Construction all around us, from the skyscrapers that loom above our skylines to to intimate frameworks beneath even very roofs require a strong and capable procedure rather commonly known as welding.
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The finished structures may be the stars of the show, but welding is what makes them possible in unifying these monuments with an invisible hero that holds everything together (often under enormous force and load). Are all familiar with some type of structural welding, but this blog post goes into the nuance and detail necessary when it comes to construction applications.
The Arsenal: Basic Welding Skills for the Jobsite
The myriad welding processes used in construction are generally matched to the properties of each material being welded and its intended application. Common welding types you’ll likely see on a construction site
Stick Welding or Shielded Metal Arc Welding (SMAW) has been one of the most versatile and very portable welding processes in use, using consumable electrodes coated with flux. This process provides good penetration and is suitable for various metals, thicknesses which makes it frequently used in construction especially structural steel welding. Stick welding, because of its portability and ability to handle windy conditions, is a common process for welders who need mobility.
Flux-Cored Arc Welding (FCAW): A quicker way to get thicker in welds over stick welding, FCAW uses a consumable wire with self shielding flux and is fed continuously. However as FCAW do not require a separate gas supply, this is particularly useful for on-site construction. You can also use shielded metal arc welding for connections where you need faster welding speeds or deeper penetration than MIG will give, such as joining beams to columns at trusses.
Submerged Arc Welding (SAW) – For high volume applications of thick steel components in closely controlled conditions, SAW is an efficient welding technology. As a process-based application, MIG welding is typically performed using an automatic approach that feeds the method with constant consumables submerged in granular flux. The flux protects the weld pool from contamination and offers an extremely stable arc, resulting in very fast welding speeds and deep penetration. It is widely used for manufacturing beams, columns and other types of structural components at workshops but not in the field directly.
Secondary Process: Gas Metal Arc Welding (GMAW) or MIG WeldingSimple to use with a clean weld beadAs it comes with an electrode on spool, this welding process is ideal for joining thin to medium gauge sheet metal assembly in construction applications. The wire electrode, a continuously fed consumable bare metal filler rod receiving the weld current from the power source (a direct-current electrode negative), travels alongside of and feed through by what is known as a MIG welding gun shielded inert gas which protects its droplet being forced to outgassing MIG welding is, at times used to produce duct work or cladding but nothing structural.
Stud Arc Welding – This is a welding process mainly reserved for the attachment of studs or other fasteners on steel structures. The stud will create an arc between the base metal and itself, this localized melting creates a bond that is generally stronger than welding with filler metals. It is generally used for applications such as attaching shear studs to support composite concrete floor systems, and welding various good connection details onto steel beams.
Welding in Construction: Material Matters
The key to why welding in construction applications has been successful is due [in part] to the steel they are joining was designed for it. A Brief Interview of Some Pointers
Mild Steel : It’s the most commonly used steel in construction and offers good weldability along with other types of welding such as stick Welding, FCAW or SAW.
High-Strength Low-Alloy (HSLA) Steels: These low-density steels are being used increasingly in constructions due to their excellent strength-to-weight ratio. HSLA steels can generally be welded by any method with some precautions required specific to the grade and quality.
Weathering Steels- these are steels that resist atmospheric corrosion and often have applications for bridges or other exposed structures. The corrosion resistance of the weathering steels in most atmospheres is considerably better than that of conventional carbon-manganese structural steels.
Precision Construction: Quality, Safeguard Built
Aside from selecting the best welding process and various material considerations, there are several other factors which help in carrying out high quality as well as safe welding in construction.
Welding Procedure Development (WPS): Detailed written Welding Procedure Specifications (WPS) indicate the specific conditions and procedures by which welding shall be performed on critical structural components such as desired power supply settings, filler metal selection, type of testing. This results in welds that meet exacting building codes and safety standards each and every time a frame is assembled.
Welder Approval: Most construction welders are required to go through intense training and other qualification tests that prove their competence to a standard of welding. This results in a highly skilled field capable of welding critical structural components to the necessary quality.
For Welding Inspection: Non-destructive testing (NDT) methods such as radiographic testing (RT( or ultrasonic testing [UT] campaigns are very important to identify internal defects within welds in structural components. The strength of these welds is, as mentioned above, also highly dependent on the emissivity and proper control over them is key to the long term stability of an entire construction project.
Safety First: Welding environments while working in construction can be harmful. Engaging only in safe work practices, wearing the proper
