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Chapter 18

Introduction to Structural Steel Topics

1.0.0 Structural Steel Members

2.0.0 Anchor Bolts

3.0.0 Bearing Plates

4.0.0 Columns

5.0.0 Girders

6.0.0 Beams

7.0.0 Bar Joists

8.0.0 Trusses

9.0.0 Purlins, Girts, and Eave Struts

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Overview This chapter will give you a brief overview of structural steel. Structural steel is used as the framework for many steel structures such as industrial and commercial buildings, advanced base structures, and bridges. Many different pieces go into fabricating and erecting the framework for a steel structure, and as a Seabee Steelworker, you must have a thorough knowledge of the various structural members. We will discuss the most common names of the steel members as well as how to fasten and secure the members to each other and to the concrete foundation they are built upon. We will also discuss where and how in the structure the steel members are used. Before any structural steel is fabricated or erected, a plan of action and sequence of events, or erection, needs to be set up. The plans, sequences, and required materials are predetermined by the engineering section and drawn up as a set of plans. This chapter describes the basics of structural steel: the terminology, use of the members, methods of connection, and basic sequence of events during erection.

NAVEDTRA 14250A 18-1

Objectives When you have completed this chapter, you will be able to do the following:

1. Describe the different types of structural steel members. 2. Describe the purpose and types of anchor bolts. 3. Describe the purpose and types of bearing plates. 4. Describe the purpose and types of columns. 5. Describe the purpose and types of girders. 6. Describe the purpose and types of beams. 7. Describe the purpose and types of bar joists. 8. Describe the purpose and types of trusses. 9. Describe the purpose and types of purlins, girts, and eave struts.

Prerequisites None


This course map shows all of the chapters in Steelworker Basic. The suggested training order begins at the bottom and proceeds up. Skill levels increase as you advance on the course map.

Introduction to Reinforcing Steel

S T E E L W O R K E R

B A S I C

Introduction to Structural Steel

Pre-Engineered Structures: Buildings, K-Spans, Towers and Antennas

Rigging

Wire rope

Fiber Line

Layout and Fabrication of Sheet metal and Fiberglass Duct

Welding Quality Control

Flux Cored Arc Welding-FCAW

Gas-Metal Arc Welding-GMAW

Gas-Tungsten Arc Welding-GTAW

Shielded Metal Arc Welding-SMAW

Plasma Arc Cutting Operations

Soldering, Brazing, Braze Welding, Wearfacing

Gas Welding

Gas Cutting

Introduction to Welding

Basic Heat Treatment

Introduction to Types and Identification of Metal


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1.0.0 STRUCTURAL STEEL MEMBERS As a Steelworker, you will use various structural members manufactured in a wide variety of cross section shapes and sizes. Figure 18-1 shows many of these shapes. The three most common types of structural members are the W-shape (wide flange), the S-shape (American Standard I-beam), and the C-shape (American Standard channel). These three types are identified by the nominal depth, in inches, along the web and the weight per foot of length, in pounds. As an example, a W 12 x 27 indicates a W-shape (wide flange) with a web 12 inches deep and a weight of 27 pounds per linear foot. Figure 18-2 shows the cross-sectional views of the W-, S-, and C-shapes. The difference between the W-shape and the S-shape is in the design of the inner surfaces of the flange. The W-shape has parallel inner and outer flange surfaces with a constant thickness, while the S-shape has a slope of approximately 17 on the inner flange surfaces. The C-shape is similar to the S-shape in that its inner flange surface is also sloped approximately 17.

Figure 18-1 Structural shapes and designations.


1.1.0 Terminology You need to know the industry standard names for every structural member you will be using to prevent miscommunications between you and the other members on site, so we will discuss the structural members names and some of their characteristics and uses.

1.1.1 W-Shape The W shape is a structural member whose cross section forms the letter H and is the most widely used structural member. It is designed so that its flanges provide strength in a horizontal plane, while the web gives strength in a vertical plane. W-shapes are used as beams, columns, and truss members, and in other load-bearing applications.

1.1.2 Bearing Pile The bearing pile (HP-shape) is almost identical to the W-shape. The only difference is that the flange thickness and web thickness of the bearing pile are equal, whereas the W-shape has different web and flange thicknesses.

1.1.3 S-Shape The S-shape (American Standard I-beam) is distinguished by its cross section being shaped like the letter I. S-shapes are used less frequently than W-shapes since the S-shapes possess less strength and are less adaptable than W-shapes.

Figure 18-2 Closer look at the W, S, and C structural members.


1.1.4 C-Shape The C-shape (American Standard channel) has a cross section somewhat similar to the letter C. It is especially useful in locations where a single flat face without outstanding flanges on one side is required. The C-shape is not very efficient for a beam or column when used alone. However, efficient built-up members may be constructed of channels assembled together with other structural shapes and connected by rivets or welds.

1.1.5 Angle An angle is a structural shape whose cross section resembles the letter L. Two types, as illustrated in Figure 18-3, are commonly used: an equal-leg angle and an unequal-leg angle. The angle is identified by the dimension and thickness of its legs, for example, angle 6 inches x 4 inches x 1/2 inch. The dimension of the legs should be obtained by measuring along the outside of the backs of the legs. When an angle has unequal legs, the dimension of the wider leg is given first, as in the example just cited. The third dimension applies to the thickness of the legs, which always have equal thickness. Angles may be used in combinations of two or four to form main members. A single angle may also be used to connect main parts together.

1.1.6 Plate Steel plate is a structural shape whose cross section is in the form of a flat rectangle. Generally, a main point to remember about plate is that it has a width of greater than 8 inches and a thickness of 1/4 inch or greater. Plates are generally used as connections between other structural members or as component parts of built-up structural members. Plates cut to specific sizes may be obtained in widths ranging from 8 inches to 120 inches or more, and in various thicknesses. The edges of these plates may be cut by shears (sheared plates) or be rolled square (universal mill plates). Frequently, plates are referred to by their thickness and width in inches, as plate 1/2 inch x 24 inches. The length in all cases is given in inches. Note in Figure 18-4 that 1 cubic foot of steel weighs 490 pounds. This weight divided by 12 gives you 40.8, which is the weight (in pounds) of a steel plate 1 foot square and 1 inch thick. The fractional portion is normally dropped and 1-inch plate is called a 40-pound plate. In practice, you may hear plate referred to by its approximate weight per square foot for a specified thickness. An example is 20-pound plate, which indicates a 1/2-inch plate. (Refer again to Figure 18-4).

Figure 18-3 Angles.


The designations generally used for flat steel have been established by the American Iron and Steel Institute (AISI). Flat steel is designated as bar, strip, sheet, or plate, according to the thickness of the material, the width of the material, and (to some extent) the rolling process to which it was subjected. Table 18-1 shows the designations usually used for hot-rolled carbon steels. These terms are somewhat flexible and in some cases may overlap

Figure 18-4 Weight and thickness of steel plate.


Table 18-1 Plate, Bar, Strip, and Sheet Designation.

Color Key Blue ..Bar Green crisscross..Plate Orange..Strip Horizontal lines..Sheet

Thickness (inches)

Width (inches)

To Over 3 1/2 Over 6 Over 8 Over 12 Over

3 1/2 Inclusive To 6 To 8 To 12 To 48 48 0.2300 and Thicker Bar Plate 0.2299 and 0.2031 0.2030 and 0.1800 0.1799 and 0.0449 Strip 0.0448 and 0.0344 0.0343 and 0.0255 Sheet 0.0254 and Thinner

1.1.7 Bar The structural shape referred to as bar has a width of 8 inches or less and a thickness greater than 3/16 of an inch. The edges of bars usually are rolled square, like universal mill plates. The dimensions are expressed in a similar manner as that for plates, for instance, bar 6 inches x 1/2 inch. Bars are available in a variety of cross-sectional shapesround, hexagonal, octagonal, square, and flat. Four different shapes are illustrated in Figure 18-5. Both squares and rounds are commonly used as bracing members of light structures. Their dimensions, in inches, apply to the side of the square or the diameter of the round. You have now been introduced to the various structural members characteristics and uses in steel construction. Next, follow along with the development of a theoretical building frame from where you, the Steelworker, would begin the structural phase after the following phases:

1. EOs have completed the earthwork. 2. UTs and CEs have completed the underground rough-in utilities. 3. You (Steelworkers) have placed the rebar for the footings and/or slab foundation,

and set the anchor bolts. 4. BUs have poured and finished the concrete, and have stripped the forms.

