Ultrasonic Testing of welds

According to AWS D1.1 Module-S1

Weld Inspection

Presented by
N.Kuppusamy
Singapore Chapter

Event Horizon

N.Kuppusamy

Gate way to Event Horizon: www.ndthorizon.com

A site dedicated to NDT and WI exam preparation.

Commencing in Oct.2005

Ultrasonic Testing

Weld Inspection using AWS D1.1 :Ed2004

2 2/24/2007 N.Kuppusamy
Introduction
 This presentation will help
technicians to perform testing
according to Section 6, Part F of Sec-6: 2004

American Welding Society

D1.1:2004 Structural Welding Code
–Steel.
It is important to remember that
this is a general training program
and the procedure should be
referenced for specific information.

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D1.1:2004 & D1.1:2004M

„ The AWS standard with the designation
D1. 1 :2O04 uses U.S. Customary Units.

„ The standard designation D1.1M:2004

uses SI Units.

„ The latter are shown within brackets [ ].

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 Sound Categories
„ human hearing range
„ frequencies between 20 Hz and 20,000 Hz

„ ultrasonic
„ frequencies > 20,000 Hz

„ infrasonic
„ frequencies < 20 Hz

This standard recommends 2.0 to 2.5MHz frequency.

We normally use up to 4MHz.

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Basic Principle
„ Pulse-Echo Equipments are used for all weld
testing.
„ Ultrasound is generated by a Piezoelectric
transducer driven by series of high voltage
(100 – 1000+ volts) pulses.
„ This sound is transmitted into the specimen
from the probe.
„ Some energy is reflected back to the probe when it encounters a
defect.
„ This reflected energy is converted to electrical signal and fed
into the flaw detector.
„ There it is filtered, amplified and displayed on a CRT (or suitable
display system).
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 What you will learn
™ Completing Form D-11 (Annex D)
™ Determine the proper transducer(s) needed
for testing a weld.
™ Calibration using an IIW, V1 (rumpus), and
DSC block.
™ Scanning for discontinuities.
™ Calculate size and location of a discontinuity.
™ Accept/Reject evaluation of a discontinuity.

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ANNEX D AWS D1.1/D1.1M:2004

Form D-11

Sample Report

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 Form D-11
Some basic information should be completed on form
D-11 prior to the inspection. These information
includes the following:
W1
^ Weld Identification 19mm
^ Material Thickness CJP – Butt

^ Type of Weld Joint SMAW

^ Welding Process Sec-6, Part C

Section 6.3.2
^ Quality Requirements
(Sec-6, Part C Acc Criteria).
^ Section Number (6.13.1 through 6.13.3).
2004
^ Year of AWS D1.1 Code used (2004).
^ Testing Date 13-8-2005

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 N.Kuppusamy
^ Inspected By

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Step 1 – Specimen Measurement

Measure the part thickness. From this thickness you will need to
calculate the skip distance. The skip distance is the area
where you will scan the part with the proper angle transducer.
Mark the end of the skip distance from the edge of the heat
affected zone (HAZ). The area in red will be used to identify the HAZ
heat affected zone.

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 Step 2 – Inspection Layout
The skip distance will equal the surface distance of the two
legs (from the HAZ). You will need to know the distance of
this area in order to perform a lamination scan followed by
an angle beam examination

Skip Distance = 2t x tan θ

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Inspection Layout
Identifying the skip distance from the edge of the HAZ will ensure
complete coverage of the weld when performing an angle beam
examination.

Skip Distance = 2t x tan θ

Angle Value
Tan 45 1
Tan 60 1.75
Tan 70 2.75

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 Step 3 – Lamination Scan
A lamination scan will be performed in the area where the
angle beam inspection will take place. This scan is
performed with a straight beam transducer.

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Lamination Scan
Perform a lamination scan from face “A”.
You will need to see at least two plate
thicknesses on the display. The first
backwall reflection shall be 50 to 75%
full screen height.
[Calibration not accurate]

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 Lamination Scan
If any area of the base metal shows a total loss of backwall
reflection, or if an indication is equal or greater to the backwall
reflection, the size and location and depth will be reported.
Lam BW+Lam 0 Deg scanning

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Lamination Scan (Para 6.26.5)

Move the transducer in all directions until the amplitude of
the signal is reduced by 50%. Mark the center of the
transducer.

