BWC 6 I2

Published by the American Association
of State Highway and Transportation Officials

These interims are being provided to owners and fabrica-
tors for informational purposes only and are intended
to alert them to proposed revisions to the AASHTO/AWS
D1.5M/D1.5.2010 Bridge Welding Code. These interims
have received initial approval from the AWS D1 Com-
mittee and the AASHTO Subcommittee on Bridges and
Structures. However, they will not officially revise the
Bridge Welding Code until they have gone through the
complete AWS consensus review and approval process
and are incorporated into the next published edition
of the AASHTO/AWS D1.5M/D1.5 Bridge Welding Code.
This review and approval process can result in additional
revisions to these interims before their final adoption.
Owners have the option of implementing these interims
in current projects by specifying their use in the project
specifications.
ISBN: 978-1-56051-543-2
Pub Code: BWC-6-I2
AASHTO 2012 Interim Revisions to
BRIDGE
WELDING CODE
6TH EDITION

2012 by the American Association of State Highway and Transportation Officials.
All rights reserved. Duplication is a violation of applicable law.
ISBN: 978-1-56051-543-2 Publication Code: BWC-6-I2

American Association of State Highway and Transportation Officials
444 North Capitol Street, NW Suite 249
Washington, DC 20001
202-624-5800 phone/202-624-5806 fax
www.transportation.org

2012 by the American Association of State Highway and Transportation Officials. All rights reserved. Duplication is
a violation of applicable law.

Cover photo provided by L.B. Foster-Precise Structural Steel Division, Georgetown, MA.

iii

INSTRUCTIONS AND INFORMATION
General
AASHTO has issued proposed interim revisions to the Bridge Welding Code (2010). This packet contains these
revisions. The pages in this packet are not designed to replace the corresponding pages in the book but rather to be kept
with the book for quick reference.

A Note on the Use of These Interims
These interims are being provided to owners and fabricators for informational purposes only and are intended to alert
them to proposed revisions to the AASHTO/AWS D1.5M/D1.5:2010 Bridge Welding Code. These interims have
received initial approval from the AWS D1 Committee and the AASHTO Subcommittee on Bridges and Structures.
However, they will not officially revise the Bridge Welding Code until they have gone through the complete AWS
consensus review and approval process and are incorporated into the next published edition of the AASHTO/AWS
D1.5M/D1.5 Bridge Welding Code. This review and approval process can result in additional revisions to these interims
before their final adoption. Owners have the option of implementing these interims in current projects by specifying their
use in the project specifications.

Affected Articles
Underlined text indicates revisions that were approved in 2012 by the AASHTO Highways Subcommittee on Bridges
and Structures. Strikethrough text indicates any deletions that were likewise approved by the Subcommittee. A list of
affected articles is included below.
All interim pages have a page header displaying the section number affected and the interim publication year. Please
note that these pages may also contain nontechnical (e.g. editorial) changes made by AASHTO publications staff; any
changes of this type will not be marked in any way so as not to distract the reader from the technical changes.
Please note that in response to user concerns, page breaks are now being added within sections between noncontiguous
articles. This change makes it an option to insert the changes closer to the affected articles.

Table i2012 Changed Articles
SECTION 2: DESIGN OF WELDED CONNECTIONS
2.11 Figure 2.4 Figure 2.5

SECTION 3: WORKMANSHIP

3.5.1.6 C-3.5.1.6 C-3.5.1.6(1) C-3.5.1.6(2) C-3.5.1.6(3) Figure C-3.4

SECTION 5: QUALIFICATION

5.3 C-5.2.3 C-5.3 C-5.7.3

SECTION 12: AASHTO/AWS FRACTURE CONTROL PLAN (FCP) FOR NONREDUNDANT MEMBERS

12.7.4 C-12.7.4
AASHTO 2012 INTERIM REVISIONS TO THE
SECTION 2 BRIDGE WELDING CODE, SIXTH EDITION

1
SECTION 2: DESIGN OF WELDED CONNECTIONS
In Article 2.11, add a new paragraph as follows:

2.11.3 Groove welds in corner- and T-joints shall be reinforced with fillet welds with a leg size equal to or greater than
T/4, but which need not exceed10 mm [3/8 in]. T shall be defined as the thickness of the thinner part being joined.


