Bridge Welding Reference Manual - Publication No. FHWA-HIF-19-088 - Technical reference

Oct 28, 2026

Bridge Welding Reference Manual provides a comprehensive technical reference for welding steel highway structures, with an emphasis on steel bridges. It explains welding specifications for highway structures, including the AASHTO/AWS D1.5/D1.5M “Bridge Welding Code” and AWS D1.1/D1.1M “Structural Welding Code–Steel,” and links them to structural performance and design intent. Coverage includes welding materials, equipment, processes, inspection techniques, fracture control plan requirements, engineer responsibilities in fabrication, and fabrication considerations such as accessibility, closed sections, distortion and restraint.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages348

Reading Time14 h 37 min

AccessFree to download

Foreword

Welding Codes and Specifications

AASHTO/AWS Bridge Welding Code

AWS Structural Welding Code–Steel

Welding Materials, Equipment, and Processes

Inspection Techniques and Methods

Fracture Control Plan (FCP)

Engineer Role in Welded Fabrication

Contract Documents and Approvals

Handling Unexpected Circumstances

Fabrication Considerations

Accessibility, Closed Sections, Distortion and Restraint

Partial Joint Penetration and Intersecting Welds

Ancillary Issues

Bridge Welding Reference Manual Publication No. FHWA-HIF-19-088 Infrastructure Office of Bridges and Structures September 2019 (with errata September 2020) FOREWORD Welding is a versatile, complex, and essential process that facilitates the use of a broad range of steel assemblies in transportation structures. Use of welding improves design efficiency for all steel structures and modern typical sections such as trapezoidal (tub) girders and long curved Igirders cannot be achieved without welding. Further, welding facilitates rapid and flexible field connections in new construction and retrofits on existing structures. Bridge engineers need to be skilled in welding design and knowledgeable in welding science to effectively and efficiently detail welded connections during bridge design. The reference manual explains welding specifications governing highway structures, namely the AASHTO/AWS D1.5/D1.5M “Bridge Welding Code”(AASHTO/AWS, 2015) and the AWSD1.1/D1.1M “Structural Welding Code-Steel”(AWS, 2015), and the relationships to structural performance and design intent. The manual provides a detailed overview of welding materials, equipment and processes; includes a discussion of various inspection techniques and methods; addresses the special welding requirements in the fracture control plan (FCP); and lays out the engineer’s role in welded fabrication including the creation of contract documents, approval, and dealing with unexpected circumstances. Additionally, the resource educates the user on fabrication considerations such as accessibility, closed sections, distortion and restraint, the use of partial joint penetration welds and intersecting welds. Finally, the document touches on ancillary issues such as field welding, aluminum, stainless steel, reinforcing steel, welding of coated members and upcoming welding innovations. This reference manual will benefit DOT employees, their representatives, and consultants involved with the welding and fabrication of steel highway structures. This includes designers, fabricators, field/construction/materials engineers and other paraprofessionals associated with structural design, material and procedure specifications, drawing approval, welding, construction, inspection, and repair. Joseph L. Hartmann, PhD, P.E. Director, Office of Bridges and Structures Office of Infrastructure Federal Highway Administration Cover Photos: Source: FHWA Notice This document is disseminated under the sponsorship of the U.S. Department of Transportation (USDOT) in the interest of information exchange. The U.S. Government assumes no liability for the use of the information contained in this document. The U.S. Government does not endorse products or manufacturers. Trademarks or manufacturers’ names appear in this report only because they are considered essential to the objective of the document. Quality Assurance Statement The Federal Highway Administration (FHWA) provides high-quality information to serve Government, industry, and the public in a manner that promotes public understanding. Standards and policies are used to ensure and maximize the quality, objectivity, utility, and integrity of its information. FHWA periodically reviews quality issues and adjusts its programs and processes to ensure continuous quality improvement. TECHNICAL REPORT DOCUMENTATION PAGE | 1. Report No. FHWA-HIF-19-088 | 2. Government Accession No. | | | 3. Recipient’s Catalog No. | | | | --- | --- | --- | --- | --- | --- | --- | | 4. Title and Subtitle
Bridge Welding Reference Manual | | | | 5. Report Date
August, 2019 | | | | | | | | 6. Performing Organization Code: | | | | 7. Author(s)
Ronnie Medlock, P.E. (Medlock, LLC); Heather Gilmer, P.E.(HRV, Inc.); Duane Miller, ScD, P.E. (Lincoln Electric); and Anthony Ream, P.E. (HDR) | | | | 8. Performing Organization Report No. | | | | 9. Performing Organization Name and Address
HDR
Suite 800, 11 Stanwix St.
Pi

FAQs

What is the main purpose of the Bridge Welding Reference Manual?

The manual aims to produce a comprehensive reference covering the technical aspects of welding highway structures, especially steel highway bridges, for DOT personnel and related consultants.

Which welding codes are covered in this manual?

It explains specifications governed by the AASHTO/AWS D1.5/D1.5M “Bridge Welding Code” and the AWS D1.1/D1.1M “Structural Welding Code–Steel,” including how they relate to performance and design intent.

What key topics are included beyond code specifications?

The manual covers welding materials, equipment and processes, inspection techniques, special requirements in the fracture control plan (FCP), and fabrication considerations such as accessibility, distortion and restraint, and special weld types.

Oct 28, 2026

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