Fechino Files: Welding

Words: Steven Fechino

As a mason contractor, welding typically falls into two categories: fabrication or repair. Fabrication is when our certified welders make structural connections on the job site, and repairs are just that—fixing one of the hundred things that break every year: equipment, scaffold pins, and even truck beds. Many masonry contractors employ certified welders because they can easily maintain a job site schedule when a few quick structural welds are required. I worked with a couple of certified welders, Mark Hampton and Firecracker (his real name was Elbert McPeak). I believe they could weld behind their back with one eye shut, one hand holding a cold soda, and balancing on one foot. Those guys were amazing.

In an abbreviated discussion, the American Welding Society (AWS) offers a Certified Welder Certification based on welding performance; however, the employee does not need to attend a particular school or have prerequisites. Prior experience will be the key to the experience needed to pass the testing requirements. To become a Certified Welder (CW), the employee has to schedule an appointment with an AWS Accredited Testing Facility, typically located in a larger city where work is plentiful. The testing is strict, but once passed, the credentials are transferable from company to company and are nationally accepted.

The test includes an application that must be filled out, a practical assessment of welding skills—such as flat, vertical, and overhead—and a written assessment from the employee. If the facility passes the employee, payment is made, a certification card is issued, and within approximately three weeks, the employee can become a certified welder. There are many certifications offered by the AWS, and the Certified Welder Certificate is the first step.

Having observed the older welders, they tend to still favor “stick” or arc welding. Arc welding (actually it is flux-cored arc welding) is popular because welders can adjust the settings in the shop, the yard where a breeze may be present, or even on a scaffold—almost to the same settings. This is because the weldment or electrode is protected by a material flux on the welding rod. This flux is direct, unlike gas that may disperse quickly when there is a slight breeze. The biggest drawback is that this method creates a bit more spatter than other methods of welding. Arc welding is convenient when welding an older piece of metal that may have mortar, scale, or even rust. While proper preparation is necessary, in some cases when fixing old or broken things, perfection is not an option. Arc welding is typically my first choice.

Welding rods are expensive and each type has its proper application. I keep my welding rods in my office closet, grabbing what I need when I have something to weld. I do not keep my welding rods outside in my shop because the humidity here in Tennessee is too high, and the flux tends to not perform as well after sitting out. They stay drier by keeping them in my office, and I lose fewer of them. I also have different rods depending on what needs to be welded. Since I do not do fabrication and tend to only fix broken things, I like to use the “Farmer Rod 6011,” a term coined by Miller Welding. This rod is definitely forgiving. The 6011 welding rod (electrode) has deep penetration, burns very fast, and has a higher rate of spatter than the electrode used for structural fabrication. This rod is easier to learn on and still provides a fully penetrated weld for repairs that need to be trusted.

On a job site, the rod of choice will typically be a 7018. This is a thicker structural rod, good for thicker welds with a bit less penetration per pass and less spatter than other rods. The 7018 can be used for repairs as well, but the 6011 is typically not used for structural fabrication. Arc welding is the only form of welding currently permitted on a job site for structural welds because the flux on the rod ensures the protection of the arc from atmospheric elements.

Younger welders definitely prefer the MIG welding process. Gas metal arc welding (MIG) was easier for me to learn, was a faster process overall, could be set to use on much thinner metals, and had two options for flux. The first option was to use a shielding gas; however, this process could only be used indoors as a slight breeze would disperse the shielding gas, and the weld would not perform as desired. Personally, I use a flux-cored wire, where the flux coats the electrode wire that dispenses from a roll of wire through a handheld “gun,” providing the welder with an ease and accuracy that trumps the arc option. This wire option allows for outdoor welding, typically of thinner gauge material.

Here is reality: everyone who has ever been too casual around someone who welds has paid severely. If you were ever in a concrete block building at night while someone was welding and you turned your back on the weld but looked at the wall, the reflection off the walls is enough to burn the living daylights out of your eyes. The reaction will show up around 2:30 a.m. when you feel like someone rubbed your eyes with masonry sand. If you ever had to do a quick weld and thought you could block the weld with your hand, again, lesson learned. If you ever welded and saw white smoke after the arc had stopped, yes, your shirt was on fire. Welding has precautions and common sense rules. I am the worst person to say I have always used proper personal protection, but when welding, I can assure you it is worth taking the extra steps. If it is hot outside when you are welding, you are going to sweat. If you are welding on a hot day with protective gear, yup, you are going to sweat, but you will not burn tissue. Believe me, from someone who is not as smart as you, the protective gear is worth it.
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