BS_5135-1984_process of arc welding of carbon and carbon manganese steels

8/3/2019 BS_5135-1984_process of arc welding of carbon and carbon manganese steels

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BS 5135: 1984UDC621.791.75: 1669.14 +669.15'741941

/-------------------- - - --'- British Standards Institution. No partof this publication may be phorocopredor otherwise reproduced without theprior permissrcn Inwriting ot BSI.

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Britis h S tandard Spec ific ation fo rProcess o f arc weld ing of carbon andcarbon manganese steels

Soudage a l'arc des aciers au carbone et au carbone-manganese - Specifications de precedel.ichtbogenschweiBen von Kohlenstoff- und Kohlenstoff-Mangan-Stahlen - Verfahran

P O L Y T E C H N I C L I R R A R Y 1Rerp ..v' C II t' I0,ee lOll .I.--~

British Standards Institution


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BS 5135: 19B4

ContentsForewordCommittees responsible 1Back page

Specification1. Scope 22. Definitions 23. Information and requirements to be agreed

and to be documented 24. Parent metal 25. Welding consumabtes 36. Equipment 37. Oull weld details 48. Fillet weld details 49. Welds in slots 410. Preparation of joint faces 411. Fusion faces 612. Assembly for welding 613. Alignment of butt joints 6'4. Fitup of parts joined by fillet welds 615. Tack welds 616. Temporary attachments 617. Protection from the weather 618. Stray arcing on work 619. triter-run cleaning 620. Details of welding procedure 721. Welding procedures to avoid cracking 722. Approval and testing of welding procedures 2823. Approval and te5ting of welders 2824. Identification 2825. Peening 2826. Inspection and testing 2827. Ouality of welds 2828. Correction of faulty welds 2829. Heat treatment 28AppendicesA. Guidance on design 29B. Guidance on butt welds (for other thanstructural hollow sections I 30

':.. Guidance on typical details for structuralhollow sections 33

D. Guidance on fracture toughness of beat-affectedlone and weld metal 39

E. Guidance on avoidance of hydrogen cracking 39F. Guidance on solidification cracking 41G. Guidance on lamellar tearing 42H. Guidance on acceptance levels 46Tables1. Hydrogen scales2. Carbon equivalent values for as 4360 steels

to be used in absence of mill sheets3. Conditions for manual metal-arc welding

with covered electrodes of fillet welds in steelhaving maximum carbon equivalent of 0.3B

4. Conditions for manual metalarc weldingwith covered electrodes of fillet welds in steelhaving maximum carbon equivalent of 0.40

5. Conditions for manual metal-ere weldingwith covered electrodes of fillet welds in steelhaving maximum carbon equivalent of 0.41

6. Conditions for manual metal-arc weldingwith covered electrodes of fillet welds in steelh


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ForewordThis revisionof this British Standard has been preparedunder the direction of the Welding Standards Committee.It is the first revision of this standard since the original1974 edition which is withdrawn.Because of its range of applicability. it has been usedextensively over a wide field of types of fabrication andhas received due recognition as a comprehensive weldingstandard. Experience gained in its use has been reflectedin the changes incorporated in this revision. princlpallv byconverting most of the previous guidance on the avoidanceof hydrogen cracking into requirements which have to befollowed whenever practicable. Appendices givingrecommendations concerning various modes of crackingand factors to be taken into account in estllblishing weldingprocedures have been retained in updated form.

B!>!J 135: 1984

Permissible stresses in welds. methods ot testmg Clndacceptance levelsare not specified because they depend onthe service conditions of the fabrication. These require-ments should be obtained from the relevant applicationstandard or by agreement between the contracting parties,An appendix has boen introduced givingguidallcil 011 fourlevel, of acceptance criteria whiChmay be used to usiu inreaching agreement.It has been aS5umedin the drafting of this standard that theexer.ution of its provisions is entrusted to appropflalelyqualified and experianced people.Compliance with a Brltl.h Standard doe. not of lueU conferImmunity from fegel obllgadonl.


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BS 5135: 1984

lBritish Standard Specification forProcess of arc welding of carbon and carbon manganese steels

1. ScopeThis British Standard specifies requirements for the proceuof manual. semi-autcmatic, automatic and mechanized arcwelding of carbon and carbon manganese steel of maximumcarbon equivalent of 0.54 (sl:e clause 4) in all product form.including ~ircular and rectangular hollow sections.In addition to the definitive requirements. it also requirelthe items detailed in clause 3 to be documented.For compliance with this standard, both the definitiverequirements and the documented items have to besatisfied.The appendices are intended to assist users of this standardby giving guidance on various topics, but adherence to whatis stated in the appendices does not form part of compliancewith this standard.This standard dOL'Snot include all the requirements for thewelding of steel for concrete reinforcement which may beaffected by other factors not covered by this standard.This standard does not cover requirements for calt tocaatfabrications which are specified in BS 4570.NOTE. The l,tle5 01 Ihe publlcalions referrlld 10 in Ihililendllrd".11 listed on Ih.. in5lde back cove r,

2. DefinitionsFor the purposes of this Britiih Standard. the definitionsgiven in BS 499 : Part 1 apply.3. Information and requirements to be agreedand to be documented3.1 Information to be luppliod by the purcha.er.The follOWing information to be supplied by the purchasershall be fully documented. Both the definitive requirementsspecified throughout the standard and the documenteditems shall be sausfied before a claim of compliance withthe standard can be made and verified.

(.. I The application standard to be used together withany supplementary requirUffients.(bl Specdicauon of the parent metal and of the requiredwuld ",ltal lind wllldlld joint properties.(cl locations. dimensions and details. i.e. form of lolnt.anylt: between fusion faces. yaps between parts.etc. of all welds.NOTE. Wh..... vmbols us"d tor ""ndllfd weld forml.Ih"V should contorm IU85 499 : P.rl 2.(d' Whether the welds are to be made in the shop orelsewhere.(e' Whether written welding procedures are required(see clause 20'.

(f) Whether welding procedure approval testing isrequired (see clause 221.(0' Whether means of identification to enable wt:lds tobe traced to the welder who made them is required andIf so the method, to be used (see clau 24).(h) Surfac. finish of weld protile.(i) Quality control arrangements.(j) Whsth.r pOU,wllld heat treaunent il required(see clause 291.

NOTE. The "ems rllle"IId 10 in this clause mav hev. IIsigniltcllnlattect upon Ihllpertormaoce of thll fabrlcalion .nd thll purch.ltlrIhould ,lnlur. that me '.quiremllnlS rtllelll .pproprillt.ly 10 ttl. ~panicular join" and intended IIIrvice lilll 01 Ihll labnc.cion.3.2 Requirements to be agreed. The following items to beagreed between the contracting parties, which are speclfil!din the clauses referred to, Ihall be fullV documented.Both the definitive requirementt specified throughout thestandard and the following documented item hall be .satisfied before a claim of compliance with the Itandardcan be mad. and verified.(al When no drening is to be carried out. the permissibleweld profile if it is not specified in the epplicationstandard (see 7.3.21.(b) The use of a special method to achieve fullpenetration without the u of backing material whl," IIbutt weld is to be welded from one side only_(see 7.4(b)(211.Ic) The material for backing when this is not part of thestructure (see 7.6.21.(dl Methods other than those 'JJeclfied in 10.11urpreparation or l:uulIlg of material (sell 10.21.(el The peening of welds (see claus. 261.(f) The method and extent of inspection and testing inthe absence of a relevant application nandard (see 26.21.(9' The acceptance requirements for welded joints in theabsence of Irelevant Itpplication Illilldard hee 27.2'.(hI When poltweld h.. lt treatment I.required but th"r"I. no application standard. the detal .. of the healtraatm.nt to bl .pplied (lei 2g.21.

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4. Parent metalThe parent metaflhall be a carbon or Clrbon mangllnelClneel whose chemicil composition, in ' 1 1 0 (mlm', determinedby ladle analysil provides a maximum carbon equivalent of0.64 when calculated using the following formula:

Mn C, + Mo + V Ni CuCarbon equivalent C + 0- + 6 + 16 ,NOTE I. nll c.rbon e(jUIY.I.nt IU,"lUtem.y nul ...... y tu 1;11.1"",m . n g . _ 11 1.of low ca ,m" , c;onlll'" Uf boron Gon'..i"tI"....nd Iherefor. Ih. gu,dance given In S thOuld be folio_d.


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NOTE 2. AII'luirllfflllnll arll nOllPlCilied lor c:arbonm.ng.n ...nllllh .bow a carbon Ilquiv.l"nt 010.64 bec.us. labric.tlontlKpllrience i, limited. Thlll188lmaker. wlliding conlum.bl. luppli.rOf olher .pp'opt'illt. lIutholileti"e M:IIH'C8hould be con.ulled whhr"gard 10 Iha w"lding procedur .. lor th... ,,"I.5. Welding consumables5.1 Hydrogen levels. When hydrogen-control1ed weldingconsumables are to be used, the contractor shall be able todemonstrate that he has used the consumables in themanner recommended by the consumable manufacturerand that the consumables have been dried or baked to theappropriate temperature levels and times.5.2 Manual metalarc welding. Electrodes shall be selectedhaving I';yard to the particular application, i.e. joint design,welding position and the properties required to meetservice conditions (see 3.1 Ibl], Where there is8 BritishStandard applicable to the electrodes selected, tliey shallcomply with and be coded in accordance with thatstandard (e.g. as 639).5.3 Covered electrode. for semiautomatic, automatic andmechanized metal-arc welding. The weld metal producedfrom covered electrodes used with semi-automatic,automatic and mechanized metal-arc welding processes"shall have mechanical properties not less than theminimum specified for the weld metal produced byelectrodes complying with as 639 having regard to theparticular application, i.e. joint design, welding positionand the properties required to meet service conditions(see 3.1(bll.5.4 Submerged arc welding. Electrode wire and fluxcombinations for submerged arc welding shall comply withthe appropriate sections of as 4165. The combination ./shall be selected having regard to the particular application,i.e. joint design, welding position and the propertiesrequired to meet service conditions (see 3.1 (bU.5.5 Gasshielded processes5.5.1 Fil ler rods and wires. Where a solid metal filter rod orwire isused with a gasshielded process, it shell comp.wwith as 2901 : Part 1 and shall be selected having regard tothe particular application. i.e, joint design, welding positionand the properties required to meet service conditicns(see 3.1(bl).Cored electrodes. when used with the appropriate shieldinggas or gas mixture. shall be selected having regard to theparticular application, i.e. joint design, welding positionand the properties required to meet service conditions"(see 3.1 (bll.5.5.2 ShielC/inggases. When a gas or gas mixture is used,it shall be of the following quality, as appropriate:(a] argon complying with BS 4365;(bl carbon dioxide complying with type 1 specified inas 4105;(c) yas mixtures that have been proved to be Ii.tisfactoryas a result of either experience or procedure approvaltests.