3
Revise the notes for Figures 2.4 and 2.5 as follows:

Notes for Figures 2.4 and 2.5
a
Groove preparations detailed for SMAW joints may be used for GMAW or FCAW.
b
Joint shall be welded from one side only.
c
Backgouge root to sound metal before welding second side.
d
Minimum weld size (E) as shown in Table 2.2; S as specified on drawings.
e
Evidence of CJP shall be required (see 4.7.5).
f
Groove welds in corner and T-joints shall be reinforced with fillet welds with a leg size equal to or greater than T/4,
but need not exceed 10 mm [3/8 in]. T shall be defined as the thinner of the attaching elements.
g f
Double-groove welds may have grooves of unequal depth, but the depth of the shallower groove shall be no less than
one-fourth of the thickness of the thinner part joined.
h g
Double-groove welds may have grooves of unequal depth, provided they conform to the limitations of Note d. Also
the weld size (E), less any reduction, applies individually to each groove.
i h
The orientation of the two members in the joints may vary from 135 to 180 provided that the basic joint
configuration (groove angle, root face, root opening) remains the same and that the design weld size shall be
maintained.
j i
For corner and T-joints, the member orientation may be changed provided the groove angle shall be maintained as
specified.
k

j
The member orientation may be changed provided that the groove dimensions shall be maintained as specified.
l k
The orientation of the two members in the joints may vary from 45 to 135 for corner joints and from 45 to 90 for
T-joints, provided that the basic joint configuration (groove angle, root face, root opening) remains the same and that
the design weld size shall be maintained.
m l
These joint details shall not be used where V-groove or U-groove details are practicable (see 2.14).


5
In Figures 2.4 and 2.5, make the following revisions to the column(s) in each table below:

Page 16: Notes
Single-V-groove weld (2) a, c, f, l k
Corner joint (C) c, f, l k
c, f, l k

Page 16: Notes
Double-V-groove weld (3) a, c, g f, i h
Butt joint (B) c, g f, i h
c, g f, i h

Page 17: Notes
Single-V-groove weld (2) a, l k
Corner joint (C) a, l k
a, l k
l k
l k
l k
l k
l k

Page 17: Notes
Single-V-groove weld (2) a, c, i h
Butt joint (B) c i h
c i h

Page 18: Notes
Square-groove weld (1) a, c, f
T-joint (T) c, f
Corner joint (C) c, f

Page 18: Notes
Single-V-groove weld (2) a, i h
Butt joint (B) a, i h
a, i h
i h
i h
i h
i h
i h

Page 19: Notes
Single-bevel-groove weld (4) a, i h, m l
Butt joint (B) a, i h, m l
i h
i h
i h


6
Joint
Page 19: Designation Notes
Single-bevel-groove weld (4) TC-U4ca a, l k
T-joint (T) TC-U4ca-GF a, l k
Corner joint (C) l k
l k
l k
l k

Page 20: Notes
Single-bevel-groove weld (4) a, c, i h, m l
Butt joint (B) c, i h

Page 20: Notes
Single-bevel-groove weld (4) a, c, f, l k
T-joint (T) c, f, l k

Page 21: Notes
Double-bevel-groove weld (5) a, c, g f, i h, m l

Page 21: Notes
Double-bevel-groove a, c, f, g f, l k
Double-bevel-groove weld (5) c, f, g f, l k
T-joint (T) c, f, g f, l k
Corner joint (C)

Page 22: Notes
Single-U-groove weld (6) a, c, i h
Butt joint (B) a, c, i h
Corner joint (C) a, c, l k
a, c, l k
c, i h
c, l k
c, i h
c, l k

Page 22: Notes
Double-U-groove weld (7) a, c, g f, i h
Butt joint (B) a, c, g f, i h
c, g f, i h
c, g f, i h

Page 23: Notes
Single-J-groove weld (8) a, c, i h, m l

7
Page 23: Notes
Single-J-groove weld (8) a, c, f, i h
T-joint (T) a, c, f, i h
Corner joint (C) c, f, i h
c, f, i h

Page 24: Notes
Double-J-groove weld (9) a, c, g f, i h, m l

Page 24: Notes
Double-J-groove weld (9) a, c, f, g f, l k, m l
Corner joint (C) c, f, g f, l k
c, f, g f, l k

Page 25: Notes
Square-groove weld (1) a, i h
Butt joint (B) i h
Corner joint (C) i h

