w59 03study guide

CWB Form 111E/2004-2

CSA STANDARD W59-03

STUDY GUIDE

CANADIAN WELDING BUREAU

A Division of the CWB Group - Industry Services

“CERTIFICATION MAKES THE DIFFERENCE”


1

CSA STANDARD W59-03 STUDY GUIDE

In order to assist welding supervisors in their study of CSA Standard W59, the Canadian Welding Bureau has complied this study guide. It includes Questions with short Answers, multiple choice and true or false exercise Questions. The clause reference for the correct Answer is shown in brackets followed by the Answer.

SHORT ANSWER FORMAT

Clause 1 1. Question: CSA Standard W59 covers the welding requirements for what type of steel construction?

Answer: (CI. 1.1,1.2,Cl. 1.4) The welding requirements of CSA Standard W59 can be applied to carbon and low alloy welded steel construction, except where other special codes such as Lloyd's or ASME, for instance, govern.

The standard is not intended for use with steels having a minimum specified yield strength> 700 MPa (100,000 psi) or for stainless steels.

2. Question: What types of structures are covered in CSA Standard W59?

Answer: (CI. 1.1) CSA Standard W59 covers statically loaded structures and cyclically loaded (repetitive loading) structures. Clause 12 deals with provisions that are specific to cyclically loaded structures only, and Clause 11 deals with provisions specific to statically loaded structures only.

Clause 2

3. Question: What is a low-hydrogen electrode?

Answer: (CI. 2.1) A low-hydrogen electrode is an electrode which deposits weld metal with a specified maximum limit of diffusible hydrogen. E4918 and E4928 are examples of low-hydrogen electrodes.

4. Question: Who is the "engineer" as described in CSA Standard W59?

Answer: (CI. 2.1) The engineer is the person representing the regulatory authority, or the purchaser.


2

Clause 3

5. Question: What are the requirements for contractor certification?

Answer: (CI. 3.1.1) Contractors shall be certified under the requirements of CSA Standard W47.1 when stipulated by the governing design standard or by the Engineer. Or, at the option of the Engineer, the fabricator must provide evidence to satisfy the Engineer that the fabricator is competent to produce the required weldments.

6. Question: What welding processes are covered in CSA Standard W59?

Answer: (CI. 3.1.2.1) This standard covers the SMAW, GMAW, MCAW, FCAW, SAW, ESW, EGW and SW processes

7. Question: Does CSA Standard W59 specify requirements for stud welding?

Answer: (CI.3.1.2.2) Yes, Clause 5 has requirements for stud welding.

8. Question: Does CSA Standard W59 contain provisions for prequalified joints?

Answer: (CI. 3.1.3.1) Yes, Clause 10 has details for the geometry of joints which are prequalified, providing all other requirements of CSA Standard W59 (See Clause 10) are followed. There are prequalified joints for SMAW, SAW, FCAW, MCAW (spray transfer mode only) and GMAW (spray transfer mode only) processes.

9. Question: What base metals can be welded under CSA Standard W59?

Answer: (CI. 3.2, Cl. 3.2.1 & Cl. 3.3.2) Steels that can be welded shall conform to the requirements of the CSA or ASTM steels listed in clauses 3.2.1 and 3.2.2 or other recognized specifications of equivalent welding quality approved by the engineer.

10. Question: The requirements for welding symbols are specified in what standard?

Answer: (CI. 3.4) Welding symbols shall be as shown in AWS Standard A2.4 together with the additional conventions developed for CSA Standard W59 and shown in Appendix D of CSA Standard W59.


3

Clause 4

11. Question: What information should be given on a design drawing?

Answer: (Cl. 4.1.1.1, Cl. 4.1.1.1.4) A design drawing should contain: (a) information for preparation of detail and erection drawings; (b) the effective throat thickness shall be defined, if there are partial penetrating joints.

12. Question: What typical welding information would you expect to find on a detail drawing?

Answer: (Cl. 4.1.1.2.1, Cl. 4.1.1.2.2, Cl. 4.1.1.2.3) A detail drawing should contain the following information:

(a) location, type, size and length of all welds; (b) distinguish between shop and field welds;

(c) groove depths and joint preparations, if there are partial penetration joints, together with the position of welding;

(d) any notes required, e.g. welding sequence, control of distortion, etc.

13. Question: What requirements are specified in CSA Standard W59 to minimize the possibility of lamellar tearing?

Answer: (Cl. 4.1.2.1& Cl. 4.1.2.2). Corner or T-joint details causing through-thickness tensile stresses resulting from welding executed under conditions of restraint shall be avoided when possible. If this type of joint cannot be avoided, measures shall be taken to minimize the possibility of lamellar tearing, such as the selection of material with improved through- thickness ductility. In the case of corner joints using single bevel or J-grooves, the preferred preparation is as shown in Figure 4.1.

14. Question: What are the types of welds as specified in CSA Standard W59?

Answer: (Cl. 4.1.3.1.1) Welds are classified as groove, fillet, plug or slot welds.

15. Question: What is a complete joint penetration (CJP) groove weld?

Answer: (Cl. 4.1.3.1.2) A CJP groove weld is one which has complete penetration and fusion of weld and base metal throughout the thickness of the joint.

16. Question: What is a partial joint penetration groove weld?

Answer: (CI. 4.1.31. .3) A partial joint penetration groove weld is defined as one having joint penetration less than complete.


