Bridge code aashto aws d1.5

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AASHTO/AWS D1.5M/D1.5:2002
Bridge Welding Code
Hamilton Nastaran, P. Eng.
Founder
WeldCanada.com
WPSAmerica.com
September 2003

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Why we are here today
Liability issuesLiability issues
Code of Ethics (77.2.i) from PE Act,Code of Ethics (77.2.i) from PE Act,
“regard the practitioner’s duty to“regard the practitioner’s duty to
public welfare as paramount”public welfare as paramount”

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Bridge walk 1987 "Pedestrian Day 1987". It
is estimated that nearly 300,000 people surged
onto the roadway.

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FOREWORD
 AASHTO – American Association of State Highway andAASHTO – American Association of State Highway and
Transportation Officials, results in the recognition of theTransportation Officials, results in the recognition of the
need for a single document that could produce greaterneed for a single document that could produce greater
economies in bridge fabrication, while at the same timeeconomies in bridge fabrication, while at the same time
addresses the issues of structural integrity and publicaddresses the issues of structural integrity and public
safety.safety.
 The first AWS code for Fusion Welding and Gas CuttingThe first AWS code for Fusion Welding and Gas Cutting
in Building Construction was published in 1928.in Building Construction was published in 1928.
 In 1934, a committee was appointed to prepareIn 1934, a committee was appointed to prepare
specifications for the design, construction, alteration andspecifications for the design, construction, alteration and
repair of highway and railway bridges.repair of highway and railway bridges.
 The first bridge specification was published in 1936.The first bridge specification was published in 1936.

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FOREWORD
 In 1974, AASHTO published the first edition of theIn 1974, AASHTO published the first edition of the
Standard Specifications for Welding of Structural SteelStandard Specifications for Welding of Structural Steel
Highway Bridges.Highway Bridges.
 In 1982, a subcommittee was formed by AASHTO andIn 1982, a subcommittee was formed by AASHTO and
AWS, with equal representation from both, to seekAWS, with equal representation from both, to seek
accommodation between the separate and distinctaccommodation between the separate and distinct
requirements of bridge owner and existing provisions ofrequirements of bridge owner and existing provisions of
AWS D1.1.AWS D1.1.
 The Bridge Welding Code is the result of an agreementThe Bridge Welding Code is the result of an agreement
between AASHTO and AWS to produce a jointbetween AASHTO and AWS to produce a joint
AASHTO/AWS Structural Welding Code for steelAASHTO/AWS Structural Welding Code for steel
highway bridges that addresses essential AASHTO needshighway bridges that addresses essential AASHTO needs
and makes AASHTO revisions mandatory.and makes AASHTO revisions mandatory.

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FOREWORD
 While D1.5 has a superficial resemblance to D1.1, thereWhile D1.5 has a superficial resemblance to D1.1, there
are significant differences, such as the lack of provisionsare significant differences, such as the lack of provisions
relating to statically loaded structures, tubular constructionrelating to statically loaded structures, tubular construction
or the modification of existing structures. Users areor the modification of existing structures. Users are
encouraged to develop their own requirements for theseencouraged to develop their own requirements for these
applications or use existing documents like, D1.1 with theapplications or use existing documents like, D1.1 with the
appropriate modifications.appropriate modifications.

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FOREWORD
 Selection of materials and in qualification and control of WPS toSelection of materials and in qualification and control of WPS to
ensure that all steel bridge members and welds have sufficientensure that all steel bridge members and welds have sufficient
toughness to resist brittle fracture. Additional steps are taken in designtoughness to resist brittle fracture. Additional steps are taken in design
and construction of bridges to avoid conditions that may lead toand construction of bridges to avoid conditions that may lead to
hydrogen-induced or fatigue cracking. The methods used to achievehydrogen-induced or fatigue cracking. The methods used to achieve
these goals are based upon the control of welding heat inputs andthese goals are based upon the control of welding heat inputs and
attendant cooling rates, and the minimizing or avoidance of stressattendant cooling rates, and the minimizing or avoidance of stress
concentrations from weld or base metal discontinuities. Control ofconcentrations from weld or base metal discontinuities. Control of
transformation cooling rates, in addition to control of weld and basetransformation cooling rates, in addition to control of weld and base
metal chemistry, ensures that required mechanical properties aremetal chemistry, ensures that required mechanical properties are
obtained in welds and adjacent HAZs. Heat input control, in additionobtained in welds and adjacent HAZs. Heat input control, in addition
to control of preheat and interpass temperatures, ensures that the baseto control of preheat and interpass temperatures, ensures that the base
metal is not degraded as a result of permanent or temporary welds.metal is not degraded as a result of permanent or temporary welds.
These same controls provide safeguards against hydrogen-inducedThese same controls provide safeguards against hydrogen-induced
cracking.cracking.

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FOREWORD
 Bridges are cyclically loaded structures, are stressed with full designBridges are cyclically loaded structures, are stressed with full design
forces more frequently, with enough applications of design loading toforces more frequently, with enough applications of design loading to
induce fatigue in the member or component.induce fatigue in the member or component.
 Fracture safety is important for all metal structures. In this code,Fracture safety is important for all metal structures. In this code,
emphasis is placed upon qualification and control of WPSs andemphasis is placed upon qualification and control of WPSs and
avoidance of hydrogen and fatigue cracks.avoidance of hydrogen and fatigue cracks.
 Nonredundant fracture critical steel bridge members require a higherNonredundant fracture critical steel bridge members require a higher
level of quality in materials and workmanship to ensure safetylevel of quality in materials and workmanship to ensure safety
equivalent to that of redundant bridge members.equivalent to that of redundant bridge members.

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FOREWORD
 Fracture avoidance, particularly avoidance of brittle fracture, is aFracture avoidance, particularly avoidance of brittle fracture, is a
primary goal of this code.primary goal of this code.
 Brittle fracture is the abrupt rupture of a member or component loadedBrittle fracture is the abrupt rupture of a member or component loaded
in tension.in tension.
 Bridge member, the loading is generally transferred to adjacentBridge member, the loading is generally transferred to adjacent
members and general collapse does not occur. By definition, in non-members and general collapse does not occur. By definition, in non-
redundant members, brittle fracture may cause collapse of theredundant members, brittle fracture may cause collapse of the
structure. Brittle fracture of a tension member is analogous tostructure. Brittle fracture of a tension member is analogous to
buckling of a compression member: rarely will either stop beforebuckling of a compression member: rarely will either stop before
failure is complete if the loading is maintained. However, this codefailure is complete if the loading is maintained. However, this code
does not address buckling of steel bridge members, as buckling isdoes not address buckling of steel bridge members, as buckling is
primarily a design or maintenance consideration.primarily a design or maintenance consideration.

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FOREWORD
 Brittle fractures may result from what may have initially appeared toBrittle fractures may result from what may have initially appeared to
be small, prior to fatigue crack initiation and propagation to criticalbe small, prior to fatigue crack initiation and propagation to critical
size.size.
 The workmanship provisions of the code dictate that notches are to beThe workmanship provisions of the code dictate that notches are to be
avoided. The quality of welds specified in Section 3 of the code takeavoided. The quality of welds specified in Section 3 of the code take
this into account, and also provide standards for workmanship andthis into account, and also provide standards for workmanship and
weld sound-ness that help ensure fracture safety in bridge fatigueweld sound-ness that help ensure fracture safety in bridge fatigue
environment.environment.
 Fatigue crack prevention is dependent upon high fracture toughness,Fatigue crack prevention is dependent upon high fracture toughness,
good design and good workmanship that minimizes stressgood design and good workmanship that minimizes stress
concentrations.concentrations.