Remember, this sequence is theoretical and may vary somewhat, depending on the type of structure being erected.

2.0.0 ANCHOR BOLTS Anchor bolts are the first element of the structural building to be set in place (Figure 18-6). They are set in position by either the Steelworkers or the Builders using templates to hold them in place during the concrete pour. They are designed to hold the column-bearing plates, which are the first members of a steel frame placed into position above the concrete. These anchor bolts must be positioned very carefully so that the bearing plates will be lined up accurately.

Figure 18-5 Bars.

Figure 18-6 Anchor bolts.


3.0.0 BEARING PLATES The column-bearing plates are steel plates of various thicknesses in which holes have been either drilled or cut with an oxygas torch to receive the anchor bolts (Figure 18-7). The holes should be slightly larger than the bolts so that some lateral adjustment of the bearing plate is possible. The angle connections, by which the columns are attached to the bearing plates, are bolted or welded in place according to the size of the column (Figure 18-8). In many civilian commercial projects, the bearing plates arrive on the project from the fabrication shop already welded directly to the columns. The fabricator may have used an automatic welder or shop personnel to do the welding, but in either case, it saves additional moves in the field when erectors can set columns and base plates simultaneously.

Figure 18-7 Column-bearing plate.

Figure 18-8 Typical column to baseplate connections.


After the bearing plate has been placed into position, shim packs are set under the four comers of each bearing plate as each is installed over the anchor bolts (Figure 18-9). The shim packs are 3- to 4-inch metal squares of a thickness ranging from 1 1/6 to 3/4 inch, which are used to bring all the bearing plates to the correct level and to level each bearing plate on its own base. The bearing plates are first leveled individually by adjusting the thickness of the shim packs. This operation may be accomplished by using a 2-foot level around the top of the bearing plate perimeter and diagonally across the bearing plate. Upon completion of the leveling operation, all bearing plates must be brought either up to or down to the grade level required by the structure being erected. With the advent of lazar levels, their more common usage, and their subsequent cost reduction, often the tops of the shims are lazar leveled or shot in (adjusted for base plate thickness) prior to base plates arriving already welded to the columns. All bearing plates must be lined up in all directions with each other. One method this may be accomplished by is using a surveying instrument called a builders level. String lines may be set up along the edges and tops of the bearing plates by spanning the bearing plates around the perimeter of the structure, making a grid network of string lines connecting all the bearing plates. If you use string lines, especially over extended distances, pay particular attention to eliminate any sag or deflection of the strings that will distort your elevations and grid lines. After all the bearing plates have been set and aligned, the space between the bearing plate and the top of the concrete footing or slab must be filled with grout, a hard, non-shrinking, compact substance (Figure 18-9). When the grout has hardened, the next step is the erection of the columns. Note: If the system used includes the welded base plate/column with the shims shot in, the grouting may be done as a collateral event after the columns are plumbed with guy lines.

Figure 18-9 Leveled bearing plate.


4.0.0 COLUMNS Typically, wide flange members, as nearly square in cross section as possible, are used for columns, but sometimes large diameter pipe is used, even though pipe columns can present connecting difficulties when you are attaching other members (Figure 18-10). Columns may also be fabricated by welding or bolting together a number of other rolled shapes, usually angles and plates (Figure 18-11).

If the structure is more than one story high, it may be necessary to splice one column member on top of another. If this is required, column lengths should be such that the joints or splices are 1 1/2 to 2 feet above the second and succeeding story levels. This will ensure that the splice connections are situated well above the girder or beam connections so that they do not interfere with other second story work. Notice in Figure 18-12 how the column splice plates are situated above the horizontal beam splice plates.

Figure 18-11 Built-up column section.

Figure 18-10 Girder span on pipe columns.

Figure 18-12 Column splice plates.


Column splices are joined together by splice plates which are bolted, riveted, or welded to the column flanges, or in special cases, to the webs as well. If the members are the same size, it is common practice to butt one end directly to the other and fasten the splice plates over the joint (Figure 18-13). When the column size is reduced at the joint, a bearing plate is used to cap the lower column, and filler plates are used between the splice plates and the smaller column flanges (Figure 18-14).

Figure 18-14 Spliced column with size change.

Figure 18-13 Spliced column with no size change.


5.0.0 GIRDERS Girders are the primary horizontal members of a steel frame structure. They span from column to column and are usually connected on top of the columns with cap plates (bearing connections) (Figure 18-15). An alternate method is the seated connection (Figure 18-16). The girder is attached to the flange of the column using angles, with one leg extended along the girder flange and the other against the column. The function of the girders is to support the intermediate floor beams.

Figure 18-16 Seated connections.

Figure 18-15 Girder span on a wide flange column.


6.0.0 BEAMS Beams are generally smaller than girders and are usually connected to girders as intermediate members or to columns. Beam connections at a column are similar to the seated girder-to-column connection. Beams are used generally to carry floor loads and transfer those loads to the girders as vertical loads. Since beams are usually not as deep as girders, there are several alternative methods of framing one into the other (Figure 18-17). The simplest method is to frame the beam between the top and bottom flanges on the girder (Figure 18-18). If it is required that the top or bottom flanges of the girders and beams be flush, it is necessary to cut away (cope) a portion of the upper or lower beam flange (Figure 18-19).

Figure 18-19 Coped beam ends.

Figure 18-17 5 beams and I girder connected to a column.

Figure 18-18 Beam connections at a girder.


7.0.0 BAR JOISTS Bar joists form a lightweight, long-span system used as floor supports and built-up roofing supports (Figure 18-20). Bar joists generally run in the same direction as a beam and may at times eliminate the need for beams. You will notice in Figure 18-21 that bar joists must have a bearing surface. The span is from girder to girder (Figure 18-22). Prefabricated bar joists designed to conform to specific load requirements are obtainable from commercial companies.

Figure 18-20 Clear span bar joists.


Figure 18-22 Installing bar joists girder to girder.

Figure 18-21 Bar joists seat connection.


8.0.0 TRUSSES Steel trusses are similar to bar joists in that they serve the same purpose and look somewhat alike. They are, however, much heavier and are fabricated almost entirely from structural shapes, usually angles and T-shapes (Figure 18-23).

Figure 18-23 Steel truss fabricated from angle-shaped members.


Unlike bar joists, trusses can be fabricated to conform to the shape of almost any roof system and are therefore more versatile than bar joists (Figure 18-24). The bearing surface of a truss is normally the column. The truss may span the entire building from outside column to outside column. After the trusses have been erected, they must be secured between the bays with diagonal braces (normally round rods or light angles) on the top chord plane (Figure 18-25) and the bottom chord plane (Figure 18-26). After these braces are installed, a sway frame is put into place (Figure 18-27).

Figure 18-27 Sway frame. Figure 18-26 Diagonal braces; bottom chord plane.

Figure 18-25 Diagonal braces; top chord plane.

Figure 18-24 Styles of trusses.


9.0.0 PURLINS, GIRTS, AND EAVE STRUTS Purlins are generally lightweight, channel-shaped, z-shaped, or top hat-shaped, and are used to span roof trusses. Purlins are the uppermost element of the erected structural steel, and they support the decking (steel or otherwise) (Figure 18-28). If the purlins are channel-shaped, they are installed with the legs of the channel facing outward or down the slope of the roof.

The purlins installed at the ridge of a gabled roof are referred to as ridge struts. The purlin units are placed back-to-back at the ridge and tied together with steel plates or threaded rods (Figure 18-29). The sides of a structure are often framed with girts. These members are attached to the columns horizontally (Figure 18-30). The girts are also channel-shaped, z-shaped, or top hat-shaped, generally the same size and shape as the roof purlins. The siding material is attached directly to the girts.

Figure 18-28 Roof purlin. Figure 18-29 Ridge struts.

Figure 18-31 Eave strut. Figure 18-30 Wall girt. NAVEDTRA 14250A 18-20

Another longitudinal member similar to purlins and girts is an eave strut. This member is attached to the column at the point where the top chord of a truss and the column meet at the cave of the structure (Figure 18-31).

