QUALIFICATION TESTS FOR FIELD WELDERS

GENERAL REQUIREMENTS

The intent of this Instructional Memorandum is to address the qualification testing of field welders to weld on any project that requires field welding (structures, bridge repair, piling, railing, casement pipes, etc.)

WELDER QUALIFICATION

When welders are tested to insure their ability to produce sound welds, it is conducted and witnessed by the District Materials Office. An Inspector will verify identification of all testers while acquiring all pertinent information required by the qualification test report.

Testing will conform to the Iowa Department of Transportation Specifications Article 2408.03, B and AASHTO/AWS D1.5 Bridge Welding Code, Clause 5.

Inspectors will issue the 3/8” test plates for the LIMITED thickness test, which will allow the welder to complete groove welds in material up to ¾” thick. For the UNLIMITED groove, material over ¾” or for example an HP 14 X 117, 1” plates with 1/4” to 3/8“ backing bar is required. 1” plates will be supplied by the Contractor or welder.  Mill Test Reports for the 1” material, including backing bar must be presented to the Inspector prior to beginning the certification test.

POSITION OF TEST WELDS
			Type of Weld & Position Of Welding Qualified*
Qualification Test						Plate & Pipe
Weld	Position			Groove		Plate Fillet
Plate-Groove	1G			F		F, H
	2G			F, H		F, H
	3G			F, H, V		F, H, V
	4G			F, OH		F, H, OH
	3G & 4G			All		All
*Positions of welding:
F=Flat		1G=Flat Groove			1F=Flat Fillet
H=Horizontal		2G=Horizontal Groove			2F=Horizontal Fillet
V=Vertical		3G=Vertical Groove			3F=Vertical Fillet
OH=Overhead		4G=Overhead Groove			4F=Overhead Fillet

ELECTRODES

Only low-hydrogen electrodes will be permitted for the certification of SMAW welders.

The following list of SMAW, GMAW, or FCAW electrodes are approved for use provided the proper

Shielded Metal Arc	Gas Metal Arc	Flux-Cored Arc w/External Shielding Gas	Flux-Cored Arc-Self Shielding
E-XX16	ER70S-2,		E6XT-6,8
E-XX18	3, 6 or 7	E7XT-1,5	E7XT-6,8

WELDING OF PLATES

In making up test welds, the welder may restrain the warping of the assembly through the use of clamps to maintain a flat sample. Plates shall not be stress relieved or straightened after welding.

Cleaning between weld passes shall be limited to hand chipping and hand wire brushing. Power chippers or grinders shall not be used during the weld test. Weld cleaning shall be done with the test weld in the same position as the welding position being qualified.

All vertical welds for grooves or fillets for field or shop test plates shall be made with the progression for all passes in the upward direction.

MINIMUM PREHEAT AND INTERPASS TEMPERATURE FOR TEST PLATES

The minimum preheat and interpass temperature shall be as specified in the AWS D1.5.

NOTE:       1.   Welding shall not be done when the ambient temperature is lower than 0°F.

FAILURE OF TESTS

A welder failing a weld test is immediately disqualified for those positions represented by the test position in which they failed, and must retest within one month by welding two weld test plates of the type and position of which they failed, both of which must pass. Failure to retest within one month shall be considered as failure of the retest.

FAILURE OF RETEST

A welder that fails a retest may not retest again for six months or one month at the discretion of the Structural Materials Engineer for the failed position. After six months, the welder may retest by welding two weld tests plates of the same type & position, which previously failed, and both of which must pass.

TEST FEES

An Iowa DOT inspector will witness the test and send the test plates to the Central Materials Lab in Ames for visual inspection.  If the test weld doesn’t pass visual inspection, the tester will be notified of the failed test and no fee is charged.  If the test weld passes visual inspection, a bend test will be performed and the tester will be notified of the results. The Fabricator will be billed $200.00 for each plate or retest plate that is bend tested.  The Office of Construction and Materials will initiate billing requests through the Office of Finance.

NEW WELDER QUALIFICATION

New welders who have successfully passed their qualification tests shall be:

a. Certified for a period of one year (starting from the month in which the test was taken)

b. For welders who have successfully passed their qualification tests without failure for three consecutive years, re-qualification will only be required every two years thereafter.

Note:  Welder re-qualification may be required at any time there is a specific reason to question the welders ability to perform and produce sound welds.