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FOREWORD
 AASHTO specifies the minimum fracture toughness ofAASHTO specifies the minimum fracture toughness of
steel plates and shapes used to construct bridge members.steel plates and shapes used to construct bridge members.
 Good toughness ensures that cracks, created by anyGood toughness ensures that cracks, created by any
condition and possibly extended by fatigue, may grow tocondition and possibly extended by fatigue, may grow to
discoverable and therefore repairable size without causingdiscoverable and therefore repairable size without causing
a brittle fracture.a brittle fracture.
 The code has been written to protect the hardness andThe code has been written to protect the hardness and
toughness of both welds and HAZs.toughness of both welds and HAZs.

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FOREWORD
 Quenched and tempered have their strength and toughness affected byQuenched and tempered have their strength and toughness affected by
excessive welding heat input. Slow cooling rates form excessiveexcessive welding heat input. Slow cooling rates form excessive
preheat and interpass temperatures, combined with high welding heatpreheat and interpass temperatures, combined with high welding heat
inputs, may also degrade the mechanical properties of welded joints ininputs, may also degrade the mechanical properties of welded joints in
these heat treated steels. Fast cooling rates produced by welding withthese heat treated steels. Fast cooling rates produced by welding with
low welding heat input, combined with low preheat and interpasslow welding heat input, combined with low preheat and interpass
temperatures may produce excessive hardness and hydrogen-inducedtemperatures may produce excessive hardness and hydrogen-induced
cracking in these same high strength steels. Proper procedures forcracking in these same high strength steels. Proper procedures for
welding quenched and tempered steels are explained in thewelding quenched and tempered steels are explained in the
Commentary.Commentary.
 Users of the code are encouraged to read all of the code and theUsers of the code are encouraged to read all of the code and the
Commentary.Commentary.
 The Commentary is a nonmandatory addition of this Code.The Commentary is a nonmandatory addition of this Code.

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Scope of the Bridge Welding Code
 1.1 Application1.1 Application
- 1.1.1 The code is not intended to be used for the- 1.1.1 The code is not intended to be used for the
following:following:
1.1. Steels with a minimum specified yield strength greaterSteels with a minimum specified yield strength greater
than 690 Mpa (100 Ksi)than 690 Mpa (100 Ksi)
2.2. Pressure vessels or pressure pipingPressure vessels or pressure piping
3.3. Base metals other than carbon or low alloy steelsBase metals other than carbon or low alloy steels
4.4. Structures composed of structural tubingStructures composed of structural tubing
5.5. Repairing Existing StructuresRepairing Existing Structures
6.6. Statically Loaded StructureStatically Loaded Structure

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 1.2 Base Metals1.2 Base Metals
- M270M (M270) steels of a designated grade are- M270M (M270) steels of a designated grade are
essentially the same as ASTM A 709M (A 709) steels ofessentially the same as ASTM A 709M (A 709) steels of
the same grade. A 709M (A709) may be used as athe same grade. A 709M (A709) may be used as a
reference and a guide to other ASTM “referencedreference and a guide to other ASTM “referenced
documents;” however, when there is a difference, thedocuments;” however, when there is a difference, the
provisions of M270M (M270), including the documentsprovisions of M270M (M270), including the documents
referenced in M270M (M270) shall govern.referenced in M270M (M270) shall govern.
- 1.2.3 Thickness Limitations- 1.2.3 Thickness Limitations
-The provisions of this code do not apply to welding base-The provisions of this code do not apply to welding base
metals less than 3 mm (1/8 in.) thick.metals less than 3 mm (1/8 in.) thick.

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 1.3 Welding Processes1.3 Welding Processes
- 1.3.1 SMAW WPSs which conform to the provisions of- 1.3.1 SMAW WPSs which conform to the provisions of
Sections 2,3 and 4, are operated within the limitation ofSections 2,3 and 4, are operated within the limitation of
variables recommended by the manufacturer, and whichvariables recommended by the manufacturer, and which
produce weld metal with a minimum specified yieldproduce weld metal with a minimum specified yield
strength less than 620 MPa (90 ksi), shall be deemedstrength less than 620 MPa (90 ksi), shall be deemed
prequalified and exempt from the tests described inprequalified and exempt from the tests described in
Section 5. WPSs for SAW, FCAW, GMAW, ESW, andSection 5. WPSs for SAW, FCAW, GMAW, ESW, and
EGW shall be qualified as described in 5.12 or 5.13, asEGW shall be qualified as described in 5.12 or 5.13, as
applicable.applicable.
- 1.3.3 Stud welding may be used, provided the WPSs- 1.3.3 Stud welding may be used, provided the WPSs
conform to the applicable provisions of Section 7.conform to the applicable provisions of Section 7.

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- 1.3.4 GMAW-S (shot circuit arc) is not recommended for- 1.3.4 GMAW-S (shot circuit arc) is not recommended for
the construction of bridge members and shall not be usedthe construction of bridge members and shall not be used
without written approval of the Engineer.without written approval of the Engineer.
- 1.3.5 Other welding processes not described in this code- 1.3.5 Other welding processes not described in this code
may be used if approved by the Engineer.may be used if approved by the Engineer.

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- 1.3.6 Welding of Ancillary Products. Unless otherwise- 1.3.6 Welding of Ancillary Products. Unless otherwise
provided in the contract documents, ancillary products,provided in the contract documents, ancillary products,
such as drainage components, expansion dams, curb plates,such as drainage components, expansion dams, curb plates,
bearings, hand rails, cofferdams, sheet piling, and otherbearings, hand rails, cofferdams, sheet piling, and other
products not subject to calculated tensile stress from liveproducts not subject to calculated tensile stress from live
load and not welded to main members in tension areas asload and not welded to main members in tension areas as
determined by the Engineer, may be fabricated withoutdetermined by the Engineer, may be fabricated without
performing the WPS qualification tests described inperforming the WPS qualification tests described in
Section 5, subject to Engineer approval.Section 5, subject to Engineer approval.

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 1.4 Fabricator Requirements1.4 Fabricator Requirements
Fabricators shall be certified under the AISC QualityFabricators shall be certified under the AISC Quality
Certification Program, Simple Steel Bridges or Major SteelCertification Program, Simple Steel Bridges or Major Steel
Bridges, as required by the Engineer, or an equivalentBridges, as required by the Engineer, or an equivalent
program acceptable to the Engineer.program acceptable to the Engineer.

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C 1.1.1 The design of bridges is not described in the code.C 1.1.1 The design of bridges is not described in the code.
This information is specified in the AASHTO StandardThis information is specified in the AASHTO Standard
Specifications for Highway Bridges or the AASHTOSpecifications for Highway Bridges or the AASHTO
LRFD Bridge Design Specifications.LRFD Bridge Design Specifications.
C 1.1.2 The code is a “workmanship” specification, meaningC 1.1.2 The code is a “workmanship” specification, meaning
the quality required is based upon what is readilythe quality required is based upon what is readily
available. “Suitability for service” is the minimum qualityavailable. “Suitability for service” is the minimum quality
required for the member or weld to perform its intendedrequired for the member or weld to perform its intended
function.function.

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Colorado Department of TransportationColorado Department of Transportation
Staff Bridge BranchStaff Bridge Branch
Bridge Design Manual, November 5, 1991Bridge Design Manual, November 5, 1991
- In addition to AASHTO Standard Specifications for Highway- In addition to AASHTO Standard Specifications for Highway
Bridges, with current interims, the following references are to be usedBridges, with current interims, the following references are to be used
when applicable for the design of steel highway bridges:when applicable for the design of steel highway bridges:
- AASHTO Guide Specifications for Fracture Critical Non-redundant- AASHTO Guide Specifications for Fracture Critical Non-redundant
Steel Bridge Members (now replaced with section 12 of D1.5).Steel Bridge Members (now replaced with section 12 of D1.5).
- AASHOT Guide Specifications for Horizontally Curved Highway- AASHOT Guide Specifications for Horizontally Curved Highway
Bridges.Bridges.
- ANSI/AASHTO/AWS D1.5 Bridge Welding Code.- ANSI/AASHTO/AWS D1.5 Bridge Welding Code.
- AASHTO Standard Specifications for Seismic Design of Highway- AASHTO Standard Specifications for Seismic Design of Highway
Bridges.Bridges.