4

17. Question: Does CSA standard W59 allow for the use of intermittent groove welds?

Answer: (Cl. 4.1.3.2.1) No. Groove welds must be continuous for the full length of the joint, except as provided in Clause 4.1.3.2.2 or as otherwise permitted by the Engineer.

18. Question: Can single fillet welds or single partial joint penetration welds be subjected, in service, to bending about the longitudinal axis of the weld if it produces tension at the root of the weld?

Answer: (CI. 4.1.3.3.2) No. These welds cannot be bent about their longitudinal axis if such bending produces tension at the root of the weld.

19. Question: What are the restrictions on the use of fillet welds?

Answer: (CI. 4.1.3.3.3.) Fillet welds may be used in joints with fusion faces forming an included angle of 60° to 135° (see Figure 4.8). Angles less than 60° are permitted; however, in such cases the weld shall be considered to be a partial joint penetration groove weld. For angles over 135° fillet welds shall not be relied upon to transmit calculated loads (see Clause 4.5).

20. Question: What is the effective length of a skewed butt joint?

Answer: (CI. 4.3.1.2) The effective length is the width of the part joined.

21. Question: What is the effective throat of a complete joint penetration groove weld connecting a 19 mm (3/4 in.) plate to a 25 mm (1 in.) plate?

Answer: (Cl. 4.3.1.3) The effective weld throat is equal to the thickness of the thinnest part joined, which in this case is 19 mm (3/4 in.).

22. Question: What is the effective throat of a partial joint penetration groove weld?

Answer: (CI. 4.3.1.4) If the groove angle is equal to or greater than 60°, the effective throat is equal to the depth of preparation. If the groove angle is between 45° and 60°, the effective throat is equal to the depth of preparation less 3mm (1/8in.).

23. Question: If a partial joint penetration groove weld is reinforced with a fillet can the fillet portion be included as part of the effective throat of the weld?

Answer: (C.I 4.3.1.5) Yes. The effective throat will be the shortest distance between the root of the groove and the surface of the fillet weld less 3 mm (1/8 in.), where such reduction is required by Clause 4.3.1.4.


5

24. Question: Is a flare bevel groove weld considered a complete or partial joint penetration weld?

Answer: (CI. 4.3.1.6.1.2, Cl. 4.3.1.6.1.3) It can be both.

25. Question: What is the effective throat thickness of a flare bevel groove weld in a butt joint?

Answer: (Cl. 4.3.1.6.1.4) The effective throat for partial joint penetration flare bevel groove welds in butt joints shall not be greater than the wall of thickness of the HSS member or 60% of the thickness of the planar edge (see Figure 4.3).

26. Question: What is the effective length of a fillet weld?

Answer: (CI. 4.3.2.2) The effective length is the overall length of the full-size fillet including end returns.

27. Question: How is the length of a curved fillet weld measured?

Answer: (CI. 4.3.2.3) The length of a curved fillet is measured along the centerline of the effective throat.

28. Question: What is the minimum allowable effective length of a fillet weld?

Answer: (CI. 4.3.4.2.2.) The minimum fillet weld length shall be 38 mm (1-1/2 in.) or 4 times the size of the fillet, whichever is larger. If the minimum length cannot be achieved then the effective fillet size shall be one-fourth of its effective length.

29. Question: What is the maximum fillet weld size that can be detailed along the edges of a plate?

Answer: (CI. 4.4.1.2) For plate thicknesses less than 6 mm (1/4 in.), the fillet weld size may be equal to the thickness of the plate. For plate thicknesses 6 mm (1/4 in.) or more, the fillet weld size shall not exceed the thickness of the plate less 2mm (1/16 in.) unless designated on the drawing to be built out to obtain full throat thickness.

30. Question: What is the minimum diameter of the hole or the width of the slot for plug and slot welds?

Answer: (CI. 4.4.2.1, Cl. 4.4.2.2) The diameter or width is equal to the thickness of the material containing the hole or slot plus 8 mm (5/16 in.).


6

31. Question: What is the required depth of filling for plug and slot welds?

Answer: (Cl. 4.4.2.3) For parts 16 mm (5/8 in.) or less, the depth of filling must be the thickness of the part. For part thickness greater than 16 mm (5/8 in.), the weld thickness must be at least half the material thickness, but not less than 16 mm (5/8 in.).

32. Question: What are the requirements in CSA Standard W59 for filler plates?

Answer: (CI. 4.6.2, Cl. 4.6.3) Fillers 6 mm (1/4 in.) in thickness or less shall not be used to transfer stress. Fillers over 6 mm (1/4 in.) in thickness shall be extended beyond the edges of the splice plate or connection material and connected with sufficient weld to transmit the splice plate or connection material stress.

33. Question: What is the minimum groove depth for a partial joint penetration groove weld in a 25 mm (1 in.) plate with a 45° groove angle?

Answer: Table 4-3 11 mm (7/16 in.)

34. Question: Two plates, each 12 mm thick are to be joined by a fillet weld. What is the minimum fillet size that may be made?

Answer: Table 4-4 5 mm (3/16 in.)

Clause 5

35. Question: What environmental factors must be taken into account when welding?

Answer: (CI. 5.1.1) The welder or welding operator, the work and welding consumables must be adequately protected against the direct effect of wind, rain and snow and all necessary means shall be provided to enable the welder or welding operator to work in reasonable comfort.

