The document provides a comprehensive overview of structural welding, detailing various welding positions, joint types, and processes, as well as the AWS D1.1:2020 code requirements for welded steel structures. It outlines the responsibilities of engineers, contractors, and inspectors in the welding process and includes sections on design, pre-qualification of welding procedures, and fabrication practices. The content emphasizes safety, various welding techniques, and specific criteria for different types of joints and loads.

1. STRUCTURAL WELDING
AND AWS D1.1; 2020
IntPE M.A.S. Upul Kumara,
BScEng (Pdn), PGDipEPCEng(Pdn), MSc (My), IntPE, CEng, FIE(SL) CPEngNZ, MAWS (USA), MASME(USA), PM-ASNT(USA),
+94 773151906
kumar.msu906.gmail.com

2. WELDING IS A NEVER ENDING PROCESS
WELDING POSITIONS

3. FLAT (1G, 1F) POSITION

4. HORIZONTAL POSITION (2G, 2F)

5. VERTICAL POSITIONS (3G, 3F)

6. OVERHEAD POSITION (4G, 4F)

7. TYPES OF WELDING JOINTS
• 1. Butt weld
the butt joint uses the following preparation styles.
• Bevel-Groove Butt Weld
• Flare-Bevel-Groove Butt Weld
• Flare-V-Groove Butt Weld
• J-Groove Butt Weld
• Square-Groove Butt Weld
• U-Groove Butt Weld
• V-Groove Butt Weld

8. 2. Corner welding joint
• The styles employed are as follows.
• Bevel-Groove Weld
• Corner-Flange Weld
• Edge Weld
• Fillet Weld
• Flare-V-Groove Weld
• J-Groove Weld
• Spot-Weld
• Square-Groove Weld or Butt Weld
• U-Groove Weld
• V-Groove Weld
TYPES OF WELDING JOINTS

9. TYPES OF WELDING JOINTS
• 3. Lap welding joints
• Welding Style for Lap Joint
• Bevel-Groove Weld
• Flare-Bevel-Groove Weld
• J-Groove Weld
• Plug Weld
• Slot Weld
• Spot-Weld

10. •4. Tee Joint
• Welding Style for Tee Joint
• Bevel-Groove Weld
• Fillet Weld
• Flare-Bevel-Groove Weld
• J-Groove Weld
• Melt-Through Weld
• Plug Weld
• Slot Weld
TYPES OF WELDING JOINTS

11. •5. Edge welding Joints
• Joint creation takes place using the
following styles.
• Bevel-Groove Weld
• Corner-Flange Weld
• Edge-Flange Weld
• J-Groove Weld
• Square-Groove Weld or Butt Weld
• U-Groove Weld
• V-Groove Weld
TYPES OF WELDING JOINTS

12. The following are some of the most used welding
types in the industry.
1. Gas Metal Arc Welding (GMAW) – MIG
2. Gas Tungsten Arc Welding (GTAW) – TIG
3. Flux Cored Arc Welding (FCAW)
4. Shielded Metal Arc Welding (SMAW) – Stick
5. Atomic Hydrogen Welding (AHW)
6. Energy Beam Welding (EBW)
7. Underwater Welding
TYPES OF WELDING PROCESSES

13. WELDING
PROCESSES
• SMAW
• GMAW
• GTAW
• SAW
• FCAW

14. BASED ON AWS D1.1;2020 VERSION
• Code comprised of following sections
• Section 1. General Requirements
• Section 2. Normative References
• Section 3. Terms and Definitions
• Section 4. Design of welded connections
• Section 5. Prequalification of WPS
• Section 6. Qualification
• Section 7. Fabrication
• Section 8. Inspection
• Section 9. Stud welding
• Section 10. Tubular Structures
• Section 11. Strengthening and Repair of Existing structures

15. SECTION 1. GENERAL REQUIREMENTS
• 1.1 Scope
• This code contains the requirements for fabricating and erecting
welded steel structures. When this code is stipulated in contract
documents, conformance with all provisions of the code shall be
required, except for those provisions that the Engineer or
contract documents specifically modifies or exempts.

16. SECTION 1. GENERAL REQUIREMENTS
• 1.2 Standard Unit of Measurements
• This standard makes use of both U.S. Customary Units and the
International System of Units (SI). The latter are shown within
brackets ([ ]) or in appropriate columns in tables and figures. The
measurements may not be exact equivalents; therefore, each
system must be used independently.