5.6 Unshielded semi-automatic arc welding. Electrodes forunshielded semi-automatic arc welding. which are usually otthe cored type, shall be selected having regard to theparticular application, i.e. jOint design, welding potitionand the properties required to meet service conditions(see 3.1 (bU.

as 5135: 1964

6.7 Storage and handling6.7.1 Gtint/rili. All consumables shall be stored and handledwith ere ~nd ineccordsnce with the ment .J fecturer ' srecommendations. Electrodes, filler wires and rods lindfluxes that show signs of damage or deterioration shall notb e t used.NOTE. EII.mph" of damagll or dlltll.io'llion include c.lcked orIIlked cOlting. on cover.d .'tK:trod ... rullV or dirty IIlectrode wireland wires with lIaked or dllmeg.d copper coatinu 5.7.2 Covered electrodes. Electrodes shall be stored inthllir original containers in a dry, preferably heated placeadequately protected from the etfects of the weathllr andin accordance with the manufacturer's recommendations.When special protection or other treatment during storageor immediately prior to use is recommended by theelectrode manufacturer, they shall be treated in accordancewith the conditions detailed bV the manufacturer.In order to ensure that the weld metal deposited bVhydrogencontrolled electrodes falls within the limits of theappropriate scale as specified in clause 21, the drying orbaking conditions indicated by the electrode manufacturershall be followed.Electrodes shall be removed from their original containersbefore drying or baking. After removal from tho oven,the electrodes shall be protected from exposure toconditions conducive to moisture absorption.NOTE 1. If the 10WII.thvdrO{l"n 111",,1 r. t,,~ui . ..d. il "'MV twnac .... rv lor weldin to be i.. ued with el8CtlUd.1 in Quivlln orIHlfId contlinen.Electrodes returned to stores shall be treated in accordancowith the electrode manufacturer's recommendUiom betorere-issue,NOTE 2. II electrodes ha"" been ,,,'pOled to poor .. orave condlllonsor it i.IUlptK:lltdIhat th.V ha"e bllcome damp, Ihe edViCe01 themanulacturer .hould be lOUQhtbelot. ule.6.7.3 Semi-eutomstic, sutomstk: lind mtIChanized welding.Wire or cored electrodes shall be suitably packed to guardagainst damage, including that dudng transportatiun.When stored, the wire or electrode shall be kept in itsoriginal bundle or package in a dry storeroom.NOTE. The pe.formanc. of coppor co.,.d Wlr., depend, on Ihecontlnuitv and rll\lullritv 01 the copp.r coating. Thll I. olllln notawerent on "i,u.1 lnspecucn but mav belmpon.nt in ellIlC.1.ppltcatloOi. Such cOOli".'.\lonl .hould bitallr."d INI_It" IhllcontrllCtor and the luppller.Flux shall be packed in such a way that it is protected trommoisture pickup and damage, inciudillll that duringtransportation. Flux with It gUlLranteedmoistura levlIlorgiving a controlled hydrugen levol as deposited shlill btlpacked in moisture-resistant containers. When stored,the flux shall be kept in iu original container in a drystoreroom.If tho composition of the flux is such that s,'6cialprotection during storao., or special trealmClllt befurtl USIIisdesirable. details of such special protection or treatmentshall btl providtld by the manufacturer .nd implementedby the contractor.6. Equipment6.1 Plant. Welding plant, instruments, cables andlCCes50riesshall comply with the requirements of theappropriate Parts of 6S 638. The contractor shall berespomiiblll for ensuring thlt the c.pacity of the welding

Thll g.oul' of proc.u ... mbr.cel grlVltv .nd IlUlo-conl8Ctwalding with long IIr.ighllengthl 01covar.d .Iac:trodll end op." .fC _IdlnyWithICOnllnuOUIcovered IIIIC1rod


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BS 5135: 19B4

plant and ancillary equipment is adequate for the weldingprocedure to be used and for maintaining all welding plantand ancillary equipment in good working order.NOTE. The Illentton of the contractor is dr.wn to the .dvice on.. fety precllUlioOl contained in Ihe He.llh and Safety .t Workbooklel no. 38 'EllClric arc welding' inued by the Health andSafety EXlCutive and published by HMSlationery OffiCI.6.2 Earthing. All electrical plant in connection wiih thewelding operation shall be adequately earthed. The weldingreturn lead from the work shall be adequate in crosssection and shall be correctly connected Ind earthed.6.3 Instrumenution. Mllans of measuring the current 'hilibe available. either Ii part of the welding plant, or by theprovision of a portable ammeter.In the cases of semi-automatic. automatic and mechanizedwelding. means shall be provided for measuring the arcVoltage. current andlor wire feed speed.Drying ovens shall be provided with means of measuringthe oven temperature,7. Butt weld details7.1 General. The details of all butt welds. e.g. form ofjoint. angle between fusion faces, gap between parts.shall be arranged to permit the use of a satisfactory weldingprocedure and the combination of weld detail and weldingprocedure shall be such that the resultant joint will complywith the requirements cf the design.NOTE 1. GUIdance on dellgn 01butt ""elds isgiv,m in A.1.appendix Bilnd lable 16.NOTE 2. Incomplelll penelralion bun welds inleRliolllllly h..,1 II\r081 Ihickne" Ihal is Ie.. Ihln Ihl par.nt metal thickne ...Thislype 01weld isKcepllble in meny circum"ancls. but for~lriClions on "" ule. IA.1.7.2 Throat thickne ... The ends of butt joints in plateshall be welded so as to provide the full throat thicknass.NOTE. This may be done by Ihe ul8 01 .l(lenlion piece. or olhermea", approved by Ihe purchaser.7.3 Weld profile7.3.1 I the as-welded COndition. the weld face shall be '"proud of the surface of the parent metal. Where a flushsurface is required. the excess weld metal shall be dressedoff. When no dressing is to be carned out. the weld profileshall be as specified in the application standard where itexists.7.3.2 When no dressing is to be carried out and noapplication standard exists. the weld profile shall beagreed between the contracting parties.7.4 Full penetration. Full penetration single, V, U , J,bevel or square butt welds shall be completed as describedin either (al or (b]:

(al by depositing a seelling run of weld metal on the backot the joint.(bl where these .or other butt welds are to be weldedfrom one side only.either(11with the aid of temporary or permanent backingmaterial. or(2 1 by agreement between the contracting partie by the adoption of an approved special method ofwelding that gives full penetration without the useof either type of backing mlterial.

NOTE. Undoor'alogua condilions. permanenl becking malerialmay be undll$"able.

7.6 Backing material7.6.1 Backing material shall consist of another stelll partof the structure when this i. appropriate.7.6.2 When it is not appropriate to U5epart of theItructure as backing material, the material to be uledmall be agreed between the contracting plrties.NOTE. Care Ihould be lIken when uling copp.r .1becklngm.l.rl.1 .1 th.r. II a ,Ilk of copp.r pick",,,, In Ih. weld mel.1.7.6.3 Where temporary or permanent backing material i.employed. the joint shall be erranged in .uch I way IS to1I00ure that complete fusion of the parti to be joined i,readily obtained.7.6 Back gouging. In III full penetrauon butt wolds. whllrethese are to be welded from both ,ide certafn waldingprocedures allow this to be done without bock gouging.but wh.ere complete penetration cannot be achieved.the back of the fint run shall be gougad out by suitablemeans to clean sound metal before welding is started onthe gouged-out side (see figure 11 .

8. Fillet weld detailsA fillet weld, 85 deposited, shall be not le55 than thespecified dimensions (see 3.1 Ic)] which shall be clearlvindicated as throat thickness and/or leg length asappropriate, taking into account the use of deeppenetration processes or partial preparation.(S4Ieclause 14 and, for guidance. appendix CI.For concave fillet welds, the actual throat thickness shallbe not Ie.. thin 0.7 times the specified leg length(see 3.1 (ell. For convel< fillet WIld" the actual throatthickne shall be not more than 0.9 times the actualleg length.Where the specified leg length {$ee3.1(c II of 8 fillet weldat the edge of a plate or 'IICtion is such thlt the parentmeul does not project beyond the weld. melting of theouter corner or corners. which reduces the throat thickness.shall not be allowed (see figure 21 .NOTE. Guidance on the d.. ign of fillet welds ilgiven in A.2.

9. Welds in slotsBecause of the risk of cracking, slou shall not be filledwith weld metal unless required bV the application standard.Slots that are required to be filled with weld metal shallonly be filled after the fillet weid hal been inlpected andapproved.

10. Preparation of joint faces10.1 If ,neparation or cutting of the material i, necelSary.this shall be done by shearing, chipping. grinding.machining, thermal cutting, thermel gouging or analternative method agreed in accordance with 10.2.When Ihqring is used. the effect of work hlrdening ,h .1I1be taken into account and precautions Ihall be taken toenaur. thlt there i. no cracking of the edge In the ca .. , where the cut edge is not a fu.ion face.the .ffect of embrittlement from shearing. thermal cuttingor thermal gouging shell not be to the detriment of thltperfonnance of the fabrication.

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as 6136: 1984

Iii1.1Fint lid. _Ided

1 1 1 1 1 1 1 1 1

IiiIbl Beckof fi,lt run gouged out to cl.. n melAl

(ill (liil

Iiilei 5cond lide welded

1 1 1 1 lill'

Figure 1. Dlagr.mm.tic rapre nadon of m.thod of gouging out full p.n.tr.don butt joints w.lded from both lid..

~1.1Deli,.ble IblAcc.pi.bI. beceUI. of full throat thlckn...

lei Not acceptable beceule of reduced throat thickn...Figure 2. Fillet weld pplied to the edge of pert

NOTE. loc.1 h.rdening c.n be reduced bV auilAbi. th.rm.1tr unent or ,,",,owed by m


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BS 5135: 1984

. ! 11.2 Fusion faces and adjacent surfaces shall be free fromcracks. notches or other irregularities which wouldint~rlelt: ""~ihlhe depaiitlCii at th:: ~,.e!dcr be the cause ofdefects. Any repair to fusion faces shall be carried outin accordance with the requirements of this standard.11.3 Fusion faces and the surrounding surfaces shall befree from heavy scale. moisture, oil. paint or any othersubstance which might affect the quality of the weld orimpede the progreS5 of wfllding.NOTE. Thil il particularlv importanl wh.n. hydrOQ.n~ontroll.d_Idlny prOCII. il Uled. Clln.,n proprietary protactlv. coating r.IfMlCI811vormul.tlld with thll intention Ih.t Ihey .hould notinlllrlerll WIthwOIldinv.The UIIIolwch co.tingal, not .xcluded bythOlr"quire"",nll 01Ihl, claule but. il .0 requlr.d by Ih. pun:II.....the connector Ihould demon" .... Iheir .cceptabillty by ma.n. ofIPlIClm"nweld, bee BS 60841.12. Assembly for weldingPa r ts to be welded shall be assembled such that the jointsto be welded are easily accessible and visible to the operator.NOTE. Jig' and manipulators lhould be u'ed. where practic.bI 00 'ha, 'hI


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20. Details of welding procedureWhen written welding procedures are requlrod by thepurchaser. they shall include sucn of the following item.as are relevant.

(il IWelding process or processes when more than oneis used in making a complete ioint.(bIarent metal specification. thickness and otherrelevant dimensions.(cl Whether shop or site welding.(d) Cleaning. degreasing. etc.(e) Classification. type and size of electrode& and otherconsumables.If I For manual welding. the size of electrode. weldingcurrent and length of run per electrode or fillet wltld leglength and number of runs. For semi-automatic,automatic and mechanized welding. the size of electrode,welding current. arc voltage, speed of travel. wire feedspeed, electrode extension or fillet weld leg length andnumber of runs and rate of flow of gas and/orconsumption ot other process materials. as appropriate.When applicable, the temperature and time adopted fordrying/baking of welding consumables betore use.(gl Sketch showing edge preparation. fit-up andapproximate number and arrangement of runs inmulti-run welds.(h) Jigging or tacking. backing. etc.(i) Welding positions.(j) Welding sequence.(k) Minimum preheating temperature and interpa"temperature range.(I) Back gouging.Im l Post-weld heat treatment.(nl Any other relevant information (see appendiK 0 forguidance on fracture toughness of heataffected zoneand weld metal).

Welders shall be provided with sufficient information toenable the welding procedure to be carried out /~atisfactorily .21. Welding procedures to avoid cracking21.1 Generll. In determining welding proceduresconsideration shall be given to the avoidance of thefollowing:(al hydrogen induced delayed cold cracking(see 21.2 and, for guidance, appendiK E);(b) solidification cracking (for guidance see appendix F);(c) lamellar tearing (for guidance see appendix Gl.