90% FSH

45% FSH

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 Lamination Scan
The area can be measured and included in the report. This area
should be avoided when performing an angle beam examination
or an alternate scanning procedure shall be used.

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Lamination Scan
Note the location and size of the lamination on report form D-11
or write an additional report with a drawing showing its location.
 Face A
Sample sketch (top view)

Weld
0.5” 0.3”

0.4”
2.5”

Face A lamination

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 Step 4 – Transducer Angle
Table 6.7 list the transducer angles needed to test the weld. For
0.60” thick material, the transducer angle used will be 70 degrees
and will be tested from face “A”. On Form D-11 record the
transducer angle and face which you will be testing from. The face
is determined from Table 6.7

Table 6.7

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Step 5 – Screen Range

Calculate the full V-path. This is determined
by the material thickness and transducer
angle. Choose the appropriate screen
range in order to see a minimum sound
path of two legs.
Skip Distance
 V-Path = 2t x Secθ
Second leg First Leg

Root

eg: TR125mm for 20mm

thickness using 70° Probe.

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Depth

0
Step 5 – Screen Range
V-path is calculated from the
Angle Value
secant values
Sec 45 1.4
Sec 60 2.0
Sec 70 3.0
 V-path = 2t x Secθ

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Transducer
Connect the probe and cable with
Flaw Detector. Verify the transducer
is coupled to the wedge and there are
no air pockets between the two.

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 Reading Time Base
For analog display, all
measurements are taken
from the leading edge of
the trace (i.e., where the
signal breaks the baseline
of the ultrasonic screen ).

For digital display

equipments either edge or
peak measurement mode
can be selected.

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Screen Range – IIW Block

Adjust the ultrasonic machine to obtain the proper screen
range. With an IIW type II block shown, the backwall
reflections will be located at 2” and 4”.

V1 Block
 2”Radius
4” Radius

Position of the signals with a 10” screen range.

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 Screen Range – IIW Block
The position of the 2” and 4” reflections when using a 5”
screen range.

Position of the signals with a 5” screen range.

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IIW Blocks
• The IIW or IIW Type-1 or Type-2 block can be used to
set convenient range.

• The IIW Block is the “true” block designed as per the

requirements of IIS/IIW-23-59 and made of steel only.

• The “type” blocks are patterned after “true” block,

but does not conform to the requirements of IIS/IIW-
23-59. Can be made with variations.

• Annex X provides other approved blocks.

Annex X

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 Screen Range – DSC Block (Annex X)
The Distance and Sensitivity Calibration (DSC) block can be
used for calibration. With the transducer placed in the
position shown, the reflections will take place at 1”, 5”, 9”, etc.

Position of the signals with a 10” screen range.

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Screen Range – DSC Block

With the transducer placed in the position shown, the reflections
will take place at 1”, 5”, 9”, etc.

Position of the signals with a 5.0” screen range.

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 DSC Block - Dimensions
All dimensions are in mm

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Screen Range – DSC Block

With the transducer placed in the position shown, the
reflections will take place at 3”, 7”, 11”, etc.

Position of the signals with a 10” screen range.

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 Screen Range – V2 (Rumpus) Block
The miniature calibration block or rumpus block can also be
used for calibration. With the transducer placed in the position
shown, the reflections will take place at 1”, 4”, 7”, 10” etc.

Position of the signals with a 5” screen range.

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Screen Range – Rumpus Block

With the transducer placed in the position shown, the
reflections will take place at 1”, 4”, 7”, 10” etc.

Position of the signals with a 10” screen range.

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 Screen Range – Rumpus Block
With the transducer placed in the position shown, the
reflections will take place at 2”, 5”, 8”, etc.

Position of the signals with a 5” screen range.

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Screen Range – Rumpus Block

With the transducer placed in the position shown, the
reflections will take place at 2”, 5”, 8”, etc.

Position of the signals with a 10” screen range.

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 Step 7 – Transducer Exit Point
„ Determine the exit point of the transducer. Peak the signal on
the ultrasonic machine and verify that the index point on the
plastic wedge matches the calibration block.