Summary This chapter briefly introduced you to the basics of structural steel: the terminology, use of the members, methods of connection, and basic sequence of events during erection. They are as valid for use in the civilian construction industry as an Ironworker as they are in the military as a Steelworker. However, you will come across many more steel working terms as you gain experience. If a term is used that you do not understand, ask someone to explain it or look it up in the manuals and publications available to you. Always remember to follow the prescribed safety precautions and wear the proper personal protective equipment--times have changed since the Ironworkers had their photo taken in 1932 (Figure 18-32).

Figure 18-32 Old School ironworkers.


Review Questions (Select the Correct Response)1. A piece of steel plate 3 square feet weighs 180 pounds. What is the classification

of this plate?

A. 20-pound B. 40-pound C. 60-pound D. 80-pound

2. A 10-foot piece of steel that is 3/8 inch thick and 2 inches wide is classified as a

_______.

A. bar B. strip C. sheet D. plate

3. What sequence is the proper order you should follow for the erection of structural

members?

A. Girders, bearing plates, anchor bolts, columns, beams B. Anchor bolts, column plates, girders, bearing plates, beams C. Anchor bolts, bearing plates, columns, girders, beams D. Bearing plates, anchor bolts, columns, girders, beams

4. When cutting the holes in bearing plates to receive anchor bolts, why do you cut

the holes larger than the bolts?

A. To allow for height adjustment B. To permit lateral adjustment C. To compensate for angle connections D. To allow space for welding of columns

5. Bearing plates are brought to their proper levels by _____.

A. installing shim packs B. welding the plates to the bearing plates C. forcing the grout under the bearing plates D. using locknuts

6. What structural shape is most often used for columns?

Standard beam A.B. Tee shape C. Pipe D. Wide flange beam


7. What structural steel member is used primarily to span from column to column horizontally?

A. Beam B. Truss C. Girder D. Column splices

8. Which member forms a lightweight, long-span system used as floor supports and

built-up roofing supports?

A. Bar joist B. Truss C. Beam D. Girder

9. Workers have installed diagonal braces between bays of a truss system. Their

next step is to secure the roof system with what structural members?

A. Angle ties B. Sway frames C. Diagonal locking bars D. Bottom chord extensions

10. When using channel-shaped purlins to span roof trusses, you should ensure the

legs face in what direction?

A. Up toward the center or apex of the roof B. Flat with the face of the channel face directly toward the truss C. Downward with both legs welded to the truss D. Outward or down toward the slope of the truss system

11. What structural members are attached to the outside perimeter columns and

used to frame the siding of a building?

A. Eave struts B. Purlins C. Girts D. Ridge plates


Trade Terms Introduced in this Chapter None


Additional Resources and References This chapter is intended to present thorough resources for task training. The following reference works are suggested for further study. This is optional material for continued education rather than for task training. Frankland, Thomas, W., The Pipefitter's and Pipe Welders Handbook, Glencoe/McGraw-Hill Publishing Company, Woodland Hills, CA, 1984. Frankland, Thomas, W., Pipe Trades Pocket Manual, Glencoe/McGraw-Hill Publishing Company, Peoria, IL, 1969. Nelson, Carl, A., Millwrights and Mechanic's Guide, 2d ed., Theodore Audel and Company, Indianapolis, IN, 1972. The Oxy-Acetylene Handbook, 2nd ed., Linde Company, New York NY, 1960. Walker, John, R., Modern Metalworking, Goodheart-Wilcox Company Inc., South Holland, IL, 1973.


CSFE Nonresident Training Course User Update CSFE makes every effort to keep their manuals up-to-date and free of technical errors. We appreciate your help in this process. If you have an idea for improving this manual, or if you find an error, a typographical mistake, or an inaccuracy in CSFE manuals, please write or email us, using this form or a photocopy. Be sure to include the exact chapter number, topic, detailed description, and correction, if applicable. Your input will be brought to the attention of the Technical Review Committee. Thank you for your assistance. Write: CSFE N7A

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A9R581F.tmp.pdfInstruction PageSW Basic CoverSW Basic CopyrightSW B Table of ContentsSW Basic Ch 1 Introduction to Types and Identification of MetalChapter 1Introduction to Types and Identification of MetalTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 BASIC METAL TYPES1.1.0 Ferrous Metals1.1.1 Iron1.1.2 Steel

1.2.0 Nonferrous Metals

2.0.0 BASIC METAL IDENTIFICATION2.1.0 Surface Appearance2.2.0 Spark Test2.3.0 Chip Test2.4.0 Magnetic Test2.5.0 Hardness Test

SummaryReview QuestionsTrade Terms Introduced in this ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 2 Basic Heat TreatmentChapter 2Basic Heat TreatmentTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 HEAT TREATMENT THEORY2.0.0 STAGES of HEAT TREATMENT2.1.0 Heating Stage2.2.0 Soaking Stage2.3.0 Cooling Stage

3.0.0 RECOGNIZING HEAT COLORS for STEEL4.0.0 TYPES of HEAT TREATMENT4.1.0 Annealing4.1.1 Ferrous Metal4.1.2 Nonferrous Metal

4.2.0 Normalizing4.3.0 Hardening4.3.1 Case Hardening4.3.1.1 Carburizing4.3.1.2 Cyaniding4.3.1.3 Nitriding4.3.2 Flame Hardening

4.4.0 Tempering

5.0.0 QUENCHING MEDIA5.1.0 Liquid Quenching5.1.1 Water5.1.2 Brine5.1.3 Oil5.1.4 Caustic Soda

5.2.0 Dry Quenching5.2.1 Air5.2.2 Solids


SW Basic Ch 3 Introduction to WeldingChapter 3Introduction to WeldingTopicsOverviewObjectivesFeatures of this Manual1.0.0 WELDING PROCESSES1.1.0 Gas Welding1.1.1 OXYFUEL GAS Welding (OFW) ACETYLENE1.1.2 OXYFUEL GAS Welding (OFW) MAPPGAS

1.2.0 Arc Welding1.2.1 Common Arc Welding Processes1.2.1.1 Shielded Metal Arc Welding (SMAW)1.2.1.2 Gas Shielded Arc Welding1.2.1.2.1 Gas Tungsten Arc Welding (GTAW)1.2.1.2.2 Gas Metal Arc Welding (GMAW) 1.2.1.2.3 Flux Core Arc Welding (FCAW) 1.2.1.3 Resistance Spot Welding

2.0.0 WELDING TERMINOLOGY2.1.0 Filler Metals2.2.0 Fluxes2.3.0 Weld Joints2.4.0 Parts of Joints2.5.0 Types of Welds2.6.0 Parts of Welds

3.0.0 WELDED JOINT DESIGN3.1.0 Butt Joints3.2.0 Corner Joints3.3.0 Tee Joints3.4.0 Lap Joints3.5.0 Edge Joints

4.0.0 WELDING POSITIONS 5.0.0 EXPANSION and CONTRACTION5.1.0 Controlling Distortion5.1.1 Preparation and Fit-up5.1.2 Heat Input5.1.3 Preheat5.1.4 Number of Weld Passes5.1.5 Jigs and Fixtures5.1.6 Allow for Distortion

6.0.0 WELDING PROCEDURES6.1.0 American Welding Society6.2.0 American Society of Mechanical Engineers

7.0.0 DRAWINGS7.1.0 Reading Drawings7.1.1 Lines

7.1.2 Dimensions7.1.3 Notes7.1.4 Views7.1.5 Handling and Care

7.2.0 Welding Symbol7.2.1 Type of Weld (Weld Symbols)7.2.2 Dimensioning7.2.3 Supplementary7.2.4 Additional Information7.2.5 Multiple-Weld7.2.6 Application of Symbol

8.0.0 SAFETY8.1.0 Eye Protection8.2.0 Welding Helmet8.3.0 Protective Clothing8.4.0 Area Awareness

SummaryReview QuestionsTrade Terms Introduced in this ChapterCSFE Nonresident Training Course User Update

SW Basic Ch 4 Gas CuttingChapter 4Gas CuttingTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 OXYGAS CUTTING EQUIPMENT1.1.0 Acetylene1.1.1 Hazards1.1.2 Cylinder Design