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AASHTO M270/ASTM A709
 Bridge Code Requirements for Base MetalBridge Code Requirements for Base Metal
- C1.2.2 All approved base metals shall conform to the- C1.2.2 All approved base metals shall conform to the
minimum CVN test values specified by AASHTO for theminimum CVN test values specified by AASHTO for the
temperature zone in which the bridge will be located.temperature zone in which the bridge will be located.
Weld metal CVN test value requirements are described inWeld metal CVN test value requirements are described in
Table 4.1/ 4.2, based upon AASHTO Temperature ZonesTable 4.1/ 4.2, based upon AASHTO Temperature Zones
I, II, or III.I, II, or III.
- C1.2.3 Minimum thickness of 3 mm and maximum- C1.2.3 Minimum thickness of 3 mm and maximum
thickness of 100 mmthickness of 100 mm
- 12.4.2 Mill orders shall specify killed fine-grain practice- 12.4.2 Mill orders shall specify killed fine-grain practice
for steel used in FCMs.for steel used in FCMs.

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AASHTO M270/ASTM A709
History of MaterialHistory of Material
Equivalent materials, SupplementaryEquivalent materials, Supplementary
requirements, Zone temperature, Fracture/requirements, Zone temperature, Fracture/
Non- Fracture Critical & UncoatedNon- Fracture Critical & Uncoated
(unpainted) material(unpainted) material

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Fracture Critical Non-redundant Members
 Historically, the following fabrication related factors haveHistorically, the following fabrication related factors have
contributed to bridge member failures;contributed to bridge member failures;
- Design details resulting in notches or stress- Design details resulting in notches or stress
concentrationsconcentrations
- Design details requiring joints difficult to weld and- Design details requiring joints difficult to weld and
inspectinspect
- Lack of base metal and weld metal toughness- Lack of base metal and weld metal toughness
- Hydrogen-induced cracks- Hydrogen-induced cracks
- Improper fabrication, welding and weld repair- Improper fabrication, welding and weld repair
- Unqualified personnel in inspection and NDT- Unqualified personnel in inspection and NDT

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 The Fracture Control Plan, addition of section 12 of D1.5 in 1995, hasThe Fracture Control Plan, addition of section 12 of D1.5 in 1995, has
replaced the “Guide Specifications for Fracture Critical Non-replaced the “Guide Specifications for Fracture Critical Non-
Redundant Steel Bridge Members-1978” developed by AASHTO.Redundant Steel Bridge Members-1978” developed by AASHTO.
 12.2.2 Fracture Critical Member (FCM) or member components are12.2.2 Fracture Critical Member (FCM) or member components are
tension members or tension components of bending memberstension members or tension components of bending members
(including those subject to reversal of stress), the failure of which(including those subject to reversal of stress), the failure of which
would be expected to result in collapse of the bridge. All attachmentswould be expected to result in collapse of the bridge. All attachments
and weld to FCMs shall be considered an FCM. Tension membersand weld to FCMs shall be considered an FCM. Tension members
whose failure would not cause collapse of the bridge are not fracturewhose failure would not cause collapse of the bridge are not fracture
critical. Compression members do not come under the provisions ofcritical. Compression members do not come under the provisions of
this plan as they do not fail by fatigue crack initiation and extension,this plan as they do not fail by fatigue crack initiation and extension,
but rather by yielding or buckling.but rather by yielding or buckling.

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 Example of complete fracture critical bridge members are tension tiesExample of complete fracture critical bridge members are tension ties
in arch bridges and tension chords in truss bridges, provided a failurein arch bridges and tension chords in truss bridges, provided a failure
of the tie or chord could cause the bridge to collapse. Some complexof the tie or chord could cause the bridge to collapse. Some complex
trusses and arch bridges without ties do not depend upon any singletrusses and arch bridges without ties do not depend upon any single
tension member for structural integrity; therefore the tension membertension member for structural integrity; therefore the tension member
would not be considered a FCM.would not be considered a FCM.
 Design evaluationDesign evaluation
- A critical part of any complete Fracture Control Plan deals with- A critical part of any complete Fracture Control Plan deals with
design and detailing.design and detailing.
- Fatigue requirements are extensively covered by AASHTO- Fatigue requirements are extensively covered by AASHTO
Specifications and, where necessary, are made more conservative forSpecifications and, where necessary, are made more conservative for
fracture critical members.fracture critical members.

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- The designer shall examine each detail for compliance with the- The designer shall examine each detail for compliance with the
fatigue requirements and ensure that the detailing will allow effectivefatigue requirements and ensure that the detailing will allow effective
joining techniques and NDT of all welded joints.joining techniques and NDT of all welded joints.
 Fine-Grain PracticeFine-Grain Practice
- Steels manufactured using killed fine-grain practice have better- Steels manufactured using killed fine-grain practice have better
resistance to crack initiation and crack propagation than steels notresistance to crack initiation and crack propagation than steels not
manufactured to this practice.manufactured to this practice.
- Fatigue crack initiation and growth is dependent upon stress range,- Fatigue crack initiation and growth is dependent upon stress range,
stress concentrations and the number of cycles.stress concentrations and the number of cycles.

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 Optional Through-Thickness and Low Sulfur requirementsOptional Through-Thickness and Low Sulfur requirements
- Lamellar tearing occurs in the Through-Thickness direction because- Lamellar tearing occurs in the Through-Thickness direction because
the base metal has limited ductility in that direction. Normally,the base metal has limited ductility in that direction. Normally,
sulfides are the most detrimental type of inclusions that contribute tosulfides are the most detrimental type of inclusions that contribute to
lamellar tearing, however, silicates and alumina may also influencelamellar tearing, however, silicates and alumina may also influence
susceptibility to lamellar tearing. Base metal with low sulfur (less thansusceptibility to lamellar tearing. Base metal with low sulfur (less than
0.010%) and improved through-thickness properties can be specified,0.010%) and improved through-thickness properties can be specified,
typically at an increased cost.typically at an increased cost.
 Optional Heat TreatmentOptional Heat Treatment
 ToughnessToughness
- Adopted after considerable research and deliberation between- Adopted after considerable research and deliberation between
representatives of AASHTO/ AISI/ AISCrepresentatives of AASHTO/ AISI/ AISC

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 Mill OrdersMill Orders
- All approved base metals shall conform to the minimum CVN test- All approved base metals shall conform to the minimum CVN test
values specified by AASHTO M270M for the temperature zone invalues specified by AASHTO M270M for the temperature zone in
which the bridge will be constructed. The Mill order shall specify thewhich the bridge will be constructed. The Mill order shall specify the
CVN that values required.CVN that values required.
- Plate frequency testing requires that each plate shall be heat number- Plate frequency testing requires that each plate shall be heat number
identified by the mill, with the corresponding number and the CVNidentified by the mill, with the corresponding number and the CVN
test values shown on the mill test report.test values shown on the mill test report.

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 Prohibited ProcessProhibited Process
- 12.5.2 For FCM, The Engineer’s approval shall be required for all- 12.5.2 For FCM, The Engineer’s approval shall be required for all
GMAW WPSs, regardless of mode of transfer (note that MCAW isGMAW WPSs, regardless of mode of transfer (note that MCAW is
also considered GMAW since 1980 by AWS).also considered GMAW since 1980 by AWS).
-12.5.2 ESW/ EGW shall be prohibited for welding FCMs.-12.5.2 ESW/ EGW shall be prohibited for welding FCMs.
 Diffusible Hydrogen of Weld MetalDiffusible Hydrogen of Weld Metal
- The resistance to brittle fracture of a welded connection is dependent- The resistance to brittle fracture of a welded connection is dependent
upon eliminating conditions that might reasonably be anticipated toupon eliminating conditions that might reasonably be anticipated to
lead to the initiation of cracks. The FCP limits the addition oflead to the initiation of cracks. The FCP limits the addition of
unacceptable levels of diffusible hydrogen during the fabrication ofunacceptable levels of diffusible hydrogen during the fabrication of
FCM members.FCM members.