21.2 Procedurel for IIvoidi", hydrogen cracking21.2.1 Introduction. Welding conditions for avoidinghydrogen cracking in carbon manganese steels hive betendrawn up in graphical form in figure 4 for the normll rlngeof compositions. expressed as carbon equivalent. covered bythis standard and these conditions shill be followedwhenever practicable. (See also 21.2.7.)NOTE.Th.. condilionah..,. boI.ndr.wn up 10 t.k ccounl ofdlff.renc in booh.viourbotl_en ditfenl Ite." of Ih. 18mec.rbonllqUiv...nl (m.king .Uowanc. for lC.tler Inherdenebllilyl andofIIOf'meiaria..onabool_n ladle .nd product ..... y.They .r.

BS6135: 1984

velld'or m voldenc.of bOlhhat.fleelad Ion. and weldm.talcreekingIn Ih. mejorlly0 ' _.dlng .ltu.I'ORl. In .om. cmef'rno::.(i..r~ d..t..rml~ InMleord.nc .. with ml, CleuH m.y notbe .dequ.t. to .vold hydroQ8ncr.cltlng.nd guldanc. on.hu.llon. whichmeyrequlr. more .trlng.nl procedur 10 evoldhydrogencrackingi, giftn inappendlllE togetherwithr.commend.tion. for Ihe.aprocedur.21.2.2 Carbon tlquivlJltmt va/utll. The carbon equivalentvalues in table 2 provide a good ba5is for the derivation of awelding procedure when using e steel complying withBS4360. Where mill shetlts indicate a higher carbonequivalent than table 2 they .hall form the basis for theprocedure.NOTE.Wh.remill Ih.. " arafIIIlillbl.whichIhowI lo_r clrbonequivalenltheymaybe UledIIIIbl.il for. I... "ringlnt procedure(but ... E.31.If. of the elements in the formula in clause 4 for calculatingcarbon equivalent. only carbon and manganese are stated onthe mill sheet. then 0.03 ahell be added to the calculatedvalue to allow for residual elements. Whltreueels ofdiHerent carbon equivalent or grlde are being joined,the higher carbon equivalent value shall be used.21.2.3 Hydrogen seB/SI. The scale to be used for any arcwelding process depends principally on the weld diffusiblehydrogen content and shall be as given in table 1.The valueused shall be that stated by the consumable manufecturerin accordance with the relevant standard where it eKists(or 15 independently determined) in conjunction with aspecified condition of supply and treatment.NOTE.Guidanceon IheUIIof ICIII for "eriou, procell. il giveninE.2.21.2.4 Prtlhtlilting. The preheating temperature is thet.mperlture of the partlnt metal immediatelv beforewelding commences. the lame vllue frequtlntly being usudas the minimum Interp'" temp.rlture for multt-run welds.Multl.,un welds may have Ilower permitted Interpantemperature than the preheat temper.turtl wherewb.aquent runl are larger thin the root run snd in thastlClie. the interpalS tempurllturtl .... 1 1 be determined fromfigure 4 for the large(run.Where preheating is applied local to the joint preparation.the required temperature shall 8Kilt In the pllfent metal fora distance of at least 75 mm in IIny direction from thlt jointpreparation. Where practicable. the tomperatultl shall bemeasured on the face opposite to that being heated.Otherwise, thu temperature shall be confirmtld on the heatedface at a time after removal of the heat source. relatod toparent metal thickness to allow tor temperature6qualization. Where fixed permanent heaters are in use andthere is no access to the reverse face for temperaturemeasurement, readings shall be taken on the exposedparent metal lurfaco immftdiately adjacent to the weldpreparation.NOTE.Th. 11m lIowed 'O f t.mper.lur. equ.liution ,hould boo1Iheord.r of 2min ' O f ch 26mm 01p.r.nI m.... Ihlckn,.21.2.6 Combln.d chickntlU. Combined thicknell Ihall bedetermined as the sum of the parent metll thicknesiolaveraged over Idistance of 76 mm from the weld line(aee figure 3'.NOTE.If Ih. Ihlckn... Incr.. lllur llv lull booyond76mm homthe weldlin., IImaybe n.ce.,v to u... nlg"" combined thlckn...v.lu.


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1.1

8S 5135: 1984

21.2.6 Arc ellergy. Arc energy values (in kJ/mml for us.with figure 4 shall be calculated as follows. with an appro-priate factor applied for processes other than manual metal-arc welding witl: covered electrodes:

.xix 10-)wwhere

V is the arc voltage (in VII is the welding current (in AIw is the welding speed (in mm/s).

NOTE. For guidance in using Olher welding proce"es. Ihe .n: energvvalues calculaled from I.hisformula should be divided bVthelollowing faclors to giv" Ihe values 10 be used in figure 4:Subme.ged are welding (single wi.e): 0.8MAG w81ding lsolid wi.e) : 1.0MIG w81dingTlG wel,1mo

: 1.0: 1.2

21.2.7 Simpli fied conditions for manual m8tal-arc Wfllding.For the manual metal-arc welding of fillet welds the dataobtainable from figure 4 have been presented in tabularform for particular carbon equ ivalent values in tables 3 to 9.For manual metal-arc welding with covered electrodes.arc energy values are expressed in tables to . 11 and 12in terms of electrode size. weld run length and runout ratio.NOTE. Whe.e single run minimum leg length fillet welds arespecilied in Ih.. design. lable 13 may be-us8d to oblain the,pp,ol(im.le arc IInergy velues for use in determining _Iding

procedurel from t.ble. 3 In 9 o. from figure 4. The velu ere.ppropril le lor the prectlc.1 .huetlon wh.n oontrlClor I.required to make .in!!l. run IIlIel welds of pacified dlm.nllonrel.t.d to the minimum leg length of th. till.1 w.lde and wtI e Inpractic. tha .tlCond leg will tM t lunve. Ihan tha minimum. e. lor.. emple In a horizontal-venlc.1 fillet Weld. In olher c.. .. .. c UnllfUV, mould be controlled by control 0 ' .Iaclrod. runout It.bl .. 10. 11.nd 12) or dlrKtlv through walding p8r1ml.u.21.3 Alternative procedure When alternative proceduresare proposed the evidence shall include consideration of allthe factors used in determining welding procedures as givenin 21.2.NOTE. Condilions which might jUllify mooificiltions to normalwelding proctlduel to avoid hvdrogen cr.cklng .re m.ntioned inappend. I(E.Table 1, Hydrogen scalesDlffu.lbl. hydrClgencontent ScalemL/100 8 of d.posIted m.t.1Ov. Up to .nd lnoludlng16 - A10 16 B6 10 C- 5 0NOTE. S.. E_3for us.. of hydrogen level, billow 2.5 mLiIOO uof depo.ited meul.

Table 2.-Carbon equivalent values for BS 4360 steels to be used in absence of mill meetsSteel grede PI... and oth., then atrucCur.1 hollow ee c :t Io . . ICl'Uctur" hollow Helione

Carbon Manual Other then menual C.rbon Menu" Oth.r then manu.1equlv.l.nt metel...-c: metel . . rc fill .. Waldl, equl.,. .. ", m.... erc metal .. ,c fillet weld.,valu. '11I"w.Id refer to figure: v"u. flll.t welda ,.far to figure: -refer to refe, totable:- ,- tebl.: .---All 40 and 43 grades 0.40 4 4(al. (bl and (dl 0.40 4 4 (a). (bl and (d I5OA. B ande 0.45 7 4(al. ( 4 1 1 . (gt 0.46 7 4(al. (el. (gland (hI

and (hISOB and C (CA I 0.41 5 4(bl. (el and (el nIl nla nlaSOD 0.41 5 4(bl. (eland (e) 0.45 7 4(al. (e), (gl and (hI5001 and E 0.41 5 4(bl. (cl and (el 0.45 7 4(.,. (III, (gland (hi50F (Q and Tl 0.35 - - nla nla nla55C 0.45 7 4(a). (el. (gland (h) 0.60 9 4(e)SSE (N) 0.48 8 4(cl 0.60 9 4(e'5SE and F (CR I 0_43 6 4(cl. (el and (gl nI. nla nlaSSE and F (Q and TI 0.38 3 4(b) nla nla nla For ,nfo.matlon onlv.


11/51

8S5135: 1984

Table 3. Conditions for manual metal-arc welding with covered electrode. of fillet weld. In .teelhaving maximum carbon equivalent of 0.38Sc.l. Sp.cifled Minimum Minimum pr...... tlne temper u. for w.ldlne plat.. of fOllowlnelavelablll 11 minimum .re .nervv. oomblned "'Iotc .._

' ' ' 1 1 ' . 1 1 9 ' ' ' - b..-don($ect ,-bl.13 20 30 40 60 80 70 80 80 Unllmlt.dtu.bh.131 m", . mm mm mm mm mn n,m mmmm kJ/mm DC DC DC DC DC DC C DC "c

Scale A 4 1.0 0 0 0 0 60 76 100 100 1005 1.4 0 0 0 0 0 0 20 50 506 2.0 0 0 0 0 0 0 0 0 08 2.8 0 0 0 0 0 0 0 0 010 3.8 0 0 0 0 0 0 0 0 0

Scale B,C or 0 4 1.3 0 0 0 0 0 0 0 0 05 1.7 0 0 0 0 0 0 0 0 06 2.2 0 0 0 0 0 0 0 0 08 3.4 0 0 0 0 0 0 0 0 010 6.0 0 0 0 0 0 0 0 0 0

For Individual run.t In 5ilualion5 of high restrainl. a higher preh.ating temp.r.rur. m.v ne,,th.' ... be nece... rv to .void weld met.' hvdrogen cr.ckingb..e ilPPdndix E I.

Table 4. Conditions for Q1anualmetal-ere welding with covered electrodes of fillet welds in .teelhaving maximum carbon equivalent of 0.40 -Sca'. Specified Minimum Minimum pr...... tlne t ....... atur. for welding p of following($I,e labld 11 minimum .re .nervy, combined thick .......1"III.ngth- beHdon".e t.tll. 13 20 30 40 1 1 0 80 70 80 80 Unllmltedtlable 131 mm mm mm mm mm mm mm mmmm kJ/mm DC DC C DC DC DC DC DC DC

Scale A 4 1.0 0 0 0 60 100 125 126 125 .1255 1.4 0 0 0 0 20 76 100 100 1006 2.0 0 (Y 0 0 0 0 '20 60 608 2.8 0 0 0 0 0 0 0 0 010 3.8 0 0 0 0 0 0 0 0 0

Scale B 4 1.3 0 0 0 0 0 20 60 50 605 1.7 0 0 0 0 0 0 0 0 06 2.2 0 0 0 0 0 0 0 0 08 3.4 0 0 0 0 0 0 0 - 0 010 6.0 0 0 0 0 0 0 0 0 0-~-.------ --- -----.- _ _ . & . .- ._----_ .... . .Scale C 4 1.3 0 0 0 0 0 0 0 0 0

or 0 5 1.7 0 0 0 0 0 0 0 0 06 2.2 0 0 0 0 0 0 0 0 08 3.4 0 0 0 0 0 0 0 0 010 6.0 0 0 0 0 0 0 0 0 0 ---

Fo. tnd,vldu.a run.t In 5Ilualion5 01 high ,..SI,.inc, a high.r pr.h.ating t.mperalur. m.v n..,.rth ..... be nee.... rv 10 ."old _'d m.t.' hvdroven cracking(,ee IIPJJllndlxEI.