17. SECTION 1. GENERAL REQUIREMENTS
• 1.3 Safety Precautions
• Safety and health issues and concerns are beyond the scope of this standard
and therefore are not fully addressed herein. It is the responsibility of the user to
establish appropriate safety and health practices. Safety and health
information is available from the following sources:
• American Welding Society:
• (1) ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes
• (2) AWS Safety and Health Fact Sheets
• (3) Other safety and health information on the AWS website
• Material or Equipment Manufacturers:
• (1) Safety Data Sheets supplied by materials manufacturers
• (2) Operating Manuals supplied by equipment manufacturers
• Applicable Regulatory Agencies

18. SECTION 1. GENERAL REQUIREMENTS
• 1.4 Limitations
• The code was specifically developed for welded steel structures that utilize carbon or low alloy steels
that are 1/8 in [3 mm] or thicker with a minimum specified yield strength of 100 ksi [690 MPa] or less.
The code may be suitable to govern structural fabrications outside the scope of the intended
purpose.
However,
• the Engineer should evaluate such suitability, and based upon such evaluations, incorporate into
contract documents any necessary changes to code requirements to address the specific
requirements of the application that is outside the scope of the code.
• The Structural Welding Committee encourages the Engineer to consider the applicability of other
AWS DI codes for applications involving
• aluminum (AWS D l.2),
• sheet steel equal to or less than 3/16 in [5 mm] thick (AWS D l.3),
• reinforcing steel (AWS D l.4),
• stainless steel (AWS D l.6),
• strengthening and repair of existing structures (AWS D l.7),
• seismic supplement (AWS D l.8),
• and titanium (AWS D l.9).
• The AASHTO/AWS D l.5 Bridge Welding Code was specifically developed for welding highway bridge
components and is recommended for those applications.

19. SECTION 1. GENERAL REQUIREMENTS
• 1.5 Responsibilities
• 1.5.1. Engineers Responsibility
• The Engineer shall be responsible for the development of the contract documents that
govern products or structural assemblies produced under this code.
• The Engineer may add to, delete from, or otherwise modify, the requirements of this code
to meet the particular requirements of a specific structure. All requirements that modify this
code shall be incorporated into contract documents.
• The Engineer shall determine the suitability of all joint details to be used in a welded
assembly.
• The Engineer shall specify in contract documents, as necessary, and as applicable, the
following:
• (1) Code requirements that are applicable only when specified by the Engineer.
• (2) All additional NDT that is not specifically addressed in the code.
• (3) Extent of verification inspection, when required.
• (4) Weld acceptance criteria other than that specified in Clause .8_.
• (5) CVN toughness criteria for weld metal, base metal, and/or RAZ when required.
• (6) For nontubular applications, whether the structure is statically or cyclically loaded.

20. SECTION 1. GENERAL REQUIREMENTS
• 1.5 Responsibilities
• (7J Which welded joints are loaded in tension.
• (8) All additional requirements that are not specifically addressed in the code.
• (9) For OEM applications, the responsibilities of the parties involved.
1.5.2 Contractor's Responsibilities. The Contractor shall be responsible for WPSs,
qualification of welding personnel, the Contractor's inspection, and performing work
in conformance with the requirements of this code and contract documents.
1.5.3 Inspector's Responsibilities
1.5.3.1 Contractor Inspection. Contractor inspection shall be supplied by the Contractor
and shall be performed as necessary to ensure that materials and workmanship meet the
requirements of the contract documents.
1.5.3.2 Verification Inspection. The Engineer shall determine if Verification Inspection shall
be performed. Responsibilities for Verification Inspection shall be established between the
Engineer and the Verification Inspector.

21. SECTION 1. GENERAL REQUIREMENTS
• 1.6 Approvals
All references to the need for approval
shall be interpreted to mean approval by
the Authority Having Jurisdiction or the
Engineer.

22. SECTION 1. GENERAL REQUIREMENTS
• 1.7 Mandatory and Nonmandatory Provisions
• Shall. Code provisions that use "shall" are mandatory unless specifically
modified in contract documents by the Engineer.
• Should. The word "should" is used to recommend practices that are
considered beneficial, but are not requirements.
• May. The word "may" in a provision allows the use of optional procedures
or practices that can be used as an alternative or supplement to code
requirements. Those optional procedures that require the Engineer's
approval shall either be specified in the contract documents, or require
the Engineer's approval. The Contractor may use any option without the
Engineer's approval when the code does not specify that the Engineer's
approval shall be required.

