AWS D1.1:2025 · Quick Reference Card

AWS D1.1:2025 Quick Reference

Single-page summary of AWS D1.1:2025 Código de Soldagem Estrutural — Steel. All 11 clauses, the most-cited tables (5.7, 5.11, 7.7, 8.1), Pré-qualificado vs qualified rules, steel categories, and Inspeção scope. For fast lookups on the shop floor or in the Inspetor booth.

AWS D1.1:2025 covers welded Aço estrutural up to 100 ksi yield Resistência and 1/8-inch Mínimo Espessura. The 11 clauses are organized by lifecycle: scope, references, terms, design, prequalification, qualification, Fabricação, inspection, plus three specialty clauses (tubular, strengthening/Reparo, stud Soldagem). Most projects use prequalified WPSs per Cláusula 5; non-Norma joints require Clause 6 PQR Ensaio.

Scope

What AWS D1.1:2025 Covers

AWS D1.1:2025 Structural Welding Code — Steel applies to the design, fabrication, and inspection of welded structural steel construction. The Código's scope per Clause 1.1 covers carbon and low-alloy steels with a minimum specified yield strength up to 100 ksi (690 MPa) and Metal de Base thickness 1/8 inch (3 mm) or greater.

Materials and structures NOT covered by D1.1: sheet steel under 1/8 inch (use D1.3), Aço inoxidável (use D1.6), aluminum (use D1.2), reinforcing bar (use D1.4), bridges with cyclic loading or fracture-critical members (use D1.5). Tubular structures are covered in Clause 9 of D1.1 with cross-references to the main body. Stud welding is covered in Clause 11.

Welding processes covered: Shielded Metal Arc (SMAW), Gas Metal Arc (GMAW), Flux-Cored Arc (FCAW gas-shielded and self-shielded), Submerged Arc (SAW), Gas Tungsten Arc (GTAW), and Electroslag/Electrogas (ESW/EGW). Each process has its own essential variables in Tables 5.5 (prequalified) and 6.6 through 6.10 (qualified).

Per AWS D1.1:2025 Clause 1.1.1: “This code contains the Requisitos for fabricating and erecting welded steel structures. When this code is stipulated in Documentos contratuais, conformance with all provisions of the code shall be required, except for those provisions that the Engineer or contract documents specifically modifies or exempts.”

— AWS D1.1/D1.1M:2025, Structural Código de Soldagem — Steel

Structure

The 11 Clauses of AWS D1.1:2025

Clause	Title	Covers
Clause 1	General Requirements	Scope, applicability, units, base metals covered
Clause 2	Normative References	Referenced standards (AWS A2.4, A3.0, A5 series, ASTM)
Clause 3	Terms and Definitions	Welding terminology defined per AWS A3.0
Clause 4	Design	Allowable stresses, Projeto de junta, fillet/groove sizing, fatigue
Clause 5	Prequalification of WPSs	Joint details, materials, parameters accepted by reference (no testing)
Clause 6	Qualification	PQR procedure, Ensaio mecânico, Soldador/operator qualification
Clause 7	Fabrication	Cutting, fit-up, Pré-aquecimento application, welder workmanship
Clause 8	Inspection	Inspector qualifications (CWI per QC1), VT, NDT, Aceitação criteria
Clause 9	Tubular Structures	Specific provisions for hollow section connections (HSS, pipe)
Clause 10	Strengthening and Repair	Existing structure modifications, Soldagem repair procedures
Clause 11	Stud Welding	Drawn-arc and capacitor-discharge stud welding requirements

The lifecycle order — design (4), prequalification or qualification (5/6), fabrication (7), inspection (8) — reflects the order operations are typically performed on a project. Specialty clauses 9, 10, and 11 augment the main body for specific construction Tipos.

Key Tables

Most-Cited Tables in D1.1:2025

Table 5.7 — Metal de Adição Requirements (Prequalified)

Table 5.7 matches base metal categories from Tabela 5.3 to allowable filler metal classifications per AWS A5 specifications. For Categoria A and B steels, Baixo Hidrogênio E70xx series electrodes are typically required for SMAW. For Category C and D, supplementary low-hydrogen and chemistry restrictions apply. The filler metal must match or under-match the base metal per the strength compatibility rules in §5.7.1.

