FUTURE INFRASTRUCTURE PROJECTS MAY BENEFIT FROM FILLER METAL CONVERSION

Regardless of the products your company fabricates, it?s difficult to argue against one simple premise: quality and efficiency are absolutely essential to your success. Not only do these factors affect the overall cost of operating your business, but they can also separate your company from your competitors.

With billions of U.S. economic stimulus dollars slated in the coming years to improve aging infrastructures and develop major new construction projects, the opportunity for growth among contracting companies stands to be significant. There is an equally sizeable opportunity for new jobs, many of which will be for welding operators.

And whether it is the fabrication of pressure vessels, the construction of new hydropower stations or the repair and restoration of our country?s bridges, companies will need to consider how they will address the volume of work that?s on the horizon. More specifically, they need to consider welding technologies that will allow them to get these jobs done as quickly and effectively as possible.

Not surprisingly, for many years contracting companies have relied heavily on stick welding to complete most, if not all, of the on-site fabrication for major infrastructure jobs. This process is not only familiar to welding operators, but it is also very often specified by the welding procedure for construction applications.

Despite these facts, the process (while it does have its place) is indisputably slow ? at least compared to wire welding. For that reason, many companies have already begun to shift toward self-shielded flux-cored welding to increase productivity, particularly for the portion of construction jobs that are completed outdoors and that have seismic requirements set forth by AWS Code D1.1. Given the scope of potential projects arising in the near future that will have both such requirements, this conversion may be a trend that is worth following.

Switching from stick welding to self-shielded flux-cored welding requires some proactive measures, all which are very fiscally and logistically reasonable ? especially if you consider the productivity advantages and the competitive edge it could create for your company.

First, if you are welding to code, you?ll need to re-qualify your welding procedures as well as your welding operators. While this may seem like a hassle, as you know, welding operators need to have their certifications re-qualified periodically anyhow; this transition to flux-cored wire may just require doing it sooner. Plus, if it means a faster, easier process for you and your welding operators, it will be well worthwhile.

Secondly, you will need to have the proper equipment ? in this case a constant voltage (CV) power source. Again, having this equipment is absolutely critical if your contracting company welds to code. And while it may be tempting to save on your equipment purchases by adding a voltage-sensing feeder to the constant current (CC) power source you currently use for stick welding, unfortunately, this system is not acceptable for self-shielded flux-cored welding to AWS code D1.1. It simply does not react quickly enough to maintain a steady voltage and can lead to weld defects, particularly porosity, that can cost you more money in downtime, rework and possibly contract fees than the upfront cost of new CV power sources.

Finally, to make a successful transition from stick electrodes to a self-shielded flux-cored wire, you?ll need to find the specific type of self-shielded flux-cored wire that is best suited for your application. There are a number of options that meet seismic requirements and offer the necessary high impact strengths for critical code work. A filler metal manufacturer or trusted welding distributor can help you make the best selection.

Remember, if your company is one that stands to grow and benefit from the many potential infrastructure repairs and new construction jobs on the horizon, it may be worth considering now how a different welding process can give you a competitive edge.

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Tim Hensley is the distribution manager for Hobart Brothers, 101 Trade Square East, Troy, OH 45373, 800-424-1543, www.hobartbrothers.com, [email protected].