12/51

T - ' - -..- -- -- -----.- ------- ------ ---- - .J

BS 5135: 19B4

J Table 5. Conditions for manual metal-arc welding with covered electrodes of fillet welds in steelhaving maximum carbon equivalent of 0.41SeIII. Specified Minimum Minimum lK..... tl... temp_tur. f weldl... pI.t. of fallowl ..., tabl. 11 minimum arc - n e r e v - . _blned thlck_l-e length- b8Md on

(see tebl.13 20 30 40 60 60 70 80 90 Unllmltedttable 131 mm mm mm mm mm mm mm mmmm kJ/mm c c c c c c "C c c

Scale A 4 1.0 a a 60 100 125 125 125 125 1255 1.4 a a a 0 50 100 100 125 1256 2.0 0 0 0 0 0 0 50 75 1006 2.6 0 0 0 0 0 0 0 0 010 3.8 0 0 0 0 0 0 0 0 0

Scale B 4 1.3 0 0 0 0 20 60 75 100 1005 1.7 0 0 0 0 0 0 20 60 506 2.2 0 0 0 0 0 0 a a 06 3.4 0 a 0 a 0 0 0 0 010 5.0 0 0 0 0 0 0 a 0 0 -Scale C 4 1.3 0 0 a 0 0 20 60 60 605 1.7 0 0 0 0 0 0 0 0 06 2.2 a 0 0 0 0 0 0 0 06 3.4 0 0 0 0 0 0 0 0 010 6.0 0 0 0 0 0 0 0 0 0

Scale 0 4 1.3 0 0 0 a a 0 0 a 06 1.7 - 0 0 a 0 0 0 a 0 06 2.2 0 a a 0 0 0 0 0 08 3.4 0 a 0 0 0 0 0 0 010 6.0 0 0 0 0 0 0 0 0 0

For Individual run.t In litu.tionl of high r.uraint. a high.r preh ting temper. cur. m .v neverth.I ... be n.c .... rv to .void weldme,.1 hvdrogen crIcking( pp.ndill EI.


13/51

BS 5135: 1984

Table 6. Conditions for manual metal-arc welding with covered electrodes of fillet welds in steelhaving maximum carbon equivalent of 0.43Scal. Specified Minimum Minimum prwh_tlng temperecur. for weldl", pl.... of followln,(I tabl. II minimum . rc .nerw . _blned Ihlokne_leg I . " . . , , , baNdoni... able 13 20 30 40 50 80 70 80 iO Unllmltedtubl.,ll mm mm mm mm mm mm mm mm

mm kJ/mm c c c c c "C c c "CScale A 4 1. 0 0 20 100 125 125 160 160 160 1505 1.4 0 0 0 76 100 126 126 160 160

6 2. 0 0 0 0 0 20 76 100 100 1268 2.8 0 0 0 0 0 0 0 50 5010 3.8 0 0 0 0 0 0 0 0 0Sca te B 4 1.3 0 0 O 20 76 100 125 126 1265 1. 7 0 0 0 0 0 60 76 100 1006 2.2 0 0 0 0 0 0 0 50 75

8 3.4 0 0 0 0 0 0 0 0 010 5.0 0 0 0 0 0 0 0 0 0Scale C 4 1.3 0 0 0 0 20 60 75 100 1005 1.7 0 0 0 0 0 0 20 50 606 2. 2 0 0 0 0 0 0 0 0 0

8 3.4 0 0 0 0 0 0 0 0 010 5. 0 0 0 0 0 0 0 0 0 0Scale 0 4 1. 3 0 0 0 0 0 0 0 0 0

5 1.7 0 6 0 0 0 0 0 0 06 2 . 2 0 0 0 0 0 0 0 0 08 3.4 0 0 0 0 0 0 0 0 0

10 6.0 0 0 0 0 0 0 0 0 0 For individual run.t In situ.tions of high restr.int higher preheating t.mp.r.ture m.y n..,.rthele .. be necessary to .void _Id m.,.1 hydrogen crac:kl(lQ(see appendiX EI.


14/51

r T!3F T'X'ft

BS 5135: 1984

Table 7. Conditions for manual metal-arc welding with covered electrodes of fillet weld. in Iteelhaving maximum carbon equivalent of 0.45. -

Scal. Sp.:illed Minimum Minimum prth.llng temper.tur. ' o t welding pl.1eI of following(51.. lable II minimum a rc . .. . IV. _blned thlokn_1"'III.nglh b..-don

(sue tabl.13 20 30 . 40 1 5 0 60 70 80 90 Unllmltedttabl.131 mm mm mm mm mm mm mm mmrom kJ/mm " c c "C "C c c c c " c

Scale A 4 1. 0 0 75 125 125 150 150 175 175 1755 1 . 4 0 0 60 1 0 0 125 125 160 150 1506 2.0 0 0 0 0 75 100 125 126 1508 2. 8 0 0 0 0 0 0 60 100 12610 3. 8 0 0 0 0 0 0 0 0 0-. -

Scale B 4 1. 3 0 0 20 75 100 125 125 150 1605 1.7 0 0 0 a 75 100 125 125 1256 2. 2 0 0 a 0 a 20 75 100 1258 3. 4 0 0 0 0 0 a 0 0 010 5.0 0 0 0 0 0 0 0 0 0

cate C 4 1. 3 0 0 0 20 76 100 126 126 1265 1.7 0 0 0 0 0 60 75 100 1006 2. 2 0 0 0 0 0 0 20 60 768 3 . 4 0 0 0 0 0 0 0 0 010 5'.0 0 0 0 0 0 0 0 0 0

cale 0 4 1.3 0 0 -0 0 0 0 0 0 05 1. 7 0 0 0 0 0 0 0 0 06 2. 2 0 0 0 0 0 0 0 0 0-8 3.4 0 0 0 0 0 0 0 0 0

10 5. 0 0 0 0 a 0 0 0 0 0

s

s

Fut' .,It.hytdual run.f In .oIualluno 01 high ,..n,aim ... h.yh.r pren .. 'Ing l.mper.lur. m.v nev."n.,." be nllC.lI.ry 10.void_Id mal.1 hVd'ogan cflcki"9h~II"lIpend .., EI.


15/51

BS 5135: 1984

Table 8. Conditions for manual metalarc welding with covered electrodes of fillet welds in stoelhaving maximum carbon equivalent of 0.48Scala Speclfltod Minimum MInimum preh .. dng temp.fiu,. fa, w.ldlng pie, .. of follOWingbile lable 11 minimum ...:'_"V-. oomblnedhlok_

I..,I.ngth- beNd on - - - - ..-.1 , , , 1 1 tebI.13 20 30 -40 &0 80 70 80 1 1 0 Unllmltedtlable 131 mm mm mm mm mm mm mm Atmmm kJ/mm "C OIC "C C C "C DC DC "c

Scale A 4 1.0 20 100 125 150 175 175 175 175 17 55 1.4 a 20 100 125 125 150 150 17 5 17 5, G 2. 0 0 0 0 75 100 125 125 150 15 08 2. 8 0 0 0 0 20 75 100 125 15 010 3.8 0 0 0 0 0 a 20 75 100-------Scale B 4 1.3 0 20 76 126 125 150 150 150 1755 1. 7 a 0 20 75 100 125 125 150 1506 2.2 0 0 0 0 60 100 125 125 1508 3.4 0 0 0 a 0 0 20 50 7510 5.0 0 0 0 a 0 0 0 0 20

Scale C 4 1.3 0 0 60 10 0 10 0 126 125 160 1505 1.7 0 0 0 60 76 100 126 126 1266 2. 2 a 0 0 a 20 60 100 100 1268 3.4 a 0 a a a 0 a 20 2010 6 . 0 a a 0 a 0 0 0 0 0_ . _ - ---

Scale 0 4 1.3 a a - 0 0 20 60 76 100 10 05 1.7 0 0 0 a a 0 20 60 606 2.2 0 0 0 0 0 0 0 0 08 3.4 0 0 0 0 0 0 0 0 010 5.0 a 0 0 a a a 0 0 0--- . ._--

For indivldu.1 run.t In ,ilulIlion. 01 high ",lIr.inl hlgh.r preh llng I.mp.nlur. m.v nownn.t.11 be n.c .... rv 10 ."old w.ld m.I.I"yd'UU.n ...... kll'Vhe.. appndll. EI.


16/51

J - - - - - - _ _ _ _ - _ _ _ - - - - _ _ . _ _ - _ . _ . . - - - - - - - - - - - = - - - - = - . : : - : -. - : - : - : - : - : - : - - - - - - - - -

BS5135: 1984

. , j Table 9. Conditions for manual metal-arc welding with covered electrodes of fillet welds in steelh::-.'ingmaximum carbon equivalent of 0.50

i

-------- ...... _.-Scal. Specified Minimum MInimum preh .. t1ngtemp.r.ture tor welding pl.t_ of followingb table 11 minimum arc .nergy-. combined ItIlok...,_

lev I.ngth- beMdonh ubi. 13 20 30' .0 60 60 70 80 80 Unllmltedtt..bl.131 mm mm mm mm mm mm mm mmmm kJ/mm c c c c c c c c c

Scale A 4 1.0 50 12 5 160 17 5 175 176 200 200 2005 1.4 0 75 125 125 15 0 175 175 116 2006 2.0 0 0 50 10 0 12 5 125 150 150 1768 2.8 0 0 0 0 50 100 126 125 16010 3.8 0 0 0 0 0 20 60 100 125---

Scale B 4 1.3 0 60 126 125 15 0 16 0 176 176 1765 1. 7 0 0 50 100 125 12 6 16 0 160 1756 2.2 0 0 0 50 10 0 12 5 125 150 1508 3.4 0 0 a a 0 a 60 100 12510 5.0 0 a 0 0 0 0 a ) 75

Scale C 4 1. 3 a 20 100 125 125 15 0 150 150 1755 1.7 0 0 20 75 100 125 125 160 1506 2. 2 0 0 0 a 60 100 126 126 1608 3. 4 a a a 0 0 a 20 60 7610 6.0 0 a 0 a 0 0 0 0 20_.

Scale 0 4 1.3 0 0 - a 20 76 10 0 100 126 1265 1. 7 a 0 0 a 0 60 76 100 1006 2.2 0 a 0 a a 0 0 60 758 3. 4 a a a 0 0 0 0 0 0

10 5.0 0 0 a 0 0 a 0 a a_ . "

.For IndIvidual run.t In situations of high reuraint. a higher preheating temperature mav nworth.I ... be nece.. ary to .void weld metel hvdrogen cr.cklng('et! appendi" EI.


17/51

enM-a.E0o< I!0.. -..-\I> -occ u'u:;::-u-0a:a:"Cc10a:c ua.?:~e. . .c u>0u-6'i~"00. . . .~~-a ;. . .0. . . . .en0.;;10. . .. . .: : : J0C: : : J. . . .- g10'":~01Cc uC: : : Ja:ci.-c u2i10. . .