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 Consumable requirementsConsumable requirements
- 12.6.3 Weld Metal Strength and Ductility Requirements- 12.6.3 Weld Metal Strength and Ductility Requirements
shall conform to the requirements of Table 4.1 and 4.2shall conform to the requirements of Table 4.1 and 4.2
- 12.6.4 Weld Metal Toughness Requirements- 12.6.4 Weld Metal Toughness Requirements
- Matching Strength Groove Welds. When matching- Matching Strength Groove Welds. When matching
strength filler metals are required, the code requires thatstrength filler metals are required, the code requires that
the minimum notch toughness of the filler metal be asthe minimum notch toughness of the filler metal be as
described in Table 12.1.described in Table 12.1.

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- Undermatching Strength Welds. When matching strength- Undermatching Strength Welds. When matching strength
filler metal is not required, the Engineer is encouraged tofiller metal is not required, the Engineer is encouraged to
use, where appropriate, lower strength high ductility welduse, where appropriate, lower strength high ductility weld
metal that will reduce residual stress, distortion, and themetal that will reduce residual stress, distortion, and the
risk of cracking or lamellar tearing in adjacent base metalrisk of cracking or lamellar tearing in adjacent base metal
HAZs. The code required a minimum notch toughness ofHAZs. The code required a minimum notch toughness of
the undermatching strength filler metal of 34 J @ -30 Cthe undermatching strength filler metal of 34 J @ -30 C
[25 ft-lb @-20 F]. Undermatching is most often associated[25 ft-lb @-20 F]. Undermatching is most often associated
with fillet welds on steels with a minimum specified yieldwith fillet welds on steels with a minimum specified yield
strength greater than 345 Mpa [50 Ksi].strength greater than 345 Mpa [50 Ksi].

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Design: See a Contract document
Bridge Design Manual, November 5, 1991Bridge Design Manual, November 5, 1991
 In addition to AASHTO Standard Specifications for Highway Bridges,In addition to AASHTO Standard Specifications for Highway Bridges,
with current interims, the following references are to be used whenwith current interims, the following references are to be used when
applicable for the design of steel highway bridges:applicable for the design of steel highway bridges:
- AASHTO Guide Spec. for Fracture Critical Non-redundant SteelAASHTO Guide Spec. for Fracture Critical Non-redundant Steel
Bridge Members (was replaced with section 12 of D1.5 in 1995).Bridge Members (was replaced with section 12 of D1.5 in 1995).
- AASHOT Guide Spec. for Horizontally Curved Highway Bridges.AASHOT Guide Spec. for Horizontally Curved Highway Bridges.
- ANSI/AASHTO/AWS D1.5 Bridge Welding Code.ANSI/AASHTO/AWS D1.5 Bridge Welding Code.
- AASHTO Standard Spec. for Seismic Design of Highway Bridges.AASHTO Standard Spec. for Seismic Design of Highway Bridges.

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Design: See a Contract document
Bridge Design Manual (Con’t)Bridge Design Manual (Con’t)
 Fatigue: Except for bridges on interstate and primary highways,Fatigue: Except for bridges on interstate and primary highways,
fatigue design shall be based on the 20 year projected ADTT asfatigue design shall be based on the 20 year projected ADTT as
derived from the final Form 463 or as reported by Staff Traffic (C9).derived from the final Form 463 or as reported by Staff Traffic (C9).
- Commentary (9) Above paragraph assumes use of the AASHTO- Commentary (9) Above paragraph assumes use of the AASHTO
Standard Specifications for fatigue design.Standard Specifications for fatigue design.
 Fatigue design for all bridges on interstate and primary highways shallFatigue design for all bridges on interstate and primary highways shall
be based on the Case I stress cycles in the AASHTO Standardbe based on the Case I stress cycles in the AASHTO Standard
Specifications (C10).Specifications (C10).
- Commentary (10) Under normal loading conditions, fatigue failure in- Commentary (10) Under normal loading conditions, fatigue failure in
steel girders is apparently more common than failure due to membersteel girders is apparently more common than failure due to member
load capacity.load capacity.

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Design: General, Spec., Fatigue
 C1.1 This AASHTO/AWS Bridge Welding Code isC1.1 This AASHTO/AWS Bridge Welding Code is
specifically written for the use of states, provinces andspecifically written for the use of states, provinces and
other governmental members associated with AASHTO.other governmental members associated with AASHTO.
Other organizations that have a need to construct weldedOther organizations that have a need to construct welded
steel bridges to support dynamic loads should study thesteel bridges to support dynamic loads should study the
relationship between the fatigue loads imposed on theirrelationship between the fatigue loads imposed on their
structure and the design truck loads and number of cyclesstructure and the design truck loads and number of cycles
provided for in the AASHTO Standard specification forprovided for in the AASHTO Standard specification for
Highway Bridges.Highway Bridges.

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Design: General, Spec., Fatigue
 C1.1.1 The design of bridges is not described in the code.C1.1.1 The design of bridges is not described in the code.
This information is specified in the AASHTO StandardThis information is specified in the AASHTO Standard
Specifications for Highway Bridges or the AASHTOSpecifications for Highway Bridges or the AASHTO
LRFD Bridge Design Specifications.LRFD Bridge Design Specifications.
 C1.1.2 The code is a “workmanship” specification,C1.1.2 The code is a “workmanship” specification,
meaning the quality required is based upon what is readilymeaning the quality required is based upon what is readily
achievable. “Suitability for service” is the minimumachievable. “Suitability for service” is the minimum
quality required for the member or weld to perform itsquality required for the member or weld to perform its
intended function.intended function.

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Design of Welded Connections
 C2.1 Engineer should make efforts to minimize the size ofC2.1 Engineer should make efforts to minimize the size of
groove weld where possible, adequate access for weldinggroove weld where possible, adequate access for welding
and visual inspection to avoid distortion and residualand visual inspection to avoid distortion and residual
stresses, and may cause lamellar tearing in corner and T-stresses, and may cause lamellar tearing in corner and T-
joints.joints.
- Residual stresses may be reduced by minimizing the- Residual stresses may be reduced by minimizing the
volume of weld metal and by lowering the yield strengthvolume of weld metal and by lowering the yield strength
of the weld metal to the minimum strength acceptable forof the weld metal to the minimum strength acceptable for
the design. Undermatching of weld metal strength isthe design. Undermatching of weld metal strength is
encouraged for fillet welds that are designed to transmitencouraged for fillet welds that are designed to transmit
only shear stress.only shear stress.

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- Some welded joint configurations for corner and T-joints- Some welded joint configurations for corner and T-joints
contribute more than others to the risk of lamellar tearing,contribute more than others to the risk of lamellar tearing,
cracks parallel to the plate surface caused by highcracks parallel to the plate surface caused by high
localized through-thickness strains induced by thermallocalized through-thickness strains induced by thermal
shrinkage. The capacity to transmit through-thicknessshrinkage. The capacity to transmit through-thickness
stresses is essential to the proper functioning of somestresses is essential to the proper functioning of some
corner and T-joints. Lamination (pre-existing planes ofcorner and T-joints. Lamination (pre-existing planes of
weakness in the base metal) or lamellar tearing may impairweakness in the base metal) or lamellar tearing may impair
this capacity.this capacity.