36. Question: Can welding be performed when the ambient temperature is below -18°C (0°F)?

Answer: (CI.5.1.2) Welding In such temperatures may only be done with the express consent of the Engineer.

37. Question: Are there special provisions in CSA Standard W59 for weld metal with atmospheric corrosion resistance and color matching of weathering steels?

Answer: (Cl. 5.2.1.4) Yes. Table 5-1, gives filler metal requirements for exposed bare applications of weathering steels.


7

38. Question: If atmospheric corrosion resistance is required but exact color matching is not required, can you deviate from the requirements of Table 5-1?

Answer: (Cl. 5.2.1.5 a-e) Yes. Allowable deviations are specified in Clause 5.2.1.5 (a), (b), (c), (d) and (e).

39. Question: What is the meaning of "H-X or -XX", as you may see after a FCAW electrode classification?

Answer: (CI. 5. 2.1.5 d, e & Cl. 5.2.4.3) An electrode designated as "H" deposits weld metal with a controlled amount of diffusible hydrogen.

40. Question: Do low-hydrogen electrodes have to be used for welding of all steels?

Answer: (CI. 5.2.2.2) No. Low-hydrogen electrodes do not have to be used for welding the steels listed in Column 2 of Table 5-3.

41. Question: What action must be taken when a container of low-hydrogen electrodes is damaged before opening?

Answer: (CI. 5.2.2.4.1 & 5.2.2.4.2) Carbon steel electrodes conforming to CSA Standard W48 shall be baked for at least 2 hrs. at a temperature between 230°C (450°F) and 260°C (500°F) before being used. Low-alloy steel electrodes conforming to CSA Standard W48 shall be baked for, at least 1 hour at a temperature between 370°C (700°F) and 430°C (800°F). Alternative baking temperatures may be used if procedures have been developed and are recommended by the manufacturer.

42. Question: What is the maximum time that an E4918 electrode may remain out of an electrode oven before it requires reconditioning?

Answer: (CI. 5.2.2.4.3) Electrodes should be used within a 4 hour period unless Clause 5.2.2.4.4 applies, otherwise they must be reconditioned in a baking oven.

43. Question: Low-hydrogen electrodes with strength higher than E49XX (E70XX) must be used within what time period?

Answer: (Cl. 5.2.2.4.5) Low-hydrogen electrodes with strength levels higher than the E49 classification must be used within a time period equal to 50% of the maximum permissible exposure time for E49 electrodes as specified in Clauses 5.2.2.4.3 or 5.2.2.4.4 otherwise they must be baked at 370°C (700°F) to 430°C (800°F) for 1 hour.


8

44. Question: How many times can a low-hydrogen electrode be rebaked, and what must be done if the electrode becomes wet?

Answer: (CI. 5.2.2.4.1 & 5.2.2.4.6) Low-hydrogen electrodes shall only be rebaked once. Wet electrodes must be discarded.

45. Question: Are the SAW and GMAW processes designated as low-hydrogen processes?

Answer: (CI. 5.2.3.2; 5.2.3.4; 5.2.4.4) Yes, provided: (a) SAW consumables are stored and conditioned as per the manufacturer's recommendations or as specified in CSA Standard W59. (b) Shielding gas mixtures for the GMAW process do not contain hydrogen.

46. Question: Surfaces and edges to be welded must be clean and free from paint, grease, moisture, etc. for what distance from the weld area?

Answer: (CI.5.3.1) The material must be cleaned within 50 mm (2 in.) Of any weld locations.

47. Question: Can occasional notches be repaired on the edge of material that is to be welded?

Answer: (C1. 5.3.4) Yes, however, a low-hydrogen electrode and an approved welding procedure must be used.

48. Question: The separation between parts to be joined by fillet welds shall not exceed what limits?

Answer: (CI. 5.4.1) The parts to be joined by fillet welds shall be brought into as close a contact as practicable. The separation between parts shall normally not exceed 5 mm (3/16 in.) except in cases involving shapes and plates 75 mm (3 in.) thick or greater when, after straightening and in assembly, the gap cannot be closed sufficiently to meet this tolerance. In such cases, a maximum gap of 8 mm (5/16 in.) is acceptable, provided that a sealing weld or suitable backing material* is used to prevent melt-through. If the separation is 2 mm (1/16 in.) or greater, the leg of the fillet weld shall be increased by the amount of the separation.

*Backing to prevent burn-through may be of flux, glass tape, iron powder, or similar material or it may be provided by means of root passes deposited by low-hydrogen electrodes or electrodes of other arc welding processes that are specified to an appropriate diffusible hydrogen designator.

49. Question: What is the maximum gap between the laying surfaces of a lap joint or between the laying surfaces of a butt joint and steel backing?

Answer: (C.I 5.4.2 & 5.4.9.2) The gap shall not exceed 2 mm (1/16 in.).


9

50. Question: What is the allowable offset between abutting parts to be joined by a groove weld?

Answer: (Cl. 5.4.4) The abutting parts are to be aligned so that the offset does not exceed 10% of the thickness of the thinner part but in no case more than 3 mm (1/8 in.).

51. Question: If a tack weld is to be incorporated into the final weld must it be subject to the same quality requirements as the final weld?