1.2.0 MAPP Gas1.2.1 Cylinder Design1.2.2 MAPP Characteristics1.2.3 Bulk MAPP Gas1.2.4 MAPP Gas Safety

1.3.0 Oxygen1.4.0 Regulators1.4.1 Single-Stage Regulators1.4.2 Double-Stage Regulators1.4.3 Problems and Safety

1.5.0 Hoses1.6.0 Cutting Torches1.6.1 Torch Body1.6.2 Cutting Torch Tips1.6.2.1 Acetylene Tip Maintenance1.6.2.2 MAPP Tip Maintenance

2.0.0 OXYGAS CUTTING OPERATIONS2.1.0 Equipment Setup2.1.1 Carburizing Flame2.1.2 Neutral Flame2.1.3 Oxidizing Flame

2.2.0 Cutting Mild-Carbon Steel2.2.1 Cutting Thin Steel2.2.2 Cutting Thick Steel

2.3.0 Cutting Cast Iron2.4.0 Gouging Mild Steel2.5.0 Beveling Mild Steel2.6.0 Electric Drive Cutting Torch Carriage2.7.0 Cutting and Beveling Pipe2.8.0 Piercing Holes2.9 0 Cutting Rivets2.10.0 Cutting Wire Rope2.11.0 Cutting on Containers

3.0.0 JUDGING CUTTING QUALITY3.1.0 Drag Lines3.2.0 Side Smoothness3.3.0 Top Edge Sharpness3.4.0 Slag Conditions

4.0.0 SAFETY PRECAUTIONS4.1.0 Backfire and Flashback4.2.0 Cylinders4.2.1 Identification of Cylinders4.2.1.1 Color Warnings4.2.1.2 Cylinder Color Bands4.2.1.3 Decals4.2.1.4 Shatterproof Cylinders4.2.1.5 Service Ownership4.2.2 Handling and Storing Gas Cylinders


SW Basic Ch 5 Gas WeldingChapter 5Gas WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 OXYGAS WELDING EQUIPMENT1.1.0 Welding Torches1.2.0 Filler Rods

2.0.0 OPERATION and MAINTENANCE of OXYGAS EQUIPMENT2.1.0 Operation 2.1.1 Selecting the Welding Torch Tip Size2.1.2 Equipment Setup2.1.3 Torch Lighting and Flame Adjustment

2.2.0 Maintaining the Equipment2.2.1 Torch Gas Leaks2.2.2 Welding Torch Tips2.2.3 Regulator Leaks

3.0.0 OXYGAS WELDING TECHNIQUES3.1.0 Forehand Welding3.2.0 Backhand Welding3.3.0 Multilayer Welding3.4.0 Joint Edge Preparation3.5.0 Ferrous Metals3.6.0 Nonferrous Metals3.6.1 Copper3.6.2 Copper-Zinc Alloy (Brasses)3.6.3 Copper-Silicon Alloy (Silicon Bronze)3.6.4 Copper-Nickel Alloy3.6.5 Nickel and High-Nickel Alloys3.6.6 Lead3.6.7 Aluminum and Aluminum Alloys3.6.7.1 Melting Characteristics3.6.7.2 WELDING RODS3.6.7.3 Welding Fluxes3.6.7.4 Welding Preparation3.6.7.5 Welding Techniques

3.7.0 Welding Pipe

SummaryReview QuestionsTrade Terms Introduced in This ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 6 Soldering, Brazing, Braze Welding, WearfacingChapter 6Soldering, Brazing, Braze Welding, WearfacingTopicsOverviewObjectivesFeatures of this Manual1.0.0 SOLDERING1.1.0 Equipment1.1.1 Sources of Heat1.1.1.1 Soldering Coppers1.1.1.1.1 Filing and Tinning Coppers1.1.1.1.2 Forging Soldering Coppers1.1.1.2 Electric Soldering Coppers1.1.1.3 Gas Torches1.1.2 Soft Solder1.1.2.1 Tin-Lead Solder1.1.2.2 Tin-Antimony-Lead Solder 1.1.2.3 Tin-Zinc Solder1.1.2.4 Tin-Antimony Solder1.1.2.5 Tin-Silver Solder1.1.2.6 Lead-Silver Solder1.1.3 Fluxes1.1.3.1 Noncorrosive Fluxes1.1.3.2 Corrosive Fluxes

1.2.0 Soldering Techniques1.2.1 Sweat Soldering1.2.2 Seam Soldering

1.3.0 Soldering Aluminum Alloys

2.0.0 BRAZING2.1.0 Equipment2.1.1 Heating Devices2.1.2 Filler Metals2.1.3 Fluxes

2.2.0 Joint Design2.2.1 Lap Joints2.2.2 Butt Joints2.2.3 Scarf Joints

2.3.0 Brazing Procedures2.3.1 Surface Preparation2.3.2 Work Support2.3.3 Fluxing2.3.4 Brazing2.3.5 Silver Brazing

3.0.0 BRAZE WELDING 3.1.0 EQUIPMENT3.1.1 Filler Metal3.1.2 Flux

3.2.0 Braze Welding Procedures

4.0.0 WEARFACING4.1.0 Wearfacing Materials4.1.1 Iron-Base Alloys4.1.2 Tungsten Carbide

4.2.0 Wearfacing Procedures4.2.1 Preheating4.2.2 Application


SW Basic Ch 7 Plasma Arc Cutting OperationsChapter 7Plasma Arc Cutting OperationsTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 PLASMA ARC CUTTING PROCESS 1.1.0 Description 1.2.0 Plasma vs. Oxy-Fuel Cutting

2.0.0 EQUIPMENT and CONSUMABLES 2.1.0 Equipment Requirements 2.1.1 Power Source 2.1.2 Rated Cutting Capacity 2.1.3 Cutting Speed

2.2.0 Consumables 2.2.1 Swirl Ring2.2.2 Electrode2.2.3 Tip 2.2.4 Retaining Cup2.2.5 Shields2.2.6 Consumables Used During Extended Cutting vs. Drag Cutting 2.2.7 Consumable Tips for Different Amperages 2.2.8 Replacing Consumables 2.2.9 Cutting Gases

2.3.0 Improving Consumable life

3.0.0 CUTTING and GOUGING OPERATING SEQUENCE 3.1.0 High Frequency Starts3.2.0 Contact Starts3.3.0 Pilot Arc Control Methods 3.4.0 Starting the Cut

4.0.0 PLASMA ARC GOUGING 5.0.0 QUALITIES of a PLASMA CUT 5.1.0 Kerf 5.2.0 Bevel Angle5.3.0 Drag Line5.4.0 Top Rounding5.5.0 Dross5.6.0 Six Steps to Good Cut Quality

6.0.0 SAFETY PROCEDURESSummaryReview QuestionsTrade Terms Introduced in this ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 8 Shielded Metal Arc WeldingChapter 8Shielded Metal Arc WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of Application 1.2.0 Advantages and Limitations

2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems 2.2.0 Electrical Terms2.3.0 Metal Transfer

3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Types of Current 3.1.2 Power Source Duty Cycle 3.1.3 Types of Power Sources 3.1.3.1 Generator and Alternator Welding Machines 3.1.3.2 Transformer Welding Machines 3.1.3.3 Transformer-Rectifier Welding Machines 3.1.3.4 Three Phase Rectifier Welding Machines 3.1.3.5 Multiple Operator System 3.1.3.6 Inverter Power Sources 3.1.4 Selecting a Power Source

3.2.0 Controls 3.3.0 Electrode Holder 3.4.0 Welding Cables 3.5.0 Ground Clamps3.6.0 Accessories 3.7.0 Equipment Operation and Maintenance

4.0.0 COVERED ELECTRODES4.1.0 Classification 4.2.0 Sizing 4.3.0 Selection of Electrode Class 4.3.1 Base Metal Strength Properties4.3.2 Base Metal Composition4.3.3 Welding Position4.3.4 Welding Current4.3.5 Joint Design and Fit-Up4.3.6 Thickness and Shape of Base Metal4.3.7 Service Conditions and/or Specifications4.3.8 Production Efficiency and Job Condition