„ You may use tape and a pen to mark the exit point. This will allow
for easier measurements when measuring the surface distance.

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Exit Point – IIW Block

The exit point and screen range can be performed at the same time.
Slide the transducer back and forth until the signal is maximized.
The pictures below shows the location of the transducer when
verifying the exit point using an IIW type II block.

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 Exit Point – DSC Block
The pictures below shows the location of the transducer
when verifying the exit point.

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Exit Point – Rumpus Block

The picture below shows the location of the transducer
when verifying the exit point.

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 Step 8 – Transducer Angle
The angle of the transducer will need to be verified. It shall
be within plus or minus 2 degrees of the required angle.

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Angle – IIW Block

Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of the
transducer when verifying the transducer angle.

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 Angle – DSC Block
The picture below shows the location of the transducer when
verifying the transducer angle.

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Angle – Rumpus Block

The picture below shows the
location of the transducer when
verifying the transducer angle.

V2

75º

70º 65º

60º

60º 45º 30º

 65º 55º 50º 40º

60º
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 Step 9 – Transducer Resolution
The resolution shall be checked with the instrument controls set at
normal test settings and the indications from the holes brought to
midscreen height. Resolution shall be sufficient to identify the peaks
of the three holes.
Resolution Block

Position of the signals with a 5” screen range.

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Step 10 – Reference Level

The amplitude of a known size reflector will be adjusted from
50-75% full screen height. The dB will be recorded as the
reference level on form D-11.

IIW block Rumpus block

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 Reference Level – IIW Block
The transducer shall be placed in the position shown and the signal
amplitude from the hole will be maximized. Adjust the dB in order to obtain
a signal from 50 to 75% full screen height. This will be used as the
reference level “b” on form D-11.

Position of the signals with a 10” screen range.

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Reference Level – DSC Block

The transducer shall be placed in the position shown and the signal
amplitude from the notch will be maximized. Adjust the dB in
order to obtain a signal from 50 to 75% full screen height. This
will be used as the reference level “b” on form D-11.

Position of the signals with a 5” screen range.

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 Reference Level – V2 Block
The transducer shall be placed in the position
shown and the signal amplitude from the hole will
be maximized. Adjust the dB in order to obtain a
signal from 50 to 75% full screen height. This will
be used as the reference level “b” on form D-11.

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 Reference dB in this
example is 42 and Position of the signals with
100mm screen range.
reference screen
height is 70% FSH

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Step 11 – Reference Level

In this example the reference level “b” would be recorded as
42 dB. The reference screen height used is 60% FSH.

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 Step 12 – Scanning Level
Scanning level is based on sound

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 path distance and not material *GAIN 62.0dB
thickness. If Statically loaded REF GAIN 42.0dB
nontubular connections (table 6.2) % CHANGE 501.2
dB CHANGE 20.0dB
are tested, the following scanning
levels will be used.
Scanning Levels
Table 6.2
Above Zero
%Change Sound Path in in. (mm)
Reference, dB
dB diff ⎞
100 x Antilog ⎜⎛
through 2.5” (65mm) 14
⎟
⎝ 20 ⎠ >2.5” to 5” (65-125mm) 19
>5” to 10” (125-250mm) 29
>10” to 15” (250-380mm) 39

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Scanning Level
If Cyclically loaded nontubular
*GAIN 62.0dB
connections (table 6.3) are REF GAIN 42.0dB
tested, the following scanning % CHANGE 1000.0
dB CHANGE 20.0dB
levels will be used.

Table 6.3
Scanning Levels
Above Zero
Sound Path in in. (mm)
Reference, dB
through 2.5” (65mm) 20
>2.5” to 5” (65-125mm) 25
>5” to 10” (125-250mm) 35
>10” to 15” (250-380mm) 45

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 Scanning Level
This shows the screen presentation when using a scanning
level 14 dB above the reference level.

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Step 13 – Initial Information Scan

Perform an initial information scan marking the location of any
suspected discontinuities.

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 Defect Root

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 Weld Configuration
You can draw a diagram of the weld on the ultrasonic screen with a
water based marker or grease pencil. The line is drawn at the end of
the 1st, 2nd, and 3rd leg. This may help you visualize the location of
the discontinuity in the weld.

