DESIGN AND CONSTRUCTION OF LUSAKA CITY

DECONGESTION PROJECT ON ENGINEERING

PROCUREMENT AND CONSTRUCTION BASIS,
ZAMBIA
PROJECT :ZAMBIA STEEL PLATE GIRDER (20.0 M SPAN)-MAKENI FLYOVER

Welding Procedure Specification

WPS No.: AFCONS/GIL/WPS/ GMAW / FILLET/ 2F/16mm. /09 Date : 12/ 04/2019
CONTRACT AGREEMENT: 9925/PUR/GAP/AZ/MFO/01 Dated :28/02/2019
CODE AND SPECIFICATION: IRS –B1, IS 9595, IS 2062-2011,IS 822,WELDED BRIDGE CODE(WBC), IS 7307,IS 4353.
DRAWING NO: AF-LUS-7502-CDSC-JNCB-PG-001
APPLICABLE FOR: FABRICATION/ ERECTION WORK OF PERMANENT STRUCTURE.-MAIN GIRDER INTERMEDIATE STIFFENER

1. Weld Joint description: Fillet.

2.Base Metal: E-350 Grade-BR(IS 2062-2011).
3.Welding Process: GMAW.
4.Welding Position: 2F.
5.Thickness: 25mm # 16mm.
6.Welding Consumables :
6.1 Wire –
GMAW
i) Class: (AWS/SFA 5.18 ER 70S-6)
ii) Diameter: 1.2mm.
iii) Drying Method: N/A
iv) Trade name/Make: ADOR, ESAB, Lincoln and also
other RDSO approved brands.
6.2 Flux -
i) Class: N/A
ii) Type: N/A.
iii) Drying Method: N/A
7.Shielding Gas: AR (20%)+CO2(80%)
8.Base Material Preparation: By flame cutting /Beveling machine & Grinding.
9.Joint design details:

Joint Design Welding Sequence

RG=0,RF=0
10.Welding Current :
i) Type: DC ii) Polarity: DCEP.
11.Welder Qualification: As per IS:7310,IS:7307
 12.Range of Thickness: 12 mm to 24 mm.

13.Welding Parameter and Technique-

Weld Electrode/ wire Current Arc Voltage Wire Feed Travel speed Gas flow rate
Pass. No. Dia.(mm) (Amp) (Volts) Speed (mm/min) (litre/min.)
(mm/min)

Pass 1
1.2 mm 260-290 27-31 180-200 5.5+/-0.5 % 12-19
(GMAW)

Pass 2
1.2mm 260-290 27-31 180-200 5.5+/-0.5 % 12-19
(GMAW)

Pass 2
1.2mm 260-290 27-31 180-200 5.5+/-0.5 % 12-19
(GMAW)

Permissible limits of variation for parameters as per IRS welded Bridge code para 19.3 Current=±10%, voltage =±7%, travel, speed=±15%.

14.Technique: Single run/ Multi layer.

15.Provision of run in and run off tabs:
16.Cleaning of weld bead before laying
next weld bead:
17.Root Preparation Before Welding
other side of groove weld:
Yes.
Chipping/Brushing/Grinding Joint to be cleaned and make dust free.
Chipping/Brushing/Grinding & DPT, Joint to be cleaned and
make dust free.

18.Preheating: 150°C Min.

19.Inter Pass Temperature: 250°C Max.
20.Peening: N/A.
21.Post Weld Treatment: N/A.
22.Rectification of Weld defects: Yes.
23.Inspection of Weld: As Per relevant codes.
24.Any Other Relevant Details: N/A.

PREP.BY CHECKED BY
CLIENT
GOODLUCK INDIA AFCONS
MINISTRY OF LOCAL GOVT.ZAMBIA
LTD.
 DESIGN AND CONSTRUCTION OF
LUSAKA CITY DECONGESTION
PROJECT ON ENGINEERING
PROCUREMENT AND CONSTRUCTION
PROJECT :ZAMBIA BASIS, ZAMBIA
STEEL PLATE GIRDER (20.0 &45.0 M SPAN)
-MAKENI FLYOVER

Proposed Welding Procedure Specification

WPS No.: AFCONS/GIL/WPS/ GMAW / FILLET/ 2F/36mm. /10 Date : 12/ 04/2019
CONTRACT AGREEMENT: 9925/PUR/GAP/AZ/MFO/01 Dated :28/02/2019
CODE AND SPECIFICATION: BSEN287-1,BSEN 1090-2,BSEN ISO 15609-2004,ISO15614-1,BSEN ISO9692-1,2
DRAWING NO: AF-LUS-7502-CDSC-JNCB-PG-001
APPLICABLE FOR: FABRICATION/ ERECTION WORK OF PERMANENT STRUCTURE.-MAIN GIRDER INTERMEDIATE STIFFENER
1. Weld Joint description: Fillet.
2.Base Metal: E-350 Grade-BR(IS 2062-2011).
3.Welding Process: GMAW.
4.Welding Position: 2F/PB
5.Thickness: 36mm # 36mm.
6.Welding Consumables :
6.1 Wire –
GMAW
i) Class: (AWS/SFA 5.18 ER 70S-6)
ii) Diameter: 1.2mm.
iii) Drying Method: N/A
iv) Trade name/Make: GEE,ADOR, ESAB, Lincoln and
Client approved brands.
6.2 Flux -
i) Class: N/A
ii) Type: N/A.
iii) Drying Method: N/A
7.Shielding Gas: AR (20%)+CO2(80%)
8.Base Material Preparation: By flame cutting /Beveling machine & Grinding.
9.Joint design details:

