WPS: SMAW-CS -1-

Ref. WPS: SMAW-CS

COMPANY NAME: .

COMPANY ADDRESS: .

WELDING PROCEDURE SPECIFICATION (WPS)

About WPS:

Welding Procedure Specification (WPS) is a general document that outlines shop and field
welding practice and limitations for a welding process. Welding parameters and ranges are
specified and used to prepare associated WPDS.

About WPDS:

Welding Procedure Data Sheet (WPDS) is a document, used in conjunction with a WPS,
detailing the welding parameters and ranges for welding a specific joint, over a range of
thicknesses and weld sizes, as illustrated on the data sheet.

Scope

This WPS covers welding and related operations of steel structures which are fabricated in
accordance with the terms specified in the latest editions of following Standards:

- CSA W47.1-Certification of Companies for Fusion Welding of Steel

- CSA W59-18-Welded Steel Construction (Metal Arc Welding)

- AWS D1.1/ D1.1M-Structural Welding Code, Steel

- AWS D1.3/D1.3M-Structural Welding Code, Sheet Steel

This WPS will be presented to the Canadian Welding Bureau (CWB) along with the related
WPDS for approval.

Welding Procedure

The welding shall be done manually using the Shielded Metal Arc Welding (SMAW) process.

Joints shall be made following the procedural stipulations indicated in Applicable Standards, and
may consist of single or multiple passes in accordance with the accepted WPDS to which this
specification refers.

Base Metals

The base metals shall conform to any of the following groups:

-Steels in Groups of Table 11.1 or Table 12.1 of CSA W59-18 Standard

-Steels in Groups of Table 3.1 of AWS D1.1 Code

-Steels in Groups of Table 1.2 of AWS D1.3 Code

Other materials and/ or specifications may be welded providing WPDS are accepted by the
Canadian Welding Bureau.

Base Metal Thicknesses

-CSA W59-18 and AWS D1.1: Base metal thicknesses from 3 mm (1/8 in) to unlimited thickness

-AWS D1.3: Structural sheet/ strip steels, including cold formed members which are less than 3 mm
(1/8 in) in nominal thickness

Above ranges may be welded under this specification providing the respective WPDS’s have
been supplied and accepted for the appropriate weld size.

Filler Metals

The filler metal shall be certified by the Canadian Welding Bureau as conforming to the CSA
Standard W48 latest edition.

Following are some of the popular electrodes:

E4918 (E7018): It is Low Hydrogen type with medium penetration; has specified minimum
impact requirements, and fast freeze electrode.

E4310/ E4311 (E6010/ E6011): It is Cellulose type for deep penetration; has specified minimum
impact requirements, and fast freeze electrode.

E4924 (E7024): It is Rutile type with high deposition rate; has not specified minimum impact
requirements, fast fill and fast freeze electrode.

E4928 (E7028): It is Low Hydrogen type with high deposition rate; has not specified minimum
impact requirements, fast fill and fast freeze electrode.

Storage and Conditioning of Electrodes

-Low Hydrogen (Basic) Electrodes:

The storage and conditioning of electrodes shall be as per applicable standard, see scope.

All basic electrodes shall be delivered in hermetically sealed containers that do not show evidence
of damage. However, if such containers show evidence of damage, the electrodes shall be
reconditioned in accordance with the requirements of applicable standard.

Immediately after being removed from hermetically sealed containers or from reconditioning ovens,
electrodes shall be stored in ovens held at a temperature of at least 120°C (250°F).

Basic electrodes of E49XX classification that are not used within 4 hours after removal from ovens
shall be reconditioned in accordance with the requirements of applicable standard.

Basic electrodes shall be re-dried no more than once.

Electrodes that have been wet shall be discarded.

-Non Low Hydrogen (Non Basic) Electrodes:

These types of electrodes shall be stored in warm and dry conditions and kept free from oil, grease,
and other deleterious matter once they have been removed from their containers and packages.

Electrodes that have been wet shall be discarded.

Position(s) of Welding

The welding shall be done preferably in the flat position, but other positions such as horizontal,
vertical and overhead are permissible providing the proper WPDS’s are prepared and approved.

