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GUIDE FOR:
SHIPBUILDING AND REPAIR QUALITY STANDARD FOR HULL STRUCTURES DURING CONSTRUCTION
July 199 8
ABSIncorporated by Act of Legislature of the State of New York 1862
Copyright 1998ABS
American Bureau of ShippingTwo World Trade Center, 106 th FloorNew York, NY 10048 U.S.A
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Foreword
This guide contains information obtained from IACS Recommendation No. 47 ."Shipbuilding and Repair Quality Standards". In order to be consistent with ABSrequirements, some specific standards have been modified from the original. Themodified standards are indicated in the "Remarks" column of the tables, along with therule reference.
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ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction 1
1.0 Applicability
This guide provides guidance on shipbuilding quality standards for the hull structure duringconstruction.
Whereas the standard generally applies to: conventional ship types hull structures constructed from normal and higher strength hull structural steel, the
applicability of the standard is in each case to be agreed upon by the Bureau
The standard generally does not apply to the new construction of special types of ships as e.g. gas tankers structures fabricated from stainless steel or other, special types or grades of steel
Details relevant to structures or fabrication procedures not covered by this standard are to be
approved on a case by case basis of procedure qualifications and/or recognized nationalstandards.
2.0 Scope
The standard covers typical construction methods and gives guidance on quality standards for the most important aspects of such construction. Unless explicitly stated elsewhere in thestandard, the level of workmanship reflected herein will in principle be acceptable for primaryand secondary structure of conventional designs. A more stringent standard may however berequired for critical and highly stressed areas of the hull, and this is to be agreed with theBureau in each case.
It is intended that these standards provide guidance where established shipbuilding or nationalstandards accepted by the Bureau do not exist.
For use of this standard, fabrication fit-ups, deflections and similar quality attributes areintended to be uniformly distributed about the nominal values. The shipyard is to takecorrective action to improve work processes that produce measurements where a skeweddistribution is evident. Relying upon remedial steps that truncate a skewed distribution of thequality attribute is unacceptable.
3.0 General Requirements
In general, the work is to be carried out in accordance with the Rules and under the survey of the classification representative.
Provisions are to be made for proper accessibility, staging, lighting, and ventilation. Weldingoperations are to be carried out under shelter from rain, snow, and wind.
Welding of hull structures is to be carried out by qualified welders, according to approved andqualified welding procedures and with welding consumables approved by the Bureau.Welding operations are to be carried out under proper supervision by the shipbuilder.
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4.0 Qualification of Personnel and Procedures
4.1 Qualification of WeldersWelders are to be qualified in accordance with 2/3 C .11of the ABS Rule Requirements for Materials and Welding. Subcontractors are to keep records of welders qualification and, whenrequired, furnish valid approval test certificates.
Welding operators using fully mechanized or fully automatic processes generally need not pass approval testing provided that the production welds made by the operators are of therequired quality. However, operators are to receive adequate training in setting or
programming and operating the equipment. Records of training and production test resultsshall be maintained on individual operators files and records, and be made available to theBureau for inspection when requested.
4.2 Qualification of Welding Procedures
Welding procedures are to be qualified in accordance with 2/3A.1.4 of the ABS RuleRequirements for Materials and Welding. The welding procedure should be supported by awelding procedure qualification record. The specification is to include the welding process,types of electrodes, weld shape, edge preparation, welding techniques and positions.
4.3 Qualifications of NDE OperatorsPersonnel performing non-destructive examination for the purpose of assessing quality of welds in connection with new construction covered by this guide are to be qualified inaccordance with the applicable Bureaus requirements or to a recognized national or international qualification scheme. Records of operators and their current certificates are to bekept and made available to the Surveyor for inspection.
5.0 Materials
5.1 Materials for Structural MembersAll Materials, including weld consumables, to be used for the structural members are to be inaccordance with Bureau approved construction plans and with the ABS Rule Requirement for Materials and Welding.
