WPS Template & PDF Guide
A WPS captures the essential variables required by the governing code. D1.1 Table 5.5 defines 21 variables for structural steel, ASME IX QW-250 lists process-specific variables for pressure equipment, and API 1104 Section 5 covers pipeline parameters. This guide compares all three codes.
The 21 Essential Variables (Table 5.5)
D1.1:2025 Table 5.5 lists the variables that must appear on every prequalified WPS. The upper section (items 1–21) defines what must be included; the lower section (items 22–31) defines permitted tolerances. When any variable is changed beyond its permitted tolerance, a new or revised WPS is required per Clause 5.2.1.
Variables listed thematically. For the official numbered order, see D1.1:2025 Table 5.5 items (1)–(21).
Common WPS Mistakes That Fail Inspection
Inspectors reviewing WPSs on the shop floor see the same errors repeatedly. Avoiding these is the difference between a smooth audit and a corrective action report.
Missing or incomplete essential variables. The most common failure is simply leaving fields blank. Every one of the 21 variables in Table 5.5 must have a value or range documented. A WPS with "TBD" or blank amperage ranges is not a valid written WPS per Clause 5.2.1. Inspectors will reject it on sight.
Preheat below minimum. The WPS must list a minimum preheat temperature that meets or exceeds the Table 5.11 requirement for the base metal group, process, and thickness. Fabricators sometimes list "N/A" for preheat when the code actually requires a minimum — particularly for Group II and Group III steels above certain thicknesses. Use the preheat calculator to verify.
Filler metal mismatch. Table 5.7 defines which filler metal classifications match each base metal group. A WPS listing E7018 for Group IV steel (which may require E8018 or higher matching) will fail verification. The filler metal classification on the WPS must match the requirements for the specific base metal group and process.
Joint detail not prequalified. Fabricators sometimes specify groove angles, root openings, or backing conditions that do not match any prequalified joint detail in Figures 5.1, 5.2, or 5.3. If the joint is not prequalified, the WPS must be qualified per Clause 6 with a PQR — the prequalified path does not apply.
Parameter ranges too wide. Writing "amperage: 50-400A" to cover every possible scenario defeats the purpose of the WPS. Inspectors expect reasonable ranges that reflect actual welding practice for the specified electrode diameter and position. Excessively wide ranges suggest the WPS was written to avoid revision rather than to control the process.
WPS not signed or dated. The WPS must bear the signature (or authorized signature equivalent) of the fabricator’s designated representative. An unsigned WPS is not an approved document. Some inspection agencies also require a revision number and date to track document control.
How to Fill Out a WPS Form
Step 1 — Identify your base metal. Find the ASTM specification on your mill test report. Look it up in D1.1 Table 5.6 to find the base metal group (I through V). This determines your preheat category and filler metal matching requirements.
Step 2 — Determine preheat. Use your base metal group with your welding process and material thickness to look up the minimum preheat and interpass temperature in Table 5.11. The preheat calculator does this lookup instantly.
Step 3 — Select the joint detail. Choose the applicable prequalified joint detail from Figures 5.1 (CJP groove welds), 5.2 (PJP groove welds), or 5.3 (fillet welds). The figure specifies root opening, groove angle, backing requirements, and weld size. See the prequalified WPS reference for the full set.
Step 4 — Match filler metal. Table 5.7 defines the matching strength filler metal for each base metal group and welding process. The filler metal classification on your WPS must match.
Step 5 — Document electrical parameters. Record amperage, voltage, and travel speed ranges for each electrode diameter and pass type. These must stay within the ranges on the WPS during production welding — deviations require a new WPS.
WPS Document Control Best Practices
A WPS is a controlled document. In AISC-certified shops, the WPS program is reviewed during the annual audit. In ASME Code shops, the Quality Assurance Manual references WPS control procedures. Good practices include:
Unique identification. Each WPS should have a unique number (e.g., WPS-001, WPS-002) that is referenced on the welder’s qualification record and on the weld map or drawing. This creates traceability from the finished weld back to the procedure used to make it.