Table 5.11 — Minimum Preheat and Temperatura Interpasse (Prequalified)

Table 5.11 is the most-referenced table in D1.1 for shop floor work. It specifies minimum preheat in degrees Fahrenheit and Celsius, organized by base metal category, Processo de Soldagem group, and base metal Faixa de espessura. Per §5.11, preheat is required when the values in Table 5.11 are above ambient Temperatura. Failure to apply preheat is the single most common cause of underbead cracking in Aço carbono welds. Use the preheat calculator for instant per-steel lookups.

Table 7.7 — Minimum Solda de Filete Size

Table 7.7 specifies minimum Perna da solda de filete Tamanho based on base metal thickness:

Base Metal Thickness (T)	Minimum Fillet Leg
Up to 1/4 inch (6 mm)	1/8 inch (3 mm)
Over 1/4 to 1/2 inch (6 to 13 mm)	3/16 inch (5 mm)
Over 1/2 to 3/4 inch (13 to 19 mm)	1/4 inch (6 mm)
Over 3/4 inch (19 mm)	5/16 inch (8 mm)

Per Footnote A, T is the thicker part for Não Baixo Hidrogênio single-pass; T is the thinner part for low-hydrogen processes. Per Footnote C, a 3/16-inch cap applies for cyclically carregado structures regardless of thickness.

Table 8.1 — Inspeção Aceitação Visual Criteria

Table 8.1 specifies visual Critérios de aceitação for fillet, CJP, and PJP welds, separated by static vs cyclic loading. Trincas of any size are unacceptable in both load conditions. Rebaixo Limites are 1/32 inch Máximo for static, 1/100 inch for cyclic per direction-of-stress rules. Porosidade individual pore diameter limit is 1/32 inch with frequency limits per the table footnotes. Per §8.9, all visual inspection shall be performed by a qualified inspector per Clause 8.1.4 — typically a CWI per AWS QC1.

Steel Categories

Base Metal Categories (Table 5.3)

AWS D1.1:2025 Table 5.3 groups prequalified base metals into four categories based on chemistry and yield strength.

Category	Yield Range	Examples
Category A	Up to 50 ksi	A36, A53 Gr B, A106 Gr B, A500 Gr B, A572 Gr 50
Category B	Up to 60 ksi	A572 Gr 60, A588, A992
Category C	Up to 70 ksi	A572 Gr 65, A709 Gr 50W, A709 Gr 70W
Category D	Over 70 ksi	A514, A709 Gr HPS 70W, A913 Gr 65/70/80

Each category has its own preheat requirements in Table 5.11, filler metal restrictions in Table 5.7, and Variável essencial ranges in Table 5.5. Higher categories require higher preheat and stricter low-hydrogen practice. Knowing the category is the first step in selecting a EPS pré-qualificada — wrong category means wrong preheat and risk of cracking.

WPS Selection

Prequalified vs Qualified WPS — Decision Logic

Per Clause 5, a prequalified WPS uses a joint, base metal, filler metal, and parameters that the code accepts as qualified by reference. To use a prequalified WPS, ALL of the following must hold:

Joint matches Figures 5.1 through 5.10 (over 100 prequalified joint details)
Base metal is in Table 5.3 (one of the four categories above)
Filler metal matches Table 5.7 for the base metal category
Preheat meets Table 5.11 minimum for category, process group, and thickness
All essential variables stay within Table 5.5 ranges per §5.5

If any prequalified condition cannot be met, a qualified WPS per Clause 6 is required. The Contratante performs a Registro de Qualificação de Procedimento de Soldagem (PQR) — weld a Corpo de prova to the proposed parameters, then perform mechanical testing per Table 6.4 (tension, bend, optional CVN). The PQR validates the specific parameter combination, and the resulting WPS is qualified for production use within the essential variable ranges of Tables 6.6 through 6.10.

Field tip: Always check prequalification first. PQR testing typically costs $2,000-$5,000 per procedure. If your joint is in Figure 5.1 to 5.10 and your steel is in Table 5.3, prequalification is the cheaper, faster path. Custom joints and high-strength steels (Category D) almost always require Clause 6 qualification.

— CWI shop floor observation, structural Fabricante, 2026

Inspection

Inspection Scope (Clause 8)

Per Clause 8, AWS D1.1:2025 inspection requirements cover three layers: visual inspection (VT), nondestructive testing (NDT), and inspector qualification.

