause difficulty in obtaining proper welds, it must be removed by grinding or
sandblasting. Ceramic ferrules used in stud welding process shall be completely removed
from area where concrete is to be placed. Stud welding shall conform to the requirements
of AWS 01.1.
3.2.8
Field Priming: After erection, the field bolt heads and nuts, field welds, other steel
surfaces which do not receive fireproofing that have not been shop primed, and any
abrasions in the shop coat shall be cleaned and primed with paint of the same quality as that
used for the shop coat.
3.2.9 Fireproofing: After erection, apply fireproofing at required locations in accordance with
SECTION 07265 - SPRAY APPLIED FIREPROOFING.

3.3 STRUCTURAL STEEL ELEVATIONS

At initial composite steel framing areas, (defined under paragraph 1.8.1 of SECTION 03300
- CONCRETE FOR BUILDING CONSTRUCTION), record top of steel elevations at each end
and at midspan of members prior to and after the completion of concreting operations.
Readings shall be taken from below the steel members. Locations of readings shall be
marked in a manner which will allow subsequent elevations to be taken at the same points.
These data shall be provided to the Floor Consultant and Contracting Officer for evaluation.
3.4 ERECTION TOLERANCES
Each individual member shall be erected, plumbed, leveled and aligned within the tolerance
defined in Sec. 7.11 and Commentary of the AISC Code of Standard Practice, except as
noted. The top surface of closure angles/plates at the building perimeter and at openings
shall be within 1/4" of their proper location prior to commencement of concreting operations.
Where this condition is not satisfied, 18 gage plate shall be attached to the angles/plates in
manner sufficient to serve as a guide for strikeoff of the concrete floor surface. The top
surface of steel beams and girders at connections to columns shall be within 3/8" of grade
required by the contract documents prior to commencement of conreting operations. The
Contractor shall record and submit this data to the Floor Consultant and Contracting Officer
for evaluation prior to placement of concrete.

3.5 TEMPORARY BRACED FRAMES

3.5.1 Temporary braced frames shall be installed in Building B as indicated by detail
S17.10/04. Fabricate and install bracing members in a manner that facilitates subsequent
removal of these members.
3.5.2 Installation of temporary bracing shall proceed ahead of concrete floor placement.
Temporary bracing shall not be interpreted as miscellaneous bracing (guy wires, etc ... ) that
may be required to erect the structure.

147

3.5.3 Remove all temporary bracing members after temporary slab leave-out strips have
been filled in with concrete and has achieved
= 3000 p.s.i. strength. Refer to SECTION

re

03300, paragraph 3.15 for information regarding temporary slab leave-out strips.
3.5.4 Temporary bracing members do not require application of cementitious fire proofing,
or prime paint.

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148

STRUCTURAL

STEEL GENERAL NOTES

Welding Notes

1. Welded construction shall conform to the American Welding Society "Structural Welding
Code" - AWS 01 .1, AWS 01 .3 - Sheet Steel , and AWS 01 .4 - Reinforcing Steel.
2. When welds are not called out on the drawings, they are minimum size continuous fillet
welds in accordance with AWS 01 .1. Fillet welds not specified as to length shall be
continuous.
3. Unless noted otherwise on the drawings, all groove welds shall be full-penetration.
4. Only low-hydrogen electrodes shall be used on ASTM A572 Grade 50 and reinforcing
steel.
5. Field welds shall receive touch-up galvanizing (or prime paint) to match finish of base
material.
Non-destructiveWeldingNotes
1. All shop and field welds shall be visually inspected for size, length, and quality in
accordance with AWS 01 .1, section 8.15.1. Welds considered suspect shall be recorded
and shall be further examined by ultrasonic testing. Welds not meeting acceptance criteria
when examined by ultrasound shall be repaired.
2. 25% of all column splice groove welds shall be inspected at random, in the field, by
ultrasonic testing in accordance with AWS 01 .1, Section 8.15.3. For each connection that
fails the UT inspection, an additional connection shall be inspected by UT.
3. Pre-production weld testing of shear connector studs shall conform to AWS 01 .1, Section

7.7.
4. All shear connector studs shall be inspected in accordance with AWS 01 .1.
5. All metal deck welds to supporting members shall be visually inspected for quality,
location, and size to verify complete penetration through deck layers, good fusion to
supporting members, and compliance with drawings. Welds shall be evaluated based on
AWS 01.3, section 4.5. Welder qualifications and procedures shall meet AWS 01.3
requirements.
6. All field welded moment connections shall be inspected by ultrasonic testing in
accordance with AWS 01 .1, Section 8.15.3. All connections that fail the UT inspection shall
be retested after corrections have been made.