Revision tracking. When a WPS is revised — to add a new electrode diameter, change a parameter range, or update a preheat value — the revision should be documented (Rev A, Rev B, or Rev 1, Rev 2). The previous revision should be archived, not deleted, so the inspection record shows which version was used for each weld.
Shop floor accessibility. The current WPS must be available at the point of welding. Whether printed and posted at the workstation, available on a tablet, or accessible through a shop management system, the welder must be able to reference the WPS while welding. A WPS locked in the QC office serves no purpose.
Supporting PQR linkage. For qualified (non-prequalified) WPSs, the supporting PQR number should be referenced on the WPS. This allows an inspector to quickly verify that the procedure has been tested. For prequalified D1.1 WPSs, no PQR reference is needed — but the WPS must explicitly state it is prequalified per Clause 5.
WPS Form Sources
AWS Annex J (D1.1:2025 page 407) provides sample WPS and PQR forms. These are informative — not mandatory. They serve as a starting point for fabricators who do not have their own standardized forms.
AWS Annex K (D1.1:2025 page 429) provides a reference checklist of all code subclauses that a prequalified WPS must address, organized by clause. Use it as a verification tool after completing the WPS to ensure nothing is missed.
Most AISC-certified fabrication shops, bridge fabricators, and inspection training programs use their own standardized WPS forms. The format does not matter — only the content. Per Clause 5.2.1, the WPS must be a written document that addresses all applicable variables. Need help filling it in? See our field-by-field WPS form guide.
Generate your WPS with Flux
Tell Flux your joint details, base metal, and process — get a complete WPS draft with all essential variables filled in.
Start with FluxMulti-Standard WPS Comparison: D1.1 vs. ASME IX vs. API 1104
Every fabrication code requires a written WPS, but the rules differ significantly in scope, qualification path, and essential variable definitions. Understanding these differences is critical when a project crosses code boundaries — for example, a structural support (D1.1) welded to a pressure vessel nozzle (ASME IX), or a pipeline tie-in (API 1104) meeting a structural connection.
Qualification Path
D1.1 offers two paths: prequalified (Clause 5, no testing required) and qualified (Clause 6, PQR required). If SMAW, SAW, GMAW, or FCAW is used on Table 5.6 steels with Clause 5 joint details, no PQR is needed. This prequalified path exists only in D1.1 — no other major code allows it.
ASME IX requires procedure qualification (PQR with destructive testing) for every WPS. There is no prequalified path. Each WPS must reference a supporting PQR that demonstrates the procedure produces acceptable results. The PQR records actual test parameters and mechanical test results (tension, guided bend, impact when required). Standard Welding Procedure Specifications (SWPSs) published by AWS may be adopted per QW-500 as an alternative, but the organization must accept responsibility for their use.
API 1104 also requires procedure qualification for every WPS per Section 5. The welder welds a test coupon under the WPS conditions, and the coupon is destructively tested (nick break, tensile, bend, macro). There is no prequalified path, and the testing requirements are specifically designed for pipeline girth welds — including requirements for radiographic testing of the qualification coupon.