23. SECTION 1. GENERAL REQUIREMENTS
• 1.8 Welding Symbols
• Welding symbols shall be those shown in AWS A2.4,
Standard Symbols for
Welding,
Brazing, and
Nondestructive Examination.
Special conditions shall be fully explained by added
notes or details.

24. WELDING SYMBOLS

25. WELDING SYMBOLS

26. WELDING SYMBOLS

27. WELDING SYMBOLS

28. WELDING SYMBOLS

29. WELDING SYMBOLS

30. WELDING SYMBOLS

31. WELDING SYMBOLS

32. WELDING
SYMBOL
(GENERAL)

33. SECTION 02, 03 WILL BE DISCUSSED LATER
• Definition of terminologies and the list of references will be
discussed during the course and a complete description
will be give in the latter part.
• Section 02 – Normative References
• Section 03 – Terms and Definitions.

34. SECTION 04. DESIGN OF WELDED
CONNECTIONS
• Part A-Common Requirements for Design of Welded Connections (Non
tubular and Tubular Members)
• Part B-Specific Requirements for Design of Non tubular Connections
(Statically or Cyclically Loaded). The requirements shall apply in
addition to the requirements of Part A.
• Part C-Specific Requirements for Design of Non tubular Connections
(Cyclically Loaded). When applicable, the requirements shall apply in
addition to the requirements of Parts A and B.

35. SECTION 04. DESIGN OF WELDED
CONNECTIONS
• Part A-Common Requirements for Design of Welded Connections (Non tubular and
Tubular Members)

36. SECTION 04. DESIGN OF WELDED CONNECTIONS
• When the length of end-loaded fillet welds exceeds 100 but not more than 300
times the weld size, the effective length shall be determined by multiplying the
actual length by the reduction coefficient
• When the length exceeds 300 times the leg size, the effective length shall be taken
as 180 times the leg size

37. SECTION 04. DESIGN OF WELDED CONNECTIONS

38. SECTION 04. DESIGN OF WELDED CONNECTIONS

40. SECTION 04. DESIGN OF WELDED CONNECTIONS

41. SECTION 04. DESIGN OF WELDED
CONNECTIONS
• PART B, Specific Requirements for Design of Nontubular Connections (Statically or
Cyclically Loaded)
• In General
• The specific requirements of Part B together with the requirements of Part A shall
apply to all connections of nontubular members subject to static loading. The
requirements of Parts A and B, except as modified by Part C, shall also apply to
cyclic loading.

42. SECTION 04. DESIGN OF WELDED CONNECTIONS

43. DESIGN OF A BUTT WELDED JOINTS
• Butt joints are extensively used in pressure vessels , The strength of butt weld joint is
obtained by considering joint efficiency (η). Normally, η = 0.75 – 0.90
• F F h
l
• Section of joint
plan of joint
Then F=hxlxηxσ
Where, h=plate thickness, σ=permissible tensile stress,
l=length of weld, η=joint efficiency.

44. DESIGN OF BUT WELDED JOINTS
• Example 01.
• A gas storage tank consists of a cylindrical Shell of 3 m inner diameter. It consists
of hemispherical shells by means of butt welded joint as shown in Figure. The
thickness of the cylindrical shell as well as the hemispherical cover is 20 mm.
Determine the allowable internal pressure to which the tank may be subjected,
if the permissible tensile stress in the weld is 85 N/mm2
. Assume efficiency of the
welded joint as 0.80.
• Solution.
F=hxlxηxσ
F=20x x3000 x0.80x 85 = 12,822,857 N
P internal x Projected area = Force (F), P internal= internal pressure
P internal= 12,822,857/1.52
xπ
P internal =1,813,333 N/m2

45. SOME OTHER EXAMPLES
API 650 Pressure vessels.

46. DESIGN OF A FILLET WELD JOINT
h= weld size, weld length.
h= weld size, weld length.
t= weld throat, (h cos , 0.707h)
σ = Permissible stress
Τ t = shear stress
Τ t = shear stress perpendicular to the weld
Τ l = shear stress along the weldment (along the axis of the weld)
σ = Permissible stress
Butt welds (Beveled grove).
Fillet welds, (Single fillet).