E ~1O-(!;Ou)CDMN~IOCDM~a .~~ ."': ....~-:q .aq",:",:U!. . . E I I I I I I NNNN ...............oooo ---E N~ION~m-g~NMlOm~~~-",:~qaq .~"1 ap~~~ .. ~~

aD E I I I NNN ...............oooooooo

f'lE ~~~~~~O~~~~S~~~~M~~E I C '1 '" NN-- ...-oooooooooooo - - _E O~~"'NNMM-N~-~M"'re~~E ~ .. "1-:q~aq",:U!~ .~~'1~ ...E '" E I N-- ...-~oooooooooooo --- ------s. . E Nm~~-m-~~-Nu)N~IOM-E _ION m~~ IO.MM NNNItI E N~~~ddddciciddddddd I I I:a'0 ~c;a;~~:5~~n:;~:n~~~Eei . . , E ";~ciciddddddddc:i I I I I I I I. ..! E ~ION~MmU) . . .. g ~ CDu)ID.MMNNNN

" E ddcidcidddcid I I I I I II I I I -. .s0 E MON~Mc ItI IDMNN:>a: N E dddcid I I I I I I I I I I I I I I IOOOIOIDIOOIDIDOSO~OE -u)~IO~mmN~ ... N U)0 E I I I I I I'" 01 10&0. MM N. . . . . . .- ,- ,-- - - -

E E OIDOIOOOIOIOOIOIDIOIOIO~81O~~~~~~~~~~~~~~ . . . ~E aD E I I I -!_ ... _ . - _ - -- - - ..--.- ------- -_--_-._. . oO~O~Ou)IDOIOIO~IDIOSIOu)ID~.s " E ~~ en ~-~M~~ CDu) MN-~~~ .MMN ~~~~-~~" . . . E I- -'0 f-- ----.---- - -_----. ." E ~S~~~~~08~~~~~~~8~i '" E I m ... . ..CD Ul ... ~ ("') ~ M NNw- ............ - - .-- . -EE ~S~~~~~g~~~Sg~~~~E. . , ItI E (l)U)U)MMNNNN ............ I I I.-- - ..._-.-. _ .. . ----- -'0E E OIOOu)IOIOIDIOSOO~~E U)-M~MO(l)U) M'". . , E &n .. '",NNN ................. I I I I I I Ia --I--- --- _ .. . .._ ..-. . ,e .nOU)OOu)Ou)IDu)~ E.:; E .n~ ...Du)MNOOlCD I I I I I I I I I Iz: " MNN"--'---' "--f---- --j

c . . . E ~:gg2~"I: N E N-'- I I I I I I I I I I I I I I I.-.~~ E E~ ~ u)CDON",u)CDONIOOIOOIDOIDO.nOO ~ cid~~~";~NNNMM ~~~~~~

BS 5135; 1984


18/51

as 5135: 1984

0'1M -c.Eou 1---+---------------------------1

r - - r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~EE

I'!ID...._-----_._---- .. .-----------,-------

> -uCC Du= =D

i E :;; ~ C f , ~ . : ; ; m ~ ~ ! ; 1 ~ M ~ ~ N1:; ... E "";"";cicicicicicicicicicicici I I I I I I- ! -f-.- ._ --------_-------------1

\f

-e nC Dc.>-. . .C)c. . .C D>oo.~~" 8: : .oC D. . .o-. .o.;;(II. . .. . . .::loc:::l. . ."Cc:(II. . .s:. . . .tnC.!!c :::la:

r - - r - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~

:!E. .'ii"0

o. . . E ~g~~~~M~~~m~~E I I I I I I I NNN~~~...:..:...:ociciciCD

E ~~~~~~8~~~~~~~~~~g~E I NN...;~...:~...:cicicicidcicicicidciciE ~~~~~~~~~m~~M~~~~~NE N ~ , . . . ; , . .. ; , . . . ; d d c i d c i c i c i c c i c i d d d c i l

E o:eg~~~;;g~;:!;~E "";ciddddcidcicici I I I I I I I I IE ~~M;:;~~E dciccidci I I I I I I I I I I I I I I

I Io E... E If--_'_ .-EE

.--------.---------c..------------i

EE

E 8wo~~~~oww~2R~2~CD E I I I I ::::i ........CDW~~~MN(C;j"'~-!--.------.------------------------1E. .:g. . .o

>-L-~c(

- _ . _ ..- . -._.- --------_.----- ..._---.- .-.-- .._-------------------- _ .-

I I I I I I I I I..-..._-.-.--.--------------------iE ~gg~~:REN-- __ IIIII-.. .--------_.__.-----------------1I I I I I I I I


19/51

as 5135: 1984

enMc oCI)e n. s : : .. . . .- ~CIC>-0.Eou* 'oM

E C5f3,...~mNcx)co""l:31O0 ....COlnMN"" 0'1. . . E I I I I I I I I IMNN~-="':~~_:~OE C5;:::~N~~m~l:3~~a;:!!g~_ _ _ _ _"1 _ _ _ _ _ _ _ _

II) E I I I I I MNNN-- ........OoooooE ... .IO~,... ... .... 8~IO,...glO~COM CX)M 010 ....COIOMN ,...10 In ~~Mc D E I IMNN~~~~~~odoodciociciE ~CX)In-NCO~O . .. .X)CX)-InOCONm~E ~~~~~~~~~~~~~~~~~~E CD E I I NN ........................ooooooooo! " E cx)ocx)COcx)lnlnCOCOM.~N~lnNm,...~E C"1~~C"1~q~~~~1l! _~ _~C"1~~",! III E I N ....................oooooooooooo:; ;-0 ~~~o~~~~~~~~~~~~~Ej . . . E N~~~ddoddcidciciciddci I I I-

.2 E g~~~:8~~~~Mre~_ 2 N~ M E ~odcicicicicicicidd I I I I I I I I-;2 ~ E ~m~~~g~~~::J E ciciddcicicidd I I I I I I I I I I II:E ~og08~1n~~ln80 NaCX)~CO : 8 e n :M. . . E I I I I I I I I I ,... , . . . , .f-- ._-_ .. _ -

E E ~881O~lngln~go~lO~N ....8 : S i n ; M~ ~NE II) E I I I I I . . . . ,... . . . .~!E E goog~~o~~~~:!!~~~~~~ M N8~,. . .coco:8.~MMNNN . . . . . . . . . . . .:;; c D E I I . . . . . . . .-08 ~1088ooo0~0~enUlUlogo~ E M N~"""" ~ NOCX)"" ~E I I ....O'Ioo,...COl.MM NNN ................. . CD . . . .EE~ E ~~~~~ggm~g~~g~~g~e~. . . . . . E I m~~~~~MMMNN~-------- . _ _ _ ..-----'0E E 0~~~~~:!!~~8~~~e88~E ~CO~~MMNNNN- . . . . . . . . . . . . . . .I , I0 . . .. . . -_. . .~ N E OlnUlIOIn~lnOUlln8li. . . M E ~~~re~ ~~!~,... I I I , I I I I~~ - --~e . . . E 1n0enOUlOlnUlUl, . N~mCOMNomCX)II: N E MN................ I I I I I I I I I I Ir--f E Ee . . . . . . . COcx)ON.COcx)ONUlOlnOUlOUlOUlOO. , cici~~~~~NNNMM ~~~~~~JtC

1\> -uCQJU~QJ- - -oa:a:"CcCQa:8.C'"Ic-L :QJ>oos:~~'"J"Co. . .. . .~4i. . .o- - -'"-;;CQ. . . .-:Joc :2"0CCQ'":. . .g'~C::Ja:


20/51

as 5135: 1984

Table 13. Valuel of arc energy for the manualmetal-arc welding of lingle run fillet weld. (lee 21.Z.7)MInimum Ani .nergy for elec;trodn to as 638 withleel.""th co.,.rl"" typ... nd electrod .fflal.ncl ..

R.nd RR B R.nd RR.. 110" .. 130" > 130"

mm kJ/mm kJ/mm kJ/mm4 1 . 0 1 . 3 -5 1.4 1.1 0 . 86 2 . 0 2 . 2 1.18 2 . 8 3.4 1.61 0 3 . 8 5 . 0 2 . 31 2 5 . 5 6 . 5 3.1

Combined thickne .. - t, + tl + tJt, Ilierage thlckneuOller e length of 75mm

rl - 0

(= f,)

0, + 0,Combined thicknolss --2-

Figure 3. E)(emplesof combined thickne..

For IlmultAneoullv depolit.ddirectly opposed twin flll.t_Id combined thlck_-I"tl + '2 r,1

18

t.

1"i


21/51

,

oo'"

I


22/51

BS 5135: 19B4

10\'-C ::l.- -.: = - " : ; ~uIII 1110.~~ ~0 f a~~~'\1.1\~ ~. . . . . . ~"~,s


23/51

I ~0 > :JC ...P E:;~u~ \. ~~ ~o.r\\ C CII E._ L GI:L 0....~ t\~,,,\.,,\\.'\, , ' " ,,'\l\~ ~'\ r - , . ' \ r\

j U'IU'Ir--

C>~

U'I'"

o~ o 0co -0 oNww s sa ulIl!lU p a ulqWO )

I1 0 > ~C'"E :6: ~ '-':It'UQlOECIIo.:sf ~c>, :L 0.-_J'\

(01\'\~~,f \ . . ' \ ,\-0 ~ ~ ~~ ' " ~ r.- r - . . .


24/51

S 5135: 19B4

j 1~ t\ ~\ 01:2c....~ f\\ ~1!~eGl~" ' c~ Egtz\ '\f\ i:a2

~ '\~\\ \I"\ 1 \ \k l ~ ~ r - . _ \ 1\- . " - f\_\ ~" ' r - - . ' ,~ ~\ .


25/51

VI. . . . ..-

0\~I\\ \ QIC-en ::lc:-\ \ E:C rog~~~ -0\ i\ \ -c~ ~VI 1: a .~\\ ~\ i\\\ \ r \~\\\

0 \\ \ r\~ \\1\\"VI r'\ 1\ \\ l\. . . . . \ \~\\- 1\- , - , \\\ ~

i ' \ . _ I~1 \ \ :~-, I\. i\\ ' "r- , r'\\ :\~i\r- , r- , '\~ ~


26/51

~N

0VIIII. . . . .!

