Chapter 19 Introduction to Reinforcing Steel - NAVY BMRnavybmr.com/study...

Chapter 19

Introduction to Reinforcing Steel Topics

1.0.0 Reinforced Concrete

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Overview As a Steelworker, you must be able to cut, bend, place, and tie reinforcing steel in its proper sequence and configurations. This chapter describes the purpose of reinforcing steel in concrete construction, identifies the types and shapes of commonly used reinforcing steel, and explains specific properties of rebar (reinforcing steel). This chapter begins with a presentation of fundamental information about concrete to help you understand rebar work fully.

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

1. Describe the different materials, purposes, and types of reinforcing steel.

Prerequisites None

NAVEDTRA 14250A 19-1

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 REINFORCED CONCRETE As a Steelworker you will be primarily concerned with reinforcing steel placement, but you should to some extent be concerned with concrete as well. Concrete with reinforcing steel added becomes reinforced concrete. Structures built of reinforced concrete, such as retaining walls, buildings, bridges, highway surfaces, and numerous other structures, are referred to as reinforced concrete structures or reinforced concrete construction. The reinforcement can be as simple as a few continuous bars in a small foundation (Figure 19-1) or as complex as a pier/footing combination for a bridge (Figure 19-2).

Figure 19-1 Simple use of reinforcement bars.

Figure 19-2 Complex use of reinforcement bars.


1.1.0 Concrete Materials Concrete is a synthetic construction material made by mixing cement, fine aggregate (usually sand), coarse aggregate (usually gravel or crushed stone), and water in proper proportions (Figure 19-3). This mixture hardens into a rocklike mass as the result of a chemical reaction between the cement and water called hydration. Concrete will continue to harden and gain strength, in a chemical process known as curing, as long as it is kept moist and warm. Durable, strong concrete is made by correctly proportioning and mixing the various materials and additives, and by properly curing the concrete following placement or the pour. The correct proportioning of the concrete ingredients (modern concrete design may include retardants, accelerators, plasticizers, air entraining agents, etc.) is often referred to as the mix. The quality of the concrete is largely determined by the quality of the cement-water paste that bonds the aggregates together. The strength of concrete will be reduced if this paste has water added to it. The proportion of water to cement is referred as the water-cement ratio. The water-cement ratio is the number of gallons of water per pounds of cement. High quality concrete is produced by using the lowest water-cement mixture possible without sacrificing workability. Because concrete is plastic when placed, forms are built to contain and form the concrete until it has hardened. In short, forms and formwork are described as molds that hold freshly placed concrete in the desired shape until it hardens. In some cases, depending on the soil texture and stability, the soil banks of excavated areas act as the formwork for footings and foundations. All the ingredients of a mix are placed in a concrete mixer, and after a thorough mixing, the concrete is transferred by numerous methods (as determined by the projects conditions), such as bucket, wheelbarrow, chute, transit truck tailgate, pump, and so forth, into the formwork in which the reinforcing steel has already been placed. Under normal, moderate weather and temperature conditions, concrete reaches its initial set in approximately 1 hour, and hardens to its final set (although not fully cured) in approximately 6 to 12 hours. As the concrete is being placed, and before the initial set, it must be vibrated in the formwork to ensure complete coverage of all reinforcing bars, but not vibrated so much that the aggregate and cement separate to form rock pockets.

Figure 19-3 Aggregate.


Finish operations, such as smooth troweled finishes, must be performed between initial and final set. After the final set, concrete must be protected from shock, extreme temperature changes, and premature drying until it cures to sufficient hardness. Concrete will be self-supportive in a few days and will attain most of its potential strength in 28 days of moist curing. For further information on concrete, refer to the American Society for Testing and Materials (ASTM) and the American Concrete Institute (ACI)-318.

1.2.0 Concrete Strength As stated previously, the strength of concrete is determined by the water-cement ratio. The strength of ready-mixed concrete ranges from 1,500 to about 5,000 pounds per square inch (psi) and, with further attention paid to proportioning, it can go even higher. Under usual construction processes, lower strength concrete will be used in footers and walls, and higher strength in beams, columns, and floors. The required strength of concrete on a given project can be found in the project plans and specifications for a specific project. NOTE: Quality control is important to ensure specific design requirements are met. If the design specifications do not meet minimum standards, structural integrity is compromised and the structure is considered unsafe. For this reason, the compressive strength of concrete is checked on all projects. The strength of the concrete is checked by the use of cylindrical molds that are 6 inches in diameter and 12 inches in height. Concrete samples must be taken on the jobsite from the concrete that is being placed. After being cured for a period that ranges between 7 to 28 days, the cylinders are broken to failure by a laboratory crushing machine that measures the force required for the concrete to fail (Figure 19-4). For further information on concrete strength and testing, refer to FM 5-472 Ch. 2 /NAVFAC MO 330/AFJMAN 32-1221(I), ASTM, and ACI 318.

