1

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) BEAD LENGTH (in mm) PITCH (in mm)

4 10 250

4 28 40 500

28 70 800

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: -

PLATE THICKNESS RANGE MISALIGNMENT

T1 ≤ 12 0.25 X T1

12 < T1 ≤ 50 3.0 Less Then

50 < T1 5.0

T1 T2

( T1 ≤ T2 )

2

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 .

Deviation tolerance Standard

The Deviation tolerance is:--

T2 (maximum ) – T1 ( minimum ) ≤ 6 mm.

T2 T1

Boss external diameter

Boss internal diameter

maximum minimum

3

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 Leg length tolerance

S 1 L ~ 1.2L

S 2 L ~ 1.2L

S 3 L ~ 1.2L

S 4 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 Tolerance limitation

Plate thickness (less than 6 mm) Plate thickness ( more than 6 mm)

W 1 0.3 0.3

W 2 0.4 0.5

W 3 0.6 0.7

Not Spec. 0.8 0.9

Items that exceeded the tolerance limitation shall be redone.

4

BEAD SURFACE BLOWHOLE;

The blowhole limitation that exists on the welding bead surface is as shown

in table:--

Quality mark Tolerance limitation (number )

Number of blowholes per 500mm Density

W 1 0 0

W 2 4 2

W 3 6 3

Not Spec. 8 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

5

OVERLAP SIZE APPLICATION EXAMPLE REMARKS

Less than 2mm

Grinder up-down chord,

stringer, cat frame, seam

beam, other main steel

frame parts.

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 (θ) is more than 60°, it is rejected.

WELD EXTERNAL APPEARANCE:

The welding Bead external appearance shall be 2

nd class or more than that of

external appearance sample issued by the welding association

Overlap

θ

θ

6

UNEVEN BEAD WIDTH: Acceptance or rejection is based on table:--

Quality

mark

Standard

Length

Bead width

Difference

Remarks

W 1 50 3 Less Than

W 2 50 4 Less Than

W 3 50 5 Less Than

REINFORCEMENT HEIGHT:--

Plate

Thickness

When not specified When A

smooth

mark is

specified

When

the

finish

mark is

specifi

ed

Remarks

Manual welding CO2

Weld

ing

Subm-

erged

arc

Weldin

-g Dow

nw

ard

Sta

ndin

g

Upw

ard

12 less

than

3 less

than

4 less

than

5 less

than

4 less

than

4 less

than

1.5 less

than

+0.5

-0.25

Less

than

Finished By a

Grinder

Between

12 and 25

2.5 less

than

More

Than 25

3.0 less

than

Welding

mark

display

Example

A1

L

A2

G

G

G

G