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- In connections where lamellar tearing might be a- In connections where lamellar tearing might be a
problem, consideration should be given in design toproblem, consideration should be given in design to
maximum component flexibility and minimize weldmaximum component flexibility and minimize weld
shrinkage strain.shrinkage strain.
- The details of welded joints provided in Figure 2.4/ 2.5- The details of welded joints provided in Figure 2.4/ 2.5
shall be considered standard and therefore based upon ashall be considered standard and therefore based upon a
long history of successful performance during welding andlong history of successful performance during welding and
in service.in service.
 5.7.7 Contractor are encouraged to use Figure 2.4/ 2.55.7.7 Contractor are encouraged to use Figure 2.4/ 2.5
joints.joints.

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 C2.12.2 Corner Joints: Since lamellar tearing is potentiallyC2.12.2 Corner Joints: Since lamellar tearing is potentially
a serious problem in corner and T-joints where shrinkagea serious problem in corner and T-joints where shrinkage
stresses pull upon the base metal in the short transverse orstresses pull upon the base metal in the short transverse or
“Z” direction, efforts should be made to minimize the“Z” direction, efforts should be made to minimize the
potential for tearing. Shrinkage stresses have less adversepotential for tearing. Shrinkage stresses have less adverse
effects on plates stressed in the longitudinal directioneffects on plates stressed in the longitudinal direction
(parallel to the rolling direction).(parallel to the rolling direction).
 Controlling weld volume, limiting weld metal yield stress,Controlling weld volume, limiting weld metal yield stress,
increasing preheats, using PWHT, and the use ofincreasing preheats, using PWHT, and the use of
controlled sulfur inclusion stress reduces the risk ofcontrolled sulfur inclusion stress reduces the risk of
lamellar tearing. Not all methods are needed for everylamellar tearing. Not all methods are needed for every
application.application.

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 The following precautions may reduce the risk of lamellarThe following precautions may reduce the risk of lamellar
tearing during fabrication in highly restrained weldingtearing during fabrication in highly restrained welding
conditions;conditions;
- On corner joints, where feasible, the bevel should be on- On corner joints, where feasible, the bevel should be on
the through-thickness memberthe through-thickness member
- The size of the weld groove should be kept to a minimum- The size of the weld groove should be kept to a minimum
consistent with the design, and unnecessary weldingconsistent with the design, and unnecessary welding
should be avoidedshould be avoided
- Subassemblies involving corner and T-joints should be- Subassemblies involving corner and T-joints should be
fabricated completely prior to final assembly. Finalfabricated completely prior to final assembly. Final
assembly should preferably be at butt jointsassembly should preferably be at butt joints

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- A predetermined weld sequence should be selected to- A predetermined weld sequence should be selected to
minimize cumulative shrinkage stresses on the mostminimize cumulative shrinkage stresses on the most
highly restrained elementshighly restrained elements
- Undermatching using a lower strength weld metal,- Undermatching using a lower strength weld metal,
consistent with design requirements, should be used toconsistent with design requirements, should be used to
allow higher strain in the weld metal, reducing stress inallow higher strain in the weld metal, reducing stress in
the more sensitive through-thickness direction of thethe more sensitive through-thickness direction of the
base metalbase metal
- “Buttering” with low strength weld metal, peening, or- “Buttering” with low strength weld metal, peening, or
other special procedures should be considered toother special procedures should be considered to
minimize through-thickness shrinkage strains in theminimize through-thickness shrinkage strains in the
base metalbase metal

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 Material with improved through-thickness ductility may beMaterial with improved through-thickness ductility may be
specified for critical connections (where tensile loading isspecified for critical connections (where tensile loading is
in through-thickness direction and in this case materialin through-thickness direction and in this case material
should be UT inspected).should be UT inspected).
 Engineer should selectively specify UT inspection, afterEngineer should selectively specify UT inspection, after
fabrication or erection or both.fabrication or erection or both.

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 C2.1.3 Partial joint penetration (PJP) groove welds are limited toC2.1.3 Partial joint penetration (PJP) groove welds are limited to
joints designed to transmit compression in butt joints with full-milledjoints designed to transmit compression in butt joints with full-milled
bearing surfaces, and to corner and T-joints. PJP groove welds alsobearing surfaces, and to corner and T-joints. PJP groove welds also
may be used in nonstructural appurtenances such as ancillary products.may be used in nonstructural appurtenances such as ancillary products.
In butt joints, they may be used to transmit compressive stress, butIn butt joints, they may be used to transmit compressive stress, but
should never be used to carry tensile stress in bridge members becauseshould never be used to carry tensile stress in bridge members because
of short fatigue life.of short fatigue life.
 Longitudinal web-to-flange welds designed for tensile stresses parallelLongitudinal web-to-flange welds designed for tensile stresses parallel
to the weld throat have the same allowable fatigue stress rangeto the weld throat have the same allowable fatigue stress range
whether designed as a fillet weld or a CJP groove weld with backingwhether designed as a fillet weld or a CJP groove weld with backing
removed. PJP groove welds and CJP groove welds with backingremoved. PJP groove welds and CJP groove welds with backing
remaining in place have a lower allowable fatigue stress range.remaining in place have a lower allowable fatigue stress range.

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 There will be no increase in bridge safety as a result ofThere will be no increase in bridge safety as a result of
specifying CJP groove welds where PJP groove welds orspecifying CJP groove welds where PJP groove welds or
fillet welds, at considerably less cost, will carry the designfillet welds, at considerably less cost, will carry the design
stress. Smaller weld volumes, consistent with design stressstress. Smaller weld volumes, consistent with design stress
requirements, create less residual stress and less chancerequirements, create less residual stress and less chance
that there will be unacceptable distortion or lamellarthat there will be unacceptable distortion or lamellar
tearing.tearing.

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 Connection DetailsConnection Details
2.17.6 Connections or splices in beams or girders when2.17.6 Connections or splices in beams or girders when
made by groove welds shall have CJP groove welds.made by groove welds shall have CJP groove welds.
Other connections or splices with fillet welds shall beOther connections or splices with fillet welds shall be
designed for the average of the calculated stress and thedesigned for the average of the calculated stress and the
strength of member, but no less than 75% of the strengthstrength of member, but no less than 75% of the strength
of member. When there is repeated application of load, theof member. When there is repeated application of load, the
maximum stress or stress range in such connections ormaximum stress or stress range in such connections or
splices shall not exceed the fatigue stress allowed by thesplices shall not exceed the fatigue stress allowed by the
AASHTO specifications.AASHTO specifications.
 2.17.5 Transition of Thicknesses or widths of butt joints2.17.5 Transition of Thicknesses or widths of butt joints
- No more than 1 transverse to 2.5 longitudinal- No more than 1 transverse to 2.5 longitudinal

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 C2.12.1 For thicker materials,the most economic CJPC2.12.1 For thicker materials,the most economic CJP
groove weld joint preparations are often J and U groovegroove weld joint preparations are often J and U groove
preparations. These joints provide the best access forpreparations. These joints provide the best access for
welding at the root and use the least amount of weld metal.welding at the root and use the least amount of weld metal.
However, J and U groove preparations are rarely used inHowever, J and U groove preparations are rarely used in
shops prior to assembly because of assumed high costsshops prior to assembly because of assumed high costs
since prior to assembly, they can only be produced bysince prior to assembly, they can only be produced by
machining.machining.
 C2.13 PJP prohibited in any application where tensileC2.13 PJP prohibited in any application where tensile
stress may be imposed by live or dead loads normal to thestress may be imposed by live or dead loads normal to the
weld throat.weld throat.

