Gentlemen,
Your help is much appreciated. More comments, opinions or guidance is welcome, but I think you have provided the written backup for the answer I was looking for. Thank you.
7:30AM Wednesday
Just as a follow up, I contacted AISC Steel Solutions, referenced this forum and I got this response:
"Doug:
It appears that you received several responses to your questions. Although the subject is not directly addressed in the AISC Specifications, we can give you our recommendations.
It is possible to use filler weld metal to fill-in the weld access hole, have it grinded down and tested using magnetic particles. However, AISC would not recommend such a practice as it is prone to cracking and may weaken the welds due to shrinkage of the large filled area. We would recommend using an epoxy or body solder as a non-structural filler. See 10.4.1 of the Code of Standard Practice.
Regards,
Sergio Zoruba, Ph.D.
AISC Steel Solutions Center
866.ASK.AISC"
Based upon all the above input, I am recommending we no longer fill rat holes with weld metal. We should only fill exposed steel with non-structural epoxy or body solder. Once again, thank you gentlemen.