The construction industry is one of the fastest-growing business sectors worldwide. With the exponential expansion of urban environments, the need for more buildings and structures is only increasing.
A construction site uses many processes to execute the end product, including welding. This blog will discuss the importance of having a planned welding process, its applications and benefits in construction, and four common Types Of Welding Procedures.
What Is A Welding Procedure Specification?
Welding seems cut and dry at the outset, but it can have several complications. Despite the expertise of the craftsmen, a weld can be subpar for a particular structure.
This calls for a standard procedure or protocol that welders can implement on construction sites, known as a welding procedure specification.
It is a list of rules and procedures to execute a particular weld that meets local ordinances. This can include mentioning the type of material, the type of weld to follow, the exact procedure, and the ideal outcome.
Therefore, following a welding procedure specification can eliminate guesswork and create high-quality, sturdy welds necessary in the construction industry.
Hence, a company must have a WPS that meets the region’s quality and safety standards before implementing any welding process.
Welding Applications for the Construction Industry
There are numerous applications of welding in the construction industry. A few are listed below
- Using metals, structural frameworks are created. These frameworks are the backbone of any structure, so the welding has to be perfect and incredibly strong.
- It also connects various structural components, such as I-beams, trusses, and columns, which act as the building’s main supports.
- Apart from structural uses, welding is also used in smaller construction projects, such as installing handrails, foot joists, stairs, and more.
- Lastly, they are also applied in electrical systems to create wire conduits, plumbing systems to install water pipes, ventilation systems to install air vents, and fuel systems to transport gas pipes.
With some clarity on applications, it’s time to examine the major benefits of welding in the construction industry.
Benefits of Welding in the Construction Industry
Durability
As mentioned above, welding is used in structural frameworks. Weighing thousands of tons, these metal beams endure incredible stress, and failure can result in a major collapse.
Fortunately, with sound welding processes and techniques, this is not an issue, and such incredible structures can be conceived and engineered quickly.
Efficiency
The construction industry makes a huge profit mainly due to its high productivity. Welding enables and improves this efficiency with technology such as ArcReach, which provides a constant power source irrespective of distance, automation equipment, and multiprocess welders, wherein different welds can be carried out in a single machine.
Versatility
Welding can be implemented in almost any type of construction process. Whether welding huge structural beams, the smallest pipes, or electrical conduits, it can all be done with one process.
Economical
While welding is economically viable due to its efficiency, the benefits of renting high-quality equipment for construction contract projects can be multiplied.
Types Of Welding Procedures On Construction Sites
1. ARC/SMAW Welding
One of the most common types of welding, arc welding, is also known as Shielded Metal Arc Welding. In this form of welding, the electrode is a stick through which electric current passes.
When this charged stick is applied to the area to be welded, it creates a high-temperature arc between the stick and the metal surface, thereby creating the weld.
The electrode eventually melts into the metal, creating a flux that shields the weld from contamination and oxidation.
As is evident, this is a manual process, but it is easy to master. It is also inaccurate, as it can create spatters that require polishing or cleaning up once the weld is completed.
Despite being a manual process, it is quite easy to maneuver and can be performed outside in harsh weather conditions. Hence, it is used in construction to fabricate steel and industrial-grade iron.
2. TIG/GTAW Welding
Tungsten Inert Gas (TIG) or Gas Tungsten Arc Welding (GTAW) is one of the most complicated yet versatile welding methods used in construction.
It primarily consists of a non-consumable tungsten electrode. An arc is created when this electrode comes in contact with the metal surface. The process also uses argon gas to shield the weld from oxidation.
The major challenge in TIG welding is perfecting the process using two hands. A welder must use a TIG torch with one hand to heat the metal and another hand to feed the electrode to create the arc.
Moreover, the heat also needs to be controlled manually, generally with a foot pedal. This complicated process also allows for better accuracy, as the technician can precisely control the heat required for a particular section.
This leads to accurate welds with no slag formation. Lastly, TIG welding is ideal for multiple materials such as brass, copper, magnesium, bronze, stainless steel, aluminum, and nickel alloys.
3. MIG/GMAW Welding
Metal Inert Gas or Gas Metal Arc Welding is a popular welding method used in construction and everyday household projects. Unlike TIG welding, the process here is straightforward.
A MIG welder is comprised of a holder with a filler material or electrode that also has shielding gas coated on it. When electricity is fed to the electrode through a constant power source, it creates an arc by coming into contact with the metal surface. The gas coating on the electrode prevents contamination.
One of the biggest advantages of MIG welding is the ease of use. With a non-expendable electrode, MIG welders can be used continuously to create highly accurate welds with minimal spatter.
This feature allows for automation, making it a major benefit in construction projects. Conversely, MIG welding is not advisable outdoors, as it is susceptible to rain, winds, and dust. Hence, its use in fabrication in the construction industry is highly dependent on the task.
4. FCA/FCAW Welders
Flux-Cored Arc Welding (FCAW) is similar to MIG welding and arc welding. Like MIG welding, FCA welders require a constant power source to carry out the process.
Hence, multi-welder machines can typically perform MIG and FCAW with a single piece of equipment. Moreover, like arc welding, FCAW doesn’t require a shielding gas.
It doesn’t use a stick electrode, either. It uses a consumable wire or electrode in its core that acts as a flux, simultaneously creating a shielding gas as the weld is performed.
Hard to perform and master, FCAW is perfect for fabricating or repairing thick metals, making it a staple in bridge construction and shipbuilding industries.
Perfect for complex welding operations, it is a staple in construction sites for residential and non-residential structures.
The only drawback to this type of welding is the formation of slag/residue, which can be easily cleaned up with a wire brush or polisher.
Conclusion: Types Of Welding Procedures
Overall, all four welding methods are used extensively on construction sites. However, before using these techniques, it’s important to create welding procedure specifications according to local laws and building codes to ensure optimal safety standards.
Dhruv Mehta is a Digital Marketing Professional who works as a brand consultant and provides solutions in the digital era. In his free time, he loves to write about manufacturing, finance & home decor. Follow him on Twitter or connect with him via LinkedIn.
