TACK WELDING WORK STANDERD (BASED ON TES 225-012) 1) BEAD LENGTH AND PITCH: - The standard tack welding
bead and pitch is as shown in the table below
PLATE THICKNESS (in mm) 4 4 28 28 BEAD LENGTH (in mm) 10 40 70 PITCH (in mm) 250 500 800
NOTE: The diameter of the tack-welding rod normally shall be less then
4mm However when tack welding is used to hang, the bead length shall be placed so that no safety problems exist. BUTT JOINT MISALIGNMENT TOLERANCE STANDERD The difference in the plate thickness level alignment when butt-welding is performed with steel plate is called misalignment. The dimensional tolerances for misalignment are as follows: -
T1 T2
( T1 T2 )
PLATE THICKNESS RANGE T1 12 12 < T1 50 50 < T1
MISALIGNMENT 0.25 X T1 3.0 Less Then 5.0
BOSS DEVIATIATION TOLERANCE STANDARD
Definition of Deviation : When a gap exist between the boss external diameter ( black face ) and the center of boss internal diameter after machining processing the difference between T2 and T1 is shown below an d is called deviation . Boss internal diameter Boss external diameter
T1 minimum
T2 maximum
Deviation tolerance Standard
The Deviation tolerance is:-T2 (maximum ) T1 ( minimum ) 6 mm.
PLATE WORK AND WELDING PARTS EXTERNAL WELD APEARANCE INSPECTION STANDERD (BASSED ON TES 525-020)
WELD INSPECTION ITEMS (1). Leg Length, (2) Under cutting, (3 ) Bead Surface Blow Holes, (4) Over lap, (5) Welding missing , (6) Cracks, (7) Bead Seam, ( 8) Craters, (9) Bead shape, (10) Weld external appearance, (11) Uneven weld width (12) weld reinforcement height. LEG LENGTH INSPECTION A determination of acceptance or rejection is based on table:-Fillet classification S1 S2 S3 S4 Leg length tolerance L ~ 1.2L L ~ 1.2L L ~ 1.2L 0.9L ~ 1.2L
L = Prescribed leg length, However: When plate thickness less than 6 mm is used the upper limitation applies with up to 1.5L. When the leg length is specified, all are L ~ 1.2L (L specified leg length) UNDER CUTTING A determination of acceptance or rejection is based on table:-Quality mark W1 W2 W3 Not Spec. Tolerance limitation Plate thickness (less than 6 mm) Plate thickness ( more than 6 mm) 0.3 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Items that exceeded the tolerance limitation shall be redone.
BEAD SURFACE BLOWHOLE; The blowhole limitation that exists on the welding bead surface is as shown in table:-Quality mark W1 W2 W3 Not Spec. Tolerance limitation (number ) Number of blowholes per 500mm 0 4 6 8
Density 0 2 3 4
NOTE: Items that exceeded the limitation shall be redone by gouging or bead placement. Density is the number of defects that exist in a 100mm*50mm area where defects are more dense. The blowholes in table are those less then 2mm (diameter and Length) If any blowholes are more than 2mm, this is considered to be a rejection item. The blowhole shape ( sharp, deep etc.) determination depends on each redone.
OVERLAP:
The overlap tolerance is 0.3mm. Items with more than 0.3mm overlap shall be redone.
WELDING MISSING
All items with a welding missing are rejected.
WELD CRACKS
All items with weld cracks are rejected.
BEAD SEAM
The bead seam shall be connected smoothly and shall have less overlap. The over lap acceptance or rejection is based on an actual example prepared by using the standard shown in
SEAM SECTION 4
Overlap
OVERLAP SIZE Less than 2mm
APPLICATION EXAMPLE Grinder up-down chord, stringer, cat frame, seam beam, other main steel frame parts.
REMARKS When the over lap exceeds 2mm, grinder correction is necessary.
NOTE (1) the overlap size is the throat difference at the seam
CRATERS:
Crater shall be heaped as much as possible. If the dent is more then 1mm, it is rejected.
BEAD SHAPE:
If reinforcement angle () is more than 60, it is rejected.
WELD EXTERNAL APPEARANCE:
The welding Bead external appearance shall be 2nd class or more than that of external appearance sample issued by the welding association
UNEVEN BEAD WIDTH:
Acceptance or rejection is based on table:-Quality mark W1 W2 W3 Standard Length 50 50 50 Bead width Difference 3 Less Than 4 Less Than
A1
Remarks
5 Less Than
A2
REINFORCEMENT HEIGHT:-Plate Thickness Downw ard When not specified Manual welding Upward Standin g CO2 Weld ing When A When smooth the finish Subm- mark is erged specified mark is specifi arc ed Weldin -g 4 less 1.5 less +0.5 than than -0.25 Less 2.5 less than than 3.0 less than
G G G G
Remarks
12 less than Between 12 and 25 More Than 25 Welding mark display Example
3 less 4 less 5 less than than than
4 less than
Finished By a Grinder
