Nondestructive Examination and

Special Inspection of
Seismic Welding

Michael J. Mayes, P.E.

Welding Engineer
NDE Level III

NASCC Steel Conference

AWS D1.1 Code Committee

April 2 and 3, 2008

AISC D1.8 Seismic Subcommittee

Special Inspection Agency Owner

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Topics

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Northridge Damage

Seismic Critical Welding

Special Inspection
Approved Fabricators
Nondestructive Examination

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What Happened?

FEMA AISC

Workmanship

Revised Seismic Provisions (341-05)

Inspection

Develop New Seismic Design

Recommendations

Design Assumptions
Material Issues

Collect Research and Future Test Data

Pre-qualified Connections (358-05)

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FEMA AWS

Weld Toughness

New D1 Subcommittee Seismic

FCAW Wires

New Seismic Welding Code D1.8

Control Deposition Rates

Pre-qualified Procedures
Limits on Heat Input
Varies by Brand and Diameter
Toughness Cannot be Determined
Nondestructively

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AWS D1.8 Lot Testing

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Filler Metal Toughness

Alternative to Lot Test

Outside Audit of Supplier QC
3 Initial Lot Tests
1 Lot Every 3 Years

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Filler Metal Toughness

Seismic Welding Procedures

Heat Input = Voltage * Current * 60

Obtain High/Low HI Certifications

Travel Speed * 1000

Adjust Parameters (Amps, Volts, T.S.)

Set-up Machines

27 V * 350 A * 60

Measure Output

12 inch/min * 1000

Make Sure It Works!

47 kJ/inch

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Mixing Filler Metals

Mixing Filler Metals

Field Welds Over Shop Welds

Repair Welds
FCAW Self Shielded Electrodes Only

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Electrode Moisture Pick-up: SMAW

FCAW Wire Storage and Exposure

Rod Ovens on Site

Testing of FCAW Wire to Establish

Storage and Exposure Limits for
Diffusible Hydrogen Level of H16

Monitor Exposure Times

Protective Packaging

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FCAW Storage Oven

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Backing Bar Issues

Remove From Critical Welds
Better Inspection Without Backing
Control of Tack Welds

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Backing Bar Issues

Backing Bar Issues

No top reinforcing weld required

Remove backing bar

Backgouge
MT Visual
Backweld
5/16 (+) reinforcing fillet
MT
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Ceramic Backing Bars

5/16"
Fillet weld beneath backing bar
FEMA 353 - 4.1.2

FEMA 350 Figure 3-8

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Copper Backing Bars

Fit-up Issues
Root Gap
Welder Qualification

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Copper Backing Bars

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Copper Backing Bars

Qualify Procedures
Control Fit-up
Welder Skill
Copper Pick-up
Welder Qualification

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Weld Tabs

Weld Tabs

Use!
Remove
No End Dams

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Weld Tabs

End Dams

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End Dams

Weld Tab Removal

Grind Smooth
500 Micro-inches
Smooth Transition to Adjacent Surfaces

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Weld Tab Removal

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Weld Access Holes

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Welder Qualifications

Weld Access Holes

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Weld Access Holes

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Seismic Welder Mock-up

AWS D1.8
Welder Mock-up
Highest Deposition Rates
Increase Qualification Period to 36
Months
Use Same Backing (steel, copper,
ceramic, etc.)

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Seismic Welder Test

New Design Concept

Plastic Hinges/Weak Lines
Lower Stress at Weld Joint

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Why Moment Frames?

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Full Scale Connection Testing

Resist Lateral Earthquake Loads

Architectural Issues
Brace Frames
Concrete Shear Walls

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Reduced Beam Sections (RBS)

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Bolted End-Plate Connections

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Side Plate Connection

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Welded Attachments in
Protected Zone

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Hole Drilled in Protected Zone

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Slotted Web Connection

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Welded Attachments in
Protected Zone

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Pins Shot Into Protected Zone

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K-Area

K-Area
Poor Properties at Flange-Web
Intersection
Avoid Welds in K-Area
Additional NDE

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K-Area

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K-Area

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K-Area

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K-Area

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K-Area

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Tack Welds

K-Area

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Backing Bar Welds

Tack Inside Weld Groove

All Tack Welds Removed or Consumed

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Welding Sequence

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Welding Sequence

Weld
Tab
54

Weld
Tab
32

10 9
1

87

Backing Bar
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10

Welding Sequence

Welding Sequence

Alternate Through Access Hole

Overlap Ends of Passes

Weld
Tab

Weld
Tab
8
4

9
5
1

7
3

10
6
2

Backing Bar
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Welder Access

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Welding Procedures

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Inspector Access

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QA/QC Checklist

Submit Prior to Welding

Engineer Approves
Inspector and Welder Has a Copy
Measure Variables

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Other Seismic Inspection Issues

Contract Documents

Welder I.D.