4.4.0 Selection of Electrode Size 4.5.0 Conformances and Approvals

5.0.0 WELDING APPLICATIONS5.1.0 Industries 5.1.1 Field Welded Storage Tanks 5.1.2 Pressure Vessels 5.1.3 Industrial Piping 5.1.4 Transmission Pipelines 5.1.5 Nuclear Power Plants 5.1.6 Structures 5.1.7 Ships 5.1.8 Transportation 5.1.9 Industrial Machinery 5.1.10 Heavy Equipment 5.1.11 Maintenance and Repair

5.2.0 Variations of the Process 5.3.0 Wearfacing5.3.1 Workpiece Preparation5.3.2 Preheating5.3.3 Techniques5.3.3.1 Bulldozer Blades5.3.3.2 Shovel teeth

5.4.0 Carbon-Arc Cutting5.4.1 Air Carbon-Arc Cutting5.4.2 Air Carbon-Arc Gouging5.4.3 Metal Electrode Arc Cutting

6.0.0 WELDING METALLURGY6.1.0 Properties of the Weld 6.1.1 Chemical Properties 6.1.2 Mechanical Properties 6.1.3 Microstructure

6.2.0 Metals Weldable 6.2.1 Steels 6.2.1.1 Mild Steels 6.2.1.2 Low Alloy Steels 6.2.1.3 Heat Treatable Steels 6.2.1.4 Chromium-Molybdenum Steels 6.2.1.5 Stainless & Higher Chromium-Molybdenum Steels 6.2.1.6 Free Machining Steels 6.2.2 Cast Irons 6.2.2.1 Gray Cast Iron 6.2.2.2 Nodular and Malleable Cast Irons 6.2.3 Copper and Copper Alloys 6.2.4 Nickel and Nickel Alloys

7.0.0 WELD AND JOINT DESIGN7.1.0 Strength 7.2.0 Position 7.3.0 Thickness 7.4.0 Accessibility 7.5.0 Weld Joint Designs7.6.0 Arc Welding Positions7.6.1 Flat-Position Welding7.6.2 Horizontal-Position Welding7.6.2.1 Electrode Movement7.6.2.2 Joint Type7.6.3 Vertical-Position Welding7.6.3.1 Current Settings and Electrode Movement7.6.3.2 Joint Type7.6.3.3 E-7018 Electrode Welding Technique7.6.4 Overhead-Position Welding7.6.4.1 Current Settings and Electrode Movement7.6.4.2 Type of Welds7.6.5 Pipe welding7.6.5.1 Pipe welding positions7.6.5.2 Pipe welding procedures7.6.5.3 Joint preparation and fit-up7.6.6 Tack welding7.6.7 Spacers7.6.8 Electrode selection7.6.9 Weather conditions

8.0.0 WELDING PROCEDURE VARIABLES8.1.0 Fixed Variables 8.1.1 Electrode Type 8.1.2 Electrode Size 8.1.3 Current Type

8.2.0 Primary Variables 8.2.1 Welding Current 8.2.2 Travel Speed 8.2.3 Welding Voltage (Arc Length) 8.2.4 Starting the Arc8.2.4.1 Breaking the Arc8.2.4.2 Reestablishing the Arc8.2.4.3 Peening

8.3.0 Secondary Variables 8.3.1 Angles of the Electrode

9.0.0 WELDING PROCEDURE SCHEDULES10.0.0 PREWELD PREPARATIONS10.1.0 Preparing the Weld Joint 10.2.0 Fixturing and Positioning 10.3.0 Preheating

11.0.0 WELDING DEFECTS and PROBLEMS11.1.0 Discontinuities Caused by Welding Technique 11.1.1 Slag Inclusions11.1.2 Wagon Tracks11.1.3 Porosity11.1.4 Wormhole Porosity (Piping Porosity)11.1.5 Undercutting11.1.6 Lack of Fusion11.1.7 Overlapping11.1.8 Burn Through 11.1.9 Arc Strikes 11.1.10 Craters 11.1.11 Excessive Weld Spatter

11.2.0 Cracking 11.3.0 Other Problems 11.3.1 Arc Blow 11.3.2 Improper Moisture Content 11.3.3 Fingernailing

12.0.0 POSTWELD PROCEDURE12.1.0 Cleaning 12.2.0 Inspection and Testing 12.2.1 Welding Quality Control

12.3.0 Repairing of Welds 12.4.0 Postheating

13.0.0 WELDER TRAINING and QUALIFICATION13.1.0 Welder Training 13.1.1 Basic Shielded Metal Arc Welding 13.1.2 Advanced Shielded Metal Arc Welding 13.1.3 Shielded Metal Arc Pipe Welding

13.2.0 Welder Qualification

14.0.0 WELDING SAFETY14.1.0 Electrical Shock 14.2.0 Arc Radiation 14.3.0 Air Contamination 14.4.0 Fires and Explosions 14.5.0 Weld Cleaning and Other Hazards 14.6.0 Summary of Safety Precautions


SW Basic Ch 9 GasTungsten Arc WeldingChapter 9Gas Tungsten Arc WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of Application 1.2.0 Advantages and Limitations

2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems

3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Power Source Duty Cycle

3.2.0 Types of Welding Current3.2.1 Direct Current3.2.2 Pulsed Current3.2.3 Alternating Current3.2.4 High-Frequency Current

3.3.0 Types of Power Sources 3.3.1 Generator and Alternator Welding Machines 3.3.2 Transformer-Rectifier Welding Machines 3.3.3 Inverter Power Sources 3.3.4 Transformer Welding Machines3.3.5 Square Wave Power Source

3.4.0 Controls 3.5.0 Welding Torches3.6.0 Gas Shielding System3.7.0 Welding Cables 3.8.0 Other Equipment3.8.1 Filler Wire Feeders3.8.2 Water Circulators3.8.3 Motion Devices

4.0.0 EQUIPMENT SETUP, ADJUSTMENT, and SHUTDOWN4.1.0 Equipment Setup4.2.0 Preparing the Electrode Tip4.3.0 Assembling the Torch4.4.0 Setting Up the Shielding Gas System4.5.0 Setting Up the Welding Parameters4.6.0 System Shutdown and Clean Up

5.0.0 ELECTRODES, SHIELDING GAS, and FILLER METAL5.1.0 Electrodes5.2.0 Shielding Gases5.2.1 Argon5.2.2 Helium5.2.3 Argon-Helium Mixtures5.2.4 Argon-Hydrogen Mixtures5.2.5 Nitrogen

5.3.0 Filler Metals5.3.1 Classification 5.3.2 Sizing

5.4.0 Selection of Filler Metal 5.5.0 Conformances

6.0.0 WELDING APPLICATIONS6.1.0 Industries 6.1.1 Industrial Piping 6.1.2 Nuclear Power Facilities 6.1.3 Ships 6.1.4 Aerospace6.1.5 Transportation6.1.6 Pressure Vessels, Boilers, and Heat Exchangers6.1.7 Maintenance and Repair6.1.8 Miscellaneous

6.2.0 Arc Spot Welding

7.0.0 WELDING METALLURGY7.1.0 Properties of the Weld 7.1.1 Chemical Properties 7.1.2 Mechanical Properties 7.1.3 Microstructure

7.2.0 Weldable Metals7.2.1 Aluminum and Aluminum Alloys7.2.2 Copper and Copper Alloys 7.2.3 Magnesium and Magnesium Alloys7.2.4 Nickel and Nickel Alloys 7.2.5 Steels 7.2.5.1 Plain Carbon and Low Alloy Steels 7.2.5.2 Cast Iron 7.2.5.3 Free Machining Steels 7.2.5.4 Stainless Steels 7.2.6 Titanium and Titanium Alloys7.2.7 Other Metals

8.0.0 WELD JOINT DESIGN8.1.0 Types of Metal8.2.0 Strength 8.3.0 Position 8.4.0 Thickness 8.5.0 Accessibility 8.6.0 Consumable Inserts8.7.0 Weld Joint Designs8.8.0 Welding Positions8.8.1 Flat-Position Welding

9.0.0 WELDING PROCEDURE VARIABLES9.1.0 Fixed Variables9.1.1 Type of Electrode9.1.2 Electrode Size 9.1.3 Type of Welding Current9.1.4 Type of Shielding Gas9.1.5 Electrode Taper Angle

