Can a shop-qualified WPS be used for field column splice welds without modification?

Only if the WPS parameters, process, and conditions are appropriate for field conditions. A WPS qualified in a controlled shop environment with SAW, for example, does not cover SMAW field work — process is an essential variable under AWS D1.1:2025 Table 6.6. The WPS used in the field must be qualified for the process and positions actually used during erection, and it must address preheat and environmental provisions relevant to field exposure.

What welding processes are typically used for field column splice CJP welds?

SMAW (shielded metal arc welding) with E7018 or E7016 low-hydrogen electrodes is the dominant field splice process because it tolerates the access constraints, variable positions, and occasional wind exposure of erection work. FCAW-S (self-shielded flux-cored wire, no external gas supply) is an alternative where wind would disrupt FCAW-G shielding gas coverage. FCAW-G can be used in field conditions if wind speed is within the limits specified in the WPS or AWS D1.1:2025 Clause 7.

What are the wind speed limits for field welding under AWS D1.1?

AWS D1.1:2025 Clause 7 requires that welding not be performed when wind velocities exceed those that would adversely affect shielding gas coverage — effectively restricting open-arc GMAW and FCAW-G in exposed conditions. SMAW and FCAW-S are significantly less sensitive to wind because shielding is integral to the electrode or wire. The WPS should specify process selection based on anticipated field conditions and cite the applicable exposure limit; the CWI confirms conditions before allowing welding to proceed.

Does a field column splice need a separate PQR from shop welds, or does the shop PQR cover it?

If the same process, base metal P-number, and joint type fall within the shop PQR's qualified range, the shop PQR covers field welds under the same WPS — there is no separate 'field' vs. 'shop' qualification category in AWS D1.1. The distinction is that field conditions (position, access, preheat maintenance) may require a WPS written specifically for field use, referencing the applicable PQR and documenting the field-specific parameters and controls.

Jul 24, 20268 min read

Field Column Splice WPS Under AWS D1.1: Erection Welding

Field erection splice welds for structural steel columns and beams require WPS tailored to SMAW or FCAW-S conditions, wind exposure, and CJP groove qualification.

AWS D1.1 field welding column splice WPS SMAW FCAW-S CJP erection structural welding

A field column splice weld is one of the highest-consequence joints in a structural steel erection sequence. It connects adjacent column sections — often at mid-height in multi-story frames — and the joint must transfer full column compression, tension (in uplift or seismic loading), and moment through a complete joint penetration (CJP) groove weld or bolted splice plate connection. Where weld splices are specified by the EOR, the WPS used in the field is a different document challenge from the shop — not because the qualification mechanics differ, but because field conditions impose constraints on process selection, preheat maintenance, and inspection access that require deliberate WPS planning before the ironworkers are in the air.

Rule library based on AWS D1.1:2025; verify against your governing edition.

How field splice welding differs from shop welding

AWS D1.1:2025 does not maintain a separate code section for "field welding" as distinct from shop fabrication. The same essential variables (Table 6.6), prequalified WPS requirements (Clause 5), and inspection provisions (Clause 9) apply to both. What the field introduces is a set of practical constraints that must be addressed in the WPS and inspection plan:

Process limitations. Shop welding optimizes for deposition rate — SAW for long continuous welds, FCAW-G for general structural work with good gas coverage. In the field, SAW is almost never used for column splices (equipment access, positioning, and flux containment are impractical at elevation). Field splices default to SMAW, FCAW-S, or carefully wind-managed FCAW-G.

Position exposure. A vertical column splice is welded in either the 2G (horizontal groove) or 3G (vertical groove) position depending on how the split is oriented. The WPS must be qualified for the position encountered; position is an essential variable under Table 6.6.

Preheat maintenance. Maintaining preheat on a large W14 or W12 column section 40 feet in the air in winter conditions is a different challenge from wrapping a joint in a heated enclosure on the shop floor. The WPS must specify minimum preheat and the method for verifying it in the field; the inspector must confirm preheat before each weld pass without a controlled environment to rely on.

Access and inspection. Visual inspection and NDE (if required) on a column splice at elevation have physical constraints. The WPS and inspection plan should address whether film RT is practical or whether UT is the specified NDE method, and how inspector access is provided.

See field vs. shop welding WPS differences for a broader comparison of how the two environments affect WPS documentation.

