1MAYES TESTING ENGINEERS, INC.

Nondestructive Examination and Special Inspection of Seismic Welding

NASCC Steel Conference

April 2 and 3, 2008

MAYES TESTING ENGINEERS, INC.

Michael J. Mayes, P.E.

Welding Engineer

NDE Level III

AWS D1.1 Code Committee

AISC D1.8 Seismic Subcommittee

Special Inspection Agency Owner

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Seismic Critical Welding

Special Inspection

Approved Fabricators

Nondestructive Examination

Topics

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Northridge Damage

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What Happened?

Workmanship

Inspection

Design Assumptions

Material Issues

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FEMA AISC Revised Seismic Provisions (341-05)

Develop New Seismic Design Recommendations

Collect Research and Future Test Data

Pre-qualified Connections (358-05)

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FEMA AWS New D1 Subcommittee Seismic

New Seismic Welding Code D1.8

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Weld Toughness

FCAW Wires

Control Deposition Rates

Pre-qualified Procedures

Limits on Heat Input

Varies by Brand and Diameter

Toughness Cannot be Determined Nondestructively

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AWS D1.8 Lot Testing

Alternative to Lot Test

Outside Audit of Supplier QC

3 Initial Lot Tests

1 Lot Every 3 Years

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Filler Metal Toughness

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Filler Metal Toughness

Heat Input = Voltage * Current * 60

Travel Speed * 1000

= 27 V * 350 A * 60

12 inch/min * 1000

= 47 kJ/inch

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Seismic Welding Procedures

Obtain High/Low HI Certifications

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

Set-up Machines

Measure Output

Make Sure It Works!

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Mixing Filler Metals

Field Welds Over Shop Welds

Repair Welds

FCAW Self Shielded Electrodes Only

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Mixing Filler Metals

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Electrode Moisture Pick-up: SMAW

Rod Ovens on Site

Monitor Exposure Times

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FCAW Wire Storage and Exposure

Testing of FCAW Wire to Establish Storage and Exposure Limits for Diffusible Hydrogen Level of H16

Protective Packaging

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FCAW Storage Oven

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Backing Bar Issues

Remove From Critical Welds

Better Inspection Without Backing

Control of Tack Welds

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Backing Bar Issues

Remove backing barBackgougeMT VisualBackweld5/16 (+) reinforcing filletMT FEMA 353 - 4.1.2

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Backing Bar IssuesNo top reinforcing weld required

Fillet weld beneath backing bar

FEMA 350 Figure 3-8

5/16"

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Ceramic Backing Bars

Fit-up Issues

Root Gap

Welder Qualification

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Copper Backing Bars

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Copper Backing Bars

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Copper Backing Bars

Qualify Procedures

Control Fit-up

Welder Skill

Copper Pick-up

Welder Qualification

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Weld Tabs

Use!

Remove

No End Dams

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Weld Tabs

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Weld Tabs

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End Dams

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End Dams

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Weld Tab Removal

Grind Smooth

500 Micro-inches

Smooth Transition to Adjacent Surfaces

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Weld Tab Removal

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Weld Access Holes

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Weld Access Holes

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Weld Access Holes

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Welder Qualifications

AWS D1.8

Welder Mock-up

Highest Deposition Rates

Increase Qualification Period to 36 Months

Use Same Backing (steel, copper, ceramic, etc.)

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Seismic Welder Mock-up

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Seismic Welder Test

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New Design Concept

Plastic Hinges/Weak Lines

Lower Stress at Weld Joint

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Why Moment Frames?

Resist Lateral Earthquake Loads

Architectural Issues Brace Frames Concrete Shear Walls

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Full Scale Connection Testing

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Reduced Beam Sections (RBS)

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Bolted End-Plate Connections

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Side Plate Connection

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Slotted Web Connection

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Welded Attachments in Protected Zone

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Welded Attachments in Protected Zone

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Hole Drilled in Protected Zone

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Pins Shot Into Protected Zone

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K-Area

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K-Area

Poor Properties at Flange-Web Intersection

Avoid Welds in K-Area

Additional NDE

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K-Area

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K-Area

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K-Area

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K-Area

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K-Area

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K-Area

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Tack Welds

Tack Inside Weld Groove

All Tack Welds Removed or Consumed

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Backing Bar Welds

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Welding Sequence

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Welding Sequence

5 4 3 2 1

10 9 8 7 6Backing Bar

WeldTab

WeldTab

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Welding Sequence

Alternate Through Access Hole

Overlap Ends of Passes

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Welding Sequence

9 108 75 64 31 2 Backing Bar

WeldTab

WeldTab

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Welder Access

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Inspector Access

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Welding Procedures

Submit Prior to Welding

Engineer Approves

Inspector and Welder Has a Copy

Measure Variables

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QA/QC Checklist

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Other Seismic Inspection Issues

Welder I.D.