f\'\\ \

\ \ \

\\ \~ -0\ \ \ \

0~

VIN. . . .

~~~~~~~~~~ww SSaUlf)!44 pau!qwo)24

01It)0 ciMIt)

U ci~ . . . .It)- ciC D. ..; 01"iI ' < 1 ;c 1 I ~ 0

!'11. u I(.... . . .0-I:1"iJ~o ~... 1'

\ J "


27/51

U\ 0 C>VI ..... C>,_r\ 1 \ 1 \ r \\ \ \ \~ 1 \ \0~ \ \ \ 1 \\ \ \ \ cuc...\ 1 \ r \ , , ' CI:JC....e '- IU-- c...UjlUcu o\ \ \ 1 \ eCIIo.'c ~ e. _ c . .. GI\ \ 40.....\ '\1 \ \ \ \\ r\ \\1 \ \ \ 1 \ \\ - t\ \ \ \

'A \ \ 1 \ ~\. . . . . ! ; : ! ,\ \. . . '\ 1\ \ \ \\ .\\ i\ ~\\\\ \ \ 1 \ \ 1 \ -

f\ f\ .\r \\C> \ \ \ r\\1\1,\ 1 \ r\ ~\\ \

~ r\ \ \ r\\'r ' \ . '\ '\ f\\~\ -"- \ 1\\ f\\\" t-, r\ \ f \ ' \'" '\"- f\. 1 \ \ ~. . . . . . . I'.. t-, '\ \~~C> - , f\~~r-, r-,


28/51

o"~Ir~~-n\.T~~~~~r.-..-~~~~~~~m\ \ \ \ I~\

\ \ 1 \ \ : \!\ '\ \ \ \"

\ \ \1 \ \

~ \ \1 \\1 \\

~ i'- .~. r\\,\\~-+-4---i---=~",-+-~"\I-[\.~\~\~,l.I--+-4---I N--+--+--+-f--+--+--+-+---4---4--'~~:..d-'\-AI\..---l'\--lo,.-A\~~\s.L-, " ,~

,._,_~ ~'J~~~~ f r~~-~ ~ NWW SSaUlp!~~pau lqwO)

26

. . .. . .


29/51

- -\ 1 \ \ 1 \ ~, \ \ \\ r \ \ r \\ \ \ \I~ , \ \ \\ ~ \ 1 \ \ \1 \ \ \ \ 1 \ ' GICl5c:-\ 1 \ 1 \ \ \ 1 \ E~ ~I..J IGI ~ 0,_.c: E1 \ \ \ \ \!:~GIL0-\ 1 \ r \ \ \'0 1 \ \ \ 1 \ \ 1 \ I~\ \ , \ \ 1 \ \r\ 1 \ \ 1 \ \ \'

l\ , \ \ 1 \ \ 1 \\ \ 1 \ ~\1 \ \~ \ \ 1\\\ '\ \ \ ~\\ 1 \ \ \\ l\\

VI I\, \ [\\ \\ ~c: t\ . 1 \ \.\1 \ \\ - , \ \ 1\ \ I\\''\, :\ \ \ \\ ~- , " \ r\'\ \\ \" f\ . \ \ [\\'\" '\ r\ I\~\ \" " - " , - , \1\ \ t\\~


30/51

S 5135: 1984

22. Approval and testmg of welding proceduresWhen Wfllt'IlIl'~ldilllllllnc.!(I ..rt~;H'! rt'(luiu!d (silt!clause 201 ilnd II requu ed !IV Ill(! IJu('cl1aser. the contractorshall satisfV the purchaser that he call make satisfactorywelds with the weldill!lIIlO


31/51

Appendix AGuidance on d8llgnNOTE 1.Typlc.l.ppllc.,lon .,.nderdl oov.rlng _Id dlgn",(l.Ctl .r. BS153 : P.r" 3a .4, Ind as 449 : Per' 2.NOTE 2. P.'Ilculer auldenc. on datlQn '0 lVold l.m.lI.r ~"'lnQIt glv.n In opfJ.ndlll O.A.1 Butt 10ln1l hfl' Ilao Ipp.ndhc BI. Butt lolnt. betweenI,.rtl of uneqUII crall ctlon .rr.ng,d In lin. will r ult Inloc.llncr .... In It" .. In addltlon to the str .. 1concentratIon eaused by the profile of the weld Itself. I f the centrepian .. of the two parts Joined do not coincide, local bendingalso will be induced at the joint. I f the stresses induced bythese effects are unacceptable, then the parts should beshared so as to reduce the stresses. Examples of plain andshaped parts are shown in figure 5, where (a) and (bl arethe more common types with (c) being a special configuration to facilitate non-destructive testing. The slope of thetaper should be basod on design requirements. If no suchrequlremGnt Is stated, It I s recommended that the slopeshould not be steeper than 1 in 4.An incomplete penetration butt weld which is welded fromone side only should not be subjected to a bending momentabout the longitudinal a)(is of the weld which would causethe root of the weld to be in tension, unless this is allowedby the application standard. ./The use of incomplete penetration butt welds to resistrepeating or alternating dynamic forces should be avoidedwhere poselble but, where they are used, the design stresses,hould be suitable for the loading conditions.Welded joints subjected to fluctuating loads should bedesigned so that the stresses satisfy the requiroments ofas 6400 : Part 10.A.2 Fillet weld The effective length of In open endedfillet weld should be taken es the overall length less twicethe leg langth, thereby discounting the contribution of thestop and start positions which are generally of reducedprofile. In any case, the effective length should not be less

BS 5135: 1984

th.n four times the leo length. Fillet welds terminating atthe ends or sides of parts should be returned continuouslyaround the corners for a distance of not less than twice theleg length of the weld unless access or the configurationrender this Impracticable. This procedure is particularlyImportant for fillet welds on the tension side of partscarrying a bending load.In fillet welded lolnts carrying a compressive load, it shouldnot be Illumed that the parulolnP.d are in contact underthe [olot, For critical applications the use of a partial oreven a full penetration weld should be considered.A single fillet weld should not be subjected to a bendingmoment about the longitudinal axis of the joint whichwould cause the root of the weld to be in tension.Where fillet welds are used in slots-or holes through one ormore of the parts being [oined, the dimensions of the slotor hole should comply with the following limits in termsof the thickness of the part or parts in which the slot orhole is formed.

(a) The width or diameter should be not less than threetimes the thickness or 25 mm, whichever is the greater.(b] Corners at the enclosed ends of slots should ~rounded with a radius of not less than 1.5 times thethickness or 12mm, whichever is the greater.(c) The distance between the edge of the part and theedge of the slot or hole. or botwt'en adjacent slots orholes, should be not less than twice the thickness andnot less than 25 mm for holes.

Fillet welds connecting parts, the fusion faces of whichform an angle of more tha n 1200 or less than 60, shouldnot be relied upon to transmit calculated loads at the fullworking stresses unless perm itted to do so by theapplication standard.

-The design throat thickness of a flat or convex fillet weldconnecting parts, the fusion faces of which form an angleof between 60 and 120, may be derived by multiplyingthe leg length by the appropriate factor as given in table 14.

(hi

(el SI,,,,, I conflQuratlon ' 0 f.cllll.,.non -d.1I,ucllv. , lInQ.Figure 6. Butt lolnt. of un.qual crot tetlon

29


32/51

5135: 1984

able 14. Factors for deriving design throatckness of flat or convex fillet weldsb.IW n fU lion flO ClII

0.70.650.60.550.5

F.e1or-------;1---to 90to 100to 106to 113to 120

account should be taken of fabrication, transport,erection stresses particularly for those fillet weldsch have been designed to carry only a light load duringpound welds, consisting of a butt weld plus a filletld. should be treated as a f illet weld for fatigue consider-" Welded joints subjected to fluctuating loads should~signed so that the stresses satisfy the requirementsS 5400 : Part 10.

pendix Bidance on butt welds (for other than structuralw sections)Introduction. The recommended dimensions of thearations are intended primarily for manual welding inflat position for general types of welded constructions.e overhead and vertical welding require manipulationhe electrode, comparatively easy access to the root ofweld is desirable for welding in these positions. This ilined by using a wider angle for the weld preparation, .ometimes by increasing the root gap. When usingtrodes with a thick covering, some modification toroot details of the weld preparation may be necessary.dimensions may be different for semi-automatic,atic or mechanized welding.

Suitable methodl of making weld preparadons. Singledouble V and bevel preparations may be machined orine tlame cut. Single and double U and J prep~rationslly have to be machined. The choice of a machined or

machine flame cut preparation should be at the option ofthe contractor except when specified by the purchaser orin the appropriate application standard.In .. s8uing the merlu of the two method, of preparationand the type of joint, the relative costs of machining, flamecutting ~nd length of weld should be taken Into account.B.3 Selection of weld preparation to control dl,tortlon.U and J preparations Ii compared with V and bevelpreparationlserve to reduce distortion by virtue of thelesser amount of weld metal required. Likewise, doublepreparations are better than single preparations in that theweld metal can be deposited in alternate runs in each sideof the joint. In the control of distortion, accuracy ofpreparation and fit.yp of paru are important considerations,II well 81a carefully planned and controlled welding. procedure.B.4 Typical forml of weld praparation. Typical forms ofweld preparation are shown in table 16. I n the case ofsquare butt joints (a) and (b), the width of the gap dependsmainly on the size and type of electrode and the gapshould be chosen accordingly .The two joints (c) and (dl are probably the most commonbutt weld preparations used in gerieral work. A root facewithout a gap usually facilitates assembly and minimilillcontraction. The production of a sound weld, with orwithout gouging out of the back of the fint run, is afunction of the gap, root face Ind the type of electrodeused. More reliable production of sound welds can beachieved by using back googing .While the double V preparlltions (e) and (f) usually show alaving In weld metal, it is more difficult in these joints toensure full fusion at the centre of the weld. If a root face isprovided for 85sembly purposes and full fusion is a require-ment, adequate gouging out of the back of the fint runmay be necessary The single and double U preparatiom (g), (h) and (j ) aredesigned to give easy access for the electrode and to ensuregood arcing conditions particularly foe the firu run.Sin{jle and double J preparations (k) and (I) and sinll18 anddouble bevel preparations (ml and (n) are used where onlyone joint member can be prepared. Proparatlons (m) and (n)are used for lesser thicknesses and where plate edges cannotbe machined. To ensure wllid soundnl!S5 great care should beexercised, especially at the root of the double bttval buttweld .


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BS 5135 : 1984

W.cdtypeTable 16. Typical fonn' of butt wefd preparation (other than structural hollow sections)

Typloool 'olnt d . . H{alOpen square{without backing IWelded from both sides

r - - ! - - - ; l _ b~rFlit position:thickness T, 3 mm to 6 mm; gap G, 3 mm.

Horizontal/vertical or vertical position:thickness T, 3 mm to 5mm; gap G, 3 rnrn,

See clause 11 for tolerances. See also clause 7{blOpen Iquare{with backinglWelded from one side withbacking which may beeither temporary or perm-anent in which case it maybe part of the structure oran integr.1 part of onemember

( - - ' -ftAll positions.For flat position only ":

Thickness T Gap Gmm3 to 55 to 8Bto 16

mm6810I this preparation is used for material over

16 mm thick the gap may be required to beincreased.See clause 11for tolerances. See also clause 7

{clSlnglll V{without backlnglWllided from bOth sidesor one side only

All positions.For flat position onlv ":gap G, 2 mm; angle Q 60;thickness T, 5 mm to 12 mm;

root face R, 1 mm;thickness T, over 12 mm:

root face R, 2 mrn,See clause 11 for tolerances. See also clause 7

[d]Single V(with blcklng)Welded from one side withbacking which may beeither temporary or perm-anent in which CIII! Itmaybe part of the structure oran integrtli part of onemember

tliJE L~r -- f1r -2 ." " ..al.J",.. " ' , I I .All pOlitions:

thickness T. over 10mm.For flat position oolv ":root faee R, 0;single root run:gap G, 6 mm; angle Q, 45;

double root run:gap G, 10mm; angle Q. 20.

See clause 11 for tolerances. See also clause 7---..-.--------t----------------+-----------------{elDouble VWelded from both sides

All positions:thickness T, over 12 mrn,

For flat position onlv"gap G. 3 mm;angle Q 60;root face R, 2 mm.

See clause 11 for tolerances. See also clause 7.

(f)Asvmmetrlc double VWeldnd from both 'ides

All polltion,:thickness T. over 12 mm,

For flat position onlv ":gapG, 3 mm:lingle a, 60; angle ( 1 , 60;root face R, 2 mm.

See clause 11 for tolerances. See also clause 7.If the deeper V is welded first and full rootpenetration is required, the lingle (J mllV beincreased to 90 to facilitate back gouging

Th" dim"nllonoof the weld J',..,.r.tlon mey ".... 10be modlfl.d feuoth.r proc....... nd 'or _Iding in"osition. olher thAnfI..I.

31


34/51

as 5135: 1984able 15. (concluded)Weld lvpe TvplcalJolnt detail- - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - , - - - - - - - - ,Dlme.,.lorll end remerk.(glingh:Ulded from both sides R r - \ f 1 _ _ , _ _ l{=~' - - - r

All posltlona:thlckn." T,over 20 mm. 'For flat position only":angle Q 20;radlusr, 6 mm;root face R, 5mm.

See clause 11 for tolerances. See also clause 7(hiDouble Ulded from both sides

vmmet r i c double Uelded from both sides