Process selection for field column splice CJP welds

SMAW with low-hydrogen electrodes

SMAW with E7018 (or E7016 in some applications) low-hydrogen electrodes is the standard field splice process for most structural steel column splices. SMAW advantages in the field:

No external shielding gas — resistant to wind and drafts
Equipment is portable and tolerates the access constraints of ironwork
Low-hydrogen electrode classifications provide the fracture toughness and ductility needed for groove weld qualification
Electrode rod control allows welders to manage tight access in flange regions

The WPS must specify E7018 or the applicable AWS A5.1 classification, condition it covers (H4 vs. H8 exposure limit), and the oven/storage requirements that maintain low-hydrogen conditioning before the rod goes to the field. See low-hydrogen electrode conditioning: H4, H8, and H16 classifications for the storage and exposure time limits that belong in the WPS.

The SMAW WPS for field CJP must document:

Electrode classification and diameter (rod diameter is often restricted in groove root passes — typically 3/32 in or 1/8 in for root passes, 5/32 in or 3/16 in for fill passes)
Minimum and maximum amperage range per diameter
Minimum preheat and maximum interpass temperature
Position(s) qualified
Joint configuration (groove angle, root opening, root face) within qualified limits

FCAW-S for exposed conditions

Self-shielded flux-cored arc welding (FCAW-S) is an alternative where wind conditions would cause FCAW-G shielding gas to be blown away. FCAW-S wire — classified under AWS A5.20 with T-S (self-shielded) designators, such as E71T-8 — generates its own shielding through the flux system, making it suitable for outdoor exposure in moderate wind.

The tradeoff: FCAW-S slag systems that provide wind resistance typically produce weld metal with lower toughness than low-hydrogen SMAW or FCAW-G, and some FCAW-S electrode classifications are not permitted for demand-critical welds under AWS D1.8 (seismic supplement) because they do not meet CVN requirements. The WPS must specify an electrode classification with mechanical properties that meet the qualification requirements for the joint and the applicable structural standard.

FCAW-S essential variables under AWS D1.1:2025 Table 6.6 are separate from FCAW-G — the two are treated as different processes for qualification purposes. An FCAW-G PQR does not qualify an FCAW-S WPS.

FCAW-G with wind management

FCAW-G can be used for field splices in conditions where wind is manageable — within enclosures, on lower-story work, or in conditions that meet the speed limits for shielding gas coverage. AWS D1.1:2025 Clause 7 imposes wind velocity limits on GMAW and FCAW-G that effectively make open-air exposure at elevation impractical without a wind screen or enclosure.

If the WPS specifies FCAW-G for field work, the CWI's pre-weld responsibility includes confirming wind conditions are within the acceptable range and that any required screening or enclosure is in place. The WPS should specify the maximum acceptable wind speed and the required enclosure provision when wind exceeds that limit.

Preheat requirements and field maintenance

Preheat for structural steel column splices under AWS D1.1:2025 Clause 5 or Table 5.3 depends on:

Base metal specification and carbon equivalent
Material thickness (the thicker section governs)
Welding process and heat input

For ASTM A992 W-shapes (the standard wide-flange for columns in structural frames), the carbon equivalent is controlled by ASTM A992 itself, which limits CE to a maximum of 0.47. At the nominal 1–2 in [25–50 mm] flange thicknesses common in column sections, prequalified minimum preheat is typically in the range of 50°F to 150°F [10°C to 65°C] depending on the exact CE and process — but the WPS must state the actual required preheat, not a generic range.

Field preheat challenges:

Propane or oxy-fuel torches are the standard field preheat tools; oven preheat is not practical on erected steel.
Preheat must be measured at least 3 in [75 mm] from the joint on both sides of the weld, per AWS D1.1:2025 requirements.
On cold days, re-preheat is required if the joint cools between passes (interpass temperature verification is as important as initial preheat).
The WPS should specify the preheat verification method — contact thermocouple, temperature-indicating crayon, or infrared pyrometer — and the interval at which preheat is checked.

The CWI's role is to verify preheat before each weld pass begins. Skipping this check on column splice welds in cold weather is a documented cause of hydrogen-assisted cracking in the root of CJP groove welds — a type of defect that may not be immediately visible and can be missed without UT.

Joint configuration and fit-up for column splice CJPs

Field column splices are typically CJP groove welds in a single-bevel or double-bevel configuration, depending on access and whether the column has a web and flange accessible from both sides. The joint configuration must be within the WPS's qualified range (groove angle, root opening, and root face dimensions are qualified within limits per Table 6.6 joint geometry variables).

