Steel deck supports the structures we rely on every day — from schools and offices to bridges and factories — thanks to its strength, fire resistance, and resilience. Often, those benefits rely on proper welding, a traditional and often used method of attachment. However, labor constraints and cost pressures can push specifiers to view mechanical fastening as a more practical alternative to welding.
At Steel Deck Institute (SDI), we believe welding can be part of a well designed and installed structure. Engineers and architects who understand welding’s impact can make smarter decisions that ensure the long-term performance of their projects. Our goal is to ensure the industry is informed so we can all improve the performance of the structures we rely on every day.
Why Welding Still Matters in Steel Deck Construction
Welding fuses steel to create a strong structural connection. It’s used as a connecting method in almost all forms of modern infrastructure. Properly made and protected welds will remain strong throughout the life of the structure.
Welding is both a science and an art. The science developed the technology to make safe and effective welds. The art comes from the tradesperson plying the trade and training the next generation of welders through apprenticeship and other training. Like other industries, welding is increasingly supported by advanced technologies such as automation.
Common Welding Challenges in the Field
Anytime you’re out in the field, you face a lot more variables than in the shop. Many of the challenges of field welding can be attributed to environmental conditions or a lack of material preparation. When welders don’t understand or adhere to procedures, quality issues can arise. Wind, water, and temperature changes can all have an impact on your weld quality.
You can mitigate many of these challenges by:
- Following established procedures
- Double-checking fit-up
- Conducting thorough training and routine inspections
SDI Technical Note 2 provides guidance on the application of the Structural Welding Code, specifically American Welding Society (AWS) D 1.3-2018 and how it applies to steel deck welding. Reviewing this with your team can help prevent many common field issues.
Field Welding & Equipment Recommendations
When welding is used, steel deck is always field welded. That means you can use engine-driven welders. If you have power in the field, you can also use an inverter welder to generate a proper weld. Field welders typically use either a stick electrode or self shielded with flux core. Both are excellent options when you’re dealing with the elements to reduce shielding gas dependency. One emerging technology we’re seeing is idle, engine-driven welders that can conserve fuel and reduce emissions.
When to Consider Mechanical Fasteners
Although welded connections are often as equally strong and stiff as mechanical ones , there are some situations where mechanical fasteners are a better choice. Typically, this is the case when you lack skilled welding labor—unfortunately, a growing issue in the industry. There’s currently a shortage of qualified welders to complete infrastructure repair and construction.
Obviously, there are some materials that make welding impossible. In those instances, mechanical fasteners are the best and often only option. Screws and power actuated fasteners can also be viable alternatives if you’re working in difficult conditions that might interfere with effective welding techniques or make access difficult.
Quality Control and Inspection
If you want to make sure your welds are high quality and meet standards, AWS D1.3 and SDI Technical Note 8 provide an industry-standard starting point. Using these as guidelines, establish documented quality assurance (QA) plans and procedures to avoid overlooking important technical issues. Setting up best practices will eliminate many human errors due to oversight.
Implement pre-weld checklists along with post-weld inspections to ensure quality and reduce unnecessary rework. The human element is usually the biggest factor in quality control.
Dealing with Weld Failures
If you experience a weld failure despite taking the above precautions, you need to start by analyzing the root cause. Consider whether there was a design flaw, a procedural gap, or a lack of adherence to your policies. This analysis will help point to a fix.
You may need to make a design change or revisit your procedures — even those that you thought were tested and firmly established. You can draw on outside experts as needed, including third-party consultants or welding manufacturer analysis labs. A good place to start is SDI’s Technical Note 8.
Coatings and Weld Preparation
Coatings that do not interfere with creating a proper weld do not need to be removed prior to welding. AWS D1.3 ‘Structural Welding – Sheet Steel” requires that the welding process be qualified using the coating being welded through.
Training and Support Resources
If you need training and support when welding steel deck, there are many options available. Lincoln Electric offers training across the United States, including many sessions hosted in Cleveland, Ohio with over 200 field engineers available for on-site help. Don’t overlook online training and certification support for welding teams, engineers, and architects. These can empower your stakeholders and principals to make effective decisions about quality control.
Trends in Welding for Steel Deck
Although welding and steel deck technology aren’t new, we’re seeing advances in the industry.
Some technology innovations we’re seeing include energy-saving welders, which are particularly appropriate given that many new infrastructure projects are based on increasing green energy availability. These welders deliver more stable arcs with lower energy consumption. We’re also seeing improved field equipment, which will bring field welding closer to shop welding in quality.
The Importance of Safety
Safety should always be the top priority, both the safety of workers and the safety of your structure, as they’re interconnected. The physical demands and often hazardous environments welders work in pose a serious risk. Implementing OSHA-compliant safety standards such as fall prevention, proper ventilation, and eye protection will lay the foundation for a culture of safety.
Directly integrate safety steps in your QA plans to avoid overlooking important measures. Taking a QA approach to safety integrates it into all aspects of your operations rather than creating a siloed, stand-alone process that is separate from performance goals. Safe welds are long-lasting welds, so take the time to protect your team and your project.
Final Thoughts for Specifiers
Welding is ideal when conditions allow for quality control and safety. It produces a strong, high quality joint and enables modern construction. The industry is facing changes that present both challenges and opportunities. The shortage of qualified welders can be a limiting factor in projects. However, new materials and technologies are making operations more cost-effective and energy-efficient.
The best steps you can take to future-proof your projects are to stay current on new materials, procedures, and training resources. SDI and our partners, such as Lincoln Electric, provide comprehensive support for engineers and architects who are looking to improve their project quality.
Elevate your Steel Deck Welding Projects
Implementing best practices and staying current on industry trends can help you overcome challenges in modern steel deck welding. Regularly reviewing industry documents, such as SDI Technical Notes 2 and 8, will help you create a culture of safety and excellence. For additional training resources, you can explore Lincoln Electric’s training programs and support options, which are widely available throughout the United States.If you have other questions or issues, you can contact SDI for project-specific consultations or further resources. Since 1939, we have set uniform industry standards for the design, manufacture, and use of steel deck products. Our library of resources can help make your next project a success. We’d love to hear from you, so feel free to contact us.