| S.No. | Checkpoint | IS Requirement | Status |
|---|---|---|---|
| A. Joint Details & Welding Information | |||
| A1 | Joint Identification & Location Acceptance: Joint ID matches drawing, location on structure documented, drawing reference cited, coordinates recorded if applicable | IS 822:1970 Section 3 | OK NC NA |
| A2 | Joint Type Verification Acceptance: Joint type (Butt/Fillet/T-joint/Corner) matches drawing and WPS; Both parent metal surfaces identified | IS 822:1970, IS 816:1969 | OK NC NA |
| A3 | Weld Process Compliance Acceptance: Process (SMAW/GMAW/SAW/FCAW) matches WPS, correct electrode classification per IS 814, electrode diameter matches WPS | IS 822:1970 Section 3; IS 816:1969 | OK NC NA |
| A4 | Welder Qualification Acceptance: Welder ID documented, qualification certificate current and valid per IS 822 (typically 2-3 years), process/position qualified for joint type | IS 822:1970 Section 4 | OK NC NA |
| A5 | Parent Metal Specifications Acceptance: Parent metal grade (Fe 500D/E250/E350) documented, thickness measured and recorded, condition (as-received/stress-relieved) noted | IS 816:1969, IS 822:1970 | OK NC NA |
| A6 | Filler Metal Specification Acceptance: Electrode type and classification per IS 814 (e.g., ER70S-2 for GMAW), size matches WPS, batch/lot number recorded | IS 814:2016 (or applicable version) | OK NC NA |
| A7 | WPS Reference & Validity Acceptance: WPS Reference cited, WPS valid for joint configuration/materials/thickness, preheat/PWHT requirements from WPS followed | IS 822:1970 Section 5; IS 816:1969 | OK NC NA |
| B. Visual Inspection (IS 822:1970) | |||
| B1 | Weld Profile (Face) Acceptance: Profile acceptable: flat (±1.5 mm) or slight convexity or slight concavity; no wavy/irregular surface; transition smooth to parent metal | IS 822:1970 Section 6 | ACCEPT REJECT NA |
| B2 | Weld Face Width (Butt Joints) Acceptance: Width measured at 3+ locations, variation ≤ 5 mm per IS 816 Table 9, no excessive build-up (reinforcement ≤ 3 mm above parent surface) | IS 816:1969 Table 9 | ACCEPT REJECT NA |
| B3 | Reinforcement Height (Butt Joints) Acceptance: Maximum reinforcement: 3 mm above parent metal surface; measured at 3+ locations | IS 816:1969 Section 6.2 | ACCEPT REJECT NA |
| B4 | Throat Thickness (Fillet Joints) Acceptance: Throat ≥ 0.7 × specified leg length (or 3 mm minimum); verified by visual profile or templates; adequate for static load | IS 816:1969 Section 6.3 | ACCEPT REJECT NA |
| B5 | Leg Length (Fillet Joints) Acceptance: Equal leg length (for equal fillet): ≥ specified dimension (e.g., 8 mm), measured perpendicular to weld face, uniform along length | IS 816:1969 Section 6.3 | ACCEPT REJECT NA |
| B6 | Undercut Inspection Acceptance: No undercut ≥ 0.5 mm depth or ≥ 50 mm cumulative length per side of butt; For fillet: none visible on toe | IS 816:1969 Table 9; IS 822:1970 | ACCEPT REJECT NA |
| B7 | Porosity & Blowholes Acceptance: No visible porosity clusters; isolated pores ≤ 1 mm diameter and ≤ 3 pores per 100 mm² acceptable; no steam holes or cracks at pores | IS 822:1970 Section 6 | ACCEPT REJECT NA |
| B8 | Cracks & Cold Cracking Acceptance: NO cracks permitted — not in weld, HAZ, or parent metal; any visible crack = REJECT | IS 822:1970 Section 6 | ACCEPT REJECT NA |
| B9 | Overlap (For Fillet Welds) Acceptance: NO overlap permitted; lap of parent metal over weld face is a defect = REJECT | IS 816:1969 Section 6.3 | ACCEPT REJECT NA |
| B10 | Incomplete Fusion (Lack of Fusion) Acceptance: No visible lack of fusion at weld toe or sidewalls; weld fully bonded to parent; any visible gap = REJECT | IS 822:1970 Section 6 | ACCEPT REJECT NA |
| B11 | Crater Fill & End Quality Acceptance: Craters at weld start/stop filled completely, no shrinkage cavity, smooth transition; for field welds, run-off/run-on tabs acceptable if removed cleanly | IS 822:1970 Section 6 | ACCEPT REJECT NA |
| B12 | Spatter & Cleaning Acceptance: Spatter removed, weld clean and free of flux residue (for SAW); no adherent slag; finish clean | IS 822:1970 Section 6 | ACCEPT REJECT NA |
| B13 | Visual Inspection Overall Verdict Acceptance: All items ACCEPT = pass visual; any REJECT = fail visual, proceed to repair or rejection decision | All items B1-B12 | PASS FAIL NA |
| C. Dimensional Verification | |||
| C1 | Weld Length vs Drawing Acceptance: Actual weld length matches drawing (±5 mm minimum acceptable unless drawing specifies tighter tolerance); continuous weld unbroken | IS 822:1970 | ACCEPT REJECT NA |
| C2 | Weld Size vs Drawing Acceptance: For Fillet: leg length = specified size (±1 mm acceptable); For Butt: reinforcement within limits, throat adequate | IS 816:1969 | ACCEPT REJECT NA |
| C3 | Angular Distortion Acceptance: Angular distortion ≤ 3° total on face side and root side combined; measured with straightedge or dial gauge over 500 mm span | IS 816:1969 Section 7.1 | ACCEPT REJECT NA |
| C4 | Linear Misalignment (Step) Acceptance: For butt welds: misalignment ≤ lesser of (t/4 or 3 mm), where t = parent thickness; measured perpendicular to weld axis | IS 816:1969 Section 7.2 | ACCEPT REJECT NA |
| C5 | Dimensional Check Verdict Acceptance: All dimensional checks ACCEPT = pass; any REJECT requires evaluation for structural impact | All items C1-C4 | PASS FAIL NA |