Answer: (CI. 5.4.7.1) Yes. When they are incorporated into the final weld, minor defects may be acceptable provided the quality of the final weld is acceptable.

52. Question: What are the requirements for seal welds?

Answer: (Cl. 5.4.10) The minimum preheat requirements shall apply. Seal welds shall not carry calculated stresses. The minimum fillet size of Table 4-4 does not apply to seal welds. Seal welds shall meet all workmanship requirements of CSA Standard W59.

53. Question: What steel should be used for extension bars, run-off plates and backing?

Answer: (CI. 5.5.1.1) Extension bars, run-off plates, and backings used for the welding of steels up to and including 480 MPa (70 ksi) minimum specified tensile strength and referred to in Clause 11.2.1 or 12.2.1 may be any of the listed steels. Extension bars, run-off plates, and backings used for the welding of steels of over 480 MPa (70 ksi) minimum specified tensile strength and referred to In Clause 11.2.1 or 12.2.1 shall be of the same material as the base material. Spacers shall be of the same material as the base material.

54. Question: What is the purpose of extension bars or run-off plates?

Answer: (CI. 5.5.1.2) These are bars or plates tacked at each end of the groove to serve as a starting and termination point for the arc and to ensure that sound welds with the specified throat are made.

55. Question: What are the requirements for the depth to width ratio of weld passes?

Answer: (Cl. 5.5.1.5) For all processes except ESW and EGW neither the depth nor the maximum width in the cross-section of weld metal deposited in each weld pass shall exceed the width of the face of the weld pass. This is intended to help prevent centerline cracking when the weld cools.


10

56. Question: What are the maximum preheat recommendations for welding quenched and tempered steels?

Answer: (CI. 5.5.1.6) For welding of quenched and tempered steels, the steel manufacturer's recommendations stating the maximum permissible heat input, preheat and interpass temperature necessary to achieve proper welding shall be taken into account.

57. Question: Prequalified joints are specified in CSA Standard W59 for the SAW process in what welding position?

Answer: (CI. 5.5.3.1.6) SAW prequalified joints are for flat position welding only, with the exception of fillet welds.

58. Question: When welding with the single electrode SAW process what are the requirements for the allowable thickness of each weld pass?

Answer: (CI. 5.5.3.2.3) The thickness of weld layers, except root and surface layers shall not exceed 6 mm (1/4 in.).

59. Question: What are the maximum allowable welding currents when making a groove weld with the SAW process using two electrodes in parallel?

Answer: (CI. 5.5.3.3.5) The maximum welding current in making a groove weld shall be as follows: (a) 700 A for parallel electrodes when making the root pass in a groove that has no root opening and does not fill the groove; (b) 900 A for parallel electrodes when making the root pass in a groove that has steel backing or a spacer bar; (c) 1200 A for parallel electrodes for all passes except in the final layer; and (d) no restriction on welding current for the final layer.

60. Question: What actions will help to control distortion and shrinkage stresses due to welding?

Answer: (a) Balance the applied heat of welding,(CI. 5.6.2). (b) Develop a welding sequence plan,(CI. 5.6.3). (c) The progression of welding' must be from points where the parts are relatively fixed in position to points that have a greater relative freedom of movement. (CI. 5.6.4.). (d) Joints in which shrinkage will be most significant must be welded first, (CI. 5.6.5). (e) Complete the welding of each component before connecting the components to one another,(CI. 5.6.6).


11

61. Question: Are preheats higher than required by Table 5-3 sometimes used?

Answer: (CI. 5.7.1) Yes. Preheats above the minimum may be required for highly restrained joints, for certain combinations of steel thickness and weld energy input levels when the steel composition contains certain elements that are at or near the maximum values permitted for the steel grade, for high-strength weld metals, and for welding joints where transfer of tensile stress occurs in the through thickness direction of the material.

62. Question: If a weldment is heated to correct distortion from welding, the maximum localized heat shall not exceed what temperature?

Answer: (Cl. 5.10.5, Cl. 5.15) Maximum localized heat shall not exceed 590°C(1100°F) for other quenched and tempered steels, nor 650°C (1200°F) for other steels.

63. Question: Does CSA Standard W59 allow welds to be peened?

Answer: (CI. 5.11) Peening is permitted only when specified by the contractor's engineer under the supervision of the engineer responsible for welding. Peening is not permitted on the root and surface layers of a weld and on quenched and tempered steels.

64. Question: If an arc strike occurs outside of the weld area what action should be taken?

Answer: (CI. 5.14) Arc strikes should be avoided on any material. If they appear on cyclically loaded structures, they should be ground smooth and the surface checked for soundness by the magnetic particle inspection method.

65. Question: What is the required preheat temperature for welding a 25 mm (1 in.) thick G40.21 grade 350W steel with a low-hydrogen SMAW electrode?

Answer: (Table 5-3) 10°C (50°F)

66. Question: When preheating, how far in advance of the welding arc must the base material be at or above the specified preheat temperature?

Answer: (Table 5-3 Note 2) The welding joint must be preheated laterally and in advance of the welding arc for a distance equal to the thickness of the part being welded, but not less than 75 mm (3 in.).

67. Question: What is the workmanship tolerance on the root face of a groove weld if the root is not to be gouged?

Answer: (Table 5-7) ± 2 mm (±1/16 in.)


12

Clause 7

68. Question: What information should be made available to the welding inspector?

Answer: (CI. 7.1.3) Complete detail drawings showing size, length, type and location of all welds.