5.2 Details, Standards and Tolerance LimitsDetails, standards and tolerance limits may be found in the following Tables
Detail Table #
Fabrication And Fairness Flanged Longitudinals And Flanged Brackets Built-Up Sections Corrugated Bulkheads Pillars, Brackets And Stiffeners Maximum Heating Temperature On Surface
For Line Heating
Block Assembly
5.1 5.2 5.3 5.4 5.5
5.6
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Detail (Contd) Table # (contd) Special Sub-Assembly Shape Fairness Of Plating Between Frames Fairness Of Plating With Frames
5.7 5.8 & 5.9 5.10 5.11
Alignment Quality Standards Of Hull Structural
Components During New Construction
5.12, 5.13 and 5.14
TheBureau may require acloser construction tolerancein areas requiring specialattention, as follows:
-Regions exposed to highstress concentrations -fatigue prone area -detail design block erection joints -higher tensile steel regions
Welding Details Typical Butt Plate Edge Preparation (Manual
Welding) Typical Fillet Weld Plate Edge Preparation
(Manual Welding)
Typical Butt And Fillet Weld Profile (ManualWelding) Lap, Plug And Slot Welding Distance Between Welds Automatic Welding
5.15 and 5.16
5.17 and 5.18
5.19 5.20 5.21 5.22
Repair Typical Misalignment Repair Typical Butt Weld Plate Edge Preparation
Repair (Manual Welding) Typical Fillet Weld Edge Preparation Repair
(Manual Welding) Typical Fillet And Butt Weld Profile Repair
(Manual Welding) Distance Between Welds Repair Erroneous Hole Repair Repair By Insert Plate Weld Surface Repair
5.23 to 5.25 5.26 and 5.27 5.28 to 5.30 5.31
5.32 5.33 5.34 5.35
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Table 5.1
Flanged Longitudinals And Flanged Brackets
Detail Standard Limit Remarks
Breadth Of Flange
Compared To Correct Size
3 mm 5 mm
Angle between flange and Web
compared to template
3 mm 5 mm per 100 mm of a
Straightness in plane of flange andweb
10 mm 25 mm per 10 m
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Table 5.2
Built-Up Sections
Detail Standard Limit Remarks
Frames and longitudinal 1.5 mm 3 mm per 100 mm of a
Distortion of face plate d 3 + a/100 mm d 5 + a/100 mm
Distortion of girder and transverseat upper edge and flange
5 mm 8 mm per span between primary members
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Table 5.3
Corrugated Bulkheads
Detail Standard Limit Remarks
Mechanical bendingR 3t mm Material to be suitable
for cold flanging(forming) and weldingin way of radius
Depth of corrugation 3 mm 6 mm
Breadth of corrugation web 3 mm 6 mm
Breadth of corrugation 3 mm 6 mm
Pitch and depth of swedgedcorrugated bulkhead comparedwith correct value
h: 2.5 mm
Where it is not alignedwith other bulkheads
P: 6 mm
Where it is aligned
with other bulkheads
P: 2 mm
h: 5 mm
Where it is not alignedwith other bulkheads
P: 9 mm
Where it is aligned
with other bulkheads
P: 3 mm
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Table 5.4
Pillars, Brackets And Stiffeners
Detail Standard Limit Remarks
Pillar (between decks)4 mm 6 mm
Cylindrical structure diameter (pillars, masts, posts, etc.) D/200 mm
max. + 5 mm
D/150 mm
max. 7.5 mm
Tripping bracket and small
stiffener, distortion at the part of free edge
a t/2 mm max. 8 mm
Snipe end of secondary face platesand stiffeners
= 30
H =15 mm
D = 25 mm
F = 15 mm
5 mm
0 mm- 5 mm
5 mm
See Rules3/2.11.2
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Table 5.5
Maximum Heating Temperature On Surface For Line Heating
Item Standard Limit Remarks
ConventionalProcessAH32-EH32 &AH36-EH36
Water cooling justafter heating under 650 C
TCMP typeAH32-EH32 &AH36-EH36(Ceq. >0.38%)
Air cooling after heating under 900 C
Air cooling andsubsequent water cooling after heating
under 900 C (startingtemperature of water cooling to be under 500 C)
TMCP typeAH32-DH32 &AH36-DH36(Ceq. 0.38%)