9.2.0 Primary Variables 9.2.1 Welding Current 9.2.2 Travel Speed9.2.3 Welding Voltage (Arc Length)

9.3.0 Secondary Variables 9.3.1 Angles of the Electrode9.3.2 Electrode Extension

10.0.0 WELDING PROCEDURE SCHEDULES11.0.0 PREWELD PREPARATIONS11.1.0 Preparing the Weld Joint 11.2.0 Cleaning the Work Metal11.3.0 Electrode Tip Preparation11.4.0 Fixturing, Positioning, and Weld Backing 11.5.0 Preheating

12.0.0 WELDING DISCONTINUITIES and PROBLEMS12.1.0 Discontinuities Caused by Welding Technique 12.1.1 Tungsten Inclusions12.1.2 Oxide Inclusions12.1.3 Porosity12.1.4 Wormhole Porosity (Piping Porosity)12.1.5 Undercutting12.1.6 Incomplete Fusion12.1.7 Overlapping12.1.8 Melt-through 12.1.9 Arc Strikes 12.1.10 Craters

12.2.0 Cracking 12.3.0 Other Problems 12.3.1 Arc Blow 12.3.2 Inadequate Shielding12.3.3 Electrode Contamination

13.0.0 POSTWELD PROCEDURE13.1.0 Cleaning 13.2.0 Inspection and Testing 13.3.0 Repairing of Welds 13.4.0 Postheating

14.0.0 WELDER TRAINING and QUALIFICATION14.1.0 Basic Gas Tungsten Arc Welding 14.1.1 Mild Steel14.1.2 Stainless Steel14.1.3 Aluminum

14.2.0 Gas Tungsten Arc Pipe Welding 14.2.1 Course Introduction 14.2.2 Small Diameter Piping and Tubing 14.2.3 8-lnch Diameter Pipe


15.0.0 WELDING SAFETY15.1.0 Electrical Shock 15.2.0 Arc Radiation 15.3.0 Air Contamination 15.4.0 Compressed Gasses15.5.0 Fires and Explosions 15.6.0 Weld Cleaning and Other Hazards 15.7.0 Summary of Safety Precautions


SW Basic Ch 10 Gas Metal Arc WeldingChapter 10Gas Metal Arc WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of Application 1.2.0 Advantages and Limitations

2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems 2.2.0 Metal Transfer 2.2.1 Short Circuiting Transfer2.2.2 Globular Transfer2.2.3 Spray Transfer2.2.4 Pulsed Current Transfer

3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Power Source Duty Cycle 3.1.2 Types of Current 3.1.3 Types of Power Sources 3.1.3.1 Generator Welding Machines 3.1.3.2 Transformer-Rectifier Welding Machines 3.1.3.3 Inverter Power Sources

3.2.0 Controls 3.3.0 Wire Feeders 3.4.0 Welding Guns3.4.1 Semiautomatic Guns3.4.2 Machine Welding Guns

3.5.0 Shielding Gas Equipment3.6.0 Welding Cables 3.7.0 Other Equipment3.7.1 Water Circulators3.7.2 Motion Devices3.7.3 Accessories

4.0.0 INSTALLATION, SETUP, and MAINTENANCE of EQUIPMENT4.1.0 Power Source Connections4.2.0 Gun Cable Assembly4.3.0 Wire Installation4.4.0 Gas Cylinder Installation4.5.0 Amperage and Voltage Settings4.6.0 Equipment Shutdown and Clean Up4.7.0 Burn Back4.8.0 Bird Nests

5.0.0 SHIELDING GAS and ELECTRODES5.1.0 Shielding Gases5.1.1 Argon5.1.2 Helium5.1.3 Carbon Dioxide5.1.4 Argon-Helium Mixtures5.1.5 Argon-Oxygen Mixtures5.1.6 Argon-Carbon Dioxide Mixtures5.1.7 Helium-Argon-Carbon Dioxide Mixtures5.1.8 Nitrogen

5.2.0 Shielding Gas Flow Rate5.3.0 Electrodes5.3.1 Classification 5.3.2 Sizing

5.4.0 Electrode Selection 5.5.0 Conformances and Approvals

6.0.0 WELDING APPLICATIONS6.1.0 Industries 6.1.1 Pressure Vessels 6.1.2 Industrial Piping 6.1.3 Transmission Pipelines 6.1.4 Nuclear Power Facilities 6.1.5 Structures 6.1.6 Ships 6.1.7 Railroads 6.1.8 Automotive 6.1.9 Aerospace6.1.10 Heavy Equipment

6.2.0 Variations of the Process 6.2.1 Arc Spot Welding6.2.2 Narrow Gap Welding

7.0.0 WELDING METALLURGY7.1.0 Properties of the Weld 7.1.1 Chemical and Physical Properties 7.1.2 Mechanical Properties 7.1.3 Microstructure

7.2.0 Metals Weldable 7.2.1 Aluminum and Aluminum Alloys7.2.2 Copper and Copper Alloys 7.2.3 Magnesium and Magnesium Alloys7.2.4 Nickel and Nickel Alloys 7.2.5 Steels 7.2.5.1 Low Carbon and Mild Steels 7.2.5.2 Low Alloy Steels 7.2.5.3 Heat Treatable Steels 7.2.5.4 Chromium-Molybdenum Steels 7.2.5.5 Free Machining Steels 7.2.5.6 Stainless Steels 7.2.6 Titanium and Titanium Alloys

8.0.0 WELD and JOINT DESIGN8.1.0 Strength 8.2.0 Position 8.3.0 Thickness 8.4.0 Accessibility 8.4.1 Backing Strips

8.5.0 Types of Metal8.6.0 Weld Joint Designs8.6.1 Welding Symbols

8.7.0 Welding Positions8.7.1 Flat-Position Welding

9.0.0 WELDING PROCEDURE VARIABLES9.1.0 Fixed Variables9.1.1 Electrode Size 9.1.2 Type of Shielding Gas

9.2.0 Primary Variables 9.2.1 Starting the Arc 9.2.2 Welding Current 9.2.3 Welding Voltage (Arc Length) 9.2.4 Travel Speed

9.3.0 Secondary Variables 9.3.1 Electrode Extension9.3.2 Electrode Angles

10.0.0 WELDING PROCEDURE SCHEDULES11.0.0 PREWELD PREPARATIONS11.1.0 Preparing the Weld Joint 11.2.0 Cleaning the Work Metal11.3.0 Fixturing and Positioning 11.4.0 Preheating

12.0.0 WELDING DISCONTINUITIES and PROBLEMS12.1.0 Discontinuities Caused by Welding Technique 12.1.1 Inclusions12.1.2 Porosity12.1.3 Wormhole Porosity (Piping Porosity)12.1.4 Undercutting12.1.5 Incomplete Fusion12.1.6 Overlapping12.1.7 Melt-through 12.1.8 Whiskers12.1.9 Excessive Weld Spatter 12.1.10 Arc Strikes 12.1.11 Craters

12.2.0 Cracking 12.3.0 Other Problems 12.3.1 Arc Blow 12.3.2 Inadequate Shielding12.3.3 Clogged or Dirty Contact Tube12.3.4 Wire Feed Stoppages


14.0.0 WELDER TRAINING and QUALIFICATION14.1.0 Welder Training 14.1.1 Basic Gas Metal Arc Welding 14.1.2 Gas Metal Arc Welding Steel Pipe


15.0.0 WELDING SAFETY15.1.0 Electrical Shock 15.2.0 Arc Radiation 15.3.0 Air Contamination 15.4.0 Compressed Gasses15.5.0 Fires and Explosions 15.6.0 Weld Cleaning and Other Hazards 15.7.0 Summary of Safety Precautions

SummaryTrade Terms Introduced in this ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 11 Flux Cored Arc WeldingChapter 11Flux Cored Arc WeldingTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 INTRODUCTION to the PROCESS 1.1.0 Methods of Application 1.2.0 Advantages and Limitations

2.0.0 PRINCIPLES of OPERATION 2.1.0 Arc Systems 2.2.0 Metal Transfer

3.0.0 EQUIPMENT for WELDING 3.1.0 Power Sources 3.1.1 Power Source Duty Cycle 3.1.2 Types of Current 3.1.3 Types of Power Sources 3.1.3.1 Generator and Alternator Welding Machines 3.1.3.2 Transformer Welding Machines