Page 25: Notes
Square-groove weld (1) a, c, i h
e, i h
c, i h

Page 26: Notes
Single-V-groove weld (2) a, c, f, l k
c, f, l k

Page 26: Notes
Double-V-groove weld (3) a, c, g f, i h
c, g f, i h

Page 27: Notes
Single-V-groove weld (2) a, l k
Corner joint (C) a, l k
a, l k
l k
l k
l k
l k
l k


8
Page 27: Notes
Single-V-groove weld (2) a, c, i h
c, i h

Page 28: Notes
Square-groove weld (1) a, c, f
T-joint (T) c, f
Corner joint (C) c, f

Page 28: Notes
Single-V-groove weld (2) a, i h
Butt joint (B) a, i h
a, i h
i h
i h
i h
i h
i h

Page 29: Notes
Single-bevel-groove weld (4) a, i h, m l
Butt joint (B) a, i h, m l
i h
i h
i h

Page 29: Notes
Single-bevel-groove weld (4) a, l k
T-joint (T) a, l k
Corner joint (C) l k
l k
l k
l k

Page 30: Notes
Single-bevel-groove weld (4) a, c, i h, m l

Page 30: Notes
Single-bevel-groove weld (4) a, c, f, l k
T-joint (T) c, f, l k

Page 31: Notes
Double-bevel-groove weld (5) a, c, g f, i h, m l


9
Page 31: Notes
Double-bevel-groove a, c, f, g f, l k
Double-bevel-groove weld (5) c, f, g f, l k
Corner joint (C)

Page 32: Notes
Single-U-groove weld (6) a, c, i h
Butt joint (B) a, c, i h
Corner joint (C) a, c, l k
a, c, l k
c, i h
c, l k
c, i h
c, l k

Page 32: Notes
Double-U-groove weld (7) a, c, g f, i h
Butt joint (B) a, c, g f, i h
c, g f, i h
c, g f, i h

Page 33: Notes
Single-J-groove weld (8) a, c, i h, m l

Page 33: Notes
Single-J-groove weld (8) a, c, f, i h
T-joint (T) a, c, f, i h
Corner joint (C) c, f, i h
c, f, i h

Page 34: Notes
Double-J-groove weld (9) a, c, g f, i h, m l

Page 34: Notes
Double-J-groove weld (9) a, c, f, g f, l k
Corner joint (C) c, f, g f, l k
c, f, g f, l k

Page 36: Notes
Single-V-groove weld (2) a, b, d, k, j
Corner joint (C) b, d, k, j
b, d, k, j

10
Page 36: Notes
Double-V-groove weld (3) a, d, h g, k j
Butt joint (B) d, h g, k j
d, h g, k j

Page 37: Notes
Single-bevel-groove (4) a, b, d, f, k j
T-joint (T) b, d, f, k j
Corner joint (C) b, d, f, k j

Page 37: Notes
Double-bevel-groove weld (5) a, d, f, h g, k j
T-joint (T) d, f, h g, k j
Corner joint (C) d, f, h g, k j

Page 38: Notes
Single-U-groove weld (6) a, b, d, k, j
b, d, k, j

Page 39: Notes
Single-J-groove weld (8) a, d, f, k j
T-joint (T) a, d, f, k j
Corner joint (C) d, f, k j
d, f, k j
d, f, k j
d, f, k j

Page 40: Notes
Double-J-groove weld (9) a, d, f, h g, k j
d, f, h g, k j
d, f, h g, k j

Page 42: Notes
Single-V-groove weld (2) a, b, d, k, j
b, d, k, j

Page 42: Notes
Double-V-groove weld (3) a, d, h g, k j
Butt joint (B) d, h g, k j
d, h g, k j


11
Page 43: Notes
Single-bevel-groove (4) a, b, d, f, k j
T-joint (T) b, d, f, k j
Corner joint (C) b, d, f, k j

Page 43: Notes
Double-bevel-groove weld (5) a, d, f, h g, k j

Page 44: Notes
Single-U-groove weld (6) a, b, d, k, j
b, d, k, j

Page 45: Notes
Single-J-groove weld (8) a, d, f, k j
T-joint (T) a, d, f, k j
Corner joint (C) d, f, k j
d, f, k j
d, f, k j
d, f, k j

Page 46: Notes
Double-J-groove weld (9) a, d, f, h g, k j
d, f, h g, k j
d, f, h g, k j

SECTION 3 AND COMMENTARY BRIDGE WELDING CODE, SIXTH EDITION

13
SECTION 3: WORKMANSHIP
In Article 3.5.1.6, replace paragraph (1) with the following:

(1) For a given location, the least panel dimension, d, is the lesser of either the web depth between flanges or the
longitudinal spacing between transverse components (stiffeners, connection plates). A girder webs variation from
flatness is the maximum offset of the web face from its theoretical location within a given panel. The theoretical web
face is based on its location at panel boundaries (flanges, stiffeners). A reference line parallel to the theoretical web
face may be used for measuring offsets. A girder webs variation from flatness shall be evaluated by comparing its
actual and theoretical locations. Offsets shall be measured from the actual web face to the theoretical web face location.