1.3.0 Purposes and Types of Reinforcing Steel Reinforced concrete was designed on the principle that steel and concrete act together in resisting force. Concrete is strong in compression but weak in tension (Figure 19-5). The tensile strength is generally rated about 10 percent of the compression strength. For this reason, concrete works well for columns and posts that are compression members in a

Figure 19-4 Concrete testing machine.


structure. But when it is used for tension members, such as beams, girders, foundation walls, or floors, concrete must be reinforced to attain the necessary tension strength. Steel is the best material for reinforcing concrete because the properties of expansion for both steel and concrete are considered to be approximately the same, that is, under normal conditions, they will expand and contract at an almost equal rate.

NOTE At very high temperatures, steel expands more rapidly than concrete and the two materials will separate. Another reason steel works well as a reinforcement for concrete is that it bonds well with concrete. This bond strength is proportional to the contact surface of the steel to the concrete. In other words, the greater the surface of steel exposed to the adherence of concrete, the stronger the bond. A deformed reinforcing bar adheres better than a plain, round, or square one because it has a greater bearing surface. In fact, when plain bars of the same diameter are used instead of deformed bars, approximately 40 percent more bars must be used. The rougher the surface of the steel, the better it adheres to concrete. Thus, steel with a light, firm layer of rust is superior to clean steel; however, steel with loose or scaly rust is inferior. Loose or scaly rust can be removed from the steel by rubbing the steel with burlap or similar material. This action leaves only the firm layer of rust on the steel to adhere to the concrete.

NOTE Reinforcing steel must be strong in tension and, at the same time, be ductile enough to be shaped or bent cold.

Figure 19-5 Various concrete stresses.


Reinforcing steel can be used in the form of bars or rods that are either plain or deformed or in the form of expanded metal, wire, wire fabric, or sheet metal. Each type is useful for different purposes, and engineers design structures with those purposes in mind. Plain bars are round in cross section. They are used in concrete for special purposes, such as dowels at expansion joints, where bars must slide in a metal or paper sleeve, for contraction joints in roads and runways, and for column spirals. They are the least used of the rod type of reinforcement because they offer only smooth, even surfaces for bonding with concrete. Deformed bars are like plain bars except that they have indentations, ridges, or both in a regular pattern. Earlier versions of deformed rebar were available as square or with a spiral twist, and workers may still encounter them during demolition or on remodeling projects of older structures. Current rebar suppliers deform the bars at the mill with patterns and markings unique to their mill and to the tensile strength of the material. Figure 19-6 shows a few of the types of deformed bars available. In the United States, deformed bars are used almost exclusively, while in Europe, both deformed and plain bars are used. There are 11 standard sizes of reinforcing bars (Figure 19-7). Bars No. 3 through No. 18, inclusive, are deformed bars. Bar numbers correspond to bar sizes to the nearest 1/8 in. (3. 175 mm) measured at the nominal diameter but not including any deformations. At various sites overseas, rebar could be procured locally and could be metric. Note: At 13.6 pounds per foot, a #18 bar (#57 metric) of any functional length quickly becomes too heavy for personnel handling and requires mechanical lifting equipment.


Figure 19-6 Sample mill patterns and tensile strength markings. NAVEDTRA 14250A 19-9

Figure 19-7 Reinforcing steel sizes and their tensile strength markings.


1.3.1 Reinforcing Bars Reinforcing bars are hot-rolled from a variety of steels in several different strength grades. Generally, reinforcing steel bars are either carbon-steel (conforming to ASTM A615) or low-alloy steel (conforming to ASTM A706). Most reinforcing bars are rolled from new steel billets, but some are rolled from used railroad-car axles or railroad rails that have been cut into rollable shapes. An assortment of strengths is available. The American Society for Testing Materials (ASTM) has established a standard branding for deformed reinforcing bars. There are a number of important ways to identify reinforcing bar from the production mill to the fabrication shop to the job site. This documentation and marking system helps provide a wealth of useful information about the manufacturing and composition of each bar of reinforcing steel. Each individual reinforcing bar is manufactured with a series of individual markings. Refer again to Figure 19-6:

The top letter or symbol identifies the producing mill and deformation pattern. The next marking is the bar size. The third marking symbol designates the manufacturing material usually either

"S" for carbon-steel (ASTM A615) or "W" for low-alloy steel (ASTM A706). Finally, there will be a grade marking (4 or 5, for 420 or 520) or the addition of

one line (420) or two lines (520) that must be at least five deformations long. The lower strength reinforcing bars show only three marks: an initial representing the producing mill, bar size, and type of steel. High strength reinforcing bars use either the continuous line system or the number system to show grade marks. In the line system, one continuous line is rolled into the 60,000 psi bars, and two continuous lines are rolled into the 75,000 psi bars. The lines must run at least five deformation spaces, as shown in Figure 19-6. Reinforcing bars typically come in two primary grades: Grade 60 (minimum yield strength of 60,000 psi) and Grade 75 (minimum yield strength of 75,000 psi). The metric equivalents for these are Grade 420 (equivalent yield strength of 420 MPa (megapascals) and Grade 520 (equivalent yield strength of 520 MPa).