Clause 8

69. Question: The procedures in CSA Standard W59 for radiography apply to what types of joints?

Answer: (CI. 8.1.1.1) The procedures apply solely for examination of groove welds in butt joints. Radiographic methods are not recommended for fillet welds.

70. Question: What is the recommended minimum steel thickness for performing radiography using radioactive isotopes?

Answer: (CI. 8.1.3.9) lr192 - the recommended minimum is 12 mm (1/2 in.), Co60 - the recommended minimum is 38 mm (1-1/2in.).

Clause 9

71. Question: What should be done when welding in the field on structures that have been painted?

Answer: (CI. 9.4.1) Surfaces to be welded shall be cleaned thoroughly, including removal of paint film.

Clause 10

72. Question: CSA Standard W59 specifies requirements for prequalified joints for which welding processes?

Answer: (CI. 10.1.3.1) Prequalified joints in CSA Standard W59 cover 5 welding processes - SMAW, SAW, FCAW, MCAW, and GMAW-SP.

73. Question: For the SMAW process, are there additional requirements placed on the welding of designated prequalified joints?

Answer: (Table 10-1) Table 10-1 defines the maximum size of electrode, the maximum thickness of weld layers and the maximum one-pass fillet size.


13

Clause 11

74. Question: Clauses 1 through 10 inclusive relate to structures, which are either statically or cyclically loaded. What do Clauses 11 and 12 cover?

Answer: Clause 11 contains special clauses, which are applicable to statically loaded structures but not applicable to cyclically loaded structures. Similarly, Clause 12 apply to cyclically loaded structures but not to statically loaded structures.

75. Question: Are high strength bolts, used in bearing, and welds in the same connection permitted to share the load in statically loaded structures?

Answer:(Cl. 11.4.3.1) No. The load cannot be distributed between bolts and welds. Welds shall be provided to carry the entire load in the connection.

76. Question: What is the visual examination acceptance criteria for welds in a statically loaded structure?

Answer: (CI11.5.4.1) A weld subject to visual inspection shall be acceptable if visual inspection shows

(a) no surface cracks; (b) no visible lack of fusion between welds and base metal; (c) no craters; (d) weld profiles in accordance with Clause 5.9; (e) that the sum of diameters of visible porosity does not exceed 10 mm (3/8 in.) in any linear 25 mm (1 in.) length of weld and does not exceed 20 mm (3/4 in.) in any 300 mm (12 in.) length of weld. Any individual pore shall have a dimension not exceeding 2.5 mm (3/32 in.); (f) that, irrespective of length, undercut does not exceed the value shown in Figure 11.4 for the primary stress direction category applicable to the area containing the undercut. further, the undercut may be twice the value permitted by Figure 11.4 (for the applicable load category) for an accumulated length of 50 mm (2 in.) in a 300 mm (12 in.) length of weld, but in no case may the undercut be greater than 1.6 mm (1 /16 in.). For weld lengths of less than 300 mm (12 in.), the permitted accumulated length of undercut shall be proportional to the actual length of weld.

77. Question: When specified, what size should the reinforcing fillet weld be for T and corner joints?

Answer: (CI. 11.4.12) The minimum fillet size shall be not less than t/4 where t is the thickness of the groove welded member, but it need not be more than 10 mm (3/8 in.).


14

78. Question: Two steel plates each consisting of GSA G40.21 Grade 300W are to be joined using the SMAW process. What would be the matching electrode classification to weld this grade of steel?

Answer: Table 11-1 or Table 12-1(E49XX).


15

MULTIPLE CHOICE AND TRUE OR FALSE EXERCISES

Clause 1 1. CSA Standard W59 can be applied to: (CI. 1.2) (a) Pressure Vessels. (b) Structures governed by Lloyds. (c) Structures governed by American Society of Mechanical Engineers (ASME). (d) Structures governed by American Petroleum Institute (API). (e) None of the above Answers are correct. 2. CSA Standard W59 contains provisions for which of the following welding processes? (CI. 1.3) (a) SMAW, GMAW,SAW,SW. (b) FCAW, EGW, ESW,MCAW. (c) GTAW, RW, GMAW. (d) (a) and (b). 3. The provisions of CSA Standard W59 are not intended for use with steels having a specified minimum yield strength of over 700 MPa (100,000 psi).(CI. 1.4) (a) True (b) False. Clause 2 4. What is a low-hydrogen electrode? (CI. 2.1) (a) An electrode depositing weld metal having a specified maximum limit to the diffusible hydrogen content. (b) Any electrode that is being used. (c) E41010 (E6010) electrodes. (d) An electrode used for basic flat only type of welding. 5. “Contractor" refers to: (CI. 2.1) (a) The steel supplier. (b) The general contractor responsible for the whole job. (c) The fabricator or erector who performs the welding. (d) The Canadian Welding Bureau.