ingle Jlded from both sides-

aR n , _ _ _ - - ,L: - _ - - t :rr~----1LJ

(-j 211T! - - - - - [ ) f ; _ ] _ jr r- r _ --rJ- - - : ' I - . . . . , - - -T1L J I \ L R'-_?a

All positions:thickness T. over 40 mm.For flat position onlv":angle Q 20;radius r, 6 mm;root face R, 6mm.See clause 11 for tolerances. See also clause 7

All positions:thickness T, over 30 mm.For flat position onIV":land L. 6mm;angle Q 20;radius r, 5 mm;root face R, 5mm.See clause 11 for tolerances. See also clause 7All positions:thickness T, over 20 mm.For flat position onlv ":land L, 5mm;angle Q, 20;radius r, 6 mm;root face R, 5mm.

See clause 11 for tolerances. See also clause 7

Jelded from both sides

All positions:thickness T, over 40 mm.For flat position onlv ":lind L, 6mm;Ingle Q. 20;radius r, 6mm;root face R, 6 mm.See clause 11 for toltlr8nces. S8. also clause 7

lded from both sides

uble bevelelded from both sides

All positions.For fl. t posi tion ani y ..:gap G. 3 mm; angle Q. 45;thickness T. 5 mm to 12 mm:root face R, 1 mm;thickness T,over 12 mm:root face R, 2 mm.

See clause 11 for tolerances. See also clause 7All positions:thickness T, over 12 mm.For flat position only-:gapG, Jmm;Ingle a, 46 ;root flCI R, 2 mm.See clluse 11 for toler.nc See Iho clIU 7 v

dimenlionl 01 the _Id prep.r.tlon INIV hew to be modified '~~ other proc:..... 8nd for w.ldlnl l in po.hion. other th." fl.


35/51

Ii::' b IJ!:): I~H4

AppendIx CGuidance on typical detaila for atructural hollow aectlonaTypical det.lIs for butt welds for structural hollow .ection. are given In table 16. Branch connections for circular andrectangullr structural hollow sections for. butt and fillet welds Ire shown in figures 6 to 9.Table 16. Tvplcel forms of butt weld preparation for structural hollow sectionsNOTE. All prep.rlllloni .re ror welding f,om one Iide onlv end in ell pOlitlonl.Weld type Dlm.nslon.vplc.1 'oInt detell(alSquare(without backing'

r,, . Thickness T. up to 3 mm:gap G, 3 mm max.(b'Square(with backing,

(clSingle V(without backing'

(d'Single V(with backing'

T~ r - c ; ,t ~ I I \. L__-:.l ~t,

-6 O Om on t~ !

R \ , ,, t L_ _j-f. ~ ~,,

Thickness T. J mm:gap G. J mm min. 5 mm max.:thickness of backing t,J mm.

Thickness T. 5 mm:gap G. 5 mm min. 6 mm max.:thickness of backing t, J mm min. 5 mm max

Thickness T.6mm:gap G. 6 mm min. B mm max.:thickness of backing r, 3 mm min. 6 mm max

Thickness T. up to 20 mm;gap G. 2 mm min. 3 mm mIlIC.;root face R. 1 mm min. 2.5 mm max.

Thickness T. up to 20 mm:gap G. 5 mm min. 8mm max.:root face R. 2.5 mm max.;thickness of hacking r. 3 mm min. 6 mm malC

f e 'Single Vflame cu t preparat ion{with backing'

I f 'ouble angle V(with backing)

Thickness T. 20 mm to 30 mm:gap G. 8 mm min. 10 mm max.:root face R. 3 mm max.;thickness of backing t , 3 mm min. 10 mm max.

33

Thickness T. 20 mm and over:gap G. B mm min. 10 mm max.:root face R. 3 mm max.;thickness of backing t, J mm min. 10mm max.


36/51

s 513!): 1984

ble 16. (concluded)DIm..tona

~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -(g)

bt!velwithout backing)

Thickne" T, up to 20 mm:gapG, 2.6 mm min. 4 mm milt.;root feceR, 1mm min. 3 mm mix.

bevelith backing) r42 S~ 2.S' - " Tr: ht,--J( r-i-J'--'--f-f - - f--l --Ii

Thickness T, up to 20 mm:gapG, 5mm min. 8mm max.:root faceR, 3 mmmax.;thicknessof backing t, 3mmmin. 6 mmmax

~ ~ 7 S .nJ, R~---J".j{~L~---f - r t- - r ; ! ; . . Thickness T, 20mm and over:ouble anglebevet 6.. ",._ 12S ~2.S _ gap G,8 mm min. 10mm max.;ith backing) Ii-i'" r root faceR, 3 mm max.;_I ...2.S /.5 J thickness of backing t,3 mm min. 10mmmix.i/./ ,-; Rv. l " - ,

L---~'- -- ' l - H , -

'bevelCuI oreperauon

th backing)

Thicknllu T, 20 mm to 30 mm:gap G,8mm min. 10mmmex.:root facli R, 3 mmmsx.,thickness of backing t, 3 mm min, 10mmmix.


37/51

,__h,_

BS 5135: 1984

o

TM

2 to 3 mm 2 to 3m m 0-90"-90 o - 30 " 10 90 "O"tlllllllX

H min_- T

2to3 mm

---~~H

d-O

Olltail .1 Y

Oet.iI I " Z For the Imeller IIngleslull penelrlltion is nOlintended providedthere isadequateIhroat thielmess

210) mm

d


38/51

S 5135: 1984

.y___:L._addled hrancn/

Oelall al X Oatail at V

L - Leg langth

mped or uraighJuI branch

1I...et weld -, -,

IJ

- ._ . . - / - - - - - -

o

0 ..I.iI81 ZFor 1I11I.mallar anglelfull Pllnetration it notint.ndlld prOllldlid.there is .dequetethroat thicknell

3 mm max

1. L"lIlenglt snould be such th.t the str."es in 'illet WIIIdl are in accordance with the ~It"mlnlb". lira ..... givan in Ihll r.I.".ntlP"c~llon .. a"lIard .nd that thll w.lld. will tranlmit th. lo.ds in the member.

2. The a"ll l" 0' Intersection 0 01the aX1I10' tha circular hollow taction. Wlould not be l"iS tn..n 30" unlo". 8daqu8tll efflciencv 0'unClion has tkoen demon5lr ed.

7. Branch connections for circular structural hollow section.: fillet welda

.---- ',._-__---------

,


39/51

Oet.1I .t )(

. .J~ I ; :,U ..

. -~r,l....__- - . . . . ; .I:Y,to25 mm

8- 60" to 90

2tolmm0-30 to 60Oet.il t ZFo, Ihe small., angletlullpene"ation isnotintended p,ovidedthe,e i. adequatethroet Ihickne

NOTE. The .ngle ollnt.,,,acllon 0 01the el(lI' 01 Ihe ,ectanQUla, hollow.action hould not be less than 30 unlen adequate efliciency 01the junction ha. been d..."on."ated.

x . . Y.~ ..8I..,

Figure 8. Branch connections for rec:tangular structural hollow sec:tions: butt welds

Whe",d < 0

\ ' I I h ft'l! d0Oa'811.a ' Y

Hmin. - T

37


40/51

r5135: 1984x y-+--A> j.

I- D ~1

Lmax.2m m m ax.i

Wl\er.d< D0.1411 01 ZFor Ih maUarang'oil pan.tratlon i.nolInland


41/51

.

Appendix 0Guidance on fracture toughness of heat-affectedzone and weid metal0.1 Heataffected zone. When toughness requirements arespecified for the heat-atfected zone it should be noted thatmost steels suffer a degree of embrittlement during weldingand therefore the fracture toughness of the heataffectedzone can be inferior to that of the parent metal. However,the fact that the heat-affected zone may be less tough isnotsignificant provided the heataffected zone has sufficientnotch ductility for the particular service conditions.The factors controlling fracture toughness are:(a) total heat input (including preheating and interpasstemperatures);(b) chemical analysis of the steel;Ic) mechanical properties of the steel;(d) post-weld heat treatment.

For some applications itmay be necessary to control theheat input by specifying the minimum and maximumallowed. This range of heat input will vary depending onsteel type, thickness, preheat and the required fracturetoughness of the heat-affected zone and the steelmakershould be consulted asto the most suitable steel to meetthe specified levelof fracture toughness of the heat-effectedzone at the heat inputs to be used.0.2 Weldmetal. The welding technique exerts considerableinfluence on the low temperature impact propertiesachieved by a welded joint. Various factors in the weldingprocedure which affect the fracture toughness propertiescan be summarized as follows:(a) consumable type;(bl electrode diameter and shielding gas;(c) heat input (including preheating and interpasstemperatures) e.g. for manual metal-arc weldingmeasured as a function of diameter, welding current,runout length and type;(dl refinement of weld as a function of single and/ormultipass welds, i.e. stringer bead and/or split weavetechnique;(el effect of plate material dilution;

BS 5135: 1984

(f) effect of welding position;(g) post-weld heat treatment .

It is emphasized that should any doubt exist as to theachievement of specific fracture toughness in weld metalat a particular temperature, the welding consumablemanufacturer and the steelmaker should be consulted.Appendix EGuidance on avoidance of hydrogen crackingE.l General. The occurrence of cracking depends on anumber of factors: composition of the steel, the weldingprocedure, welding consumables, and the stress involved.If the cooling rate associated with welding istoo rapid,excessive hardening may occur in the heat-effected zone.tt sufficient hydrogen is present in the weld the hardenedzone may crack spontaneously under the influence ofresidual stress after the weld has cooled to near ambienttemperature. Welding conditions can be selected to avoidcracking which ensure that the heat-affected zone coolssufficiently slowly, by control of weld run dimensions inrelation to material thickness and if necessary by applyingpreheat and controlling interpass temperature. The hydro'gen input to the weld can be controlled by using hydrogencontrolled welding processes and consumables and to someextent by the use of preheat and interpass temperaturecontrol. Similar considerations apply to hydrogen crackingin the weld metal where although hardening will be on areduced scale actual hydrogen levelsand stress levelsarelikely to be higher. In general, welding conditions selectedto avoid heat-affected zone hydrogen cracking will alsoavoid cracking in the weld metal. However, In someconditions of high restraint weld metal hydrogen crackingcan become the dominant mechanism.It cannot be stated too strongly that the most effectiveassurance of avoiding hydrogen cracking is to reduce thehydrogen input to the weld metal from the weldingconsumables. The benefits, in terms of a reduction inpreheat level and an increase in the number of situationswhen no preheat is required, that can arise from the useof progressively lower hydrogen levelsare shown byexamples in table 17.

Table 17. Examples of maximum combined thickness weldable without preheat-Diffusible hydrogen content M.ximum combined thicknessp.p.m of ml/100 IIof C.rbon equiv.lent of 0.49 C.rbon equiv.lent of 0.43fused metel deposited metel

ArcenefVV Arcen.rgy Arc enet'1IV ArcenefVV1.SkJ/mm 3kJlmm 1.5 kJlmm 3kJlmm

mm mm mm mm> 9 > 15 25 60 45 90 100 100 100 > 100 1P.P.m. - 1cm'/m'


42/51

E.2 Hydrogen scal... The following is general guidance one selection of the appropriate hydrogen scale forocesses other than manual metal-are welding.lid electrode wire for gasshielded arc welding should beed with scale C unless otherwise assessed. This scaieould be used alsowith other suitably assessed consumies after appropriate drying treatments, as recommendedthe manufacturer.G welding should be used with scale D. This scale shouldso be used with other suitably assessed consumables afterying or other treatments, e.g. clean solid electrode wiresr gasshielded arc welding, and some basic coveredectrodes after drying at temperatures recommended bymanufacturer. Itshould be noted that on occasionsese temperatures could exceed 400 C.bmerged arc welding, flux cored wire weldi ng and

covered wire welding consumables can haveydrogen levelscorresponding to any of the scales A to Dnd therefore need assessing in the case of each namedoduct..3 Conditions requiring more stringent procedures.ds made involving any of the following factors may.Jire the use of more stringent welding procedures thanse derived from 21.2.(a) high restraint;(b) thick sections;(c) low carbon equivalent steels;(d) alloyed weld metal;(e) 'clean' or low sulphur steels.

dequate quantification of the effects of these factors one need for a more stringent procedure and on the changesthe welding procedure required to avoid cracking cannotmade at the present time. The following should therefore0 considered as guidelines only.t restraint isa complex function of section thickness,ld preparation. geometry. and the stiffness of thebrication. Welds made in section thicknesses above

~O mm and ~oot runs in double bevel buttts may require more stringent procedures.r carbon manganese steels of low carbon contents than about 0.10 %) the carbon equivalent formula;ied in clause 4 does not adequately indicat~ the riskrneat-attected zone hydrogen cracking and may under-timate it. Thus welding procedures for such steels mayQ~iremodification. In addition, welding proc~d~resved from 21.2 may not be adequate for aVOidingweldtal hydrogen cracking when welding steels of low carbonuivalent (less than approximately 0.42). This is morely to be the case when welding thick sections (i.e.ater than about 50 mm) and with higher yield steels.e use of alloyed weld metal (other than carbon, siliconmanganese) may lead to higher operative stresses.ther or not this causes an increased risk of heat-affectedcracking. the weld deposit would generally be hardermore susceptible to cracking itself.cent experience and research has indicated that loweringinclusion content of the steel. principally by loweringsulphur content (but also the oxygen contentl mayease the hardenability of the steel. From a practicalnt of view this effect may result in an increase in theess of the heat-affected zone, and possibly a smallease in the risk of heat-affected zone hydrogen cracking.ratequantification of the effect is not presentlyticable but some increase in hardness (and risk of heatpoP.m. - 1 cm'/m'

