AWS D1.4/D1.4M:2011

An American National Standard

Structural Welding Code— Reinforcing Steel

Including Metal Inserts and Connections in Reinforced Concrete Construction

AWS D1.4/D1.4M:2011

An American National Standard

Approved by the American National Standards Institute

January 31, 2011

Structural Welding Code—

Reinforcing Steel

Including Metal Inserts and Connections in Reinforced Concrete

Construction

7th Edition

Supersedes AWS D1.4/D1.4M:2005

Prepared by the American Welding Society (AWS) D1 Structural Welding Committee

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This code covers the requirements for welding reinforcing steel in most reinforced concrete applications. It contains a body of rules for the regulations of welding reinforcing steel and provides suitable acceptance criteria for such welds.

International Standard Book Number: 978-0-87171-786-3

American Welding Society 550 N.W. LeJeune Road, Miami, FL 33126

© 2011 by American Welding Society

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their pro- visions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties.

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On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discovered, are posted on the AWS web page (www.aws.org).

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 550 N.W. LeJeune Road, Miami, FL 33126 (see Annex C). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addi- tion, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D1 Committee on Structural Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D1 Committee on Structural Welding and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS D1 Committee on Structural Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.

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Personnel

AWS D1 Committee on Structural Welding

D. K. Miller, Chair The Lincoln Electric Company

A. W. Sindel, 1st Vice Chair Alstom Power, Incorporated

T. L. Niemann, 2nd Vice Chair Minnesota Department of Transportation

S. Morales, Secretary American Welding Society

N. J. Altebrando STV, Incorporated

F. G. Armao The Lincoln Electric Company

E. L. Bickford Acute Technological Services

B. M. Butler Walt Disney World Company

R.D. Campbell Bechtel National, Incorporated

H. H. Campbell III Pazuzu Engineering

L. E. Collins Team Industries, Incorporated

R. B. Corbit Exelon Nuclear Corporation

1. A. Dennis Consultant

   M. A. Grieco Massachusetts Department of Transportation

   C. W. Holmes Modjeski and Masters, Incorporated

   J. J. Kenney Shell International E & P

   J. H. Kiefer ConocoPhillips Company

   V. Kuruvilla Genesis Quality Systems

   J. Lawmon American Engineering & Manufacturing, Incorporated

   N. S. Lindell Inspectech Incorporated

   D. R. Luciani Canadian Welding Bureau

2. L. Luckowski Department of the Army

P. W. Marshall MHP Systems Engineering

M. J. Mayes Mayes Testing Engineers, Incorporated

D. L. McQuaid D. L. McQuaid and Associates, Incorporated

R. D. Medlock High Steel Structures, Incorporated

J. Merrill MACTEC, Incorporated

J. B. Pearson, Jr. LTK Engineering Services

D. C. Phillips Hobart Brothers Company

D. D. Rager Rager Consulting, Incorporated

R. E. Shaw, Jr. Steel Structures Technology Center, Incorporated

T. J. Schlafly American Institute of Steel Construction

D. R. Scott PSI (Retired)

R. W. Stieve Greenman-Pederson, Incorporated

M. M. Tayarani Massachusetts Department of Transportation

K. K. Verma Federal Highway Administration

B. D. Wright Advantage Aviation Technologies

* Deceased

Advisors to the D1 Committee on Structural Welding

W. G. Alexander WGAPE

E. M. Beck MACTEC, Incorporated

O. W. Blodgett The Lincoln Electric Company (Retired)

G. L. Fox Consultant

G. J. Hill G. J. Hill and Associates, Incorporated

M. L. Hoitomt Hoitomt Consulting Services

D. R. Lawrence II Blue Scoep Steel (Retired)

*W. A. Milek, Jr. Consultant

J. E. Myers Consultant

J. W. Post J. W. Post and Associates, Incorporated

P. J. Sullivan Massachusetts Department of Transportation (Retired)

AWS D1I Subcommittee on Reinforcing Steel

J. Merrill, Chair Mactec Engineering and Consulting

N.S. Lindell, Vice Chair Inspectech Incorporated

M. E. Gase Soils and Materials Engineers, Incorporated

D. P. Gustafson Consultant

