Make the Welding Inspector Mad!
working for a foreman who was about as cocky and arrogant as they come. He treated
just about everyone he met with disdain. He'd just been promoted to foreman and
was trying to be a tough guy. We were working on a pretty tall high-rise, his
first "big job." That's where "Mr. Tough Guy" learned real
quickly that you do NOT act cocky and disdainful to a welding inspector!
inspectors usually have quite a few jobs going at once meaning they stay BUSY!
Inspectors will stop in a lot of times unexpectedly to check out welds
on the structures, and we had been going along fine for the first few floors with
all our welds passing. Welding inspectors use destructive and non-destructive
methods of testing to make sure the welds are sound. "See below." The
most widely used test in the shop and field is the visual test which every good
welder should do to each and every weld they make. Once an inspector is familiar
with a welder, they'll usually randomly check various welds visually to make sure
the welds are in compliance with the specifications for the job. (WPS - or welding
Our not-so-wise boss was in a bad mood and decided
to take it out on the weld inspector one day. He told the inspector he needed
to hurry up and get out of our way the same way a drill sergeant would tell a
new recruit to get down and do pushups! The inspector didn't say a word; he just
nodded and walked off.
The next morning when we got to the job there was
a sea of red all over the floor we were working on. Red tags stated the welds
were to be gouged out and re-done. It wasn't that the welds were bad; they just
were "technically" not up to specifications. Our welding inspector was
not a happy camper. Our tough guy boss was almost in tears!
us, we were able to talk to the inspector and explain what an idiot our boss was
and that he was not speaking for our crew. The inspector politely told us that
we better keep that no good blankety-blank away from him or next time he'd shut
the whole job down! He then took back his cards, cussed us again, and left. Did
that foreman learn from that job? Don't know because that was the LAST time I
ever worked for that guy!
Defects in welds include:
(the cardinal sin of welding when the steel is cut into but no filler metal added
therefore leaving a weak spot.)
- Underfill (not enough filler metal added.)
Inclusion (slag welded over and thus becoming part of the weld.)
(worm holes in the weld.)
- Longitudinal Cracks (crack in the length of
- Arc Strikes (where the arc has been struck outside of the intended
Defects are found by two types of tests.
examination of the weld to make sure it is defect free.
- Magnetic particle
- Penetrant dye testing.
check for containers.
Non-destructive are used on structures because
it would not be practical to cut out a piece of beam on a building, or a column
on an underwater oil derrick for a destructive test.
- Plate and Pipe coupon guided bend test.
- Tensile strength
- Impact test.
usually used in educational testing, shop testing, and tests welders take to get
certified or hired on at a jobsite.