Per §8.9, all welds shall be visually inspected. Visual inspection is performed by personnel meeting the qualification requirements of §8.1.4 — typically a Inspetor de soldagem certificado (CWI) per AWS QC1, or an equivalent inspector qualification. VT is performed before any volumetric NDT per §8.13.

Per §8.13 and §8.14, NDT methods include Ensaio Radiográfico (RT), Ensaio Ultrassônico (UT), Ensaio por Partículas Magnéticas (MT), and Líquidos Penetrantes testing (PT). The contract documents specify which welds require NDT and which method. CJP welds in tension typically require either RT or UT per §8.14.5. Statically loaded structures may require less NDT than cyclically loaded.

Acceptance criteria per Table 8.1 for VT, Table 8.2 for tension-loaded welds (RT/UT), and Table 8.3 for compression-loaded welds. The CWI's authority and responsibilities are defined in §8.1 through §8.4 — the inspector verifies WPS, monitors fit-up and welding, performs VT, witnesses or reviews NDT, and signs off on weld acceptance.

Citation

How to Cite AWS D1.1 in Procedures and Reports

Formal references: AWS D1.1/D1.1M:2025 Structural Welding Code — Steel, American Welding Society, Miami, FL. The /D1.1M suffix indicates the metric companion document — for SI unit projects use D1.1M:2025.

Within procedures, WPS forms, and inspection reports, the short form AWS D1.1:2025 is acceptable along with the specific clause, table, or figure being referenced. Examples of acceptable inline citations:

per AWS D1.1:2025 Table 5.11 — preheat reference
per AWS D1.1:2025 §8.9 — inspection scope reference
per AWS D1.1:2025 Clause 6.2.1 — PQR testing reference
per AWS D1.1:2025 Figure 5.4 — prequalified joint reference

The 2025 edition is the current edition as of April 2026 and supersedes D1.1:2020. Drawings and contracts that reference “AWS D1.1” without an edition default to the latest edition unless explicitly fixed (uncommon and requires explicit owner agreement). When a project transitions from one edition to the next, all related WPSs, PQRs, and inspector qualifications should be reviewed for any code changes that affect the work — see the dedicated AWS D1.1:2025 changes guide for the most-impactful 2025 updates.

Frequently Asked

AWS D1.1:2025 — FAQ

What does AWS D1.1:2025 cover?

AWS D1.1:2025 Structural Welding Code — Steel covers the design, fabrication, and inspection requirements for welded structural steel construction. It applies to carbon and low-alloy steels with a minimum specified yield strength up to 100 ksi (690 MPa) and base metal thickness 1/8 inch (3 mm) or greater. The code is referenced by AISC 360 Specification for Structural Steel Buildings and by most state DOT bridge specifications for non-fracture-critical work. The code covers SMAW (stick), GMAW (MIG), FCAW (flux core), SAW (submerged arc), GTAW (TIG), and ESW/EGW (electroslag/electrogas) processes. It does not cover sheet steel under 1/8 inch (governed by D1.3), stainless steel (D1.6), aluminum (D1.2), reinforcing bar (D1.4), bridges with cyclic loading or fracture-critical members (D1.5), or tubular structures (Clause 9 of D1.1 with cross-references to D1.1 main body). The 11 clauses are organized by lifecycle: scope, normative references, terms, design (Clauses 4 and 9), prequalification (5), qualification (6), fabrication (7), inspection (8), and three specialty clauses (9 tubular, 10 strengthening/repair, 11 stud welding).

What is the difference between Clause 5 and Clause 6 in D1.1?

Clause 5 of AWS D1.1:2025 covers prequalified Welding Procedure Specifications — joint configurations, materials, and parameters that the code accepts as qualified by reference, eliminating the need for procedure qualification testing. Clause 5 includes prequalified joint details (Figures 5.1 through 5.10), prequalified base metal categories (Table 5.3), prequalified filler metal classifications (Table 5.7), preheat requirements (Table 5.11), and essential variables for prequalified WPSs (Table 5.5). Clause 6 covers procedure qualification testing — when prequalification is not applicable (non-prequalified joint, non-prequalified material, or essential variable outside prequalified ranges), the contractor must perform a Procedure Qualification Record (PQR) per Clause 6.2.1 to qualify a WPS. Clause 6 includes test specimen requirements (Figures 6.1 through 6.18), mechanical test acceptance criteria (Table 6.4), and the essential variables that govern PQR scope (Tables 6.6 through 6.10 by process). The practical rule: if you can build to Clause 5 with prequalified WPS, do so — it eliminates testing cost. If your joint or material falls outside prequalification, you need a PQR per Clause 6.

