5.22.4.3 Correction. Root openings greater than
those allowed in 5.22.4.1, but not greater than twice the
thickness of the thinner part or 3/4 in. [20 mm], whichever
is less, may be corrected by welding to acceptable
dimensions prior to joining the parts by welding.
5.22.4.4 Engineer’s Approval. Root openings
greater than allowed by 5.22.4.3 may be corrected by
welding only with the approval of the Engineer.
5.22.5 Gouged Grooves. Grooves produced by gouging
shall be in substantial conformance with groove profile
dimensions as specified in Figure 3.3 and 3.4 and provisions
of 3.12.3 and 3.13.1. Suitable access to the root
shall be maintained.
5.22.6 Alignment Methods. Members to be welded
shall be brought into correct alignment and held in position
by bolts, clamps, wedges, guy lines, struts, and other
suitable devices, or by tack welds until welding has been
completed. The use of jigs and fixtures is recommended
where practicable. Suitable allowances shall be made for
warpage and shrinkage.
5.23.11 Tolerance on Stiffeners
5.23.11.1 Fit of Intermediate Stiffeners. Where
tight fit of intermediate stiffeners is specified, it shall be
defined as allowing a gap of up to 1/16 in. [2 mm] between
stiffener and flange.
5.23.11.2 Straightness of Intermediate Stiffeners.
The out-of-straightness variation of intermediate stiffeners
shall not exceed 1/2 in. [12 mm] for girders up to 6 ft
[1.8 m] deep, and 3/4 in. [20 mm] for girders over 6 ft
[1.8 m] deep, with due regard for members which frame
into them.
5.23.11.3 Straightness and Location of Bearing
Stiffeners. The out-of-straightness variation of bearing
stiffeners shall not exceed 1/4 in. [6 mm] up to 6 ft
[1.8 m] deep or 1/2 in. [12 mm] over 6 ft [1.8 m] deep.
The actual centerline of the stiffener shall lie within the
thickness of the stiffener as measured from the theoretical
centerline location.
5.23.11.4 Other Dimensional Tolerances. Twist of
box members and other dimensional tolerances of members
not covered by 5.23 shall be individually determined
and mutually agreed upon by the Contractor and the
Owner with proper regard for erection requirements.
5.24 Weld Profiles
All welds meet the visual acceptance criteria of Table
6.1 and shall be free from cracks, overlaps, and the unacceptable
profile discontinuities exhibited in Figure 5.4
except as otherwise allowed in 5.24.
5.24.1 Fillet Welds. The faces of fillet welds may be
slightly convex, flat, or slightly concave as shown in Figure
5.4. Figure 5.4(C) shows typically unacceptable fillet
weld profiles.
5.24.2 Intermittent Fillet Welds. Except for undercut,
as allowed by the code, the profile requirements of
Figure 5.4 shall not apply to the ends of intermittent fillet
welds outside their effective length.
5.24.3 Convexity. Except at outside welds in corner
joints, the convexity C of a weld or individual surface
bead shall not exceed the values given in Figure 5.4.
5.24.4 Groove or Butt Welds. Groove welds shall be
made with minimum face reinforcement unless otherwise
specified. In the case of butt and corner joints, face
reinforcement shall not exceed 1/8 in. [3 mm] in height.
All welds shall have a gradual transition to the plane of
the base-metal surfaces with transition areas free from
undercut except as allowed by this code. Figure 5.4(D)
shows typically acceptable groove weld profiles in butt
joints. Figure 5.4(E) shows typically unacceptable weld
profiles for groove weld butt joints.
5.24.4.1 Flush Surfaces. Butt welds required to be
flush shall be finished so as to not reduce the thicknesses
of the thinner base metal or weld metal by more than
1/32 in. [1 mm], or 5% of the material thickness, whichever
is less. Remaining reinforcement shall not exceed
1/32 in. [1 mm] in height. However, all reinforcement
shall be removed where the weld forms part of a faying
or contact surface. All reinforcement shall blend
smoothly into the plate surfaces with transition areas free
from undercut.
5.24.4.2 Finish Methods and Values. Chipping and
gouging may be used provided these are followed by
grinding. Where surface finishing is required, roughness
values (see ASME B46.1) shall not exceed
250 microinches [6.3 micrometers]. Surfaces finished to
values of over 125 microinches [3.2 micrometers]
through 250 microinches [6.3 micrometers] shall be finished
parallel to the direction of primary stress. Surfaces
finished to values of 125 microinches [3.2 micrometers]
or less may be finished in any direction.
5.25 Technique for Plug and Slot Welds
5.25.1 Plug Welds. The technique used to make plug
welds when using SMAW, GMAW, (except GMAW-S),
and FCAW processes shall be as follows:
5.25.1.1 Flat Position. For welds to be made in the
flat position, each pass shall be deposited around the root
of the joint and then deposited along a spiral path to the
center of the hole, fusing and depositing a layer of weld
metal in the root and bottom of the joint. The arc shall
then be moved to the periphery of the hole and the procedure
repeated, fusing and depositing successive layers to
fill the hole to the required depth. The slag covering the
weld metal should be kept molten until the weld is finished.
If the arc is broken or the slag is allowed to cool,
the slag must be completely removed before restarting
the weld.
5.25.1.2 Vertical Position. For welds to be made in
the vertical position, the arc is started at the root of the
joint at the lower side of the hole and is carried upward,
fusing into the face of the inner plate and to the side of
the hole. The arc is stopped at the top of the hole, the slag
is cleaned off, and the process is repeated on the opposite
side of the hole. After cleaning slag from the weld, other
layers should be similarly deposited to fill the hole to the
required depth.
5.25.1.3 Overhead Position. For welds to be made in
the overhead position, the procedure is the same as for
the flat position, except that the slag should be allowed to
cool and should be completely removed after depositing
each successive bead until the hole is filled to the required
depth.
5.25.2 Slot Welds. Slot welds shall be made using techniques
similar to those specified in 5.25.1 for plug welds,
except that if the length of the slot exceeds three times
the width, or if the slot extends to the edge of the part, the
technique requirements of 5.25.1.3 shall apply.
5.26 Repairs
The removal of weld metal or portions of the base
metal may be done by machining, grinding, chipping, or
gouging. It shall be done in such a manner that the adjacent
weld metal or base metal is not nicked or gouged.
Oxygen gouging shall not be used in quenched and tempered
steel. Unacceptable portions of the weld shall be
removed without substantial removal of the base metal.
The surfaces shall be cleaned thoroughly before welding.
Weld metal shall be deposited to compensate for any deficiency
in size.
5.26.1 Contractor Options. The Contractor has the option
of either repairing an unacceptable weld or removing
and replacing the entire weld, except as modified by