Electrical Characteristics

Welding equipment will be used having a drooping voltage characteristic. The welding current
specified will be direct current (straight or reverse polarity) or alternating current. The current range
will be as per electrode manufacturer's instructions and will show on the WPDS.

Minimum Preheat and Interpass Temperature

The minimum preheat before welding will comply with Table 5.3 of the CSA Standard W59-18,
Table 3.3 of the AWS D1.1 or as per Clause 7.4 and Annex A of the AWS D1.3. Minimum
preheat to be maintained or exceeded during welding.

If welding is interrupted for some time so that the temperature of the base metal falls below the
minimum preheat temperature, and then arrangements will be made to preheat again prior to
recommencing welding.

The weldment shall be allowed to cool to the ambient temperature without external quench media
being supplied. In other words, do not cool using water or by immediate placement in frigid
conditions which will cause a quick temperature change.

Heat Treatment and Stress Relieving

This will not be applicable to structures welded under this specification, unless a specific WPDS
showing all the parameters is submitted to the Canadian Welding Bureau and acceptance is
obtained.

Types of WPDS:

There are two types of WPDS, Prequalified or non Prequalified. Prequalified WPDS uses
prequalified joint as specified in a governing code or standard that does not require validation of
welding parameters through the performance of a procedure qualification test.

Prequalified joints and requirements for Prequalified WPDS are outlined in the following parts of
Standards:

-Section 10 of the CSA W59-18: Joints that conform to the provisions of Clause 10, shall be
deemed as prequalified, and therefore approved for use without performing joint welding
qualification tests, provided that welding procedures also conform to Clause 4, 5, and 10
WPS: SMAW-CS -4-

-Clause 3 of the AWS D1.1: In order for a WPDS to be prequalified, conformance with all of the
applicable requirements of Clause 3 shall be required.

-Clause 5 of the AWS D1.3: In order for a WPDS to be prequalified, conformance with all of the
applicable requirements of Clause 5 shall be required.

Note: The use of a Prequalified joint shall not exempt the Engineer from using engineering
judgment in determining the suitability of application of these joints to a welded assembly or
connection.

Preparation of Base Material

The edges or surfaces of parts to be joined by welding shall be prepared by oxy-acetylene machine
cutting. Where hand cutting is involved the edge will be ground to a smooth surface. All surfaces
and edges shall be free from fins, tears, cracks or any other defects which would adversely affect
the quality of the weld.

All loose or thick scale, rust, moisture, grease or other foreign material that would prevent proper
welding or produce objectionable fumes, shall be removed.

Welding Technique

The correct amperage and voltage, speed of travel, thickness of layers, number of passes, position,
material, electrodes and any special instructions will be as per WPDS.

Arc strikes outside of the area of welds should be avoided on any material.

The size of any single-pass weld or the size of the first pass of a multiple-pass weld size shall be
such as to minimize the possibility of cracking.

Prior to depositing weld metal on the underside of a welding groove, the root shall be gouged, or
chipped to sound metal, unless otherwise specified on the applicable WPDS.

Back-gouging, when specified in WPDS, shall produce a groove contour substantially

Larger size electrodes may be used for fill passes of the thicker material while smaller size
electrodes usually applicable for root pass and/ or for thinner material.

Quality of Welds

Cracks or blow holes that appear on the surface of any pass shall be removed before depositing
the next covering pass. The procedure and technique shall be such that undercutting of base
metal or adjacent passes is minimized.

-CSA W59-18: Fillet weld profiles and Groove weld profiles in butt joints shall meet the desirable
or acceptable weld profiles shown in Figure 5.3 of CSA Standard W59-18. The reinforcement in
groove welds shall not exceed 3 mm (1/8 in) and shall have a gradual transition to the plane of
the base metal surface. In general, quality of welds will be such as to meet either the
requirements of Clause 11.5.4 for statically-loaded structures or Clause 12.5.4 for cyclically-
loaded structures of CSA Standard W59-18.