Joint Design Welding Sequence

RG=0,RF=0
10.Welding Current :
i) Type: DC ii) Polarity: DCEP.
11.Welder Qualification: As per BSEN287-1
12.Range of Thickness: 5 mm to Unlimited
 13. Welding Parameter

Weld Electrode/ wire Current Arc Voltage Wire Feed Travel speed Gas flow rate
Pass. No. Dia.(mm) (Amp) (Volts) Speed (mm/min) (litre/min.)
(mm/min)

Pass 1
1.2 mm 150-220 22-24 2150 120 12-19
(GMAW)

Pass 2
1.2mm 150-220 22-24 2150 124 12-19
(GMAW)

Pass 2 22-24
1.2mm 150-220 2160 124 12-19
(GMAW)

14.Technique: Single run/ Multi layer.

15.Provision of run in and run off tabs:
16.Cleaning of weld bead before laying
next weld bead:
17.Root Preparation Before Welding
other side of groove weld:
Yes.
Chipping/Brushing/Grinding Joint to be cleaned and make dust free.
Chipping/Brushing/Grinding & DPT, Joint to be cleaned and
make dust free.

18.Preheating: 150°C Min.

19.Inter Pass Temperature: 250°C Max.
20.Peening: N/A.
21.Post Weld Treatment: N/A.
22.Rectification of Weld defects: Yes.
23.Inspection of Weld: As Per relevant codes.
24.Any Other Relevant Details: N/A.

PREP.BY CHECKED BY
CLIENT
GOODLUCK INDIA AFCONS
MINISTRY OF LOCAL GOVT.ZAMBIA
LTD.
 DESIGN AND CONSTRUCTION OF
LUSAKA CITY DECONGESTION
PROJECT ON ENGINEERING
PROCUREMENT AND CONSTRUCTION
PROJECT :ZAMBIA BASIS, ZAMBIA
STEEL PLATE GIRDER (20.0 &45.0 M SPAN)
-MAKENI FLYOVER

Proposed Welding Procedure Specification

WPS No.: AFCONS/GIL/WPS/ GMAW / FILLET/ 2F/36mm. /11 Date : 12/ 04/2019
CONTRACT AGREEMENT: 9925/PUR/GAP/AZ/MFO/01 Dated :28/02/2019
CODE AND SPECIFICATION: BSEN287-1,BSEN 1090-2,BSEN ISO 15609-2004,ISO15614-1,BSEN ISO9692-1,2
DRAWING NO: AF-LUS-7502-CDSC-JNCB-PG-001
APPLICABLE FOR: FABRICATION/ ERECTION WORK OF PERMANENT STRUCTURE.-MAIN GIRDER INTERMEDIATE STIFFENER

1.Weld Joint description: Fillet.

2.Base Metal: E-350 Grade-BR(IS 2062-2011).
3.Welding Process: SAW.
4.Welding Position: 1F/PA
5.Thickness: 36mm # 36mm.
6.Welding Consumables :
6.1-Wire –
SAW
i) Class: (AWS/SFA 5.23 EM12K)
ii) Diameter: 3.15mm & 4.0 mm
iii) Drying Method: N/A
iv) Trade name/Make: GEE, ADOR, ESAB, Lincoln and
Client approved brands.
6.2 Flux -
i) Class: AWS SFA 5.28 F7A4
ii) Type: N/A.
iii) Drying Method: As per Manufacture Recommendation.
6.1 Shielding Gas: N/A
7 Base Material Preparation: By flame cutting /Beveling machine & Grinding.
8 Joint design details:

Joint Design Welding Sequence

 9 Welding Current :
i) Type: DC ii) Polarity: DCEP.
10 Welder Qualification: As per BSEN287-1
11 Range of Thickness Qualified: 5 mm to Unlimited

12 Welding Parameter and Technique-

Weld Electrode/ wire Current Arc Voltage Wire Feed Travel speed Gas flow rate
Pass. No. Dia.(mm) (Amp) (Volts) Speed (mm/min) (litre/min.)
(mm/min)

Pass 1
3.15 mm 450-550 27-30 1500 500 N/A
(Saw)

Pass 2
4.0mm 450-550 27-30 1510 470 N/A
(Saw)

13 Technique: Single run/ Multi layer.

14 Provision of run in and run off tabs: Yes.
15 Cleaning of weld bead before laying
16 next weld bead: Chipping/Brushing/Grinding Joint to be cleaned and make dust free.
17 Root Preparation Before Welding
other side of groove weld: Chipping/Brushing/Grinding & DPT, Joint to be cleaned and
make dust free.
18 Preheating: 150°C Min.
19 Inter Pass Temperature: 250°C Max.
20 Peening: N/A.
21 Post Weld Treatment: N/A.
22 Rectification of Weld defects: Yes.
23 Inspection of Weld: As Per relevant codes.
24 Any Other Relevant Details: N/A

PREP.BY CHECKED BY
CLIENT
GOODLUCK INDIA AFCONS
MINISTRY OF LOCAL GOVT.ZAMBIA
LTD.