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 Prohibited Joints /WeldsProhibited Joints /Welds
 2.3.1.4 Flare groove welds shall not be used to join structural steel in2.3.1.4 Flare groove welds shall not be used to join structural steel in
bridgesbridges
 2.14 Prohibited Joints /Welds2.14 Prohibited Joints /Welds
- All PJP groove welds in butt joints except those conforming to- All PJP groove welds in butt joints except those conforming to
2.17.32.17.3
- CJP groove welds made from one side only without any backing, or- CJP groove welds made from one side only without any backing, or
with backing other than steel, that has not been qualified inwith backing other than steel, that has not been qualified in
conformance with 5.13conformance with 5.13
- Intermittent groove/ fillet weld- Intermittent groove/ fillet weld
- Flat position bevel-groove and J-groove welds in butt joints where- Flat position bevel-groove and J-groove welds in butt joints where
V-groove and U-groove welds are practicableV-groove and U-groove welds are practicable
- Plug and slot welds in members subject to tension and reversal of- Plug and slot welds in members subject to tension and reversal of
stressstress
-Tubular structure-Tubular structure

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 Prohibited Welding ProcessProhibited Welding Process
- C12.5.2- C12.5.2 GMAW-SGMAW-S Short-circuiting transfer is suited forShort-circuiting transfer is suited for
sheet metal applications of less than 1 mm thick andsheet metal applications of less than 1 mm thick and
typically less than 6 mm. It may lead to a condition wheretypically less than 6 mm. It may lead to a condition where
fusion to the base materials is not achieved (cold lap).fusion to the base materials is not achieved (cold lap).
- 2.13.1.1 All PJP groove welds made by- 2.13.1.1 All PJP groove welds made by GMAW-SGMAW-S shallshall
be qualified by the WPS qualification tests described inbe qualified by the WPS qualification tests described in
5.135.13

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 Processes to be AvoidedProcesses to be Avoided
- 12.5.2 GMAW process of any modes of transfer shall not- 12.5.2 GMAW process of any modes of transfer shall not
be used in the construction of bridge members without thebe used in the construction of bridge members without the
written approval of the Engineer.written approval of the Engineer.
- 1.3.4 Short circuiting- 1.3.4 Short circuiting GMAW-SGMAW-S is restricted because ofis restricted because of
its propensity to form fusion discontinuities called coldits propensity to form fusion discontinuities called cold
laps. Properly qualified GMAW WPSs, operated in thelaps. Properly qualified GMAW WPSs, operated in the
spray of globular mode of metal transfer are allowed.spray of globular mode of metal transfer are allowed.

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 Welds in combination with Rivets and BoltsWelds in combination with Rivets and Bolts
- 2.16 In new work, rivets or bolts in combination with- 2.16 In new work, rivets or bolts in combination with
welds shall not be considered as sharing the stress, and thewelds shall not be considered as sharing the stress, and the
welds shall be provided to carry the entire stress for whichwelds shall be provided to carry the entire stress for which
the connection is designed. Bolts or rivets used inthe connection is designed. Bolts or rivets used in
assembly may be left in place if their removal is notassembly may be left in place if their removal is not
specified.specified.

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There are approximately 600,000 rivets
in each tower of Golden Gate Bridge.

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Design:Welded Connections
 Compare Bridge Code with CSA W59Compare Bridge Code with CSA W59

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Golden Gate Bridge

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Golden Gate Bridge
 The dream of spanning the Golden Gate Strait had been around forThe dream of spanning the Golden Gate Strait had been around for
well over a century before the Golden Gate Bridge opened to traffic onwell over a century before the Golden Gate Bridge opened to traffic on
May 28, 1937. On Sunday, May 24, 1987, this dream come true wasMay 28, 1937. On Sunday, May 24, 1987, this dream come true was
celebrated as the Golden Gate Bridge turned fifty. With great fanfare,celebrated as the Golden Gate Bridge turned fifty. With great fanfare,
people from all over the world came to pay homage to the Bridge,people from all over the world came to pay homage to the Bridge,
become part of an historical celebration and create lifelong memories.become part of an historical celebration and create lifelong memories.
The day began as "Bridge walk 87", a reenactment of "Pedestrian DayThe day began as "Bridge walk 87", a reenactment of "Pedestrian Day
37". It is estimated that nearly 300,000 people surged onto the37". It is estimated that nearly 300,000 people surged onto the
roadway.roadway.
 Just over four years. Construction commenced on January 5, 1933 andJust over four years. Construction commenced on January 5, 1933 and
the Bridge was open to vehicular traffic on May 28, 1937.the Bridge was open to vehicular traffic on May 28, 1937.
 The cost to construct a new Golden Gate Bridge would beThe cost to construct a new Golden Gate Bridge would be
approximately $1.2 billion in 2003 dollars. The total price depends onapproximately $1.2 billion in 2003 dollars. The total price depends on
a many factors including the extent of the environmental reviews anda many factors including the extent of the environmental reviews and
the cost of labor and materials.the cost of labor and materials.

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Golden Gate Bridge
 Many misconceptions exist about how often the Bridge is painted.Many misconceptions exist about how often the Bridge is painted.
Some say once every seven years, others say from end-to-end eachSome say once every seven years, others say from end-to-end each
year. Actually, the Bridge was painted when it was originally built.year. Actually, the Bridge was painted when it was originally built.
For the next 27 years, only touch up was required. By 1965,For the next 27 years, only touch up was required. By 1965,
advancing corrosion sparked a program to remove the original paintadvancing corrosion sparked a program to remove the original paint
and replace it with an inorganic zinc silicate primer and acrylicand replace it with an inorganic zinc silicate primer and acrylic
emulsion topcoat. The program was completed in 1995. The Bridgeemulsion topcoat. The program was completed in 1995. The Bridge
will continue to require routine touch up painting on an on-goingwill continue to require routine touch up painting on an on-going
basis.basis.

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Golden Gate Bridge
 The fabricated steel used in the construction of the Golden GateThe fabricated steel used in the construction of the Golden Gate
Bridge was manufactured by Bethlehem Steel in plants in Trenton,Bridge was manufactured by Bethlehem Steel in plants in Trenton,
New Jersey and Sparrows Point, Maryland and in plants in threeNew Jersey and Sparrows Point, Maryland and in plants in three
Pennsylvania towns: Bethlehem, Pottstown, and Steelton. The steelPennsylvania towns: Bethlehem, Pottstown, and Steelton. The steel
was loaded, in sections, onto rail cars, taken to Philadelphia andwas loaded, in sections, onto rail cars, taken to Philadelphia and
shipped through the Panama Canal to San Francisco. The shipment ofshipped through the Panama Canal to San Francisco. The shipment of
the steel was timed to coincide with the construction of the bridge.the steel was timed to coincide with the construction of the bridge.
 http://www.goldengatebridge.org/research/factsGGBDesign.htmlhttp://www.goldengatebridge.org/research/factsGGBDesign.html
 http://www.goldengatebridge.org/photos/bridgewalk.html#http://www.goldengatebridge.org/photos/bridgewalk.html#
 http://www.goldengatebridge.org/research/facts.htmlhttp://www.goldengatebridge.org/research/facts.html

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Electrode/ Wire
 AWS Definition about Metal Core WireAWS Definition about Metal Core Wire
GMAW may be performed with solid electrodes or metal-GMAW may be performed with solid electrodes or metal-
cored electrodes.cored electrodes.
- When introduced in the mid 1970s, metal-cored- When introduced in the mid 1970s, metal-cored
electrodes were originally classified as flux cored forelectrodes were originally classified as flux cored for
FCAW-G welding.FCAW-G welding.
- In early 1990, the AWS A5 Filler Metal Committee- In early 1990, the AWS A5 Filler Metal Committee
determined that it was more appropriate to classify thedetermined that it was more appropriate to classify the
welding performed with MCAW as GMAW, becausewelding performed with MCAW as GMAW, because
metal-cored electrodes did not leave behind the residualmetal-cored electrodes did not leave behind the residual
slag blanket consistent with the FCAW process.slag blanket consistent with the FCAW process.

