Guys,
I'm playing devils advocate here. A correction was made in the 2008 D1.1 to the ASTM specification reference in clause 7.2.6, indicating that the base material for studs is cold drawn bar conforming to ASTM A29 grades 1010 thru 1020. This is not a prequalified base metal in Table 3.1, so if studs are to be manually welded with an approved process, including fillet welded repairs, it seems that the procedure would have to be qualified. The option of fillet welding studs is addressed in Section 7, but when fillet welded, the fact that this is not a prequalified base metal changes things.... I think.
There is a note at the end of clause 7.1..... Note: Approved steels; for studs, see 7.2.6; for base metals, see Table 3.1 (Groups I and II). I understand that A29 grades 1010 thru 1020 are approved base metal for the studs, and I understand that they can be applied to any base metal within Group I and II.... but if the two base metals are joined together manually, it seems that a PQR would be required, simply because A29 is not shown in Table 3.1
I'm pretty sure that wasn't the intent, but I agree that a strict reading of the code will get you there.
This is in the commentary:
"Studs welded by the use of automatically timed welding equipment or fillet welded by SMAW are considered to have been welded by a prequalified WPS."
Two problems. First, it's in the commentary, not on the code. Second, it only mentions SMAW, not GMAW or FCAW, but I would think that was simply an oversight when they added FCAW & GMAW. That base metal isn't any less prequalified for GMAW/FCAW than it is for SMAW, so if it's not an issue for SMAW, it shouldn't be an issue for the other processes either.
Hg
I agree with you. I personally think it was just an oversight.
D1.1 Clause 3.3 pretty much sums up prequalified materials....only what is listed in Table 3.1 is prequalified, no exceptions...however I think that you could use option #2 and call out D1.1 Clause 3.4 and get the EOR to approve the use of the stud material in a prequalified WPS.
Some additional words to consider:
7.5.5 FCAW, GMAW, SMAW Fillet Weld Option.
At the option of the Contractor, studs may be welded
using prequalified FCAW, GMAW, or SMAW processes,
provided the following requirements are met: ...
7.6.1 Purpose. Studs which are shop or field applied in
the flat (down-hand) position to a planar and horizontal
surface shall be considered prequalified by virtue of the
manufacturer’s stud base qualification tests (Annex G),
and no further application testing shall be required. The
limit of flat position is defined as 0°–15° slope on the surface
to which the stud is applied. Some nonprequalified
stud applications that require tests of this section are the
following:
(1) Studs which are applied on nonplanar surfaces or
to a planar surface in the vertical or overhead positions.
(2) Studs which are welded through decking. The
tests shall be with material representative of the condition
to be used in construction.
(3) Studs welded to other than Groups I or II steels
listed in Table 3.1.
So, if studs are welded in the flat (down-hand) position to Group I or II steels and not through decking, they would not seem to fit in the category of stud applications that do require qualification tests.
But that still refers to automatic stud welding.
Unfortunately, although the commentary makes the rather sensible intent clear, there's no way to get there from the code itself, so it all depends on how flexible the inspector or engineer will be about intent vs. letter of law. If someone wanted to get all legalistic, they could probably make you do a PQR for fillet welding of studs.
Hg
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