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 1 2 3
1 2 3

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N.Kuppusamy

Configuring weld on the screen

1st leg – Root Indication
1 2 3
2nd leg marking -Cap
3rd leg marking -Root

1 2 3

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 Step 14 – Surface Distance Angle Value
Calculate the surface distance in order Sin 45 0.70
to determine if the signal is located in Sin 60 0.87
the weld. Sin 70 0.94
Surface Distance = Beam Path x Sin θ

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55 (Or) Surface Distance = Depth x Tan θ N.Kuppusamy

Step 15 – Discontinuity Depth

Calculate the depth in order to determine Angle Value
if the signal is located in the weld. Sec 45 1.4
Sec 60 2.0
Beam Path
Depth of flaw = Sec 70 3.0
Sec θ

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 Step 16 – Sound Path
Move the transducer in all directions in order to peak the
signal from the discontinuity. Record the “Sound Path”
(Angular Distance) on Form D-11. Refer Para 6.32 for
scanning patterns.

Scanning Patterns

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Step 17 – Sound Path

Record the “Leg” on Form D-11.

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Step 18 – Indication Level
Increase or decrease the dB until the screen height from the
discontinuity is equal to the reference level. Record the dB under
indication level (column “a”).
59 dB reference level - 60% FSH.
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Step 19 – Attenuation Factor

Subtract one inch from the sound path distance and multiply the
remainder by two. This number will be rounded to the nearest whole
number. If the number is less than 0.5 dB it will be lowered to the
nearest whole number. If the number is 0.5 or greater, it will be
increased to the nearest whole number.

In this example, the

sound path is 1.9”

1.9” – 1 = 0.9
0.9 x 2 = 1.8

= 2 dB (Rounded to the
nearest whole number)

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 Attenuation Factor
On Form D-11, fill out the attenuation factor “c”. This is
located under “Decibels- Attenuation Factor”.

In this example, the sound

path is 1.0”

1.0 – 1 = 0.0
0.0 x 2 = 0.0

If the attenuation factor is

less than 0.5, the attenuation
factor will be zero.

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Step 20 – Indication Rating

The indication rating is calculated by taking the “Indication
level” minus “Reference level” minus “Attenuation factor”.
A-B-C=D
The answer “D” is your
indication rating and can be
positive or negative.

Write this number in column

“D” under “Decibels -
Indication Rating”

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Indication Rating
More severe
„ -ve Indication rating is more severe than -ve
+ve indication rating.
 For Example:
Reference level =46 db and
Reference 0
Indication level = 40db means
Level
The indication is 6dB or 100%
greater than the reference level.

+ve
Less Severe
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Step 21 – Discontinuity Length

Maximize the signal amplitude from the discontinuity.

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 Step 22 – Discontinuity Length
Slide the transducer parallel with the weld until the signal amplitude
has reduced by 50%. From 60%FSH to 30%FSH in this example.
Mark the location next to the weld aligned with the center of the
transducer. Perform this procedure in both directions.

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Discontinuity Length
Measure and Record the length on Form D-11.

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 Step 23 – Discontinuity Class
From Table 6.2 or 6.3, determine the Discontinuity Severity Class.
This is based on the Indication Rating and Length.

Class A (large discontinuity)

Any indication in this category shall be rejected regardless of length
Class B (medium discontinuity)
Any indication in this category having a length greater than ¾”
(19mm) shall be rejected.
Class C (small discontinuity)
Any indication in this category having a length greater than 2”
(50mm) shall be rejected.
Class D (minor discontinuity)
Any indication in this category shall be accepted regardless of length
or location in the weld.
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Step 24 – Discontinuity Evaluation

On Form D-11 under “Discontinuity Evaluation” list the class of
the discontinuity.

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 Step 25 – Accept/Reject
On Form D-11 under “Remarks” accept or reject the discontinuity.
 P258 TS001
W1
19mm
CJP – Butt
SMAW
Sec-6, Part C - Section 6.3.2

1 70° A 1 52 50 2 0 13mm 1.6” 0.53 -0.1” 31” Class A Reject

Reference Points X and Y

-
Distance from X
+
 Step 26 – Distance from “Y”
One side of the plate or weld can be identified with a “Y” location
point. From the edge of the weld measure to the beginning of the
discontinuity. Record “Distance from “Y” on Form D-11.