affected zone hydrogen cracking) might be observed insteels with sulphur levelsless than approximately 0.008 %""1m).While modifications to the procedures derived from 21.2to deal with welds involving the above factors can inprinciple be derived through a change in arc energy orpreheat or weld hydrogen level. the most effectivemodification is to lower the weld hydrogen level. This canbe done either directly by lowering the hydrogen input tothe weld (use of lower hydrogen welding process orconsumables) or by increasing hydrogen loss from theweld by diffusion through the use of higher preheat andinterpass temperatures. In many situations the use ofwelding consumables depositing weld metal containinglessthan 2.5 mL hydrogen per 100 g deposited metal(1.5 p.p.m ." of fused metal) will avoid weld metal as wellas heat-affected zone hydrogen cracking.Where this is not possible it may be necessary to increasethe preheat temperature to 200 c and to maintain it as apost-heat fora period of time dependent on thickness,e.g. a period of 2 h to 3 h has been found to be beneficialin many instances.

.4 Relaxations. Relaxations of the welding proceduresdetermined from 21.2 may be possible under the followingconditions.(a) General preheating. If the whole component or awidth more than twice that stated in 21.2 is preheated.it is generally possible to reduce the preheatingtemperature by up to 50 C.(b) Limiredheat sink. If the heat sink is limited in oneor more directions (e.g. when the shortest heat path isless than ten times the fillet leg length) especially in thethicker plate (e.g. in the case of a lap joint wheretheoutstand isonly marginally greater than the fillet weldleg length). it is possible to reduce preheating levels.(c) Austenitic electrodes. In some circumstances wheresufficient preheating to ensure crack-free welds isimpracticable an advantage may be gained by usingcertain austenitic electrodes, for example class 19.12.3or 25.20 in BS 2926 or high nickel alloy. In such cases'preheat may not be necessary. especially if the conditionof the electrode coating is such as to deposit weld metalcontaining very low levels of hydrogen.(d) Joint geometfy. Close fit fillet welds (where the gapis 0.5 mm or less) and root runs in single V butt weldsmay justify relaxations in the welding procedure.

E .S ExampleStep 1. Decide carbon equivalent value using table 2,21.2.1.21.2.2 and E.3. Assume steel is BS 4360 : GradeSOC,not controlled rolledTable 2 gives a carbon equivalent of 0.45.Step 2. Decide provisionally on welding process andconsumables. Classify as A. B. Cor Dusing 21.2.3 andtable 1 to determine which carbon equivalent scale to use.Assume manual metal-ere welding using hydrogen con-trolled electrodes complying with BS 639, and that the weldhydrogen level is appropriate to scale Bin tab'e 1.Step 3. Decide whether fillet or butt weld and refer totable 2.Assume fillet weld.

Ml


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Table 2 refers to table 7.Step 4. Decide minimum specified individual fillet leglength required by design drawing.Assume5mm.Table 7, scale B, 5 mm leg length now requires step 5.Step 5. Decide combined thickness of joint to be welded'with single run fillet of 5 mm leg length.Refer to 21.2.5.Assume calculated combined thickness of 70 mm.Step 6. Return to table 7 and read off the minimumpreheat required: scale B, 5 mm fillet, 70 mm combinedthickness requires 100C preheat.Step 7. Tables 7 and 13 give arc energy values (see 21.2.6)corresponding to the 5 mm fillet using the particularelectrode chosen (1.7 kJ/mm).Tables 10, 11 and 12 give the electrode size and runcutconditions which correspond. Thus table 11 offers a choiceof electrode sizes and run lengths from 450 mm ofelectrode ranging:from 3.2 mm diameter and 145 mm run lengthto 8mm diameter and 910 mm run length.

Practical considerations would probably limit this to amaximum diameter of 5 mm electrode and correspondingrun length of 355 mm.Variation at step 3Step A. Assume butt weld.Table 2 refers to figures 4(a), 4(e), 4(g) and 4(h).Figure 4(gl is relevant to 0.45 carbon equivalent and scale B.Step B. Decide minimum run dimension to be used inmaking butt weld. This will most often be the root run.Assume 4 mm electrode to be run out in about 320 mm ofrun length.Refer to table 11. This gives minimum arc energy forindividual runs forming the butt weld of 1.2 kJ/mm.Step C Decide combined thickness of butt joint.reCfl"fringto 21.2.5.~C < i : , : , : ~ .:!,:~~~atd!cml':;: :~~thir:"ness of 50 mm.Step D. Return to figui'ii 2i(g) and plot coordinates of,1.2 kJ/mm arc energy and 50 mm combined thickness.Read off minimum preheating and !nt~rp"ss temperaturerequired (by interpolation. if necessary, or by readin~ thepreheat line immediately above or to the left of the 'coordinated poind which in this example is 100C.Variation at either step 7 or step D. In the event thatpreheat is undesirable. proceed as follows.Step W. Re-examine figure 4(g) to determine minimumarc energy for no preheat (20C line, normally).For fillet example: 2.2 kJ/mmFor butt example: 1.6 kJ/mmStep X. If by reference to table 11 these arc energies arefeasible, proceed using electrode diameter and run lengthchosen from table 11.If not feasible, proceed to step Y.Step Y. Using table 7 for the fillet weld example andfigures 4(a) and 4(e) for the butt weld example, examinethe feasibility of using lower hydrogen levels (by the use ofhigher electrode drying temperatures or change of consumabies) to avoid the need for preheat at acceptable arc energylevels.

as 5135: 1984

Appendix FGuidance on solidification crackingF.1 Solidification cracking of the weld metal is usuallyfound as centreline cracking. It is more often found in rootruns and, although frequently open at the surface andvisible after deslagging, may be just below the surface andcovered by up to 0.5 mm of sound metal. Solidificationcracks can be deep and can seriously reduce the efficiencyof a joint. When welding carbon manganese steels, this typeof cracking is most commonly found in submerged arcwelds, rarely with manual metal-arc welding but cansometimes be a problem with gas and self-shielded processes.F.2 Solidification cracking is associated with impurities,particularly sulphur and phosphorus, and is promoted bycarbon picked up from the parent metal at high dilutionlevels whilst manganese reduces the risk of cracking.Because welding consumables are generally purer than thematerials being welded, impurity levels and cracksusceptibilities are usually greatest in weld runs of highdilution, e.g. root runs of butt welds. To minimize the riskof cracking, consumables are preferred with low carbonand impurity levels and relatively high manganese contents.F.3 For submerged arc welds a formula" has beendeveloped in which the solidification crack susceptibilityin arbitrary units known as units of crack susceptibility(UCS) has been related to the composition of the weldmetal (in % (m/mll as follows:230C + 1905 +-75P + 45Nb - 12.3Si - 5.4Mn

This formula is valid for weld metal containing the following:C 0.03t to 0.23S 0.010 to 0.050p 0.010 to 0.045Si 0.15 to 0.65Mn 0.45 to 1.6Nb o to 0.07

Alloying elements and impurities in the weld metal up tothe following limits do not exert a marked effect on valuesof UCS:t %Ni0.5 %Cr0.4% Mo0.07 % V0.3 %Cu

0.02% Ti0.03%:~0.002%80.01 "Pb0.03 '" Co

In the above formula, vefues of less than 10 UCS indicate ahigh resistance to cracking and above 30 a low resistance.Within these approximate limits the risk of cracking ishigher in weld runs with a high depth/width ratio, madeat high welding speeds or where fit-up is near the maximumallowable.For fillet weld runs having a depth/width ratio of about 1.0,ues values of 20 and above indicate a risk of crackingwhilst for butt welds the values of about 25 UCS are critical.Decreasing the depth/width ratio from 1.0 to 0.8 in filletwelds may increase the allowable UCS by about 9. However,very low depth/width ratios, such as are obtained whenpenetration into the root is not achieved, also promotecracking.

See BAILEY. N. and JONES, S.B. Solidification cracking of ferritic steels during submerged ere welding. The Welding Institute, 1977.tCcontents of less th.n O.OB" to be teken .s equel to 0.08 '"


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s 5135: 1984,Appendix GGuidance on lamellar tearingG.1 General. In certain types of joint. where the weldingntraction s.trai~sact in the throUgh-thickn~ss (shorttransverse) dIrectIon of a plate,lameliar tearang may occur.Lamellar tearing isa parent metal phenomenon whichoccurs mainly in plate material. The risk of cracking is -luenced by two factors: plate susceptibility and strainoss the joint. With very susceptible plate, tearing canccur even if strains are low, i.e. in a joint of low restraint.re .resistan.t m~terials might n~t tear unless used inituatlons whIch Imposed very hIgh throughthickness

f'tate susceptibility. Since tamellar tearing ~.!:~ WI,onnon-metallic inclusions in a plate link u::, under theence of welding strains, p!ate $I!sceptibility if controlledy the quantity and distribution of the inclusions it contains.present there is no reliable non-destructive teehniqua foretecting these inclusions. The short transverse tensile testa" be used to assess susceptibility (see figure 10) and thetransverse reduction of area (STRA) has been corre-~edwith the incidence of lamellar tearing in differentes of fabrication (see figure 11). In the case of low oxv-steels (aluminium treated or vacuum degassed typesl,Iphur content has been found to be a useful guide to thelusion content and thus to the STRA. Figure 12 gives8likely lowest and highest values of STRA to be expectedan aluminium treated steel of a given sulphur content.he da ta are for pia te 12.5 mm to 50 mm thick but itUldbe noted that the relationshipof STRA (in % 1 toIphur content (in %) is to some extent thicknessls giving reduction of area values of over 20 % STRAe considered lamellar tearing resistant and materials 'witharanteed STRA are available. These are usually aluminiumted steels of low sulphur content, although additions ofearth or calcium compounds may also be made both touce the inclusion content and to favourably alter theclusion shapes. ,Jhenappropriate, the contractor should discuss with the

raker the supply of lamellar tearing resistant steel.

Friction weldedextension stubs

inal shortan~verse tensilepecrmen

10. Short trlnlv.,.. ten"l. test specimen withion welded .xtensions

G.3 Joint configuration and throughthlcknasl Itr.lnt.The risk of lamellar tearing for. given steel increases withthrough-thickness strain, and the latter isusually high injoints of high tensile restraint. However, tearing may alsooccur if the bending restraint is low. since angular distortioncan increase the strain in weld root or toe areas (seefigure 13). In some cases, design changes can be made whichreduce the throughthickness strain. Examples of the typesof detail and joint configtHation in which lamellar tearing ispossible are shown in fjgure 14. typical locations of thecracks being illwft.c"":ed. If m. plat.e.~sceptibilitv issuspected tn'_"',igh, susceptible:Joints and details shouldbe mo$~o." or avoided. For " " ' e . the,Tfillet (figure~.(t:t)11is less susceptible th... .Tbutt (figure 14(ell andthe -"et on nozzle is less susceptible than the set throughnozzle. Alia a chamfer could be applied to the horizontalplate in fig~re 14(f) so that welding stresses would no longer,be perpendicular to the plate. Replacing a susceptible plateconnection by a casting or forging may also be possible.In,most structures of,any

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BS_5135-1984_process of arc welding of carbon and carbon manganese steels