Fit-up in the field is inherently less controlled than shop work:

Column sections may have mill end-of-column variation
Plumb and level adjustments after erection can shift the joint geometry slightly
Wind load on the erected frame during welding can introduce dynamic loading on the joint

The WPS's qualified fit-up range (per Clause 5 prequalified geometry or per the PQR-qualified joint detail) sets the limits within which the joint can proceed without engineering disposition. The CWI must check fit-up and alignment before welding begins. Gaps or misalignment outside the qualified range are an NCR, not a field fix by the welder.

NDE requirements for field column splice welds

AWS D1.1:2025 NDE requirements for CJP groove welds in statically loaded structures are specified in Clause 9 (inspection) and may be augmented by the project quality plan or IBC Chapter 17 special inspection requirements. For field column splices, the NDE method selection is practical:

UT is generally preferred for field CJP groove weld inspection because the equipment is portable, does not require film processing, and provides results on-site. TOFD or phased-array UT can be used if the system meets applicable acceptance criteria under D1.1.
RT (radiographic testing) requires film or digital detector placement inside the column section, which may not be physically accessible for flange welds. RT is more practical for flange splices with open access behind the joint but becomes difficult at elevation with limited positioning.

The WPS and NDE plan should specify the method and the hold point at which NDE is performed. Root pass inspection — either visual examination of the root from the back side (if accessible) or UT focused on the root region — is a particularly important hold point for CJP groove welds where lack-of-fusion or root cracking would be buried under fill passes if not caught early.

The CWI's checklist for field column splice welding

A CWI supervising erection splice work should confirm the following before welds are started on any column section:

WPS is applicable: Process, position, joint geometry, base metal, and electrode classification match what is actually being welded. The WPS and supporting PQR are accessible on-site.
Preheat is confirmed: Temperature verified at the required distance from the joint, both flanges and the web, before the root pass begins.
Electrode condition verified: E7018 electrodes from a heated rod oven, within the permissible exposure time for the H-suffix designation on the WPS.
Wind conditions acceptable: If FCAW-G, wind screening is in place. If SMAW or FCAW-S, conditions are within limits.
Fit-up within qualified range: Groove angle, root opening, and alignment confirmed before welding.

After welding:

Visual inspection per AWS D1.1:2025 Clause 9: Weld profile, undercut, overlap, and surface-breaking indications reviewed before NDE.
NDE complete and accepted: UT or RT results recorded and accepted per the applicable acceptance criteria before the joint is encased or covered.

Maintaining a field inspection log for each splice — weld identification, WPS used, welder ID, preheat records, parameter notes, and NDE results — is the documentation backbone that makes erection work auditable after the fact. The weld map and inspection records travel with the project file. See weld map and WPS traceability in production for how weld identification links to the WPS record in audit-ready documentation. Try wpswelding.com's WPS and inspection tracking tools free for 14 days.

FAQ

Frequently asked.

Can a shop-qualified WPS be used for field column splice welds without modification?: Only if the WPS parameters, process, and conditions are appropriate for field conditions. A WPS qualified in a controlled shop environment with SAW, for example, does not cover SMAW field work — process is an essential variable under AWS D1.1:2025 Table 6.6. The WPS used in the field must be qualified for the process and positions actually used during erection, and it must address preheat and environmental provisions relevant to field exposure.
What welding processes are typically used for field column splice CJP welds?: SMAW (shielded metal arc welding) with E7018 or E7016 low-hydrogen electrodes is the dominant field splice process because it tolerates the access constraints, variable positions, and occasional wind exposure of erection work. FCAW-S (self-shielded flux-cored wire, no external gas supply) is an alternative where wind would disrupt FCAW-G shielding gas coverage. FCAW-G can be used in field conditions if wind speed is within the limits specified in the WPS or AWS D1.1:2025 Clause 7.
What are the wind speed limits for field welding under AWS D1.1?: AWS D1.1:2025 Clause 7 requires that welding not be performed when wind velocities exceed those that would adversely affect shielding gas coverage — effectively restricting open-arc GMAW and FCAW-G in exposed conditions. SMAW and FCAW-S are significantly less sensitive to wind because shielding is integral to the electrode or wire. The WPS should specify process selection based on anticipated field conditions and cite the applicable exposure limit; the CWI confirms conditions before allowing welding to proceed.
Does a field column splice need a separate PQR from shop welds, or does the shop PQR cover it?: If the same process, base metal P-number, and joint type fall within the shop PQR's qualified range, the shop PQR covers field welds under the same WPS — there is no separate 'field' vs. 'shop' qualification category in AWS D1.1. The distinction is that field conditions (position, access, preheat maintenance) may require a WPS written specifically for field use, referencing the applicable PQR and documenting the field-specific parameters and controls.