Essential Variables Comparison
| Variable Category | D1.1:2025 | ASME IX:2025 | API 1104 |
|---|---|---|---|
| Base Metal | Table 5.6 Groups I–V | P-Numbers & Group Numbers (QW/QB-422) | Specified min. yield strength & wall thickness |
| Welding Process | SMAW, SAW, GMAW, FCAW (prequalified); any process (qualified) | Any process per QW-250 through QW-265 | SMAW, SAW, GMAW, FCAW, GTAW, combination |
| Position | 1G, 2G, 3G, 4G, 1F–4F (per Clause 5.4) | 1G–6G, 1F–4F (per QW-461) | Roll, fixed (2G, 5G, 6G, 6GR) |
| Filler Metal | Matching classification per Table 5.7 | F-Number (QW-432) & A-Number (QW-442) | AWS filler metal group designation |
| Preheat | Table 5.11 minimum preheat | QW-406 (decrease >55°C is essential) | Minimum preheat per qualified range |
| PWHT | Required per Clause 5.28 for specific steels | QW-407 (addition, deletion, or range change is essential) | Per project specification and material |
| Electrical Parameters | Amperage, voltage, travel speed ranges (Table 5.5) | Heat input range (QW-409); specific variables per process | Voltage, amperage, travel speed type & range |
| Joint Design | Prequalified per Figures 5.1–5.3; any design for qualified WPS | Not directly an essential variable (covered by qualification range) | Joint design type per Section 5.3 |
| Qualification Record | PQR per Clause 6 (not required for prequalified WPS) | PQR per QW-200 (always required) | PQR per Section 5 (always required) |
ASME IX WPS Essentials
ASME IX organizes essential variables by welding process in Tables QW-252 through QW-265. Each table lists the variables that apply to a specific process (SMAW, SAW, GMAW, GTAW, etc.) and classifies them as essential, supplementary essential (when impact testing is required), or nonessential. A change in an essential variable requires requalification of the WPS — meaning a new PQR with fresh test coupons.
The base metal grouping system is fundamentally different from D1.1. Instead of five groups based on preheat category, ASME IX assigns every material specification a P-Number and Group Number in Table QW/QB-422. A WPS qualified on one P-Number material generally covers all materials within that same P-Number, with some exceptions for Group Number changes in impact-tested applications. This system covers over 2,000 material specifications across ferrous alloys, stainless steels, nickel alloys, aluminum, copper, titanium, and zirconium.
Filler metals are classified by F-Number (usability grouping, Table QW-432) and A-Number (weld metal chemistry, Table QW-442). A change in F-Number is always essential. A change in A-Number is essential for certain processes and when impact testing is required.
API 1104 WPS Essentials
API 1104 governs welding of pipelines and related facilities. Its WPS requirements in Section 5 are specifically designed for girth welds on pipe — typically single-V groove joints welded in fixed position. The essential variables include process type, base metal (grouped by specified minimum yield strength), wall thickness range, joint design, filler metal group, electrical characteristics (AC/DC, polarity), position, direction of welding (uphill or downhill for vertical joints), shielding gas composition and flow rate, preheat, and interpass temperature limits.
A distinguishing feature of API 1104 is the qualification testing requirements: test coupons are subjected to tensile, nick break, and guided bend tests. Radiographic examination of the test weld is also commonly performed. The standard allows qualification on a range of wall thicknesses and pipe diameters — the qualified range depends on the test coupon dimensions.
Unlike D1.1 and ASME IX, API 1104 treats the direction of welding (uphill vs. downhill) as an essential variable. Changing from downhill root pass to uphill root pass, or vice versa, requires requalification. This is critical for pipeline productivity — downhill welding is faster but requires different techniques and parameters.
Choosing the Right Code for Your WPS
Structural steel fabrication (buildings, bridges, industrial structures): Use D1.1. The prequalified path eliminates qualification testing costs for common joints on common steels — the most efficient path when the fabricator is using standard processes on Table 5.6 materials.
Pressure vessels and boilers (ASME Boiler and Pressure Vessel Code): Use ASME IX. All WPSs require PQR backing. The P-Number system provides the most comprehensive material classification of any welding code. Required for ASME Code-stamped equipment.
Pipelines and piping systems (cross-country pipelines, gathering lines, facilities): Use API 1104. The qualification testing and essential variables are optimized for the specific challenges of field pipeline welding — fixed position, varying wall thickness, uphill/downhill progression.
Crossover situations: When a project requires compliance with multiple codes (e.g., pipe rack structural members under D1.1 supporting a piping system under ASME B31.3 referencing ASME IX), each code’s WPS requirements must be met independently. A WPS qualified under ASME IX cannot be used for D1.1 work unless it also meets the D1.1 prequalification rules or has been separately qualified per Clause 6.