Distance from “Y” = 1.0” Distance from “Y” = 0.3”

Step 27 – Distance from “X”

From the center of the weld (marked in black), if the discontinuity is located
opposite the “Y” location mark, it will be measured as a positive number. This
will be recorded under “Distance from X” on Form D-11.

Distance from X = 0.2”

 Step 28 – Distance from “X”
From the center of the weld (marked in black), if the discontinuity
is located on the same side as the “Y” location mark, it will be
measured as a negative number. This will be recorded under
“Distance from X” on Form D-11.

Distance from X = -0.2”

Step 29 – Scanning Level

Return to the scanning level and locate the next discontinuity for
evaluation.
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 Form D-11 General Notes:
• In order to attain Rating “d”
(1) With instruments with gain control, use the formula a - b - c = d.
(2) With instruments with attenuation control, use the formula b - a - c = d.
(3) A plus or minus sign shall accompany the “d” figure unless “d” is equal
to zero.
• Distance from X is used in describing the location of a weld discontinuity in a
direction perpendicular to the weld reference line. Unless this figure is zero,
a plus or minus sign shall accompany it.
• Distance from Y is used in describing the location of a weld discontinuity in a
direction parallel to the weld reference line. This figure is attained by
measuring the distance from the “ Y end of the weld to the beginning of said
discontinuity.
• Evaluation of Retested Repaired Weld Areas shall be tabulated on a new line
on the report form. If the original report form is used, Rn shall prefix the
indication number. If additional forms are used, the R number shall prefix the
report number.

N.uppusamy

AWS D1.1:2002 Vs 2004 Edition

(Major Changes)
2002 Edition ) 2004 Edition
Rejectable ) unacceptable
Bases ) Basis
Basis ) Bases
Individual ) Engineer or technician
)
Approval Approval of Engineer
)
Nondestructive Inspection Nondestructive Examination

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 Definitions
„ Code: A standard enacted or enforced as a law
„ Standard: Document to control and govern practices in an
industry or application, applied on a national or
interna-tional basis and usually produced by consensus.
„ Specification: A set of instructions or standards invoked
by a specific customer to govern the results or
performance of a specific set of tasks or products

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2/24/2007 N.Kuppusamy 77

Definitions
Defect
1. General. An imperfection, fault or error in manufactured materiel and
service (A lack, want, deficiency or absence of something necessary for
completeness, perfection or adequacy in form or function).
2. Critical defect. A defect that judgment and experience indicate is likely to
result in hazardous or unsafe conditions for individuals depending on, using or
maintaining the product.
3. Major defect. Other than critical defect which is likely to result in
failure or to reduce materially the usability of the unit product for its
intended purpose.
4. Minor defect. A defect that is not likely to reduce materially the usability
of a unit product for its intended purpose, or is a departure from established
standards having little bearing on the effective use or operation of the unit.
5. Latent defect. A hidden or concealed defect, one which could not be
discovered by reasonable and customary inspection; one not apparent on face
of goods, product or a document.

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 CLASS R Criteria

6.13.3.1 Class R (Applicable When UT is Used as an Alternate to RT).

All indications having one-half (6 dB) or less amplitude than the standard sensitivity
level (with due regard for 6.27.6) shall be disregarded.

Indications exceeding the disregard level shall be evaluated as follows:

2/24/2007 N.Kuppusamy 79

Class X
6.13.3.2 Class X (Experience-Based, Fitness for Purpose Criteria
Applicable to T-, Y-, and K-Connections in Redundant Structures with
Notch-Tough Weldments).

All indications having half (6 dB) or less amplitude than the

standard sensitivity (with due regard for 6.27.6) shall be disregarded.
Indications exceeding the disregard level shall be evaluated as follows:

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 6.26.12 Steel Backing.

• UT of CJP groove welds with steel backing shall be

performed with a UT procedure that recognizes potential
reflectors created by the base metal-backing interface (see
Commentary C6.26.12 for additional guidance scanning
groove welds containing steel backing).

