AWS D1.1 Structural Steel

Exam blueprint

Sourced from AWS D1.1/D1.1M:2020 — Structural Welding Code, Steel

• General + scope (Clause 1)5%
• Design (Clause 4)15%
• Prequalification of WPSs (Clause 5)15%
• Qualification (Clause 6 — WPS + welder)20%
• Fabrication (Clause 7 — workmanship + technique)15%
• Inspection (Clause 8)15%
• Welding symbols (AWS A2.4)10%
• Tubular structures (Clause 9, summary only)5%

1. 01Welding symbols (AWS A2.4)

   ~75min

   How to read the standardized welding symbol on a drawing — reference line, arrow, weld type symbol, dimensions, finishing, and tail. The most-tested skill on the exam because every other question depends on it.

   • Anatomy of a welding symbol

     A welding symbol has: a horizontal REFERENCE LINE; an ARROW pointing to the joint; a TAIL with reference notes; SYMBOLS above and below the reference line indicating arrow-side and other-side welds; DIMENSIONS to the left of the symbol (size + length-pitch); FINISHING and CONTOUR symbols. The rule: a symbol BELOW the reference line means weld on the ARROW SIDE; a symbol ABOVE means weld on the OTHER SIDE.

   • Fillet vs. groove welds

     A fillet weld joins two surfaces at approximately 90° (think of an L-shape). A groove weld joins two pieces edge-to-edge with the joint prepared by chamfering (V, bevel, U, J, etc.). Symbol: a fillet is a right triangle on the reference line; a groove is shaped like the prep itself (V for V-groove, etc.). Size convention: fillet leg length goes to the left of the symbol.

   • Field weld + weld-all-around symbols

     The flag at the intersection of arrow and reference line means FIELD WELD (made on site, not in shop). The circle at the intersection means WELD ALL AROUND (full perimeter of the joint). Combined, they tell you exactly where and how to deposit metal.

   Practice questions (2)

   1. 1. A drawing shows a welding symbol with a fillet (right-triangle) symbol BELOW the reference line and a 1/4 to its left. What does it specify?

      • A.1/4-inch fillet weld on the OTHER side
      • B.1/4-inch fillet weld on the ARROW side✓ correct
      • C.1/4-inch groove weld on the arrow side
      • D.1/4-inch fillet, both sides

      A symbol BELOW the reference line denotes the arrow side. The 1/4 to the left of the fillet symbol is the leg length. So this is a 1/4-inch fillet on the arrow side. If the same symbol appeared above the line, it would be the other side.

   2. 2. A symbol has a small flag at the intersection of arrow and reference line. What does the flag indicate?

      • A.Weld all around
      • B.Field weld (made at the site, not shop)✓ correct
      • C.Reject
      • D.Use a particular consumable

      The flag at the corner of arrow + reference line is the standard symbol for FIELD WELD. The circle at the corner is WELD ALL AROUND. Both can appear on the same symbol.

2. 02Welder + WPS qualification (Clause 6)

   ~90min

   The difference between procedure qualification and welder performance qualification, and the essential variables that, if changed, require re-qualification.

   • WPS qualification vs. welder qualification

     A WELDING PROCEDURE SPECIFICATION (WPS) is a document that tells the welder how to make a weld — process, base metal, filler, position, preheat, etc. PROCEDURE qualification proves the WPS produces sound welds with required properties; WELDER PERFORMANCE qualification proves a particular welder can make sound welds following a qualified WPS. Both are required before production welding.

     Reference: AWS D1.1 Clause 6

   • Essential variables — when to re-qualify

     Essential variables are properties that, if changed beyond stated limits, invalidate the qualification. Examples: process change (SMAW to FCAW), filler-metal classification change, position outside the qualified range, postweld heat treatment, preheat temperature dropping below qualified, base-metal group change. Non-essential variables (like joint design within prequalified limits) do not require re-qualification.