T. Huerter Professional Service Industries

E. D. Pratt Hanson Structural Precast

D. R. Scott PSI (Retired)

T.W. Studebaker Terracon Consultants

Advisors to AWS D1I Subcommittee on Reinforcing Steel

K. Landwehr Schuff Steel Company

M. J. Mayes Mayes Testing Engineers, Incorporated

J. E. Myers Consultant

D. D. Rager Rager Consulting, Incorporated

Foreword

This foreword is not part of AWS D1.4/D1.4M:2011, Structural Welding Code— Reinforcing Steel, but is included for informational purposes only.

In 1961, the American Welding Society published its first reinforcing steel welding standard, AWS D12.1-61, Recommended Practices for Welding Reinforcing Steel, Metal Inserts and Connections in Reinforced Concrete Construction. The D12 Committee was disbanded some time after publication of the 1961 code and before publication of the 1975 edition.

The 1961 document was replaced with a greatly revised version, AWS D12.1-75, Reinforcing Steel Welding Code, with the format patterned after the AWS D1.1-72, Structural Welding Code. The 1975 code was produced by the AWS Structural Welding Committee but was not renumbered to reflect this committee change. As with ANSI/AWS D1.1, AWS D12.1-75 was designed as a self-contained code, including within it the qualification of welders and procedures, and requirements for workmanship, quality, and inspection.

The listings of materials and welding processes were revised in the D12.1-75 code. Items newly introduced were the carbon equivalent method for determining preheat, the parenthetical inclusion of metric (SI) conversions, and the two different methods of joint strength determination.

The AWS D12.1-75 document was revised and the title changed to ANSI/AWS D1.4-79, Structural Welding Code— Reinforcing Steel. Since the 1979 edition of ANSI/AWS D1.4, Structural Welding Code—Reinforcing Steel, was issued, further use by designers, engineers, and fabricators has necessitated a number of changes to the requirements; the 1992, 1998, and 2005 editions reflected these changes. This edition, AWS D1.4/D1.4M:2011, has additional revisions.

The following is a summary of the significant technical revisions in this edition:

1. Subclause 1.2.1 was revised top address precast concrete components.

2. New definitions were added under 1.5.

3. Safety information was clarified in 1.7.

4. Figure 2.1 was revised to clarify the centerline, nominal radius, and effective throat.

5. Subclause 3.2.1 was revised to address indirect butt joints.

6. Figure 3.2 was updated to illustrate degree ranges in all sketches.

7. Figures 3.3 and 3.4 were revised to restrict the gaps between bars to nothing over 1/4D or 3/16 in [5 mm], whichever is less.

8. Subclause 4.4.2 was modified to differentiate between the sum of maximum dimensions of all porosity versus maximum dimensions of any single porosity or fusion-type discontinuity.

9. New subclause 5.1.3 was added to address coated reinforcing steel and filler metal selection.

1. Subclause 5.3 was added to list requirements for maximum wind velocity and minimum ambient temperature.

2. New subclauses 5.10 and 5.11 were added to restrict electrodes used for GMAW and FCAW.

3. Subclause 5.12 was added to restrict the shielding gas used for GMAW and FCAW-G.

4. Table 5.1 was updated to meet the most current A5 specifications.

5. Clause 6 was revised to list the details for fillet weld prequalified essential variables.

6. New Table 6.1 lists the prequalified essential variables for fillet welds.

7. The essential variable requiring requalification for a change in the shape or any one type of groove was removed from Table 6.2.

8. Table 6.4 was corrected to include lap joints in indirect butt joints.

9. New Table 6.5 was added to clarify acceptance criteria for macroetch.

10. Figure 6.4 was updated.

11. All sketches in Figures 6.5 and 6.6 were redrawn for clarity.

12. New Figure 6.7 was added to illustrate welder qualification tests for fillet weld to plate.

13. Figures 7.1 and 7.2 were redrawn to increase the backing to 3/16 in [5 mm].

14. Annex B was updated.

Changes in Code Requirements. Underlined text in the subclauses, tables, or figures indicates an editorial or technical change from the 2005 edition. A vertical line in the margin indicates a revision from the 2005 edition.