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Electrode/ Wire
 Table 4.1 versus Table 4.2Table 4.1 versus Table 4.2
- C5.7.4 Table 4.1 Processes – all welding processes approved for use- C5.7.4 Table 4.1 Processes – all welding processes approved for use
by the code have been used successfully for many years and haveby the code have been used successfully for many years and have
longer history of successful use than Table 4.2 processes, and arelonger history of successful use than Table 4.2 processes, and are
considered to be more tolerant of changes in process variables withoutconsidered to be more tolerant of changes in process variables without
adversely affecting weld soundness or required mechanical properties.adversely affecting weld soundness or required mechanical properties.
- C5.7.5 Table 4.2 Processes – welding consumables in this table are- C5.7.5 Table 4.2 Processes – welding consumables in this table are
either those that produce very high strength weld metal or require aeither those that produce very high strength weld metal or require a
higher level of care to produce sound welds.higher level of care to produce sound welds.
- The placement of a welding process in Table 4.2 does not indicate- The placement of a welding process in Table 4.2 does not indicate
that the process is inherently less suitable than another. GMAW andthat the process is inherently less suitable than another. GMAW and
FCAW-S WPSs may require closer control of welding variables andFCAW-S WPSs may require closer control of welding variables and
techniques to provide sound welds with the specified properties,techniques to provide sound welds with the specified properties,
compare to SAW, SMAW, and FCAW-G processes.compare to SAW, SMAW, and FCAW-G processes.

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Electrode/ Wire
 WPS Qualification for consumablesWPS Qualification for consumables
 12.6.1 All welding consumables shall be heat or lot tested12.6.1 All welding consumables shall be heat or lot tested
by the manufacturer to meetby the manufacturer to meet FCPFCP based on AWS A5.01based on AWS A5.01
- 12.6.1.1 For manufacturer audited by one or more of the- 12.6.1.1 For manufacturer audited by one or more of the
ABS, ASME or Lloyd's Register of Shipping then ClauseABS, ASME or Lloyd's Register of Shipping then Clause
12.6.1 requirement can be exempted12.6.1 requirement can be exempted
 What is recommended for matching & ExposedWhat is recommended for matching & Exposed
Bare ApplicationBare Application

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Procedure Qualification Test
 Pre-Qualified ProceduresPre-Qualified Procedures
- C1.9 Each weld shall be made using an approved WPS.- C1.9 Each weld shall be made using an approved WPS.
Two exceptions are:Two exceptions are:
1) SMAW that has a minimum specified yield strength1) SMAW that has a minimum specified yield strength
less than 620 Mpa (90 Ksi), provided the WPSless than 620 Mpa (90 Ksi), provided the WPS
conforms to manufacturer’s recommendations forconforms to manufacturer’s recommendations for
weld variables, and the welding shall be done inweld variables, and the welding shall be done in
conformance with provisions of Section 4, Part Bconformance with provisions of Section 4, Part B
((please note that only SMAW on Table 4.1 is pre-please note that only SMAW on Table 4.1 is pre-
qualifiedqualified).).
2) 1.3.6 Ancillary product welding2) 1.3.6 Ancillary product welding

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 1.3.6 Welding of Ancillary Products exempt from1.3.6 Welding of Ancillary Products exempt from
WPS:WPS:
- SMAW, SAW, FCAW and GMAW WPSs, provided- SMAW, SAW, FCAW and GMAW WPSs, provided
that welding is performed in conformance with all otherthat welding is performed in conformance with all other
provisions of the codeprovisions of the code
- All welding shall be conducted within limitations of- All welding shall be conducted within limitations of
welding variables recommended by the filler metalwelding variables recommended by the filler metal
manufacturermanufacturer
- Weld attaching ancillary products to main members- Weld attaching ancillary products to main members
shall meet all requirements of the Code, including WPSshall meet all requirements of the Code, including WPS
qualification testingqualification testing
- The Engineer is the final judge- The Engineer is the final judge

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 Limited Prequalification for SMAW as explained beforeLimited Prequalification for SMAW as explained before
- For FCMs only E7016, E7018, E7018-1 and E8018-X- For FCMs only E7016, E7018, E7018-1 and E8018-X
(including those with the “C” alloy and “M” military(including those with the “C” alloy and “M” military
classifications and the optional supplemental designatorclassifications and the optional supplemental designator
“R” designating moisture resistance, shall be prequalified.“R” designating moisture resistance, shall be prequalified.

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Test Plate ThicknessTest Plate Thickness
- 5.6.1 WPSs for SMAW, FCAW, GMAW, and SAW shall- 5.6.1 WPSs for SMAW, FCAW, GMAW, and SAW shall
be based on PQR test plates with thicknesses greater thanbe based on PQR test plates with thicknesses greater than
or equal to 25 mm, and shall qualify the WPS for use onor equal to 25 mm, and shall qualify the WPS for use on
all steel thicknesses covered by this code.all steel thicknesses covered by this code.
- 5.6.2 EGW and ESW WPSs. Test plates shall conform to- 5.6.2 EGW and ESW WPSs. Test plates shall conform to
Table 5.4 (17).Table 5.4 (17).
- 5.6.3 Fillet weld soundness test plate thickness shall- 5.6.3 Fillet weld soundness test plate thickness shall
conform to Figure 5.8.conform to Figure 5.8.

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- C5.6 Previous editions of the code have required WPS qualification on- C5.6 Previous editions of the code have required WPS qualification on
two thicknesses of steel.two thicknesses of steel.
- Study/ research: The thicker plates were expecting to generate higher- Study/ research: The thicker plates were expecting to generate higher
cooling rates, resulting in higher strength levels and lower ductilitycooling rates, resulting in higher strength levels and lower ductility
and thin plates also expected to result in lower toughness values.and thin plates also expected to result in lower toughness values.
From previous data on several tests, the average yield strength of thinFrom previous data on several tests, the average yield strength of thin
plate specimens was 94% and the average tensile strength was 99% ofplate specimens was 94% and the average tensile strength was 99% of
that associated with the thicker plate. CVN test values were affectedthat associated with the thicker plate. CVN test values were affected
to a greater extent than the tensile strength and elongation values, butto a greater extent than the tensile strength and elongation values, but
no uniform trend was seen. This was deemed to be due to otherno uniform trend was seen. This was deemed to be due to other
variables than the cooling rate. Frank and Abel evaluated severalvariables than the cooling rate. Frank and Abel evaluated several
hundred PQRs and found that plate thickness, as well as a variety ofhundred PQRs and found that plate thickness, as well as a variety of
other essential variables described in the code, did not serve as a goodother essential variables described in the code, did not serve as a good
predictor of the probable mechanical properties. After analyzing thispredictor of the probable mechanical properties. After analyzing this
data, committee decided to standardize all WPS testing on one platedata, committee decided to standardize all WPS testing on one plate
thickness.thickness.

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Position of test weldsPosition of test welds
- 5.8.1 Each WPS shall be tested in the position in which- 5.8.1 Each WPS shall be tested in the position in which
welding will be performed in the work, except that testwelding will be performed in the work, except that test
welds made in the flat positions qualify for flat andwelds made in the flat positions qualify for flat and
horizontal welding.horizontal welding.
Base Metal for WPSBase Metal for WPS
Backing for WPSBacking for WPS
- 5.4.5 Steel backing used in weld tests shall be of the- 5.4.5 Steel backing used in weld tests shall be of the
same specification and grade as the weld test plates, butsame specification and grade as the weld test plates, but
CVN tests shall not be required.CVN tests shall not be required.

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NDTNDT
- C5.17 All WPS are required to be radiographed with the- C5.17 All WPS are required to be radiographed with the
provisions of Section 6 to demonstrate soundness beforeprovisions of Section 6 to demonstrate soundness before
mechanical testing, regardless of the welding process used.mechanical testing, regardless of the welding process used.
- 6.10 Backing need not be removed for RT- 6.10 Backing need not be removed for RT
- 6.26.5.2 NDT for M270M [M270] Grades 690/690W- 6.26.5.2 NDT for M270M [M270] Grades 690/690W
[100/100w] steel shall performed not less than 48 hours[100/100w] steel shall performed not less than 48 hours
after completion of welds.after completion of welds.

