The AWS D1.1 Structural Steel Welding Code remains integral to structural steel fabrication, qualification, and inspection. The 2025 edition introduces multiple revisions that bring terminology, documentation, and qualification requirements into closer alignment with modern welding practice.
These revisions build on established rules, with practical effects in procedure documentation, heat control, and inspection consistency. The 2025 update applies to new or modified work, and WPSs, qualification records, and inspection programs developed under this edition should follow the current AWS D1.1 requirements.
Unified Terminology Across the Code
Clause 3 expands and refines definitions to standardize the use of technical terms across design, fabrication, and inspection. New and clarified terms include allowable strength, design strength, and the distinctions between matching, undermatching, and overmatching filler metals. The revisions also align terminology more closely with ASNT and ASME standards.
Terminology related to magnetic particle (MT) and penetrant testing (PT) has also been aligned with inspection clauses, improving consistency in evaluation and recordkeeping.
Clearer language means fewer misinterpretations during design review, procedure preparation, and quality verification.
Updated Requirements for WPS Qualification
The 2025 code strengthens Welding Procedure Specification (WPS) documentation requirements. Preheat and interpass temperatures must now be listed on every WPS, with methods for establishing minimum preheat defined through tables, Annex B calculations, or qualification tests. The maximum interpass temperature must also be recorded when impact or material limits apply. See Table 5.11 for Prequalified Minimum Preheat and Interpass Temperature.
Plug and Slot welds now have their own WPS qualifications, with corresponding specimen and testing requirements. Macroetch testing procedures were revised to ensure adequate evaluation for these weld types.
For users of ProWrite D1, these changes are already supported. The software now includes a pulsed spray option for GMAW processes when creating PQRs, WPSs qualified by PQR, and WPQs. This update, reflected in the Welder-to-WPS analysis, enables shops to correctly document and qualify pulsed spray transfer per AWS D1.1 (2025).
Additionally, ProWrite has updated paragraph references for travel speed, shielding gases, and fillet weld notes to match the revised code citations.
These updates allow welding engineers and inspectors to develop and verify WPSs using current clause references without manual cross-checking.
Download CEI’s Certified Welding Inspector–prepared 2025 AWS D1.1 Code Changes Guide for full clause explanations, including prequalification examples, qualification ranges, and updated table references.
Reorganization of Prequalified Procedure Tables
The prequalified WPS section has been restructured into process-specific tables:
-
Table 5.1 – Shielded Metal Arc Welding (SMAW)
-
Table 5.2 – Submerged Arc Welding (SAW)
-
Table 5.3 – Gas Metal Arc Welding (GMAW, solid wire)
-
Table 5.4 – Flux Cored and GMAW (metal-cored wire)
A major procedural change appears in Table 5.3, which establishes minimum amperage requirements for GMAW solid wire based on electrode diameter. FCAW and GMAW metal-core processes remain tied to manufacturer recommendations, but electrode diameter limits now depend on both position and base-metal thickness.
These revisions improve clarity in process selection and parameter control. Within ProWrite D1, the updated references and amperage limits are built into the prequalification database, providing automatic checks during WPS entry.
Fabrication and Heat Treatment Revisions
Fabrication requirements now define how far preheat must extend from the weld based on material thickness:
-
Under 1.5 in. (38 mm): at least twice the thickness
-
1.5 in. and above: equal to the thickness but not less than 3 in. (75 mm)
The maximum furnace temperature when loading assemblies for postweld heat treatment has increased to 800°F (430°C), up from 600°F (315°C). The code also clarifies when weld tabs may be omitted. This update aligns the language more closely with ASME standards.
These changes formalize expectations for uniform heating and controlled PWHT across different joint configurations.
Inspection and Personnel Qualification
The inspection requirements refine both acceptance criteria and personnel qualification.
-
Linear discontinuities are defined as longer than three times their width; rounded indications are three times or less and must be cleaned before evaluation.
-
Table 8.1 updates visual undercut limits, now tied to weld length and base-metal thickness.
-
Nondestructive testing (NDT) personnel are now required to hold ASNT certification, eliminating ambiguity about qualification standards.
ProWrite’s inspection modules reflect these updates, with revised fillet-note references and clause citations for visual and NDT evaluation, ensuring inspection reports correspond precisely to AWS D1.1 (2025).
Addition of Type D Studs
The 2025 edition introduces Type D studs, produced from deformed wire or bar conforming to ASTM A706/A706M. These studs are typically used for embedded plate or reinforced-concrete applications that require flush profiles or higher bond strength.
Qualification of both procedures and welders is now required for this stud category. ProWrite’s stud welding module includes data fields for Type D studs, supporting proper procedure and qualification documentation.
Welding Documentation Software Alignment
CEI’s ProWrite software reflects the AWS D1.1 (2025) updates throughout its D1 module. The platform supports:
-
Pulsed spray options for GMAW PQR, WPS, and WPQ creation
-
Updated paragraph and table references aligned with 2025 revisions
-
Validation of GMAW amperage minimums and electrode size limits
-
Preheat and interpass temperature fields required under the new code
-
Stud-welding qualification documentation, including Type D studs
-
Automated tracking of welder and procedure qualifications to maintain code compliance
With the 2025 requirements incorporated into ProWrite, procedure, qualification, and inspection documentation now reflects the latest AWS language and clause references.
Download the Complete AWS D1.1 (2025) Code Changes Guide
For the full clause-by-clause analysis, tables, and practical compliance commentary prepared by CEI’s Certified Welding Inspector, download the 2025 AWS D1.1 Code Changes Guide.
This reference provides detailed interpretations to support qualification updates, WPS revisions, and inspection readiness under the 2025 code.
Leave a Comment