Informative Annexes. These annexes are not code requirements but are provided to clarify code provisions by showing examples, providing information, or suggesting alternative good practices.

Errata. It is the Structural Welding Committee’s Policy that all errata should be made available to users of the code. Therefore, any significant errata will be published in the Society News Section of the Welding Journal and posted on the AWS web site at: https://www.aws.org/technical/d1/.

Suggestions. Your comments for improving AWS D1.4/D1.4M:2011, Structural Welding Code—Reinforcing Steel are welcome. Submit comments to the Managing Director, Technical Services Division, American Welding Society, 550

N.W. LeJeune Road, Miami, FL 33126; telephone (305) 443-9353; fax (305) 443-5951; e-mail info@aws.org; or via the AWS web site <https://www.aws.org>.

Table of Contents

Page No.

Personnel v

Foreword vii

Table of Contents ix

List of Tables xi

List of Figures xi

1. General Provisions 1

   1. Scope 1

   2. Application 1

   3. Reinforcing Steel Base Metal 1

   4. Welding Processes 2

   5. Definitions 2

   6. Welding Symbols 2

   7. Safety Precautions 3

   8. Standard Units of Measurement 3

   9. Reference Documents 3

2. Allowable Stresses 5

   1. Base-Metal Stresses 5

   2. Allowable Stresses in Welds 5

   3. Effective Weld Areas, Lengths, Throats, and Sizes 5

3. Structural Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 |

1. Transition in Bar Size Number 9

2. Eccentricity 9

3. Joint Types 9

4. Direct Butt Joints 9

5. Indirect Butt Joints 9

6. Lap Joints 9

7. Interconnection of Precast Members 9

1. Workmanship 17

   1. Preparation of Base Metal 17

   2. Assembly 17

   3. Control of Distortion, Shrinkage, and Heat 17

   4. Quality of Welds 18

2. Technique 21

   1. Filler Metal Requirements 21

   2. Minimum Preheat and Interpass Temperature Requirements 21

   3. Welding Environment 21

   4. Arc Strikes 22

   5. Weld Cleaning 22

   6. Tack Welds 22

   7. Progression of Welding 22

   8. Welding of Coated Base Metal 22

   9. SMAW Electrodes 22

   10. GMAW Electrodes 23

   11. FCAW Electrodes 23

   12. Shielding Gas 23

3. Qualification 27

   1. General 27

   2. WPS Qualification 27

   3. Welder Qualification 29

   4. Retests 31

   5. Period of Effectiveness 31

   6. Records 32

4. Inspection 45

   1. General Requirements 45

   2. Inspection of Base Metals 45

   3. Inspection of WPS Qualification and Equipment 45

   4. Inspection of Welder Qualifications 45

   5. Inspection of Work and Records 45

   6. Obligations of the Contractor 46

   7. Nondestructive Testing 46

   8. Personnel Qualification 46

   9. Radiographic Testing 47

Annex A (Informative)—Sample Welding Forms 53

Annex B (Informative)—Nominal Dimensions of ASTM Standard Reinforcing Bars 59

Annex C (Informative)—Guidelines for the Preparation of Technical Inquiries for Structural Welding Committee 61

Annex D (Informative)—Safe Practices 63

Annex E (Informative)—Temperature-Moisture Content Charts 71

List of AWS Documents on Structural Welding Code 73

List of Tables

Table Page No.

2.1 Allowable Stresses in Welds 6

3.1 CJP Groove Weld Requirements for Direct Butt Joints 10

4.1 Radiographic Acceptance Criteria 18

1. Matching Filler Metal Requirements 24

2. Minimum Preheat and Interpass Temperatures 25

3. Permissible Atmospheric Exposure of Low-Hydrogen Electrodes 25

1. Prequalified WPS Fillet Weld Requirements 32

2. PQR Essential Variable Changes Requiring WPS Requalification for SMAW, GMAW,

   and FCAW 33

3. Number and Type of Tests for WPS Qualification 34

4. Welder Qualification—Number, Type of Test, Production Welds, and Positions Qualified 35

5. Macroetch Acceptance Criteria 36

7.1 Hole-Type Image Quality Indicator (IQI) Requirements 50

List of Figures

Figure Page No.