In Article 3.5.1.6, revise the last sentence in paragraph (2) as follows:

See Annex C for tabulation and illustration of terms.


15
Revise Article C-3.5.1.6 and add Article C-3.5.1.6(1) as follows:

C-3.5.1.6 The provisions for web flatness are based upon aesthetics and relative freedom from web buckling and are
contained in 3.5.1.6 (1)-(4). Lack of web flatness is most pronounced on fascia girders that are painted with glossy type
paints and is sometimes referenced as reflective distortion or oil canning. Measurement of web distortion shall consider
the curvature of the member and deduct the curvature arc from the actual distortion dimension.

Thin girder webs and large stiffener welds worsen the problem of web distortion. Each web panel is bounded by four
welded sides that shrink. It is difficult to correct web distortion without leaving unsightly marks. Heat curving
members with heavy, wide flanges and radii under 300m [12in.] can create severe web distortion, or oil can effects.
For these cases, precutting or precurving the flanges before assembly to the web will reduce this effect.

The provisions for out-of-flatness of girder webs at ends where bolted splices shall be found in 3.5.1.6 (3). This
provision allows twice the maximum out-of-flatness allowed elsewhere in the girder. At such locations at the end of the
web, it is common to find more extensive distortion. At the end, there is no lateral support for the web prior to
assembly of the bolted splice. Lateral displacement of 100mm [4 in.] or more are possible I deep girders. This
condition is produced as a result of welding around three sides of relatively thin web panels, and leaving the forth side
unrestrained. Temporary elastic distortions of this type should not be cause for repair. The high strength bolts in the
web connection will usually straighten the web to within tolerance without damage to the member or its connections.

C-3.5.1.6(1) Measurement of Web Flatness. The webs variation from flatness is the distance from the actual web
surface to its theoretical location, measured normal to the plane of the theoretical web. The web face is presumed to be
in its theoretical location at panel boundaries. Measurement of web distortion considers the curvature of the member
and deducts the curvature arc from the actual distortion dimension. See Figure C-3.4.

Revise Article C-3.5.1.6(2) as follows:

C-3.5.1.6(2) Flatness of Girder Webs. In addition to the dimensional tolerances based upon workmanship standards
provided in 3.5, these requirements for the flatness of girder webs are intended to avoid initiating web buckling under
anticipated construction or service conditions, and are also intended to ensure the aesthetic quality of the bridge. These
tables reflect values tabulated using the flatness tolerance formulas.

Web distortion is exacerbated by using thin web plates, using fillet welds that are larger than necessary to attach any
intermediate stiffeners and connection plates, and by heat curving of girders to short radii after the completion of
welding. Some designers consider 10 mm or 12 mm [3/8 in or 1/2 in] to be the minimum plate girder web thickness to
avoid significant distortion and avoid the need for large numbers of transverse intermediate and longitudinal web
stiffeners.

Most bridge girders have a web depth of 1200 mm [48 in] or more. While 8 mm [5/16 in] fillet welds are commonly
used to attach intermediate stiffeners and connection plates, 6 mm [1/4 in] fillet welds are typically better for the
connection of one-sided intermediate stiffeners to the webs of fascia girders. Welds of this size reduce the amount of
stiffener reflection distortion that occurs in the unstiffened side of fascia girders that is generally exposed to public
view.

The material savings gained by using thinner webs web stiffeners to allow reductions in web thickness are often more
than offset by the increased labor costs necessary to install the stiffeners, and to make corrections to correct the web
distortion that may result. Serious web distortion may occur during heat curving, or by the improper use of heating
torches when preheating for welding. Unstiffened areas of girder should be protected from concentrated, high intensity
heat.

Heat curving members with heavy, wide flanges and radii under 300 m [1000 ft] can create severe web distortions (oil
can effects). Precutting or precurving the flanges before attachment to the web will reduce these effects. Improper use
of heating torches when preheating for welding can cause serious distortions as well. Unstiffened areas of girder webs
should be protected from concentrated, high intensity heat.