149

BIBLIOGRAPHY

American Institute of Steel Construction (AISC). 1989. Code of Standard Practice for Steel
Buildings and Bridges (AISC-01). In Manual of Steel Construction: Allowable Stress
Design, 5-223 - 5-261. Chicago: American Institute of Steel Construction.
____

. 1989. Manual of Steel Construction:Allowable Stress Design. 9th ed. Chicago:

American Institute of Steel Construction.

____

. 1989. Specification for Structural Steel Buildings: Allowable Stress Design and
Plastic Design with Commentary (AISC-02). In Manual of Steel Construction:
Allowable Stress Design, 5-11 - 5-220. Chicago: American Institute of Steel
Construction.

American Society of Civil Engineers (ASCE). 1990. ASCE 7-88: Minimum Design Loads for
Buildings and Other Structures. New York: American Society of Civil Engineers.
American Society for Nondestructive Testing (ASNT). 1984. Recommended Practice No.
SNT-TC-1A: Personnel Qualification and Certification in Nondestructive Testing.
Columbus, Ohio: American Society for Nondestructive Testing.
American Welding Society (AWS). 1981. AWS AS.1- 81: Specification for Covered Carbon
Steel Arc Welding Electrodes. Miami: American Welding Society.
____

. 1981. AWS AS.5 - 81: Specification for Low Alloy Steel Covered Arc
Welding Electrodes. Miami: American Welding Society.

____

. 1986. AWS B1-10-86: Guide for the Nondestructive Inspection of Welds. 2d

ed. Miami: American Welding Society.

--~~

1988. AWS QC1-G: Guide to AWS Welding Inspector Qualification and

Certification.
Miami: American Welding Society.

____

. 1988. AWS QC-1-88: Standard for AWS Certification of Welding Inspectors.

14th ed. Miami: American Welding Society.

____

. 1992. AWS D1.1- 92: Structural Welding Code- Steel.

American Welding Society.

13th ed. Miami:

International Conference of Building Officials (ICBO). 1991. Uniform Building Code. Whittier,
California: International Conference of Building Officials.
U.S. Army Corps of Engineers, Fort Worth District. 1992. "Resident Engineer's Quality
Assurance Program for the Construction of the New Brooke Army Medical Center
DACA-63-92-C-0050." Robert A. Rowe.

150

VITA

Erik fvaan Moorhead was born in North East, Pennsylvania on November 13, 1961,
the son of Douglas Patterson Moorhead and Marlene Boettcher Moorhead.

After

compfeteing his work at Harbor Creek High School, Harbor Creek, Pennsylvania, in 1979, he
entered The Pennsylvania State University in University Park, Pennsylvania. He received the
degrees of Bachelor of Science and Bachelor of Arts from the Pennsylvania State University
in August, 1984. Until 1987 Mr. Moorhead was employed as an HVAC design engineer by
Hellmuth, Obata and Kassabaum in St. Louis, Missouri. From 1987 through 1993 he was
employed as a structural design engineer by the U.S. Army Corps of Engineers, Seattle
District. In September, 1991, Mr. Moorhead entered the Graduate Schoof at the University
of Texas at Austin under the Corps of Engineers' Mission Related Graduate Studies Program.
From 1993 through 1995 he was employed by the U.S. Army Corps of Engineers, Fort Worth
District, as Chief Field Engineer for the construction of Brooke Army Medical Center, San
Antonio, Texas. Mr. Moorhead is currently employed by the U.S. Army Corps of Engineers,
Savannah District, as Chief Field Engineer for the construction of Womack Army Medical
Center, Fort Bragg, North Carolina. Mr. Moorhead is a registered Civil Engineer in the State
of Washington and an AWS Certified Welding Inspector.

Permanent Address:

540 E. Morganton Road

Southern Pines, North Carolina 28387

This report was typed by the author.

151