"The WPS form is just a container. What matters is that every essential variable from Table 5.5 is documented, traceable, and followed on the shop floor."
— Standard fabrication guidance, consistent with D1.1:2025 Clause 5.2.1
Frequently Asked Questions
D1.1:2025 Clause 5.2.1 states that a prequalified WPS may follow any convenient format. There is no mandatory form. AWS Annex J provides sample forms as a starting point, and Annex K provides a reference checklist of code subclauses that a prequalified WPS must address. Most fabricators develop their own WPS forms tailored to their shop operations, as long as all 21 essential variables from Table 5.5 are documented.
D1.1:2025 Table 5.5 lists 21 essential variables that must be included in a written prequalified WPS. These cover the welding process, position, base metal group, filler metal classification, electrode diameter, amperage range, voltage range, travel speed range, shielding gas, transfer mode (for GMAW), preheat and interpass temperatures, joint design, weld type, single or multiple pass, and postweld heat treatment. When any of these variables is changed beyond its permitted tolerance, a new or revised WPS is required.
AWS D1.1:2025 Annex J (informative) provides sample welding procedure specification forms. These are not mandatory forms but reference templates. Most steel fabrication shops, AISC-certified facilities, and welding inspection training programs have their own standardized WPS forms. The form layout does not matter as long as all required variables from Table 5.5 are addressed and the WPS is a written document per Clause 5.2.1.
A WPS template is a blank form with labeled fields for each essential variable — ready to be filled in for a specific weld. A WPS PDF is a completed welding procedure specification saved as a portable document. In practice, fabricators fill in the template for each joint configuration, then distribute the completed WPS as a PDF to the shop floor, the inspector, and the project file. The template is reusable; each completed WPS is job-specific.
A prequalified WPS follows the prescriptive rules in D1.1 Clause 5 without any testing. If the welding process is SMAW, SAW, GMAW, or FCAW, the base metal is in Table 5.6, the joint detail matches Figures 5.1-5.3, and all 21 essential variables from Table 5.5 are within limits, no procedure qualification record (PQR) is needed. A qualified WPS requires physical testing per Clause 6 — the fabricator welds a test coupon, destructively tests it (bend, tensile, macro), and documents the results on a PQR. Qualified WPSs are mandatory for processes like ESW/EGW, for base metals not listed in Table 5.6, or whenever a prequalified variable limit is exceeded. ASME IX has no prequalified path — every WPS must be backed by a PQR.
Yes, significantly. D1.1 allows prequalified WPSs with no testing if prescriptive rules are followed. ASME IX requires every WPS to be backed by a procedure qualification record (PQR) with physical test results — there is no prequalified path. D1.1 uses base metal Groups (I through V) from Table 5.6, while ASME IX uses P-Numbers and Group Numbers from Table QW/QB-422. D1.1 essential variables are listed in Table 5.5 with 21 items for prequalified WPSs. ASME IX essential variables are spread across Tables QW-250 through QW-265, organized by welding process. API 1104 adds a third approach focused on pipeline-specific variables like travel speed limitations and uphill vs. downhill progression.
Yes — a single WPS can cover any joint configuration that falls within the ranges documented on that WPS. For example, a D1.1 prequalified WPS for SMAW on Group I steel with a specific filler metal and parameter ranges can be used for every joint on a project that matches those conditions, regardless of whether it is a groove weld, fillet weld, or different plate thickness (within the preheat and parameter limits). The WPS defines the envelope of acceptable parameters. Each joint that falls within that envelope can be welded using the same WPS. If a joint requires a parameter outside the WPS range, either revise the existing WPS or write a new one.
Reference data from AWS D1.1/D1.1M:2025, ASME BPVC IX:2025, and API 1104. Not affiliated with AWS or ASME.