TMCP typeEH32 & EH36(Ceq. 0.38%)
Water cooling justafter heating or air cooling
Water cooling justafter heating or air cooling
under 1000 C
under 900 C
NOTE:
( )Ceq CMn
6
Cr Mo V
5
Ni Cu
15%= + +
+ ++
+
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Table 5.6
Block Assembly
Item Standard Limit Remarks
Flat Plate AssemblyLength and Breadth
Distortion
Squareness
Deviation of interior membersfrom plate
2.5 mm
10 mm
5 mm
5 mm
5 mm
20 mm
10 mm
10 mm
Curved Plate Assembly
Length and Breadth
Distortion
Squareness
Deviation of interior membersfrom plate
2.5 mm
10 mm
10 mm
5 mm
5 mm
20 mm
15 mm
10 mm
Measured along thegirth
Flat Cubic AssemblyLength and Breadth
Distortion
Squareness
Deviation of interior membersfrom plate
Twist
Deviation between upper andlower plate
2.5 mm
10 mm
10 mm
5 mm
10 mm
5 mm
5 mm
20 mm
10 mm
10 mm
20 mm
10 mm
Curved cubic assembly
Length and Breadth
Distortion
Squareness
Deviation of interior membersfrom plate
Twist
Deviation between upper andlower plate
2.5 mm
10 mm
10 mm
5 mm
15 mm
7 mm
5 mm
20 mm
15 mm
10 mm
25 mm
15 mm
measured along withgirth
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Table 5.7
Special Sub-Assembly
Detail Standard Limit Remarks
Distance between upper and lower gudgeon
5 mm 10 mm
Distance between aft edge of bossand aft peak bulkhead
5 mm 10 mm
Twist of sub -assembly of sternframe 5 mm 10 mm
Deviation of rudder from shaftcenter line
4 mm 8 mm
Twist of rudder plate 6 mm 10 mm
Flatness of top plate of mainengine bed
5 mm 10 mm
Breadth and length of top plate of main engine bed
4 mm 6 mm
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Table 5.8
Shape
Detail Standard Limit Remarks
Deformation for the whole length 50 mm per 100 m against the
line of keel sighting
Deformation for the distance between two adjacent bulkheads
15 mm
Cocking -up of fore body 30 mm
Cocking-up of aft-body 20 mm
Rise of floor amidships
15 mm
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Table 5.9
Shape
Detail Standard Limit Remarks
Length between perpendiculars 50 per 100 m Applied to ships of 100m length andabove. For theconvenience of themeasurement the pointwhere the keel isconnected to the curveof the stern may besubstituted for the fore
perpendicular in themeasurement of the
length.
Length between aft edge of bossand main engine 25 mm
Molded breadth at midship 15 mmApplied to ships of 15m breadth andabove. Measured onthe upper deck
Molded depth at midship 10 mm Applied to ships of 10meter depth and above
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Table 5.10
Fairness of Plating Between Frames
Item Standard Limit Remarks
Shell plate Parallel part(side & bottom shell)
4mm
Fore and aft part 5mm
Tank Top plate 4mm
BulkheadLongitudinal bulkhead
Transverse bulkhead
Swash bulkhead
6mm
6mm
6mm
8mm
300
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Table 5.11
Fairness Of Plating With Frames
Detail Standard Limit Remarks
Shell Plate Parallel part 2 /1000mm 3 /1000mm
Fore and aft part
3 /1000mm 4 /1000mm
Strength deck (excludingcross deck) andtop plate of double bottom
3 /1000mm 4 /1000mmTo be measured
between on trans.space (min. l = 3m)
Bulkhead 4 /1000mm 5 /1000mm
Others 5 /1000mm 6 /1000mm
l = span of frame (minimum l =3m)
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Table 5.12
Alignment
Detail Standard Limit Remarks
Alignment of butt weldsa 0.15t strength
a 0.2t other a 3.0 mm
Alignment of fillet welds Strength and higher tensile:
a t1/3 measuredon the median
a (5t 1- 3t 2)/6measured on theheel line
Other:a t1/2 measuredon the median
a (2t 1- t2)/2measured on theheel line
Where t 3 is less than t 1then t 3 should besubstituted for t 1 in thestandard
Alignment of fillet welds Strength and higher
tensile:a t1/3 measuredon the median