16

Clause 3 6. CSA Standard W59 contains requirements for stud welding. (CI. 3.1.2.2) (a) True (b) False 7. Clause 10 has details of joint geometry for joints, which are prequalified, providing that welding procedures also conform to Clauses 4, 5 and 10 of CSA Standard W59. (CI. 3.1.3.1) (a) True (b) False 8. Prequalified joints are included in CSA Standard W59 for which of the following welding processes? (CI. 3.1.3.1) (a) FCAW, SMAW, GMAW (spray transfer mode), MCAW (spray transfer mode), SAW. (b) SMAW. SAW, FCAW. (c) GTAW, GMAW (spray transfer mode), SW. (d) ESW, EGW, SAW. 9. Steel base metals must conform to the requirements of CSA or ASTM standards or other recognized specifications of equivalent welding quality approved by the engineer. (CI. 3.2) (a) True (b) False Clause 4 10. What information must be included on design drawings? (CI. 4.1.1.1.1) (a) All information necessary for preparation of erection drawings. (b) All information necessary for preparation of detail drawings. (c) Length and type of groove weld requirements. (d) (a) and (b). 11. What information must be shown on erection and detail drawings? (CI. 4.1.1.2.1, 4.1.1.2.2, 4.1.1.2.3). (a) Location, type, size, and length of all welds. (b) Shop and field welds. (c) Groove depth and geometry If the weld is a partial joint penetration groove weld. (d) Any special fabrication procedures required such as the welding sequence. (e) All of the above.


17

12. What weld types does CSA Standard W59 cover? (Cl. 4.1.3.1.1) (a) Groove and fillet welds. (b) Plug and slot welds. (c) Corner and T welds. (d) (a) and (b). 13. What is a complete joint penetration groove weld? (CI. 4.1.3.1.2) (a) A type of fillet weld. (b) A weld having fusion of weld and base metal throughout the thickness of the joint. (c) A weld having joint penetration less than complete. (d) A weld having complete side-wall fusion of weld and base metal only. 14. A partial joint penetration groove weld is defined as one having joint penetration that is less than complete. (CI. 4.1.3.1.3) (a) True (b) False 15. Single fillet and single partial joint penetration groove welds shall not be subjected to bending about the longitudinal axis of the weld if tension is produced at the root of the weld. (CI. 4.1.3.3.2) (a) True (b) False 16. What is the effective weld length for any groove weld, perpendicular or skewed to the direction of stress? (CL 4.3.1.2) (a) The skewed length of the weld . (b) The width of the part joined. (c) The length of the part joined. (d) None of the answers are correct. 17. All flare bevel groove welds in butt joints made from one side are classified as partial joint penetration grooves. (CI. 4.3.1.6.1.2). (a) True (b) False


18

18. What is the effective throat thickness for flare-bevel-groove welds on a solid bar when filled flush to the surface of the bar? (CI. 4.3.1.6.2.5, Table 4.1) (a) Two-tenths of the radius of the bar. (b) One-quarter of the radius of the bar. (c) Three-tenths of the radius of the bar. (d) One-half of the radius of the bar. 19. What is the effective length of a fillet weld? (Cl.. 4.3.2.2) (a) The overall length of the full-size fillet, not including end returns. (b) The overall length of the full-size fillet, including end returns. (c) Two inches minimum. (d) Five times the size of the fillet minimum. 20. What is the minimum fillet size required when joining a 12 mm (1/2in.) plate to a 20 mm (3/4 in.) plate? (Table 4-4) (a) 5 mm (3/16 in.). (b) 6 mm (1/4 in.). (c) 8 mm (5/16 in.). (d) 10 mm (3/8 in.). 21. What is the minimum effective length of a fillet weld? (CI. 4.3.4.2.2) (a) 38 mm (1-1/2 in.) or 4 times the size of the fillet, whichever is larger. (b) 50 mm (2 in.) or 4 times the size of the fillet, whichever is larger. (c) 60 mm (2-1/2 in.) or 5 times the size of the fillet, whichever is larger. (d) 75 mm (3 in.) or 5 times the size of the fillet, whichever is larger. 22. What is the maximum fillet weld size that shall be detailed along the edges of material? (CI. 4.4.1.2) (a) The thickness of the material, for material less than 6 mm (1/4 in.) thick. (b) The thickness of the material less 2 mm (1/16 in.), for material 6 mm (1/4 in.) or more in thickness, that has not been detailed to be built to obtain the full throat thickness. (c) The maximum fillet weld size shall always be the full thickness of the material. (d) (a) and (b).


19

Clause 5 23. The operator and the work shall be adequately protected against the direct effect of the wind, rain, and snow. and all necessary means shall be provided to enable the operator to work in reasonable comfort. (CI. 5.1.1) (a) True (b) False 24. Below what ambient temperature shall welding not be done without the express consent of the engineer? (CI. 5.1.2) (a) Temperature is not a concern. (b) -32°C (-26°F). (c) -18°C (0°F). (d) 0°C (32°F). 25. The size, length and location of welds shall be: (CI. 5.1.3) (a) Modified as necessary to conform to actual job site conditions. (b) Increased slightly to ensure that there is enough weld metal to achieve the required factor of safety.• (c) Changed to make the job easier for the steel erector. (d) Not less than those specified by design requirements and detail drawings, nor shall they be substantially In excess of those requirements without approval of the Engineer. 26.Back-gouging shall conform to the geometry of a prequalified single U-joint. (CI. 5.1.4) (a) True (b) False 27. Electrodes must: (CI. 5.2) (a) Meet AWS specifications. (b) Be packaged in hermetically sealed packages. (c) Conform to CSA W48 or the applicable AWS AS Standard. (d) Meet certain length and weight requirements. 28. All low-hydrogen electrodes shall be delivered in sealed containers? (CI. 5.2.2.4.1) (a) True (b) False