47. DESIGN OF A FILLET WELD
• Example 02.
AWS rule is Applied stress less than the
minimum of 0.3 x and 0.4x
Applied force = 50,000N
Area = 2x(0.707x6xL)= 8.48L
Then, applied stress =
AWS D1.1 says,
Allowable stress shall be minimum of
(1.) 0.3 x
(2.) 0.4x
0.3 x 410 = 123 Mpa
0.4x 250 = 100 Mpa (consider as per the rule )
Therefore,
50,000 100x8.48L
L 58.96 mm
selected L would be 60 mm
Additional Check;
What is be if YS=450 MPa and UTS=550MPa
E 7018 Rods (36 mm, say 40mm.)

48. SECTION 05 & 06.
WPS, PQR AND WPQ
• WPS - is a formal written document
describing standard welding procedures
• PQR - is completed the test piece is
subjected to Non-destructive and
destructive testing as specified in the
applicable standard, if all testing is
successful a WPS is written from and
supported by the PQR
• WPQ- A Welder Performance
Qualification (WPQ) is a test certificate
that shows whether a welder possesses
the necessary experience and
knowledge to perform the specifications
of a particular weld procedure.
WPS
WPQ
PQR

50. SECTION 05. PRE-QUALIFICATION OF WPS
• 5.1 General
• This clause contains requirements for prequalified Welding Procedure
Specifications (WPSs). These WPSs are exempt from the requirements for
testing required
• It is divided into eight parts as follows:
• Part A - WPS Development
• Part B - Base Metal
• Part C - Weld Joints
• Part D -Welding Processes
• Part E - Filler Metals and Shielding Gases
• Part F - Preheat and Interpass Temperature Requirements
• Part G-WPS Requirements
• Part H -Post Weld Heat Treatment

51. SECTION 05. A. PREQUALIFIED
WPS DEVELOPMENTS

54. SECTION 05. B. BASE METALS IN WPS
DEVELOPMENT WORK

59. PART C – WELDING JOINTS

60. PART C. WELD JOINTS

63. 7. FABRICATION
• Baking Electrodes.
• Electrodes exposed to the atmosphere for periods greater than those allowed,
shall be baked as follows:
• (1) All electrodes having low-hydrogen coverings conforming to AWS A5.1 shall
be baked for at least two hours between 500°F and 800°F [260°C and 430°C], or
• (2) All electrodes having low-hydrogen coverings conforming to A WS A5.5 shall
be baked for at least one hour at temperatures between 700°F and 800°F [370°C
and 430°C].
• All electrodes shall be placed in a suitable oven at a temperature not exceeding
one half the final baking temperature for a minimum of one half hour prior to
increasing the oven temperature to the final baking temperature. Final baking
time shall start after the oven reaches final baking temperature.

64. 7 FABRICATIONS
Surfaces to be welded, and surfaces adjacent to the weld, shall
be cleaned to remove excessive quantities of the following:
• (1) Water
• (2) Oil
• (3) Grease
• (4) Other hydrocarbon based materials
Welding on surfaces containing residual amounts of
foreign materials is permitted provided the quality
requirements of this code are met.

65. FABRICATION
• Machining, thermal cutting, gouging (including plasma arc cutting and
gouging), chipping, or grinding may be used for joint preparation, or the
removal of unacceptable work or metal, except that oxygen gouging shall
only be permitted for use on as-rolled steels
• Electric arc cutting and gouging processes (including plasma arc cutting
and gouging) and oxyfuel gas cutting processes are recognized under this
code for use in preparing, cutting, or trimming materials.
• In making welds under conditions of severe external shrinkage restraint, once
the welding has started, the joint shall not be allowed to cool below the
minimum specified preheat until the joint has been completed or sufficient
weld has been deposited to ensure freedom from cracking

66. 7. FABRICATION
•Statically Loaded Nontubular Structures.
Variations from flatness of webs having a depth, D, and a thickness, t, in panels
bounded by stiffeners or flanges, or both, whose least panel dimension is d shall
not exceed the following:
• Intermediate stiffeners on both sides of web
where D/t < 150, maximum variation = d/100
where D/t 2'. 150, maximum variation = d/80
• Intermediate stiffeners on one side only of web
where D/t < 100, maximum variation = d/100
where D/t 2'. 100, maximum variation = d/67
• No intermediate stiffeners
where D/t 2'. 100, maximum variation = D/150

