Steel Structure Inspection based on AWS D1.1

Steel structure Inspection based on AWS D1.1?

The Steel Structure Inspection Course based on AWS D1.1 focuses on the inspection, fabrication, and construction of steel structures, in accordance with the American Welding Society (AWS) D1.1 Structural Welding Code – Steel. This code is one of the most widely used standards for welding structural steel in construction projects, including buildings, bridges, and other large steel structures. The course is designed to give participants the skills and knowledge required to inspect steel structures, ensuring compliance with AWS D1.1 standards.

Course Overview:

The course covers the fundamentals of structural welding inspection, focusing on welding processes, joint configurations, inspection techniques, non-destructive testing (NDT), and quality control procedures specific to structural steel. It prepares participants to understand the requirements of AWS D1.1 and to conduct thorough inspections during the fabrication and erection phases of steel structures.

Objectives of the Course:

• Gain an in-depth understanding of AWS D1.1 requirements for structural steel welding and inspection.
• Learn how to inspect welding processes and ensure compliance with the AWS code.
• Understand the types of welds and joint configurations used in structural steel.
• Acquire knowledge of destructive and non-destructive testing (NDT) techniques for inspecting welds.
• Become proficient in reading and interpreting welding symbols on engineering drawings and welding procedure specifications (WPS).
• Learn about welding procedure qualification (WPQ) and welder qualification as per AWS D1.1 standards.
• Understand the process for documenting and reporting inspection results.

Key Topics Covered in the Course:

1- Introduction to AWS D1.1 Standard

• Overview of the AWS D1.1 code, its scope, and its importance in ensuring the structural integrity of steel structures.
• Understanding the different categories of welds and joints covered by AWS D1.1, including complete joint penetration (CJP) and partial joint penetration (PJP) welds.
• Importance of AWS D1.1 in ensuring the safety and durability of steel structures in industries such as construction, oil & gas, and transportation.

2- Steel Structure Design and Welding Requirements

• Base metal requirements: Understanding the classification of base metals (structural steel) used in the construction of steel structures.
• Welding processes: Familiarization with the welding processes commonly used in structural steel fabrication, including:
  • Shielded Metal Arc Welding (SMAW)
  • Gas Metal Arc Welding (GMAW)
  • Flux-Cored Arc Welding (FCAW)
  • Submerged Arc Welding (SAW)
• Weld types and configurations: Identifying and inspecting different weld types such as groove welds, fillet welds, plug welds, and slot welds.

3- Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR)

• Developing and qualifying a Welding Procedure Specification (WPS) based on AWS D1.1 requirements.
• Understanding the Procedure Qualification Record (PQR) and how it demonstrates the suitability of a welding procedure.
• Welder Qualification: Ensuring that welders are properly qualified and meet the AWS D1.1 standards for specific welding processes, positions, and materials.

4- Weld Inspection Procedures

• Visual inspection: Understanding the importance of Visual Testing (VT) as the primary method for detecting surface defects in welds.
• Inspection of joint preparation: Ensuring that joint fit-up, alignment, and cleaning meet AWS D1.1 standards before welding begins.
• In-process inspection: Monitoring welding parameters during welding, such as preheat, interpass temperature, and weld bead geometry.
• Post-weld inspection: Inspecting the final weld to check for defects such as cracks, porosity, undercut, lack of fusion, and other discontinuities.

5- Non-Destructive Testing (NDT) Methods

• Overview of AWS D1.1 Chapter 6 and its requirements for NDT.
• Common NDT methods used in the inspection of structural welds:
  • Ultrasonic Testing (UT): Used to detect internal flaws and ensure proper fusion in welds.
  • Radiographic Testing (RT): Inspecting the internal quality of welds by capturing X-rays or gamma rays.
  • Magnetic Particle Testing (MT): Detecting surface and near-surface defects in ferromagnetic materials.
  • Liquid Penetrant Testing (PT): Identifying surface-breaking defects in non-porous materials.
  • Visual Testing (VT): The most common method for inspecting weld surfaces for compliance with code requirements.

6- Welding Symbols and Drawings

• Understanding how to read and interpret welding symbols on engineering drawings.
• Familiarization with the AWS A2.4 Standard, which specifies the welding symbols used in structural steel construction.
• Interpreting weld joint details such as size, length, and contour, as indicated by welding symbols on drawings.
• Weld maps: Keeping track of weld locations, types, and inspection status for large structural projects.

7- Structural Welding Inspection and Acceptance Criteria

• Learning about weld quality and acceptance criteria for structural steel, including the evaluation of weld profiles and discontinuities.
• Dimensional inspection: Ensuring proper alignment and fit-up of structural steel components.
• Tolerances: Understanding the acceptable tolerances for misalignment, undercut, reinforcement, and other weld features as per AWS D1.1.
• Weld repair: Procedures for repairing non-conforming welds, including the steps for re-inspection.

8- Documentation and Record-Keeping

• Inspection reports: Preparing accurate and comprehensive reports for weld inspections.
• Record-keeping: Ensuring proper documentation of welding procedures, welder qualifications, inspection results, and NDT findings.
• Quality assurance: Role of the inspector in ensuring that all welding and fabrication activities conform to AWS D1.1 standards.

9- Inspection During Construction

• Pre-welding inspection: Ensuring the correct preparation of materials, joint alignment, and cleanliness.
• In-process inspection: Monitoring welding parameters, heat input, and compliance with WPS during the welding process.
• Post-welding inspection: Evaluating the finished welds for defects and ensuring they meet the required standards.
• Final acceptance criteria: Verifying that all welded joints meet AWS D1.1 acceptance criteria before releasing the structure for service.

Target Audience:

• Welding Inspectors: Individuals responsible for inspecting welded joints and ensuring compliance with AWS standards.
• Fabrication and Erection Supervisors: Engineers and supervisors responsible for overseeing steel structure fabrication and assembly.
• Welding Engineers: Professionals involved in the development and qualification of welding procedures.
• NDT Technicians: Technicians performing non-destructive testing on structural welds.
• Quality Control Personnel: Individuals responsible for maintaining quality and ensuring that all welding and fabrication activities meet code requirements.

Certification:

Upon successful completion of the course, participants typically receive a certification that demonstrates their knowledge and ability to inspect structural steel welding as per AWS D1.1. This certification is widely recognized and valuable for professionals involved in the construction and inspection of steel structures.