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UT of Tubular T-, Y-, and

K- Connections
• All UT shall be in conformance with a written procedure which has
been prepared or approved by an individual qualified as SNT-TC-IA,
Level III, and experienced in UT of tubular structures.
• The procedure shall be based upon the requirements of this section and
Section 6, Part F, as applicable.
• The type of weld joint configuration to be examined (i.e., the applicable
range of diameter, thickness, and local dihedral angle). Conventional
techniques are generally limited to diameters of 12-3/4 in. [325 mm]
and larger, thicknesses of 1/2 in. [12 mm] and above, and local dihedral
angles of 30" or greater. Special techniques for smaller sides may be
used, provided they are qualified as described herein,

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 UT of Tubular T-, Y-, and
K- Connections
(i) Basic Sensitivity. Reference level screen height obtained
using maximum reflection from the 0.060 in. [ 1.5 mm]
diameter hole in the IIW block (or other block which
results in the same basic calibration sensitivity) as
described in 6.25 (or 6.29).
(2) Distance Amplitude Correction. The sensitivity level shall
be adjusted to provide for attenuation loss throughout the
range of sound path to be used by either distance amplitude
correction curves, electronic means, or as described in
6.26.6.4.
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UT of Tubular T-, Y-, and

K- Connections
Weld scanning of T-, Y-, and K connections shall be performed
from the branch member surface (see Figure 6.25).
All examinations shall be made in leg I and II where possible.
For initial scanning, the sensitivity shall be increased by 12 dB
above that established in 6.27.3 for the maximum sound path.
Indication evaluation shall be performed with reference to the
standard sensitivity.

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 UT of Tubular T-, Y-, and
K- Connections
• A report form which clearly identifies the work and
the area of inspection shall be completed by the UT
operator at the time of inspection.
• An example of such a form is shown in Annex D,
Form D-11.

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Instrument Requirement

The equipment shall meet the following:

• Pulse Echo type, A-Scan Equipment suitable for probes
between 1 to 6 MHz.
• Probe: 2 to 2.5MHz
Crystal size for normal probes :½”Ø to 1”Ø

Crystal Size for Angle Probes

• Maximum Width 15 to 25mm.
• Maximum Height 15 to 20mm.
• Maximum width-to-height ratio: 1.2 to 1.0
• Maximum width-to-height ratio: 1.0 to 1.0

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 Linearity
• Horizontal linearity: within ±2% screen width (2mm
per 100mm range)
• dB accuracy: within ±2dB in a minimum allowable
range of 60dB.
Angles:
Angle probes shall produce a sound beam within ±2° of
nominal angles (i.e., 70°, 60° and 45°)

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Periodic Calibrations
• Horizontal linearity – every 40 hours of instrument use.
• Gain control – Every 2 months
• Maximum Internal reflections – Every 40 hours of instrument use.
(screen area beyond ½ sound path above reference level height shall be
free of any indication)
• Probe angle – Each 8 hours of use.
• Sensitivity and Sweep distance calibration – Just prior to and at the
location of testing of each weld.
• Recalibration – a) After change of operator, b) Each 30 minute time
interval, and c) When electrical circuitry is disturbed.
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 Electrical Circuitry Disturbances.

1. Transducer changing
2. Battery change
3. Electrical outlet change
4. Coaxial cable change
5. Power outage (failure)

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Scanning Patterns
Longitudinal Discontinuities
6.32.1.1 Scanning Movement A. weld axis
Rotation angle a =10°
6.32.1.2 Scanning Movement B.
Scanning distance b shall be such that
the section of weld being tested is
covered.
6.32.1.3 Scanning Movement C.
Progression distance c shall be
approximately one-half the transducer
width.
Note: movements A, B, and C may be
combined into one scanning pattern.