2.1 Effective Throat for Flare-Groove Welds 7

1. Direct Butt Joints Showing Transition Between Bars of Different Sizes 10

2. Direct Butt Joints 11

3. Indirect Butt Joints 12

4. Lap Joints 13

5. Details of Joints of Anchorages, Base Plates, and Inserts 14

1. Minimum Distance to Cold Bending Radius Tangent Points 19

2. Acceptable and Unacceptable Weld Profiles 20

1. Direct Butt Joint Test Positions for Groove Welds 36

2. Indirect Butt Joint Test Positions for Flare-Groove Welds or Fillet Welds 37

3. Positions of Groove Welds 38

4. Positions of Fillet Welds 39

5. Full Section Tension Test Specimens for WPS Qualification Tests 40

6. Full Section Tension Test and Macroetch Test Specimens for Welder Qualification Tests 42

7. Bend Test Specimen for Welder Qualification Tests 43

1. Source Position 51

2. Film Placement 52

1. Temperature-Moisture Content Chart to be Used in Conjunction with Testing Program

   to Determine Extended Atmospheric Exposure Time of Low-Hydrogen Electrodes 66

2. Application of Temperature-Moisture Content Chart in Determining Atmospheric

Exposure Time of Low-Hydrogen Electrodes 67

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Structural Welding Code—Reinforcing Steel

1. Scope

   1. General Provisions

      The code shall apply to the welding of the following:

      1. Reinforcing steel to reinforcing steel, and

      2. Reinforcing steel to carbon or low-alloy structural steel.

   When the code is stipulated in contract documents, conformance with all provisions shall be required, except for those provisions that the Engineer or contract documents specifically modifies or exempts.

2. Application

   1. This code shall be used in conjunction with the prescribed general building code requirements and is applicable to all welding of reinforcing steel, using the processes listed in 1.4, and performed as a part of reinforced concrete construction or in the manufacture of precast concrete components.

   2. The weldments specified in this code shall not be used where impact properties are a requirement of the general specification. Impact testing requirements of welded reinforcing bars are not included in this code.

   3. All references to the need for approval shall be interpreted to mean approval by the Engineer.

3. Reinforcing Steel Base Metal

   1. Reinforcing steel base metal in this code shall conform to the requirements of the latest edition of one of the ASTM specifications listed within this paragraph. Combinations of any of these reinforcing steel base metals, when welded, shall use a WPS (welding procedure specification) qualified in conformance with Clause 6:

      1. ASTM A 82/A 82M

      2. ASTM A 496/A 496M

      3. ASTM A615/A615M

      4. ASTM A 706/A 706M

      5. ASTM A 767/A 767M zinc-coated (galvanized) steel reinforcing bars that meet the requirements of ASTM A615/615M or ASTM A706/706M

      6. ASTM A 775/A 775M epoxy-coated steel reinforcing bars that meet the requirements of ASTM A615/615M or ASTM A706/706M

      7. ASTM A 934/A 934M epoxy-coated prefabricated steel reinforcing bars that meet the requirements of ASTM A615/615M or ASTM A706/706M

      Manufacturing and testing requirements for mats and fabric are covered by the respective ASTM specification. For join- ing the ASTM A 82/A 82M and A 496/A 496M to other reinforcing wires, reinforcing bars, or structural steels, the Engineer shall specify filler metal and the provisions of this code shall apply.

   2. When a reinforcing steel not listed in 1.3.1 is approved under the provisions of the general building code or by the Engineer, its chemical composition and carbon equivalent shall be provided and welding procedure shall be qualified in accordance with the requirements of 6.2 and all other requirements prescribed by the Engineer.

   3. Base metal, other than those previously listed, shall be one of the structural steels listed in the latest edition of AWS D1.1, Structural Welding Code—Steel, or any steel stipulated in the contract documents or approved by the Engineer.