20

29. A container of low-alloy steel electrode has been delivered in a damaged condition. What shall be done with the electrodes? (CI. 5.2.2.4.1) (a) The electrodes shall be used immediately. (b) The electrodes shall be stored in an oven and held at a temperature of at least 120°C (250°F) for four hours prior to use. (c) The electrodes shall be baked for at least one hour at a temperature between 370°C and 430°C (700°F and 800°F) before being used. (d) The electrodes must be discarded and new ones ordered. 30. A batch of low-hydrogen electrodes has become wet. At what temperature must the electrodes be baked to remove the moisture? (CI. 5.2.2.4.1) (a) Wet low-hydrogen electrodes cannot be rebaked. They must be discarded. (b) 120°C (250°F). (c) 150°C (300°F). (d) 370°C (700°F). 31. At what minimum temperature shall low-hydrogen electrodes be stored immediately after being removed from sealed containers or from drying ovens? (CI. 5.2.2.4.2) (a) 65°C (150°F). (b) 95°C (200°F). (c) 120°C (250°F). (d) 150°C (300°F). 32. How many times can low-hydrogen electrodes be rebaked? (Cl. 5.2.2.4.6) (a) Low-hydrogen electrodes cannot be rebaked. (b) Once. (c) Twice. (d) Three times. 33. The separation between parts to be joined by fillet welds shall normally not exceed: (CI. 5.4.1) (a) 2 mm (1/16 in.). (b) 3 mm (1/8 in.). (c) 5 mm (3/16 in.). (d) 8 mm (5/16 in.).


21

34. What is maximum gap permitted between faying surfaces of lap joints? (CI. 5.4.2) (a) 2 mm (1/16 in.). (b) 3 mm (1/8 in.). (c) 5 mm (3/16 in.). (d) 6 mm (1/4 in.). 35. What is the workmanship tolerance on a groove angle of a joint? (CI. 5.4.5.1, Table 5-7) (a) +5,-10. (b) +10, -5. (c) +5, -5. (d) +10, -10. 36 Tack welds that are incorporated into the final weld shall be made with electrodes meeting the requirements of the final welds and shall be cleaned thoroughly. (CI. 5.4.7.2) (a) True (b) False 37. Seal welds shall be included in any strength calculations. (CI. 5.4.10) (a) True (b) False 38. A welding procedure and sequence shall be such as to minimize distortion and shrinkage when welding reinforcing parts to members. (CI. 5.6.1) (a) True (b) False 39. The direction of general progression in welding on a member shall be from points that are relatively fixed to points that have a greater relative freedom of movement. (CI. 5.6.4) (a) True (b) False 40. Under what conditions may preheat temperatures that are above the minimum shown in Table 5-3 be required? (CI. 5.7.1) (a) For highly restrained welds. (b) For high-strength weld metal. (c) For joints where transfer of tensile stress occurs in the through-thickness direction of the material. (d) All of the above.


22

41. Preheat temperatures lower than shown in Table 5-3 may be used. (CI. 5.7.2.1, 5.7.2.2, 5.7.2.3) (a) True (b) False 42. What is the minimum preheat temperature requirement for welding a 40 mm (1-1/2 in.) thick 300W (44W) steel with a low-hydrogen electrode? (Table 5-3) (a) 10°C (50°F). (b) 50°C (125°F). (c) 80°C (175°F). (d) 110°C (225°F). 43. What is the maximum allowable groove weld reinforcement in a butt joint? (CI. 5.9.3) (a) 2 mm (1/16 in.). (b) 3 mm (1/8 in.). (c) 5 mm (3/16 in.). (d) 6 mm (1/4 in.). 44. What corrective action must be taken for excessive convexity? (CI. 5.1 0.1) (a) Reduce by removal of excess weld metal. (b) Remove defective portions and re-weld. (c) Clean and deposit additional weld. (d) All of the above. 45. Under what conditions may peening be used on a weld? (CI. 5.11) (a) On quenched and tempered steel. (b) On the root and surface layers of the weld. (c) Only under the supervision of the engineer responsible for welding. (d) To repair any defects such as cracks. 46. Slag shall be removed from all finished welds and before welding over previously deposited metal. (CI. 5.13) (a) True (b) False


23

47. Arc strikes outside of the area of permanent welds should be avoided on any materials. (CI. 5.14) (a) True (b) False Clause 7 48. The welding inspection organization shall be notified, in advance, of the start of any welding operations. (CI. 7.1 .4) (a) True (b) False 49. Who is responsible for meeting all of the quality control requirements of this Standard? (CI. 7.3.1) (a) The welding supervisor. (b) The engineer responsible for welding. (c) The Contractor. (d) The welder. Clause 8 50. What type of weld is suitable for inspection by radiographic methods? (Cl. 8.1.1.1) (a) Fillet welds in lap joints. (b) Groove welds in butt joints. (c) Groove welds in T joints. (d) Fillet welds in corner joints. 51. What is the minimum recommended material thickness for which the radioactive isotope lr192 may be used for radiographing a steel weld? (CI. 8.1.3.9) (a) 3 mm (1/8 in.). (b) 6 mm (1/4 in.). (c) 12 mm (1/2 in.). (d) 25 mm (1 in.).