3.2.0 Controls 3.3.0 Wire Feeders 3.3.1 Machine Welding Guns

3.4.0 Fume Extractors3.5.0 Shielding Gas Equipment 3.6.0 Welding Cables3.7.0 Other Equipment3.7.1 Water Circulators3.7.2 Motion Devices3.7.3 Accessories

4.0.0 EQUIPMENT SETUP, OPERATION, and SHUT DOWN4.1.0 Protective Clothing and Tools4.2.0 Obtaining Materials4.3.0 Set Up Equipment4.4.0 Adjust Equipment4.5.0 Perform the Weld4.6.0 Shut Down Equipment

5.0.0 SHIELDING GAS and ELECTRODES5.1.0 Shielding Gas5.1.1 Carbon Dioxide5.1.2 Argon-Carbon Dioxide Mixtures5.1.3 Argon-oxygen mixture

5.2.0 Electrodes5.2.1 Classification 5.2.2 Electrode Selection 5.2.3 Conformance and Approvals

6.0.0 WELDING APPLICATIONS6.1.0 Industries 6.1.1 Structures 6.1.2 Ships 6.1.3 Industrial Piping 6.1.4 Railroads 6.1.5 Automotive Products 6.1.6 Heavy Equipment 6.1.7 Maintenance and Repair

6.2.0 Flux Cored Arc Spot Welding

7.0.0 WELDING METALLURGY7.1.0 Properties of the Weld 7.2.0 Chemical Properties 7.3.0 Mechanical Properties 7.4.0 Microstructure 7.5.0 Metals Weldable 7.5.1 Steels 7.5.1.1 Low-carbon and Mild Steels 7.5.1.2 Low-alloy Steels 7.5.1.3 Heat Treatable Steels 7.5.1.4 Chromium-Molybdenum Steels 7.5.1.5 Free Machining Steels 7.5.1.6 Stainless Steels

8.0.0 WELD and JOINT DESIGN8.1.0 Process Method8.2.0 Type of Metal8.3.0 Strength 8.4.0 Position 8.5.0 Thickness 8.6.0 Accessibility 8.6.1 Backing Strips

8.7.0 Weld Joint Designs8.8.0 Arc Welding Positions8.8.1 Flat-Position Welding8.8.2 Horizontal-Position Welding8.8.2.1 Electrode Movement8.8.2.2 Joint Type8.8.3 Vertical-Position Welding8.8.3.1 Current Settings and Electrode Movement8.8.3.2 Joint Type8.8.4 Overhead-Position Welding8.8.4.1 Current Settings and Electrode Movement8.8.4.2 Type of Welds8.8.5 Pipe welding8.8.5.1 Pipe welding positions8.8.5.2 Pipe welding procedures8.8.5.3 Joint preparation and fit-up8.8.6 Tack welding8.8.7 Spacers8.8.8 Electrode selection8.8.9 Weather conditions

9.0.0 WELDING PROCEDURE VARIABLES9.1.0 Fixed Variables 9.1.1 Electrode Type 9.1.2 Electrode Size

9.2.0 Primary Variables 9.2.1 Welding Current 9.2.2 Welding Voltage (Arc Length) 9.2.3 Travel Speed

9.3.0 Secondary Variables 9.3.1 Electrode Extension9.3.2 Electrode Angles

10.0.0 WELDING PROCEDURE SCHEDULES11.0.0 PREWELD PREPARATIONS11.1.0 Preparing the Weld Joint 11.2.0 Cleaning the Work Metal11.3.0 Fixturing and Positioning 11.4.0 Preheating

12.0.0 WELDING DEFECTS and PROBLEMS12.1.0 Discontinuities Caused by Welding Technique 12.1.1 Slag Inclusions12.1.2 Wagon Tracks12.1.3 Porosity12.1.4 Wormhole Porosity (Piping Porosity)12.1.5 Undercutting12.1.6 Lack of Fusion12.1.7 Overlapping12.1.8 Melt-Through 12.1.9 Excessive Weld Spatter 12.1.10 Arc Strikes 12.1.11 Craters

12.2.0 Cracking 12.3.0 Other Problems 12.3.1 Arc Blow 12.3.2 Inadequate Shielding 12.3.3 Clogged or Dirty Contact Tube 12.3.4 Wire Feed Stoppages


14.0.0 WELDER TRAINING and QUALIFICATION14.1.0 Welder Training 14.1.1 Basic Flux Cored Arc Welding


15.0.0 WELDING SAFETY15.1.0 Electrical Shock 15.2.0 Arc Radiation 15.3.0 Air Contamination 15.4.0 Compressed Gases15.5.0 Fires and Explosions 15.6.0 Weld Cleaning and Other Hazards 15.7.0 Summary of Safety Precautions


SW Basic Ch 12 Welding Quality ControlChapter 12Welding Quality ControlTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 INTRODUCTION 2.0.0 NONDESTRUCTIVE TESTING2.1.0 Visual Inspection2.2.0 Magnetic Particle Inspection2.3.0 Liquid Penetrant Inspection2.4.0 Radiographic Inspection2.5.0 Ultrasonic Inspection2.6.0 Eddy Current Testing

3.0.0 DESTRUCTIVE TESTING3.1.0 Free-Bend Test3.2.0 Guided-Bend Test3.3.0 Nick-Break Test3.4.0 Impact Test3.5.0 Fillet-Welded Joint Test3.6.0 Etching Test3.7.0 Tensile Strength Test


SW Basic Ch 13 Layout and Fabrication of Sheet-Metal and Fiber and Glass DuctChapter 13Layout and Fabrication of Sheet Metal and Fiberglass DuctTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 TOOLS and EQUIPMENT1.1.0 Layout Tools 1.1.1 Scriber1.1.2 Flat Steel Square1.1.3 Combination Square1.1.4 Protractor1.1.5 Prick Punch1.1.6 Dividers 1.1.7 Trammel Points1.1.8 Circumference Ruler

1.2.0 Cutting Tools 1.3.0 Sheet Metal Bending and Forming Equipment1.3.1 Stakes1.3.2 Other Forming Tools1.3.2.1 Bar Folder1.3.2.2 Brakes1.3.2.3 Roll Forming Machine1.3.2.4 Combination Rotary Machine

2.0.0 SHEET METAL DEVELOPMENT 2.1.0 Parallel Line Development 2.2.0 Radial Line Development2.3.0 Triangular Development2.4.0 Fabrication of Edges, Joints, Seams, and Notches 2.4.1 Edges2.4.2 Joints2.4.3 Seams2.4.4 Notches

3.0.0 JOINING and INSTALLING SHEET METAL DUCT 3.1.0 Metal Screws3.2.0 Rivets3.3.0 Riveted Seams

4.0.0 SHEET METAL DUCT SYSTEMS 4.1.0 Shop Procedures 4.2.0 Shop Drawings 4.3.0 Duct Material 4.4.0 Reinforcement and Support 4.5.0 Flexible Connections4.6.0 Hanging Duct

5.0.0 FIBERGLASS DUCT SYSTEMS5.1.0 Characteristics5.2.0 Fabrication5.3.0 Installation

6.0.0 SAFETYSummaryReview QuestionsTrade Terms Introduced in this ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 14 Fiber LineChapter 14Fiber LineTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 FIBER LINE1.1.0 Types of Natural Fiber Line 1.1.1 Manila1.1.2 Sisal1.1.3 Hemp1.1.4 Coir1.1.5 Cotton

1.2.0 Types of Synthetic Fiber Lines 1.3.0 Fabrication of Line1.3.1 Fibers1.3.2 Yarns1.3.3 Strands1.3.4 Lines

1.4.0 Types of Lays of Line1.4.1 Hawser-Laid1.4.2 Shroud-Laid1.4.3 Cable-Laid

1.5.0 Size Designation1.6.0 Handling and Care of Fiber Line1.6.1 Uncoiling1.6.2 Uncoiling Nylon1.6.3 Making Up1.6.4 Whipping1.6.5 Inspecting1.6.6 Storing

1.7.0 Strength of Fiber Line1.7.1 Breaking Strength 1.7.2 Safe Working Load1.7.3 Safety Factor1.7.4 Breaking Strength of Nylon Line

