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Re: welding studs to existing, corroded steel

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AWS D1.1 section 5.15 has the requirements for "Preparation of Base Material".  Part of it reads as follows:

.....Surfaces to be welded, and surfaces adjacent to a weld, shall also be free from loose or thick scale, slag, rust, moisture, grease, and other foreign material that would prevent proper welding or produce objectionable fumes.  Mill scale that can withstand vigorous wire brushing, a thin rust-inhibitive coating, or antispatter compound may remain with the following exception: for girders in cyclically loaded.......

If your beams came from the mill with delamination of the flanges then you have more serious problems than stud welding.  If these are beams that have been in place for a long time and it is just surface lamination from corrosion then you would want to give them a good wire brushing and possibly a little grinding if the loose laminations are not totally removed from brushing.  You could try sand blasting but it may not get down to solid metal if the corrosion is significant however you could try it first and see how it goes.  Light rust is not a big issue here but you certainly want to be welding to sound metal.

Thomas Hunt, S.E.
ABS Consulting

"Glass, Gordon" <GGlass(--nospam--at)>

06/04/2003 04:22 AM
Please respond to seaint

        To:        <seaint(--nospam--at)>
        Subject:        welding studs to existing, corroded steel

Does anyone have experience or documentation regarding the welding of shear studs to existing top flanges which may have susbstantial laminating corrosion.  Asside from the amount of sound steel remaining, what minimum level of SSPC is acceptable to acheive development of the shear stud weldment to acheive strength.

Gordon Glass
Burgess & Niple, Ltd.

220 Lexington Green Circle, Suite 110

Lexington, KY 40503

Phone: 859-273-0557

FAX: 859-273-3332