What is AWS D1.1 Table 5.11?

AWS D1.1:2025 Table 5.11 specifies minimum preheat and interpass temperatures for prequalified WPSs. The table is organized by base metal category (A, B, C, or D from Table 5.3), welding process group, and base metal thickness range. Each row gives the minimum preheat in degrees Fahrenheit and Celsius. For example, Category B steel (most common A36, A572 Gr 50) welded with low-hydrogen process at thickness over 3/4 inch through 1-1/2 inch requires 150°F (65°C) minimum preheat. Footnotes A through E define exceptions including minimum preheat for restraint conditions, the relationship between preheat and interpass temperature (per Clause 7.6.5, minimum interpass equals minimum preheat), and the exception for bridges where supplementary requirements may apply. Per AWS D1.1:2025 §5.11, preheat is required for all welding when the values in Table 5.11 are above ambient temperature. Failure to maintain minimum preheat is the single most common cause of underbead cracking in carbon steel welds. Use the Clause5 preheat calculator at /welding/preheat-calculator/ for instant per-steel lookups.

What is AWS D1.1 Table 7.7?

AWS D1.1:2025 Table 7.7 specifies minimum fillet weld sizes based on base metal thickness. The table has four rows: base metal thickness up to 1/4 inch requires 1/8 inch minimum fillet leg; over 1/4 to 1/2 inch requires 3/16 inch minimum; over 1/2 to 3/4 inch requires 1/4 inch minimum; over 3/4 inch requires 5/16 inch minimum. Per Footnote A, T equals the thicker part joined for non-low-hydrogen processes without preheat (single-pass required), but T equals the thinner part joined for low-hydrogen processes and non-low-hydrogen with cracking prevention per Clause 6.8.4. Per Footnote B, the minimum fillet size need not exceed the thinner part thickness. Per Footnote C, a 3/16-inch cap applies for cyclically loaded structures regardless of base metal thickness. These minimums exist to prevent underbead cracking caused by insufficient heat input into thick base metal — too small a fillet on thick plate cools too quickly, locking in residual stresses and hydrogen. For edges 1/4 inch or thicker, the maximum fillet size is material thickness minus 1/16 inch per Clause 4.5.2.9.

What is AWS D1.1 Table 8.1?

AWS D1.1:2025 Table 8.1 specifies visual inspection acceptance criteria for fillet welds, complete joint penetration (CJP) groove welds, and partial joint penetration (PJP) groove welds, separated by statically loaded vs cyclically loaded structures. The table covers crack acceptance (cracks of any size are unacceptable for both static and cyclic), weld profile (acceptable convex profile per Figures 8.4 through 8.6), undersize tolerance (5% of weld length may be undersize per the diminished-thickness rule), undercut (1/32 inch maximum for static, 1/100 inch for cyclic per direction-of-stress rules), porosity (1/32 inch maximum diameter for individual pores, with frequency limits), and fusion (complete fusion required, no incomplete fusion at root or sidewall). Per AWS D1.1:2025 §8.9, all visual inspection shall be performed by personnel meeting the qualification requirements of Clause 8.1.4 — typically a Certified Welding Inspector (CWI) per AWS QC1 or an equivalent inspector qualification. Visual inspection is performed before any volumetric NDT (UT or RT) per Clause 8.13.

What are the four base metal categories in AWS D1.1?

AWS D1.1:2025 Table 5.3 groups prequalified base metals into four categories based on chemistry and yield strength. Category A includes mild carbon steels with specified minimum yield strength up to 50 ksi — the most common is A36 (36 ksi yield), plus A53 Gr B, A106 Gr B, A500 Gr B, A572 Gr 50. Category B includes higher-strength carbon and low-alloy steels with yield up to 60 ksi — A572 Gr 60, A588, A992. Category C includes medium-strength low-alloy steels with yield up to 70 ksi — A572 Gr 65, A709 Gr 50W, A709 Gr 70W. Category D includes high-strength low-alloy steels with yield over 70 ksi — A514, A709 Gr HPS 70W, A913 Gr 65/70/80. Each category has its own preheat requirements (Table 5.11), filler metal restrictions (Table 5.7), and essential variable ranges (Table 5.5). Higher categories require higher preheat and stricter low-hydrogen practice. Knowing the category is the first step in selecting a prequalified WPS — wrong category means wrong preheat and risk of cracking.