48 Hour Delay Before Inspection (only for K-Area)

Lamellar Testing

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Contract Documents

Identify Seismic Critical Welds

Specify AISC Seismic Provisions (AISC 341-05) Appendix Q

Specify AWS D1.1 and AWS D1.8

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Engineer Must Define Seismic Critical Welds

SMRF

OMRF

EBF

Lateral Systems

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Engineer Responsibilities

Use Pre-qualified Connections

Review Welding Procedures

Project QA/QC Plan

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Fabricator/Erector Issues

Submittals QC Plans Welding Procedure Specifications (WPS)

Preconstruction Meetings

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Cost Impacts?

Welder Training

Welder Qualifications

Slower Production Rates

Hold Points

Increased NDE

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Inspector Qualifications - QC

Fabricators Inspector Qualifications / Duties per QC Manual AWS-CWI

Erectors Inspector?

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Inspector Qualifications - QA

Special Inspector Represents Owner Represents Building Department

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Special Inspector Qualifications

International Building Code (IBC) IBC 1704.1 The special inspector shall

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

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Special Inspector Qualifications

Vary Between Jurisdictions

WABO and OBOA ICC Exams, Documented Experience,

Interview

Portland, Las Vegas, Los Angeles, San Francisco

CWI Required by AISC Seismic

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Inspection Requirements

IBC Requirements 100% Visual Inspection Shop and

Field Continuous vs. Periodic Inspection

AISC Seismic Additional NDE Requirements

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Inspection Requirements

Periodic Inspection Allowed For: Single Pass Fillet Welds Deck Welding Welded Studs Cold Formed Steel Welding Stairs and Railing Approved Fabricators

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Approved Fabricators

IBC 1704.2.2 Approval (by Building Official) based on: Review of QC Procedures Periodic Audits by Approved Special

Inspector

AISC Certified Fabricators?

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Fabrication Inspection

Same Inspector/Agency as Erection?

Demand Competence!

Shop Inspection Typically Required for Seismic

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Tubular Joints - TKY

Not Covered by Bridge Code

Nonstandard Testing

Require Mock-ups

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Tubular Mockups

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NDE Requirements

No Requirements Per IBC

No Requirements Per AWS D1.1

Contract Documents

Tubular Requirements

AISC Seismic Provisions

Understand and Clarify!

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AISC Seismic NDE Requirements

MT of K-Area

UT of CJP Welds

MT (25%) of CJP Welds

UT for Lamellar Tearing and Lamination

MT or PT For Beam Cope and Access Holes

MT for Tab Removal Sites

MT for RBS Repairs

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

Exception: Attempt of Defraud or Gross Nonconformance

AWS D1.1 6.6.5Non Specified NDT

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Methods of InspectionNon-destructive Examination (NDE)

Visual

Liquid Pene

trant

Magnetic Partic

le

Ultrasonic

Radiography

Microwave

Acoustic Emission

Thermography

Laser Interferometry

Replication

Flux Leakage

Acoustic Microscopy

Magnetic

Measure

ments

Tap Testing

Eddy Current

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Non-destructive Examination Structural Welding

Radiography Bridge Girder Splices Not Practical for Buildings UT and RT Should Not be Used

Together!

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Non-destructive Examination Structural Welding

Dye Penetrant Testing Wont Work With Rough Surfaces Not Practical for Buildings

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Non-destructive Examination Structural Welding

Magnetic Particle Testing (MT)

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

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Magnetic Particle Testing (MT)

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Magnetic Particle Testing (MT)

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Magnetic Particle Testing (MT)

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Ultrasonic Inspection (Pulse-Echo)

plate

crack

0 2 4 6 8 10

initial pulse

crackecho

back surfaceecho

Oscilloscope, or flaw detector screen

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Ultrasonic Testing (UT)

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Ultrasonic Testing (UT)

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Ultrasonic Testing (UT)

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Inspection Issues

Transducer

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Ultrasonic Limitations

Operator Skill/Training

Does Inspector Ever Find Flaws?

Flaw Orientation

Access to Weld

Dont Use for Partial Penetration Welds

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UT Technician Qualifications

Varies from Company to Company

Check Personnel on Real Samples

AWS D1.8 Annex E

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UT Flaw Detection

Should Be Very Accurate

Use Confirming Sound Paths

Welder Should Find Flaws

Remove Backing Bars

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UT Flaw Sizing

Unique Skills Required

Amplitude Techniques Wont Work

AWS is Conservative

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Ultrasonic Testing

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Questions?