To reduce lateral distortion when correcting distortion by heat-shrink methods, heating should be done near
intermediate stiffeners or connection plates whenever possible. If care is not taken, the heating patterns may cause
distortions that will remain visible throughout the life of the structure.


16

Revise Article C-3.5.1.6(3) as follows:

C-3.5.1.6(3) Excessive Distortion. Ends of girder webs that are not stiffened have very little resistance to lateral
distortion. The distortion is caused by web panel perimeter shortening, the result of welding to the top and bottom
flanges and to stiffeners on one side of the end panel, but not at the free end of the girder. Lateral displacements of
several millimeters have been observed at the field splice ends of deep girder webs. These displacements, when
straightened and stiffened by bolted web connections, are almost always temporary and of no structural significance.
This subclause allows displacements of twice that provided in 3.5.1.6(2). Thin splice plates may not have enough
stiffness to bring a highly distorted web back within tolerances of 3.5.1.6(2). Provided the high-strength bolted splice
pulls the web into position without unusual force, there is no damage to the girder. Generally, very little force is
necessary.

C-3.5.1.6(3) End Panels. Provisions for out-of-flatness of girder webs in end panels with bolted splices are described
in 3.5.1.6 (3). End panels with bolted splices are permitted twice the maximum out-of-flatness allowed elsewhere in the
girder. This is because there is no lateral support along one edge for the relatively thin web while the other three sides of
the panel are being welded. Lateral displacements of 100 mm [4 in] or more are possible in deep girders. Temporary
distortions of this type should not be cause for repair. The installation of high strength bolts in the web connection tends
to straighten the web without the use of excessive force, and without damaging the member or its connections.

Although the web-ends may have the distortion permitted by this subclause when each girder segment is in the web-
vertical position, adjacent webs and their splice places must be brought into common alignment prior to shop drilling
splices. Drilling holes with the webs fully displaced to the allowable tolerances would lock those displacements into the
completed structure. For large segment displacements, special field bolting and pinning may be needed to bring webs
and splice plates together before routine bolt tightening is performed.


17
Insert new Figure C-3.4 as follows:
Panel boundary;
may be flange or
stiffener
Variation from flatness
* Total Reference = Variation
Web
Straight edge may be placed parallel
to theoretical face of web to measure
deviations in flatness
Theoretical faces of
web, based on
position at panel
boundaries
Total * Total * Reference Reference

Figure C-3.4Typical Method to Determine Variations in Girder Web Flatness (See C-3.5.1.6)
AASHTO 2012 INTERIM TO THE

19
SECTION 5: QUALIFICATION
Revise Article 5.3 as follows:

5.3 Duration

All WPSs, except as provided in 1.3.6, 5.11, and 12.7, shall be based upon tests which have been performed not more
than 60 months in advance of production welding. This requirement applies to WPS qualification test, pretests, and
verification tests.

All approved PQRs are valid indefinitely unless application of the WPS results in consistently substandard welds.


21
In Article C-5.2.3, revise paragraph 2, sentence 1 as follows:

The Engineer is encouraged to accept evidence of prior qualification, provided the tests were properly conducted and
witnessed within the past 60 months.

Replace Article C-5.3 with the following:

C-5.3 Duration

Previous editions of the code had time limits on PQRs. These were removed because bridge welding experience and
associated testing under this code demonstrated that repeated tests of the same welding parameters did not offer
additional useful information about the properties of the welds accomplished with the procedure nor an effective
reflection of the fabricators welding practices.


23
Delete the last sentence of Article C-5.7.3.


25
SECTION 12: AASHTO/AWS FRACTURE CONTROL
PLAN (FCP) FOR NONREDUNDANT MEMBERS
Revise Article 12.7.4 as follows:

12.7.4 Period of Effectiveness. When a specific Contractor has not previously performed a WPS qualification test
satisfying the provisions of this or a previous AASHTO FCP code, the required tests shall be completed within one year
prior to the start of production welding. All subsequent tests shall be conducted at a frequency that will ensure no PQR
used as a basis for preparation of WPSs is more than 36 60 months old.


27
In Article C-12.7.4, add the following to the end of the Article:

Once a project has begun, it is unnecessary to repeat WPS qualification testing simply because the 60-month period
since testing has elapsed.


BWC 6 I2

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