What is the difference between prequalified and qualified WPS?

A prequalified WPS per AWS D1.1:2025 Clause 5 uses a joint configuration, base metal, filler metal, and welding parameters that the code accepts as qualified by reference. The contractor writes the WPS document but does not perform mechanical testing — the code's body of historical test data substitutes for project-specific qualification. To use a prequalified WPS, all of the following must hold: joint matches Figures 5.1 through 5.10, base metal is in Table 5.3, filler metal matches Table 5.7 for the base metal category, preheat meets Table 5.11, and all essential variables stay within Table 5.5 ranges. A qualified WPS per Clause 6 is required when any of the prequalified conditions cannot be met. The contractor must perform a Procedure Qualification Record (PQR) — weld a test coupon to the proposed parameters, then perform mechanical testing per Table 6.4 (tension, bend, optional CVN). The PQR validates the specific parameter combination and the resulting WPS is qualified for production use within the essential variable ranges of Tables 6.6 through 6.10. Prequalified is faster and cheaper; qualified is more flexible.

What welding processes does AWS D1.1 cover?

AWS D1.1:2025 covers six welding processes: Shielded Metal Arc Welding (SMAW, stick), Gas Metal Arc Welding (GMAW, MIG), Flux-Cored Arc Welding (FCAW, both gas-shielded FCAW-G and self-shielded FCAW-S), Submerged Arc Welding (SAW), Gas Tungsten Arc Welding (GTAW, TIG), and Electroslag and Electrogas Welding (ESW/EGW). Each process has its own essential variables in Tables 5.5 (prequalified) and 6.6 through 6.10 (qualified). SMAW and GMAW are the most common in structural fabrication. FCAW is dominant for in-position welding on heavy structural members. SAW is used for shop production of long welds (girders, beams). GTAW is used for root passes on critical CJP welds and for stainless overlay. ESW/EGW are specialty processes for very thick sections — note that ESW requires a project-specific qualification per §6.2.4 because of its high heat input characteristics. Note: Stud welding is covered separately in Clause 11. Resistance welding is not covered by D1.1; use AWS C1.1 for resistance spot welding of steel.

Where do I find essential variables for D1.1 WPS?

Essential variables for AWS D1.1:2025 prequalified WPSs are in Table 5.5, organized by welding process. For example, SMAW has essential variables including electrode classification (A5.1 or A5.5), electrode diameter (which determines amperage range), polarity (DCEP for low-hydrogen E70xx series), preheat (Table 5.11), interpass temperature (≥ minimum preheat per §7.6.5), travel speed (within prequalified ranges by joint type), and welding position. Essential variables for qualified WPSs are in Tables 6.6 (SMAW), 6.7 (SAW), 6.8 (GMAW/FCAW), 6.9 (GTAW), and 6.10 (ESW/EGW). The qualified-WPS essential variables are stricter and define the range over which a single PQR qualifies a WPS — for example, base metal thickness range qualified by a single PQR is the test coupon thickness ±25% (most processes, see Tables 6.6 through 6.10). Changes to essential variables require either re-qualification or a separate PQR. Supplementary essential variables apply when notch toughness testing is specified.

How do I cite AWS D1.1 in a procedure or report?

AWS D1.1 is cited as 'AWS D1.1/D1.1M:2025 Structural Welding Code — Steel, American Welding Society, Miami, FL' in formal references. Within procedures, WPS forms, and inspection reports, the short form 'AWS D1.1:2025' is acceptable along with the specific clause, table, or figure being referenced — for example, 'per AWS D1.1:2025 Table 5.11' or 'per AWS D1.1:2025 Clause 8.9'. The /M suffix indicates the metric companion document — for SI unit projects use 'D1.1M:2025'. The 2025 edition is the current edition as of April 2026 and supersedes D1.1:2020. Drawings and contracts that reference 'AWS D1.1' without an edition default to the latest edition unless explicitly fixed (which is uncommon and requires explicit owner agreement). When a project transitions from one edition to the next, all related WPSs, PQRs, and inspector qualifications should be reviewed for any code changes that affect the work — see the dedicated AWS D1.1:2025 changes guide at /welding/aws-d1-1-2025-changes/ for the most-impactful 2025 updates.

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