Other:a t1/2 measuredon the median
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Table 5.13
Alignment
Detail Standard Limit Remarks
Alignment of flange of T -longitudinal
a 0.04b strength a = 8.0 mm
Alignment of height of T-bar, L-angle bar or bulb
Primary membersa 0.15t
Secondary membersa 0.20t
3.0 mm
Alignment of panel stiffener d L/50
Gap between bracket/intercostaland stiffener
a 2.0 mm 3 mm
Alignment of lap weldsa 2.0 mm
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Table 5.14
Alignment
Detail Standard Limit Remarks
Gap between beam and framea 2.0 mm
Position of scallop d 75 mm
Gap around stiffener cut-out s 2.0 mm
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Table 5.15
Typical Butt Plate Edge Preparation (Manual Welding)
Detail Standard Limit Remarks
Square buttt 5 mmG = 3 mm
see Note 1
Single level butt t > 5 mmG 3 mmR 3 mm
= 50 - 70
see Note 1
Double bevel butt t > 19 mmG 3 mmR 3 mm
= 50 - 70
see Note 1
Double vee butt uniform bevelsG 3 mmR 3 mm
= 50 - 70
see Note 1
Double vee butt, non-uniform bevel
G 3 mmR 3 mm
6 h t/3 mm = 50 = 90
see Note 1
NOTE 1Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriatewelding procedure specification.For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.16
Typical Butt Plate Edge Preparation (Manual Welding)
Detail Standard Limit Remarks
Single vee butt, one side weldingwith backing strip (temporary or
permanent)
G = 3 - 9 mm = 30 -45
see Note 1
Single vee butt G 3 mm = 30 - 70
R 3 mm
see Note 1
NOTE 1Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriatewelding procedure specification.For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.17
Typical Fillet Weld Plate Edge Preparation (Manual Welding)
Detail Standard Limit Remarks
Tee FilletG 2 mm
see Note 1
Small angle fillet = 50 -70 = 70 - 90
G 2 mm
see Note 1
Single bevel tee with permanent backing G 4 - 6 mm = 30 - 45 Not normally for strength members
also see Note 1
Single bevel teeG 3 mmR 3 mm = 50
see Note 1
NOTE 1Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriatewelding procedure specification.For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.18
Typical Fillet Weld Plate Edge Preparation (Manual Welding)
Detail Standard Limit Remarks
Single J tee G =2.5- 4 mmr = 12 -15 mm
R = 3 mm 35
see Note 1
Double bevel tee symetrical
t > 19 mmG 3 mmR 3 mm
= 50
see Note 1
Double bevel tee assymetrical t > 19 mmG 3 mmR 3 mm
see Note 1
Double J bevel symmetrical G =2.5- 4 mmr = 12 -15 mm
R 3 mm 35
see Note 1
NOTE 1
Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriatewelding procedure specification.For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.19
Typical Butt And Fillet Weld Profile (Manual Welding)
Detail Standard Limit Remarks
Butt weld toe angle 60h 0.2R maximum h = 6 mm
Butt weld undercut D = 0 mm 0.5 mm
Fillet weld leg length s = leg lengtha = throat depth
s 0.9s da 0.9a d
over short weld lengths
sd= design sad= design a
Fillet weld toe angle 90 In areas of stress
concentration andfatigue, the Bureaumay require a lesser angle
Fillet weld undercut D = 0 mm 0.5 mm
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Table 5.20
Lap, Plug And Slot Welding
Detail Standard Limit Remarks
Fillet weld in lap joint b = 2t 2 + 25 location of lap joint to be approved by theBureau
Fillet weld in joggled lap joint b 2t2 + 25
Plug welding when t 12 mml = 60 mmR = 6 mm, 40 -50 G = 12 mmL > 2l
when 12 >> 12 mml = 100 mmG = 2tL = 2 l- 3l max. 250 mm
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Table 5.21
Distance Between Welds
Detail Standard Limit Remarks
Scallops over weld seams
d
for r 30 mmd 5 mm
Distance between two butt welds d 0 mm
Distance between butt weld andfillet weld
d 10 mm
Distance between butt welds for cut-outsd 30 mm
for margin platesd 300 mm
150 mm