1.3.2 Tension in Steel Steel bars are strong in tension. Structural grade is capable of safely carrying up to 18,000 psi and intermediate, hard, and rail steel, 20,000 psi. This is the safe or working stress; the breaking stress is about triple this. When a mild steel bar is pulled in a testing machine, it stretches a very small amount with each increment of load. In the lighter loadings, this stretch is directly proportional to the amount of load (Figure 19-8, View A). The amount is too small to be visible and can be measured only with sensitive gauges. At a point during the pull (known as the Yield Point), such as 33,000 psi for mild steel, the bar begins to neck down (Figure 19-8, View B) and continues to stretch perceptibly with no additional load. Then, when it seems the bar will snap like a rubber band, it recovers strength (due to work hardening). Additional pull is required (Figure 19-8, View C) to produce additional stretch and final failure (known as the ultimate strength) at about 55,000 psi for mild steel.


Common specifications are ASTM A 615 for carbon steel rebar, ASTM A 706 for seismic rebar, ASTM A 955 for stainless steel rebar, and ASTM A 996 for rail steel rebar and axle steel rebar. American Association of State Highway and Transportation Officials (AASHTO) Specifications M31M / M 31-02, Deformed and Plain Billet-Steel Bars for Concrete Reinforcement contain more information on reinforcing bar tension testing.

1.4.0 Additional Types of Reinforcing Steel Not all concrete reinforcing needs heavy reinforcing bars; some projects require only lightweight reinforcing. In these cases, expanded metal or welded wire fabric can be used.

1.4.1 Expanded Metal Expanded metal is made from sheets of solid metal that are uniformly slit and stretched to create diamond-shaped openings. As expanded metal is made, each row of diamond-shaped openings is offset from the next (Figure 19-9). This product is called standard expanded metal. The sheet can be rolled to produce flattened expanded metal. The lightweight properties and open area percentages of expanded metal allow it to be easily formed for a variety of energy-saving applications, such Figure 19-9 Expanded metal.

Figure 19-8 Tension in steel bars.


as light diffusers, screens, grilles, and filters. Expanded metal is also manufactured in heavy gauges for applications such as reinforcing concrete walkways, ramps, and catwalks of all types.

1.4.2 Welded Wire Fabric Welded wire fabric is fabricated from a series of wires arranged at right angles to each other and electrically welded at all intersections. Welded wire fabric, referred to as WWF within the NCF, has various uses in reinforced concrete construction. In building construction, it is most often used for floor slabs on well compacted ground. Heavier fabric, supplied mainly in flat sheets, is often used in walls and for the primary reinforcement in structural floor slabs. Additional examples of its use include road and runway pavements, box culverts, and small canal linings. Welded wire fabric (WWF or wire mesh) is available in rolls of lighter gauge wire for light building construction and in sheets of heavier gauge wire for highways and buildings when roll gauge sizes will not give sufficient reinforcement (Figure 19-10). WWF is available in square and rectangular patterns in a wide variety of wire gauges welded at each intersection.

When welded wire fabric in either the old or the new designations is ordered, the wire spacing (in each direction) comes first followed by the wire gauge (in each direction). The old designation used number (in inches) for spacing and number (in wire gauge) for the size of the WWF. The new designation uses number (in inches) for spacing but a letter and a number (in wire cross section) for size. For example, in the old designation, 6x6 4x4 mesh would be 6-in. squares with 4-gauge wire in each direction, whereas 4x4 6x6 mesh would be 4-in. squares with 6-gauge wire in each direction. In the new designation, these would be 6x6 W4xW4, and 4x4 W2.9xW2.9 respectively. Table 19-1 provides some typical WWF designations used for structural concrete.

Figure 19-10 Welded wire.


When WWF is used, specifications and designs usually indicate the minimum lap. As a practical matter, although a minimum lap of 2 in. may be sufficient for nonstructural concrete, for placement purposes a 1-square lap, regardless of the mesh spacing, is common to facilitate the installers ability to tie the laps together at intersections. The unit weight of WWF is designated in pounds per one hundred square feet of fabric Five feet, six feet, seven feet, and seven feet six inches are the standard widths available for rolls, while the standard panel widths and lengths are seven feet by twenty feet and seven feet six inches by twenty feet.