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 WPS Qualification Test,WPS Qualification Test,
Pretest,Verification of Pretest PQRsPretest,Verification of Pretest PQRs

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Type of tests and purpose as listed in Table 5.5Type of tests and purpose as listed in Table 5.5
- 5.15 Mechanical testing shall verify that the WPS produces the- 5.15 Mechanical testing shall verify that the WPS produces the
strength, ductility, and toughness required by Tables 4.1, 4.2, or asstrength, ductility, and toughness required by Tables 4.1, 4.2, or as
approved by the Engineer for the filler metal tested. Please note thatapproved by the Engineer for the filler metal tested. Please note that
CVN test values ofCVN test values of FCMsFCMs shall be as specified in 12.6.4 (shall be as specified in 12.6.4 (not Tablenot Table
4.1/ 4.24.1/ 4.2). The tests are as follows:). The tests are as follows:
- 5.15.1 Groove Welds- 5.15.1 Groove Welds
1) All weld-metal tension tests to measure tensile strength, yield1) All weld-metal tension tests to measure tensile strength, yield
strength, and ductility.strength, and ductility.
2) CVN test, to measure relative fracture toughness.2) CVN test, to measure relative fracture toughness.
3) Macroetch tests, to evaluate soundness, and to measure effective3) Macroetch tests, to evaluate soundness, and to measure effective
throat of weld size:also, used to gage the size and distribution of weldthroat of weld size:also, used to gage the size and distribution of weld
layers and passes.layers and passes.

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4) RT test to evaluate weld soundness.4) RT test to evaluate weld soundness.
- In addition, the following tests shall be required for matching weld- In addition, the following tests shall be required for matching weld
strength groove welds (strength groove welds (so not required for undermatchingso not required for undermatching).).
5) Reduced section tensile test, to measure tensile strength.5) Reduced section tensile test, to measure tensile strength.
6) Side-bend test, to evaluate soundness and ductility.6) Side-bend test, to evaluate soundness and ductility.
- 5.15.2 Fillet Welds- 5.15.2 Fillet Welds
- 5.15.2.1 Mechanical properties shall be measured by testing groove- 5.15.2.1 Mechanical properties shall be measured by testing groove
weld unless otherwise specified in the contract documents.weld unless otherwise specified in the contract documents.
- 5.15.2.2 Macroetch to evaluate soundness and to gage the size,- 5.15.2.2 Macroetch to evaluate soundness and to gage the size,
shape, and distribution of individual weld passes as per Figure 5.8.shape, and distribution of individual weld passes as per Figure 5.8.
Please note that for single pass fillet weld or single pass PJP groovePlease note that for single pass fillet weld or single pass PJP groove
weld only macro etches suggested, see C 5.10.1/ C 5.10.2.weld only macro etches suggested, see C 5.10.1/ C 5.10.2.

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Options for WPS Qualification orOptions for WPS Qualification or
PrequalificationPrequalification
Essential variableEssential variable

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 What else about WPSWhat else about WPS

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Control of test & documentation
Test Results Required, RetestsTest Results Required, Retests
What should be included in WPDSWhat should be included in WPDS
What types of information should be noticed to ourWhat types of information should be noticed to our
clients in our outgoing letterclients in our outgoing letter
Sample letters, communication withSample letters, communication with
engineer before and afterengineer before and after
Suggestion: New form (questionnaire) and additionSuggestion: New form (questionnaire) and addition
notes to quality manualnotes to quality manual

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Arch bridge
Beam bridge
Suspension bridge
Cable-stayed bridge

Types of bridges

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Arch Bridge
Bixby Creek Bridge, Monterey,
CA
Arch bridges are one of the oldest types of bridges and have great natural strength. Instead
of pushing straight down, the weight of an arch bridge is carried outward along the curve of
the arch to the supports at each end. These supports, called the abutments, carry the load
and keep the ends of the bridge from spreading out.
Arch Bridge

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Suspension bridge
Golden Gate Bridge,
San Francisco, CA
Aesthetic, light, and strong, suspension bridges can span
distances from 2,000 to 7,000 feet -- far longer than any
other kind of bridge. They also tend to be the most
expensive to build. True to its name, a suspension bridge
suspends the roadway from huge main cables, which
extend from one end of the bridge to the other. These
cables rest on top of high towers and are secured at each
end by anchorages.
Suspension bridge
anchorage

The towers enable the main cables to be draped over long
distances. Most of the weight of the bridge is carried by
the cables to the anchorages, which are imbedded in
either solid rock or massive concrete blocks. Inside the
anchorages, the cables are spread over a large area to
evenly distribute the load and to prevent the cables from
breaking free.
Suspension Bridge

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Beam bridge
A beam or "girder" bridge is the simplest and most inexpensive kind of bridge. According to Craig
Finley of Finley/McNary Engineering, "they're basically the vanillas of the bridge world."
In its most basic form, a beam bridge consists of a horizontal beam that is supported at each end by
piers. The weight of the beam pushes straight down on the piers.
The beam itself must be strong so that it doesn't bend under its own weight and the added weight of
crossing traffic. When a load pushes down on the beam, the beam's top edge is pushed together
(compression) while the bottom edge is stretched (tension).
Beam Bridge

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Cable-stayed bridge
Clark Bridge, Alton, IL
Cable-stayed bridges may look similar to suspensions bridges -- both have roadways that hang from
cables and both have towers. But the two bridges support the load of the roadway in very different
ways. The difference lies in how the cables are connected to the towers. In suspension bridges, the
cables ride freely across the towers, transmitting the load to the anchorages at either end. In cable-
stayeded bridges, the cables are attached to the towers, which alone bear the load.
The cables can be attached to the roadway in a variety of ways. In a radial pattern, cables extend
from several points on the road to a single point at the top of the tower. In a parallel pattern, cables
are attached at different heights along the tower, running parallel to one other.

Cable-Stayed Bridge

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Parallel attachment pattern
Radial attachment pattern
Types of Cable Attachment

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Following are some link for different Suspension Bridges. The length of
main span portion of suspended structure (distance between towers) are
shown only that not include side spans:
 Akashi-Kaikyo Bridge,Akashi-Kaikyo Bridge, Japan,Japan,6,532 feet main span,6,532 feet main span, 19981998
 Great Belt East Bridge,Great Belt East Bridge, Denmark,Denmark, 5,328 feet main span,5,328 feet main span, 19971997
 Humber Bridge,Humber Bridge, England,England, 4,626 feet main span,4,626 feet main span, 19811981
 Jiangyin Yangtze River Bridge,Jiangyin Yangtze River Bridge, China,China, 4,544 feet main span,4,544 feet main span, 19991999
 Tsing Ma Bridge,Tsing Ma Bridge, China,China, 4,518 feet main span,4,518 feet main span, 19971997
 Verrazano Narrows Bridge,Verrazano Narrows Bridge, New York,New York, 4,260 feet main span,4,260 feet main span, 19641964
 Golden Gate BridgeGolden Gate Bridge,, San Francisco,San Francisco, 4,200 feet main span,4,200 feet main span, 19371937
 High Coast Bridge,High Coast Bridge, Sweden,Sweden, 3,970 feet main span,3,970 feet main span, 19971997
 Mackinac Straits Bridge,Mackinac Straits Bridge, Michigan,Michigan, 3,800 feet main span,3,800 feet main span, 19571957
 Minami Bisan-Seto Bridge,Minami Bisan-Seto Bridge, Japan,Japan, 3,609 feet main span,3,609 feet main span, 19881988
 Second Bosphorous,Second Bosphorous, Turkey,Turkey, 3,576 feet main span,3,576 feet main span, 19921992
 First Bosphorous,First Bosphorous, Turkey,Turkey, 3,523 feet main span,3,523 feet main span, 19731973

George Washington Bridge,George Washington Bridge, New York,New York, 3,500 feet main span,3,500 feet main span, 19311931

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