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 Transverse Discontinuities

6.32.2.1 Ground Welds. Scanning pattern D shall be used when welds are
ground flush.
6.32.2.2 Unground Welds. Scanning pattern E shall be used when the weld
reinforcement is not ground flush. Scanning angle e = 15° max.
Note: The scanning pattern shall cover the full weld section.
6.32.3 ESW or EGW Welds (Additional Scanning Pattern). Scanning Pattern
E Search unit rotation angle e between 45° and 60°.
Note: The scanning pattern shall cover the full weld section.
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Transfer Correction
• Transfer correction for surface curvature and roughness
[where amplitude methods (DAC) are used).
• Standard sensitivity for examination of production welds
using amplitude techniques shall be: basic sensitivity +
distant amplitude correction + transfer correction. This
calibration shall be performed at least once for each joint to
be tested.
• Transfer correction may be used to accommodate UT through
tight layers of paint not exceeding 10 mils [0.25 mm] in
thickness.
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 Base Metal Acceptance Criteria
Section 5. 5.15 Preparation of Base Metal
Surfaces on which weld metal is to be deposited shall be smooth,
uniform, and free from fins, tears, cracks, and other
discontinuities which would adversely affect the quality or
strength of the weld. Surfaces to be welded, and surfaces
adjacent to a weld, shall also be free from loose or thick scale,
slag, rust, moisture, grease, and other foreign material that would
prevent proper welding or produce objectionable fumes. Mill scale
that can withstand vigorous wire brushing, a thin rust-inhibitive
coating, or anti-spatter compound may remain with the following
exception: for girders in cyclically loaded structures, all mill scale
shall be removed from the surfaces on which flange-to-web welds
are to be made.
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Base Metal Acceptance Criteria

5.15.1 Mill-Induced Discontinuities.
The limits of acceptability and the repair of visually observed
cut surface discontinuities shall be in conformance with Table
5.4, in which the length of discontinuity is the visible long
dimension on the cut surface of material and the depth is the
distance that the discontinuity extends into the material from
the cut surface. All welded repairs shall be in conformance with
this code. Removal of the discontinuity may be done from
either surface of the base metal. The aggregate length of
welding shall not exceed 20% of the length of the plate surface
being repaired except with approval of the Engineer.
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 Base Metal Acceptance Criteria
5.15.1.1 Acceptance Criteria.
For discontinuities greater than 1 in. [25 mm] in length and
depth discovered on cut surfaces, the following procedures
shall be observed.
(1) Where discontinuities such as W, X, or Y in Figure 5.1 are
observed prior to completing the joint, the size and shape of
the discontinuity shall be determined by UT. The area of the
discontinuity shall be determined as the area of total loss of
back reflection, when tested in conformance with the
procedure of ASTM A 435, Specification for Straight Beam
Ultrasonic Examination of Steel Plates.

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Base Metal Acceptance Criteria

5.15.1.1 Acceptance Criteria.

(2) For acceptance of W, X, or Y discontinuities, the area of the discontinuity (or the
aggregate area of multiple discontinuities) shall not exceed 4% of the cut material
area (length times width) with the following exception: if the length of the
discontinuity, or the aggregate width of discontinuities on any transverse section, as
measured perpendicular to the cut material length, exceeds 20% of the cut material
width, the 4% cut material area shall be reduced by the percentage amount of the
width exceeding 20%. (For example, if a discontinuity is 30% of the cut material
width, the area of discontinuity cannot exceed 3.6% of the cut material area.) The
discontinuity on the cut surface of the cut material shall be removed to a depth of 1
in. [25 mm] beyond its intersection with the surface by chipping, gouging, or grinding,
and blocked off by welding with a low-hydrogen process in layers not exceeding 1/8
in. [3 mm] in thickness for at least the first four layers.
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 Base Metal Acceptance Criteria
5.15.1.1 Acceptance Criteria.

(3) Repair shall not be required if a discontinuity Z, not

exceeding the allowable area in 5.15.1.1(2), is discovered after
the joint has been completed and is determined to be 1 in. [25
mm] or more away from the face of the weld, as measured on
the cut base-metal surface. If the discontinuity Z is less than 1
in. [25 mm] away from the face of the weld, it shall be removed
to a distance of 1 in. [25 mm] from the fusion zone of the weld
by chipping, gouging, or grinding. It shall then be blocked off by
welding with a low- hydrogen process in layers not exceeding
1/8 in. [3 mm] in thickness for at least the first four layers.

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Base Metal Acceptance Criteria

5.15.1.1 Acceptance Criteria.

(4) If the area of the discontinuity W, X, Y, or Z

exceeds the allowable in 5.15.1.1(2), the cut material
or subcomponent shall be rejected and replaced, or
repaired at the discretion of the Engineer.

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