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Table 5.22
Automatic Welding
Detail Standard Limit Remarks
Submerged Arc Welding (SAW)0 G 0.8 mm G 5 mm edge preparation as per
Table 5.15 and 5.16
SAW may follow WPSapproved by theBureau
See Note 1
NOTE 1Different plate edge preparation may be accepted or approved by the Bureau on the basis of an appropriatewelding procedure specification.For welding procedures other than manual welding, see paragraph 4.2 Qualification of weld procedures
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Table 5.23
Typical Misalignment Repair
Detail Repair Standard Remarks
Alignment of butt jointsStrength membersa > 0.15t 1 or a > 3 mm release and adjust
Othersa > 0.2t 1 or a > 3 mmrelease and adjust
Alignment of fillet weldsStrength and Higher tensile steelt1/3 < a t1/2 generally increase weldthroat by 10%
a > t1/2-release and adjust over a minimumof 50a
Othera > t1/2 release and adjust over a minimumof 30a
Where t 3 is less than t1 then t 3should be substituted for t 1 instandard
Alignment of flange of T-longitudinal
When 0.04b > 0.08b or 8 mmgrind corners to smooth taper over aminimum distance L=50a
Alignment of height of T-bar, L-angle bar or bulb
When 3 mm > 6 mmrelease and adjust over minimum L = 50afor primary structure and L = 30aelsewhere
Alignment of lap welds 2 mm > 5 mmmembers to be re-aligned
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Table 5.24
Typical Misalignment Repair
Detail Repair Standard Remarks
Gap between bracket/intercostaland stiffener
When 2mm < a 5mm weld leg length to be increased by increase in gap
When 5mm < a 10mm chamfer 30 - 40 and build up with welding
When a > 10mm increase gap to 50mm andfit collar plate
b= (2t + 25)mm, min. 50mm
Gap between beam and frame
a > 2 mm release and adjust
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Table 5.25
Typical Misalignment Repair
Detail Repair standard Remarks
Position of scallopWhen d < 75 mm, web plate to be cut
between scallop and slot, and collar plate to be fitted
OR fit small collar over scallop
OR fit collar plate over scallop
Gap around stiffener cut-out When 2mm < s 5mm weld leg length to beincreased as much as increase in gapopening over 2mm
When 5 mm < s 10 mm nib to bechamfered and built up by welding
When s > 10 mm cut off nib and fit collar plate with same height as nib
20 mm b 50mm
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Table 5.26
Typical Butt Weld Plate Edge Preparation Repair (Manual Welding)
Detail Repair standard Remarks
Square butt When G 10 mm chamfer to 45 and buildup by welding
When G > 10 mm build up with backingstrip; remove, back gouge and seal weld; or,insert plate, min. width 300mm
Single bevel butt
Double bevel buttWhen 3mm < G 3t/2 mm (maximum25mm)
build up gap with welding on one or bothsides of preparation, with possible use of
backing strip as necessary, to maximum t/2.
Where a backing strip is used, the backingstrip is to be removed, the weld back gouged, and a sealing weld made
Double vee butt, uniform bevels
When G > 25 mm or 3t/2 an insert plate, of minimum width 300mm, to be welded in
place
Double vee butt, non-uniform bevel
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Table 5.27
Typical Butt Weld Plate Edge Preparation Repair (Manual Welding)
Detail Repair Standard RemarksSingle vee butt, one side weldingwith backing strip When G 25mm or G t/2 build up edge preparation
on one or both sides, grind edge preparation, weldwith backing strip, remove backing strip, back gouge,and back weld
When G > 25mminsert plate, min. width 300 mm
Single vee butt, one side welding
When 3 mm < G 3t/2 mm (maximum 25 mm) buildup gap with welding on one or both sides of
preparation, with possible use of backing strip asnecessary, to maximum t/2.