Identify Seismic Critical Welds

48 Hour Delay Before Inspection (only

for K-Area)

Specify AISC Seismic Provisions (AISC

341-05) Appendix Q

Lamellar Testing

Specify AWS D1.1 and AWS D1.8

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Engineer Must Define Seismic

Critical Welds

Engineer Responsibilities

SMRF

Use Pre-qualified Connections

OMRF

Review Welding Procedures

EBF

Project QA/QC Plan

Lateral Systems

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Fabricator/Erector Issues

Cost Impacts?

Submittals

Welder Training

QC Plans
Welding Procedure Specifications (WPS)

Preconstruction Meetings

Welder Qualifications
Slower Production Rates
Hold Points
Increased NDE

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12

Inspector Qualifications - QC

Inspector Qualifications - QA

Fabricators Inspector

Special Inspector

Qualifications / Duties per QC Manual

Represents Owner

AWS-CWI

Represents Building Department

Erectors Inspector?

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Special Inspector Qualifications

Special Inspector Qualifications

International Building Code (IBC)

Vary Between Jurisdictions

IBC 1704.1 The special inspector shall

be a qualified person who shall
demonstrate competence, to the
satisfaction of the building official

WABO and OBOA

ICC Exams, Documented Experience,
Interview

Portland, Las Vegas, Los Angeles, San

Francisco
CWI Required by AISC Seismic

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Inspection Requirements

Inspection Requirements

IBC Requirements

Periodic Inspection Allowed For:

100% Visual Inspection Shop and

Field

Single Pass Fillet Welds

Continuous vs. Periodic Inspection

Welded Studs

AISC Seismic Additional NDE

Requirements

Deck Welding
Cold Formed Steel Welding
Stairs and Railing
Approved Fabricators

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Approved Fabricators

Fabrication Inspection

IBC 1704.2.2 Approval (by Building

Official) based on:

Same Inspector/Agency as Erection?

Review of QC Procedures
Periodic Audits by Approved Special
Inspector

Demand Competence!
Shop Inspection Typically Required for
Seismic

AISC Certified Fabricators?

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Tubular Joints - TKY

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Tubular Mockups

Not Covered by Bridge Code

Nonstandard Testing
Require Mock-ups

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NDE Requirements

AISC Seismic NDE Requirements

No Requirements Per IBC

MT of K-Area

No Requirements Per AWS D1.1

UT of CJP Welds

Contract Documents

MT (25%) of CJP Welds

Tubular Requirements

UT for Lamellar Tearing and Lamination

AISC Seismic Provisions

MT or PT For Beam Cope and Access

Holes

Understand and Clarify!

MT for Tab Removal Sites

MT for RBS Repairs
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14

AWS D1.1 6.6.5

Non Specified NDT
Owner Responsible for All Costs
Including:
Handling
Surface Prep
NDT
Repair of Defects
Delays

Exception: Attempt of Defraud or Gross

Nonconformance
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Methods of Inspection
Non-destructive Examination (NDE)

Visual

Tap T

Micro
w

g
estin

Ther
ave

mog
ra

article
etic P
Magn

phy

Acoustic
raphy
Microsco
Radiog
py
Acousti
s
t
c Emis
n
e
sion
urem
trant
eas
cM
Pene
i
t
e
n
Ult
iquid
Edd
g
L
a
r as
M
yC
o ni
u rre
c
nt
Lase
Replication
r Inte
r
fe
ge
rome
a
Flux Leak
try
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Non-destructive Examination
Structural Welding

Non-destructive Examination
Structural Welding

Radiography

Dye Penetrant Testing

Bridge Girder Splices

Wont Work With Rough Surfaces

Not Practical for Buildings

Not Practical for Buildings

UT and RT Should Not be Used

Together!

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Non-destructive Examination
Structural Welding

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Magnetic Particle Testing (MT)

Magnetic Particle Testing (MT)

Ultrasonic Testing (UT)
Limitations
Technician Qualifications
Flaw Detection
Flaw Sizing
AWS D1.1 Appendix K

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15

Magnetic Particle Testing (MT)

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Magnetic Particle Testing (MT)

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Ultrasonic Inspection (Pulse-Echo)

Ultrasonic Testing (UT)

initial
pulse

crack
echo

back surface
echo

crack
0

10

plate

Oscilloscope, or flaw
detector screen

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Ultrasonic Testing (UT)

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Ultrasonic Testing (UT)

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Inspection Issues

Ultrasonic Limitations
Operator Skill/Training
Does Inspector Ever Find Flaws?
Flaw Orientation

Transducer

Access to Weld
Dont Use for Partial Penetration Welds

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UT Technician Qualifications

UT Flaw Detection

Varies from Company to Company

Should Be Very Accurate

Check Personnel on Real Samples

Use Confirming Sound Paths

AWS D1.8 Annex E

Welder Should Find Flaws

Remove Backing Bars

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UT Flaw Sizing

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Ultrasonic Testing

Unique Skills Required

Amplitude Techniques Wont Work
AWS is Conservative

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Questions?

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