     Reference: AWS D1.1 6.7

   • Welder position qualification — what 3G qualifies

     Welder qualifications are tested in standard positions: 1G/1F (flat), 2G/2F (horizontal), 3G/3F (vertical), 4G/4F (overhead). Passing a 3G plate test qualifies for 1G, 2G, and 3G. Passing 4G qualifies for 1G, 2G, and 4G. Passing BOTH 3G and 4G (or a single 5G/6G pipe test for pipe) qualifies for ALL positions.

   Practice questions (2)

   1. 1. A welder qualified in 3G plate is asked to weld an overhead beam joint. Are they qualified?

      • A.Yes — 3G qualifies all plate positions
      • B.No — 3G does not qualify 4G (overhead)✓ correct
      • C.Yes, after a 1-hour refresher
      • D.Only if the same WPS is used

      3G plate qualifies the welder for 1G, 2G, and 3G — but NOT 4G (overhead). To weld overhead joints, the welder must pass a 4G test (or 3G + 4G, or 6G pipe). Many candidates miss this — assuming any vertical qualification covers overhead.

   2. 2. Mid-shift, a welder switches from E7018 (SMAW) to E71T-1 (FCAW). What does AWS D1.1 require?

      • A.Nothing — both produce sound welds
      • B.Re-qualify for the new process✓ correct
      • C.Tack-weld test only
      • D.Notify the inspector verbally

      Process change (SMAW → FCAW) is an essential variable in welder qualification. The welder must re-qualify for FCAW before depositing FCAW production welds. Existing SMAW qualification covers SMAW only.

3. 03Inspection (Clause 8)

   ~75min

   Visual inspection criteria, NDT methods (RT, UT, MT, PT) and when each applies, and acceptance standards for weld discontinuities. The CWI is the gatekeeper.

   • Visual inspection acceptance — Table 8.1

     Visual inspection (VT) is the first and most important inspection step. Statically loaded structures and cyclically loaded structures have different acceptance criteria for crack length, undercut depth, weld profile, and undersized welds. Cracks of any size are rejectable in BOTH static and cyclic structures — there is no acceptable crack.

     Reference: AWS D1.1 Clause 8 + Table 8.1

   • NDT methods — RT, UT, MT, PT

     RADIOGRAPHY (RT) uses X-rays to find internal volumetric flaws — best for porosity, slag, incomplete fusion. ULTRASONIC (UT) uses sound waves — best for cracks and lack of fusion. MAGNETIC PARTICLE (MT) finds surface and near-surface flaws on ferromagnetic materials. PENETRANT (PT) finds surface-breaking flaws. Choice depends on weld type, code section, and what flaws are most likely.

   Practice questions (1)

   1. 1. A static-loaded structural fillet weld shows a 1/8-inch crack. AWS D1.1 acceptance?

      • A.Acceptable — under the static crack limit
      • B.Rejectable — cracks of any size are rejected✓ correct
      • C.Acceptable if confirmed as a crater crack
      • D.Acceptable if length is less than 1/4 inch

      AWS D1.1 Table 8.1 lists 'cracks of any size' as rejectable in BOTH statically and cyclically loaded structures. There is no acceptable crack length. Crater cracks specifically are not exempt.

External resources

• Official
  AWS D1.1/D1.1M Structural Welding Code — Steel ↗

  The actual code. AWS publishes a new edition every ~4 years; whichever edition your jurisdiction has adopted (typically named in the AISC code clause) is what governs your test. Buy or borrow the actual book — there is no acceptable substitute.

• Official
  AWS A2.4 — Standard Symbols for Welding, Brazing, and NDE ↗

  The standardized welding-symbol catalog D1.1 references for drawings. ~10% of D1.1 exam questions test you on A2.4 symbol reading.

• Official
  AWS CWI Body of Knowledge ↗

  If you're studying for D1.1 alongside CWI, AWS's CWI Body of Knowledge gives you a free roadmap of the broader inspection topics — most of which appear on D1.1 procedure-qualification tests.