-CSA W47.1: Acceptable and unacceptable weld profiles are shown in Figure 14
WPS: SMAW-CS -5-

-AWS D1.1 5.23 Weld Profiles: All welds shall meet the visual acceptance criteria of Tables 6.1
and 9.16, and shall be free from cracks, overlaps, and the unacceptable profile discontinuities
exhibited in Figure 5.4, and Table 5.8, and Table 5.9, except as otherwise allowed in 5.23.1,
5.23.2, and 5.23.3

-AWS D1.3: Weld Acceptance Criteria shall meet the requirements of Section 8 of AWS D1.3

Weld Metal Cleaning

Slag or remaining after a pass, shall be removed before applying the next covering pass. Prior to
painting, etc., all slag shall be removed and the parts shall be free of loose scale, oil and dirt.

Essential Variables

CSA W47.1:

Essential Variables are defined in CSA W47.1 Clause 11:

CSA W47.1: Clause 11.4.2: Essential variables for soundness and mechanical testing shall be
as specified in Table 11, Table 12 and Clause 11.4.3

CSA W47.1: Clause 11.4.3: The PQR mechanical test essential variable changes requiring a
requalification for the SMAW process shall be as follows:

(a) a change in the base metal steel group (number) as defined in Table 17

(b) a change in welding process

(c) an increase in filler metal classification strength level

• For the SMAW process, a strength level greater than E49XX requires requalification

(d) a change of thickness outside the range allowed by Table 13

Essential Variables when reference code in WPDS is combination of either CSA W47.1/
AWS D1.1 or CSA W47.1/ AWS D1.3:

AWS D1.1:

AWS D1.1 Table 4.5: PQR Essential Variable Changes Requiring WPDS Requalification

Following are general changes requiring a requalification for SMAW process based on Table 4.5
of AWS D1.1, however for full detail list of essential variables, Table 4.5 of AWS D1.1 applies:

(a) a change in welding position not qualified by Table 4.1 [Plate]/ Table 9.9 [Pipe] of AWS D1.1

(b) a change in diameter or thickness or both not qualified by Table 4.2 [Plate]/Table 9.10 [Pipe]

(c) an increase in filler metal classification strength level

(d) a change in base metal or combination of base metals not listed on the PQR or qualified by
Table 4.8 of AWS D1.1

(e) Vertical welding: For any pass from uphill to downhill or vice versa
WPS: SMAW-CS -6-

(f) a change in groove type (e.g. single-V to double-V), except qualification of any CJP groove
weld qualifies for any groove detail conforming with the requirements of 3.12 (PJP-Figures 3.2)
or 3.13 (CJP-Figures 3.3), (9.10 or 9.11 [Tubular]) of AWS D1.1

(g) a change in the type of groove to a square groove and vice versa

(h) the omission, but not inclusion, of backing or backgouging

AWS D1.3:

AWS D1.3 Table 6.2: PQR Essential Variable Changes Requiring WPDS Requalification

Following are general changes requiring a requalification for SMAW process based on Table 6.2
of AWS D1.3, however for full detail list of essential variables, Table 6.2 of AWS D1.3 applies:

(a) a change in welding position not qualified by Table 6.1 of AWS D1.3

(b) an increase exceeding 30% in the thickness of coating of sheet steel

(c) an increase in filler metal classification strength level

(d) a change in the diameter and a change in the classification of the electrode

(e) a change in the type of coating or the addition, but not deletion, of coating material on base
metal

(f) Vertical welding: For any pass from uphill to downhill or vice versa

(g) an increase in the root opening of a square groove weld

(h) for square groove welds in butt joints, a change in welding from both sides to welding from
one side, but not vice versa

(i) the deletion, but not addition, of permanent or removable backing

Note: When required by the CSA W47.1 Standard or when there is a conflict that make the CSA
W47.1 take precedence over the AWS D1.1 code or AWS D1.3, essential variables of the CSA
W47.1 Clause 11, may apply (this should be decided by an authorized company’s engineer with
approval of the CWB).

Engineer or Supervisor Signature CWB Acceptance