Table 19-1 Common Stock Sizes of Welded Wire Fabric.

Style Designation Weight Approximate

Pounds per 100 Square Feet Current Designation (by W-Number)

Previous Designation (by Steel Wire Gauge)

Panels/Sheets

6 x 6 W 1.4 x W 1.4 6 x 6 10 x 10 21

6 X 6 W 2.1 X W 2.1 6 X 6 8 X 8 29

6 X 6 W 2.9 X W 2.9 6 x 6 6 x 6 42

6 x 6 W 4.0 x W 4.0 6 x 6 4 x 4 58

4 x 4 W 1.4 x W 1.4 4 x 4 10 x 10 31

4 x 4 W 2.1 x W 2.1 4 x 4 8 x 8 43

4 x 4 W 2.9 x W 2.9 4 x 4 6 x 6 62

4 x 4 W 4.0 x W 4.0 4 x 4 4 x 4 86

Rolls

6 x 6 W 1.4 x W 1.4 6 x 6 10 x 10 21

6 x 6 W 2.9 x W 2.9 6 x 6 6 x 6 42

6 x 6 W 4.0 x W 4.0 6 x 6 4 x 4 58

6 x 6 W 5.5 x W 5.5 6 x 6 2 x 2 80

4 x 4 W 4.0 x W 4.0 4 x 4 4 x 4 86

1.4.3 Sheet-Metal Reinforcement Sheet-metal reinforcement is used mainly in floor slabs and in stair and roof construction. It consists of annealed sheet steel bent into grooves or corrugations about one-sixteenth inch (1.59 mm) in depth with holes punched at regular intervals.

Summary This chapter discussed the fundamental information about reinforced concrete and the reasons why it is necessary to use reinforcement steel with concrete. Also discussed were the different materials, purposes, and types of reinforcing steel. Specifically discussed was the identification system used on the most common reinforcement bar used by the Seabees. The mechanical properties of the steel and ASTM specifications of the steel reinforcement bars were also discussed. Always remember to follow the prescribed safety precautions and wear the proper personal protective equipment.


Review Questions (Select the Correct Response)1. What is the primary factor that determines the strength of concrete?

A. Dryness B. Water-to-cement ratio C. Age D. Type of steel reinforcement

2. (True or False) Concrete is strong in tension but weak in compression.

A. True B. False

3. Which factor makes steel the best material for reinforcing concrete?

A. Steel adds compressive strength. B. The expansion properties of both steel and concrete are approximately the

same. Steel is easily bent to fit all shapes of forms. C.

D. Steel adheres well to concrete. 4. What type of surface condition on rebar provides the best adherence with

concrete?

A. Clean and smooth B. Loose or scaly rust C. Painted D. Light, firm layer of rust

5. On what part of rebar are diameter measurements taken?

A. On the round/square where there are no deformations B. On the deformations where the diameter is greatest C. On the diagonal of its widest section D. On the diameter of the deformation plus the height of the deformation

6. What does the first letter or symbol identify on a reinforcement bar brand?

A. Producing mill B. Bar size C. Manufacturing material D. Grade mark

7. What is the metric equivalent to a grade 60 reinforcement bar?

A. 220 B. 320 C. 420 D. 520


8. At what pounds per square inch will a steel bar begin to neck down?

A. 22,000 B. 33,000 C. 66,000 D. 77,000

9. When the number designation 8x8x10x10 is used, what do these numbers

indicate about a roll of wire mesh?

A. The wire gauge is 8 and the crosswise spacing is 10 inches. B. The wire gauge is 10 and the crosswise and lengthwise spacing is 8

inches. C. The wire gauge is 8 and the length spacing is 8 inches. D. The crosswise spacing is 10 inches and the wire gauge is 10.

10. What is the common spacing, in square laps, on wire mesh fabric that facilitates the installers ability to tie laps together?

A. 1 B. 2 C. 3 D. 4


Trade Terms Introduced in this Chapter Plasticizer An admixture for making mortar or concrete workable with

little water.


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. Consolidated Cross-Reference, TA-13, Department of the Navy, Navy Facilities Engineering Command, Alexandria, VA, 1989. Concrete and Masonry, FM 5-428, Headquarters Department of the Army, Washington, DC, 1998. Concrete Construction Engineering, 2nd ed. Nawy, E.G. Boca Raton, FL, 2008 Construction Print Reading in the Field, TM 5-704, Headquarters Department of the Army, Washington, DC, 1969. Placing Reinforcing Bars, 8th ed, Concrete Reinforcing Steel Institute, Schaumburg, IL, 2005.


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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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