Where a backing strip is used, the backing strip is to be removed, the weld back gouged, and a sealingweld made
Single vee butt When G > 25 mm or t/2 an insert plate, of minimumwidth 300 mm, to be welded in place
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Table 5.28
Typical Fillet Weld Plate Edge Preparation Repair (Manual Welding)
Detail Repair Standard Remarks
Tee Fillet 2 mm < G 5mm leg length increased toRule leg + (G-2)
5 mm < G 16 mm Chamfer to 30 to 45 , build up with welding, on one side, with or without backing strip, grind and weld
G > 16 mm or G > 1.5t - new plate to beinserted (min. 300mm)
Liner treatmentt2 t t1G 2mma = 5 mm + fillet leg length
Not to be used in cargo area or areas of tensile stress
perpendicular to liner
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Table 5.29
Typical Fillet Weld Plate Edge Preparation Repair (Manual Welding)
Detail Repair standard Remarks
Single bevel tee 3 mm < G 5mm build up weld
5 mm < G 16 mm - build up with welding, with or without backing strip, remove backing strip if used,
back gouge and back weld
G > 16mm new plate to be inserted of minimumwidth 300mm
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Table 5.30
Typical Fillet Weld Plate Edge Preparation Repair (Manual Welding)
Detail Repair standard Remarks
Single J tee as single bevel tee
Double bevel tee symmetricalWhen 3 mm < G 16 mm build upwith welding using ceramic or other approved backing bar, remove, back gouge and back weld
Double bevel tee assymmetrical
When G > 16 mm-insert plate of minimum height 300 mm to be fitted
Double J bevel symmetrical
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Table 5.31
Typical Fillet And Butt Weld Plate Edge Preparation Repair (Manual Welding)
Detail Standard Remarks
Fillet weld leg lengthIncrease leg or throat by welding over
Fillet weld toe angle
> 90 grinding, and welding, wherenecessary, to make < 90
Short beads, less than
50mm
Microgrooves of groundedge to be parallel to mainstress direction
Butt weld toe angle
> 90 grinding, and welding, wherenecessary, to make < 90
Butt weld undercut
Where 0.5 < D 1 mm undercut to be
ground smooth (localized only)
Fillet weld undercut Where D > 1 mm undercut to be filled bywelding
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Table 5.32
Distance Between Welds Repair
Detail Standard Remarks
Scallops over weld seams Hole to be cut and ground smooth toobtain distance
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Table 5.33
Erroneous hole repair
Detail Standard Remarks
Holes made erroneously D < 200 mm Strength membersopen hole to minimum 75 mm dia. fitand weld spigot piece
OR open hole to over 300 mm and fitinsert plate
Fillet weld to be madeafter butt weld
The fitting of spigot
pieces in areas of highstress concentration or fatigue is to be approved
by the BureauOther membersopen hole to over 300 mm and fitinsert plate
OR fit lap plate
t1 = t2 L = 50 mm, min
Holes made erroneously D > 200 mmStrength membersopen hole to over 300 mm and fitinsert plate
Other membersopen hole to over 300 mm and fitinsertt plateOR fit lap plate
t1 = t 2 L = 50 mm, min
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ABS Guide For Shipbuilding And Repair Quality Standard For Hull Structures During Construction 37
Table 5.34
Repair by insert plate
Detail Repair standard RemarksRepair by insert plate
L = 300 mm minimum
B = 300 mm minimum
R = 5t mm100mm minimum
(1) seam with insert piece is to bewelded first
(2) original seam is to be released andwelded over for a minimum of 100mm
Repair of built section by insert plate
L min 300 mm
Welding sequence(1) (2) (3) (4)
Web butt weld scallop to be filledduring final pass (4)
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Table 5.35
Weld surface repair
Detail Repair standard Remarks
Weld spatter 1. Remove spatter observed before blasting with scraper or chipping hammer etc.
2. For spatter observed after
blasting:a) Remove with a chipping
hammer, scraper, etc. b) For spatter not easily
removed with a chippinghammer, scraper, etc.,
grind the sharp angle of spatter to make it obtuse
In principal, no grinding isapplied to weld surface
Irregularity of manual weldWhen the surface irregularityexceeds 3mm, apply grinding untilthe irregularity becomes less than3mm
Arc StrikeRemoved the hardened zone bygrinding
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