67. 7. FABRICATION
•Cyclically Loaded Nontubular Structures.
Variation from flatness of webs having a depth, D, and a thickness, t, in panels
bounded by stiffeners or flanges, or both, whose least panel dimension is d shall
not exceed the following:
Intermediate stiffeners on both sides of web Interior girders
where D/t < 150 maximum variation = d/115
where D/t 2'. 150-maximum variation = d/92
Fascia girders
where D/t < 150 maximum variation = d/130
where D/t 2'. 150-maximum variation = d/105
Intermediate stiffeners on one side only of web Interior girders
where D/t < 100-maximum variation = d/100
where D/t 2'. 100-maximum variation = d/67

68. 7.
FABRICATIONS
Measuring bevel angle
Measuring leg length
Measuring R (reinforcement)

69. 8. INSPECTION
•8.1.3 Definition of Inspector Categories
8.1.3.1 Contractor's Inspector.
This inspector is the duly designated person who acts for, and in behalf of, the
Contractor on all inspection and quality matters within the scope of the contract
documents .
8.1.3.2 Verification Inspector.
This inspector is the duly designated person who acts for, and in behalf of, the
Owner or Engineer on all inspection and quality matters within the scope of the
contract documents .
8.1.3.3 Inspector(s).
When the term inspector is used without further qualification as to the specific
inspector category described above, it applies equally to inspection and
verification within the limits of responsibility described in

70. QUALIFICATION OF INSPECTION PERSONNEL
• 8.1.4.2 Basis for Qualification of Welding Inspectors.
• Inspectors responsible for acceptance or rejection of material and workmanship on the basis of
visual inspection shall be qualified. The acceptable qualification basis shall be one of the following:
• (1) Current or previous certification as an AWS Certified Welding Inspector (CWl) or Senior Certified
Welding Inspector (SCWl) in conformance with the requirements of AWS QCl, Standard for AWS
Certification of Welding Inspectors,
• (2) Current or previous certification as a Level 2 or Level 3 Welding Inspector in conformance with
the requirements of Canadian Standard Association (CSA) Standard Wl 78.2, Certification of
Welding Inspectors,
• (3) Current or previous qualification as a Welding Inspector (WI) or Senior Welding Inspector (SWI) in
conformance with the requirements of AWS B5.1, Specification for the Qualification of Welding
Inspectors,
• (4) Current or previous qualification as an ASNT SNT-TC-lA- Level II in conformance with the
requirements of ASNT Recommended Practice No. SNT-TC JA. Personnel Qualification and
Certification in Nondestructive Testing. or ANSI/ASNT CP-189 ASNT Standard for Qualification and
Certification of Nondestructive Personnel or An individual who, by training or experience, or both,
in metals fabrication, inspection and testing, is competent to perform inspection of the work.

71. 8. INSPECTION

72. 8. INSPECTION
Bridge Cam Gauge

73. 8. INSPECTION

74. 8. INSPECTION

75. 8. INSPECTION
Surface Breaking Discontinuity
Sub surface Discontinuity

77. 8.
INSPECTION

78. 8.
INSPECTION

79. 8.0
INSPECTION

80. 9.0 STUD WELDING

81. 10. TUBULAR STRUCTURES

82. EVEN IN PLUMBING ENGINEERING

83. 11. STRENGTHENING AND REPAIR OF EXISTING STRUCTURES

84. 11. STRENGTHENING AND REPAIR OF EXISTING STRUCTURES

85. 11. STRENGTHENING AND REPAIR OF EXISTING STRUCTURES

86. 11. STRENGTHENING AND REPAIR OF EXISTING STRUCTURES

87. BS 5950-1: 2000 REQUIREMENT
STRUCTURAL ENGINEERING VIEW
• Section 6.7 Welded connection
• Section 6.8 Design of fillet welds
• Section 6.9 Design of but welds

88. THE END
• Thanks to IESL and the audience for listening me
• To all my present and future clients for giving me an opportunity to
gather these practical experiences.
• IntPE M.A.S. Upul Kumara,
• BScEng (Pdn), PGDipEPCEng(Pdn), MSc (My), IntPE, CEng, FIE(SL) CPEngNZ, MAWS (USA), MASME(USA), PM-ASNT(USA),
• +94 773151906
• kumar.msu906.gmail.com