24

Clause 9 52. What is to be done before welding on existing structures? (CI. 9.4.1) (a) Increase the amperage to burn through the paint and other foreign matter. (b) Clean thoroughly all foreign matter, including paint film in the area immediately adjacent to the weld. (c) Wash the old material with soap and water. (d) Use a larger diameter electrode. Clause 10 53. Clause 10 contains provisions for prequalified joint for which of the following welding processes? (Cl. 10.1.1, Cl. 10.1.3.1) (a) SMAW,GMAW, SAW,MCAW. (b) FCAW,GTAW, RW,MCAW. (c) FCAW,SAW,GMAW. (d) SMAW, SAW, FCAW, GMAW (spray transfer mode), MCAW (spray transfer mode). 54. What is the maximum size SMAW electrode that is permitted under any conditions for welding prequalified joints? (Table 10-1) (a) 4 mm (5/32 in.). (b) 5 mm (3/16 in.). (c) 6 mm (1/4 in.). (d) 8 mm (5/16 in.). Clause 11 55. Clause 11 supplements Clauses 1 through 10 and covers the:(CI. 11.1.1) (a) Design and construction of statically loaded steel structures. (b) Design and construction of cyclically loaded steel structures. (c) Design and construction of cyclically and statically loaded steel structures. (d) None of the answers are correct. 56. Side or end fillet welds terminating at ends or sides, respectively, of parts or members shall, wherever practicable, be returned continuously around the corners for a distance at least twice the nominal size of the weld. (Cl. 11 .4.6.1) (a) True (b) False


25

57. Under Clause 11 extensions or run-off bars used at termination of groove welds need not be removed unless required by the Engineer. (CI. 11.5.1) (a) True (b) False 58. Under Clause 11steel backing in groove welds need not be removed unless required by the Engineer. (CI. 11.5.2) (a) True (b) False 59. The visual inspection of completed welds is optional. (CI. 11.5.4) (a) True (b) False 60. Craters are not considered a weld defect in statically loaded steel structures. (CI. 11.5.4.1) (a) True (b) False Clause 12 61. Clause 12 supplements Clauses 1 through 10 and covers the: (CI. 12.1.1). (a) Design and construction of statically loaded structures. (b) Design and construction of cyclically loaded structures. (c) Design and construction of cyclically and statically loaded structures. (d) None of the above answers are correct. 62. Under Clause 12 extensions or run-off bars used in groove welds shall be removed upon completion of welding. (CI. 12.5.1) (a) True (b) False 63. Under Clause 12, steel backing of welds that are transverse to the direction of applied load shall be removed and the joint shall be ground or finished smooth. (CI. 12.5.2.3) (a) True (b) False


26

64. Visible porosity in groove welds is not a consideration in cyclically loaded structures. (CI. 12.5.4.1) (a) True (b) False


27

The Canadian Welding Bureau (the Bureau), federally incorporated, "not-for-profit" organization is accredited by the Standards Council of Canada as a Certification on Body for the administration of GSA Standards W47.1, W47.2, W186,W178.1 and the W48 Series of Standards. Le Bureau canadien de soudage (le Bureau),une organisation féctéralement incorporée à but non lucratif est accréditée par le conseil Canadien des normes comme une organisation de certification pour l'administration des normes CSA W47.1, W47.2, W186, W178.1 et des normes CSA de Ia series W48.

CANADIAN WELDING BUREAU / BUREAU CANADIEN DE SOUDAGE

A Division of the CWB Group - Industry Services / Division du Groupe CWB - Services À L'lndustrie

HEAD OFFICE / SIEGE SOCIAL

7250 West Credit Ave., Mississauga, Ontario L5N 5N1 Telephone:(905) 542-1312 / 1-800-844-6790 (In Canada only)

Fax: (905) 542-1318 WEB: www.cwbweb.com

REGIONAL OFFICES ACROSS CANADA / BUREAUX REGIONAUX AU CANADA B.C.: 505-8840 210'" Street, Suite 411,Langley, B.C. VIM 2Y2 Tel: (604) 455-0335 / Toll Free: '1-800-503-0792 (within BC / Alberta / Midwest) Fax:(604) 455-0301 / E-Mail:[email protected] Alberta / Manitoba / Suite 206,9622 – 42nd Avenue, Edmonton, Alberta T6E 5Y4 Saskatchewan: Tel: (780) 465-7788 / Toll Free: 1-800-503-0793 (within Alberta / BC / Midwest) Fax: (780) 469-1856 / E Mail: [email protected] Ontario: 2000 Argentia Road, Plaza 1,Suite 300,Mississauga,Ontario L5N 1P7 Tel: (905) 826-5133 / Toll Free: 1-800-844-9246 (In Canada Only) Fax: (905) 826-9733 / E-Mail:[email protected] Quebec: 950 Michelin, Laval, Quebec H7L 5C1 Tel: (450) 663-8668 / Toll Free: 1-877-663-8668 (For Area Codes: 418 / 514 / 450 / 819 / 613) Fax:(450) 663-5565 / E-Mail: [email protected] Atlantic: 73 Tacoma Drive,6thFloor,Dartmouth,Nova Scotia B2W 3Y6 Tel: (902) 435-1114 / Toll Free: 1-800-503-0796 (For Area Codes: 902 / 709 / 506) Fax:(902) 434-2255 / E-Mail:[email protected]

w59 03study guide

Documents