1.8.0 Knots, Bends, and Hitches1.8.1 Line Parts1.8.2 Overhand Knot1.8.3 Figure-Eight Knot1.8.4 Square Knot1.8.5 Sheepshank1.8.6 Bowline1.8.7 French Bowline1.8.8 Spanish Bowline1.8.9 Running Bowline1.8.10 Becket Bend1.8.11 Clove Hitch1.8.12 Scaffold Hitch1.8.13 Barrel Hitch

1.9.0 Splicing Fiber Line1.9.1 Eye Splice1.9.2 Short Splice1.9.3 Long Splice1.9.4 Back Splice

1.10.0 Splicing Nylon Line


SW Basic Ch 15 Wire RopeChapter 15Wire RopeTopicsOverviewObjectivesPrerequisitesFeatures of this Manual1.0.0 WIRE ROPE1.1.0 Construction 1.1.1 Wires1.1.2 Strands1.1.3 Core

1.2.0 Grades 1.2.1 Mild Plow Steel1.2.2 Plow Steel1.2.3 Improved Plow Steel

1.3.0 Lays1.4.0 Lay Length1.5.0 Classification1.6.0 Selection1.6.1 Tensile Strength1.6.2 Crushing Strength1.6.3 Fatigue Resistance1.6.4 Abrasion Resistance1.6.5 Corrosion Resistance

1.7.0 Measuring1.8.0 Safe Working Load1.9.0 Failure1.10.0 Attachments1.11.0 End Fittings1.11.1 Clips1.11.2 Clamps1.11.3 Thimble1.11.4 Wedge Socket1.11.5 Basket Socket1.11.5.1 Dry Method1.11.5.2 Poured Method1.11.6 Splices

1.12.0 Handling and Care1.12.1 Coiling and Uncoiling1.12.2 Kinks1.12.3 Reverse Bends1.12.4 Sizes of Sheaves1.12.5 Seizing and Cutting

1.13.0 Inspection1.14.0 Cleaning and Lubricating1.15.0 Storage


SW Basic Ch 16 RiggingChapter 16RiggingTopicsOverviewObjectivesPrerequisites1.0.0 BLOCK and TACKLE1.1.0 Terminology1.2.0 Block Construction1.3.0 Block to Line Ratio1.4.0 Types of Blocks 1.4.1 Standing1.4.2 Traveling1.4.3 Snatch

1.5.0 Reeving Blocks1.6.0 Types of Tackle1.6.1 Single-whip1.6.2 Runner1.6.3 Gun Tackle1.6.4 Single-luff Tackle1.6.5 Twofold Purchase1.6.6 Double-Luff1.6.7 Three-fold Purchase1.6.8 Compound Tackle

1.7.0 Allowance for Friction1.8.0 Block Safety

2.0.0 SLINGS2.1.0 Slings and Rigging Gear Kits2.2.0 Wire Rope Slings2.3.0 Fiber Line Sling2.3.1 Synthetic Web Slings

2.4.0 Chain Slings2.4.1 Metal Mesh Slings

2.5.0 Using Wire Rope and Fiber Slings2.5.1 Endless2.5.2 Single Leg2.5.3 Bridle

2.6.0 Sling Inspection2.6.1 Synthetic Web Slings2.6.2 Synthetic Round Slings2.6.3 Wire Rope Slings2.6.4 Wire Mesh Slings2.6.5 Alloy Chain Slings

2.7.0 Proof Testing Slings2.8.0 Safe Working Loads of Slings2.9.0 Sling Angle2.10.0 Storage

3.0.0 CHAINS3.1.0 Inspection3.2.0 Safe Working Loads3.3.0 Handling and Care

4.0.0 ADDITIONAL LIFTING EQUIPMENT4.1.0 Hooks4.1.1 Slip Hooks4.1.2 Grab Hooks4.1.3 Mousing a Hook4.1.4 Inspection4.1.5 Hook Strength

4.2.0 Shackles4.2.1 Safe Working Load4.2.2 Mousing a Shackle

4.3.0 Beam Clamps

5.0.0 OTHER LIFTING EQUIPMENT5.1.0 Spreader Bars5.2.0 Pallets5.3.0 Jacks5.4.0 Planks and Rollers5.5.0 Blocking and Cribbing5.6.0 Scaffolds5.6.1 Planking and Runway Scaffold5.6.2 Swinging Platform Scaffold5.6.3 Needle-Beam Scaffold5.6.4 Boatswains Chair5.6.5 Safety

6.0.0 FIELD-ERECTED HOISTING DEVICES6.1.0 Holdfasts6.1.1 Natural Types6.1.2 Single-Picket6.1.3 Combination-Picket6.1.4 Combination Log Picket6.1.5 Deadman6.1.6 Steel Picket

6.2.0 Gin Poles6.3.0 Tripods6.4.0 Shears

7.0.0 SAFE RIGGING OPERATING PROCEDURESSummaryReview QuestionsTrade Terms Introduced in this ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 17 Pre-Engineered StructuresChapter 17Pre-Engineered StructuresTopicsOverviewObjectivesPrerequisites1.0.0 PRE-ENGINEERED BUILDINGS1.1.0 Pre-Erection Work1.2.0 Erection Procedures1.2.1 Bolting Rigid Frames1.2.2 Frame Erection1.2.3 Brace Rods1.2.4 Sag Rods1.2.5 Brace Angles and Base Angles1.2.6 End-Wall Framing/Doors/Windows1.2.7 Sheeting1.2.8 Building Insulation1.2.9 Multiple buildings Set Side by Side

1.3.0 Disassembly Procedures1.3.1 Marking

2.0.0 K-SPAN BUILDINGS2.1.0 ABM 120 System2.1.1 Operating Instructions2.1.2 Machinery Placement2.1.3 Foundations2.1.4 Building Erection

2.2.0 ABM 240 System

3.0.0 STEEL TOWERS3.1.0 Assembly and Erection of Sections3.2.0 Dismantling a Tower

4.0.0 ANTENNA TOWERS4.1.0 Guyed Towers4.2.0 Freestanding Towers4.3.0 Tower Assembly4.4.0 Erection of Guyed Towers4.4.1 Davit Method4.4.2 Gin Pole Method

4.4.3 Hand Assembly4.5.0 Guying4.5.1 Temporary Guying4.5.2 Permanent Guying4.5.2.1 Single-Guy Layer4.5.2.2 Two-Guy Layers4.5.2.3 Three-Guy Layers4.5.3 Guy Tension4.5.3.1 Initial Tension4.5.3.2 Final Tension4.5.4 Guy Anchors4.5.4.1 Screw Anchor4.5.4.2 Expansion Anchor4.5.4.3 Concrete Anchor

SummaryReview QuestionsTrade Terms Introduced in This ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 18 Introduction to Structural SteelChapter 18Introduction to Structural SteelTopicsOverviewPrerequisites1.0.0 STRUCTURAL STEEL MEMBERS1.1.0 Terminology1.1.1 W-Shape1.1.2 Bearing Pile 1.1.3 S-Shape 1.1.4 C-Shape 1.1.5 Angle 1.1.6 Plate 1.1.7 Bar

2.0.0 ANCHOR BOLTS 3.0.0 BEARING PLATES 4.0.0 COLUMNS 5.0.0 GIRDERS 6.0.0 BEAMS 7.0.0 BAR JOISTS 8.0.0 TRUSSES 9.0.0 PURLINS, GIRTS, AND EAVE STRUTS SummaryReview QuestionsTrade Terms Introduced in this ChapterAdditional Resources and ReferencesCSFE Nonresident Training Course User Update

SW Basic Ch 19 Introduction to Reinforcing SteelChapter 19Introduction to Reinforcing SteelTopicsOverviewObjectivesPrerequisites1.0.0 REINFORCED CONCRETE1.1.0 Concrete Materials1.2.0 Concrete Strength1.3.0 Purposes and Types of Reinforcing Steel1.3.1 Reinforcing Bars1.3.2 Tension in Steel

1.4.0 Additional Types of Reinforcing Steel1.4.1 Expanded Metal1.4.2 Welded Wire Fabric1.4.3 Sheet-Metal Reinforcement


APPENDIX IAPPENDIX IIAPPENDIX IIISW Basic Back Cover

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