Author: norfas

Tips for Thru-Deck Structural Steel Welding

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Stud welding is used extensively throughout the construction industry for residential and commercial buildings, industrial facilities, infrastructure, and more. The widespread use of stud welding in construction is largely due to the powerful fastening and composite building capabilities that different operations provide. With shear connectors, builders can secure concrete onto steel beams; bar anchors allow connections between bearing plates and concrete; and many other studs are key in structural steel welding processes. If you’re using stud welding operations in your construction projects, Northland Fastening Systems (NFS) has the tools, supplies, and expertise you need. We provide a complete selection of drawn arc and CD welding studs, welding tools for rent or purchase, welding accessories, and the advice of our own welding technicians. We also provide repairs and services for many standard stud welding tool models.

Structural Steel Welding

Within the structural steel welding industry, one of the most valuable operations is thru-deck welding. Thru-deck welding allows builders to attach various sizes, thicknesses, and materials of steel decking to beams and other building components. Decking materials are used in several kinds of building construction for its strength, flexibility, and cost-effectiveness.

Thru-Deck Studs

When welding thru-deck studs, the following steps should be taken into account.

  • Make sure you are using the right tools for the job, including thru-deck studs, a drawn arc welding unit calibrated correctly, the best power supply suited to the task, and thru-deck welding ferrules. Thru-deck welding ferrules have wider gaps between teeth than other ferrules. These gaps allow more oxygen to reach the weld, creating better stud penetration through the deck to the underlying beam.
  • Attach the decking as securely to the beam as possible and use grounding correctly. Grounding can be done with a welding ground C-clamp attached in a spot on the beam that has been ground down to bare metal.
  • Check your power source(s). Thru-deck welding sites can be larger than others. This means you often need power extensions to reach far away welds. This can be done successfully, but keep in mind how cable length and wire size can impact power supply.
  • Clean and dry the decking. For accurate thru-deck welding, sweep away dust and debris before each weld. If there are unavoidable wet conditions, the weld point should be dried with a blower or heat gun to remove moisture from in between the beam and the deck.
  • Monitor temperatures. Thru-deck welding temperatures should be above 0ºF according to the American Welding Society (AWS) “Ambient and Base-Metal Temperature Requirements.”

Standardized Procceure

Thru-deck welding is a highly standardized procedure used today on many construction sites. However standardized, it still is a technical process that requires a deep understanding and well-manicured conditions.

To learn more about thru-deck structural steel welding, contact NFS at (651) 730-7770. You can also request a quote online to get started with us today.

Importance of Testing Practices in the Stud Welding Process

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In any industry, diagnostics, testing, and quality control are all critical parts of the fabrication process. In the stud welding industry, suppliers and manufacturers alike follow ISO 9001, ISO 13918, and many other regulations for testing in order to provide reliable, high-quality services, construction, and equipment. The stud welding process has several different operations, including drawn arc, capacitor discharge (CD), and short cycle welding. With each of these welding processes, welders should perform tests at the beginning of each job to ensure their tools are calibrated correctly, the right materials are used, and the surface is prepared sufficiently. Without these tests, operators could go on to finish a job with weak, brittle, or messy welds. Whether you’re working with handheld, portable units in the field or you operate a fully automated production line in a facility, you can find the supplies you need at Northland Fastening Systems (NFS). We offer a comprehensive range of studs, welding accessories, and tools for rent or purchase. We also provide a repair service for most models, and our own welding technicians are happy to give advice and guidance.

Stud Welding Process

While some tests in the stud welding process can vary from operation to operation, there are three standard tests that should be performed on at least 10 weld samples before a full project is begun. These tests include:

Bend test:

The bend test is a typical test that either confirms or denies the strength of the weld connection point. The stud is bent back and forth at opposing 30º-angles until the stud breaks or the connection point fails. If the stud fails first, the weld is correct. Another version of this test bends studs at a 90º-angle over a pin with four times the diameter of the stud. Studs that bend over the pin without the connection point failing are performed correctly. Fractures in the plate metal or the weld point are signs of a poorly performed weld.

Tension/tensile test:

Weld quality can also be measured for tensile strength. Tension or tensile tests are typically done on shear connectors and other stud systems that will face large amounts of tensile stress. In a tensile testing machine, force is applied to a stud until failure. If the stud fails at the tension point before the weld connection or welding surface shows damage, that weld is accurate.

Torque test:

With a torque test arrangement or torque testing device, welding points can also be measured for accuracy. While bend tests are destructive tests, causing the weld to fail, torque tests can be done without serious damage to the weld point. Torque tests use a torsion meter as defined stress is applied. If the deformation of the stud falls within acceptable ranges, the weld was performed correctly.

To learn more about testing in the stud welding process, contact NFS at (651) 730-7770 or request a quote online.

 

How New Technology and Better Stud Welding Products Make Industry More Sustainable

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Since the beginning of the 20th century, stud welding began to be used more prevalently throughout industries beyond its original applications in shipbuilding. The several wars that the United States and much of the rest of the world faced also played a large role in the expanded use of strong, fast connecting systems like stud welding in manufacturing. Today, stud welding is used in most industries, from automotive to food grade equipment. However, many changes in the way people build are causing stud welding to develop once more to keep up with sustainability and energy-efficient designs. Over the last 10 years, engineers and fabricators have worked to improve the functioning lifespan, weight, and other properties of welded studs. If you are a manufacturer working with drawn arc, capacitor discharge (CD), or short cycle stud welding operations, you can find the high-quality supplies you need at Northland Fastening Systems (NFS). We provide a complete range of stud welding products, including tools for rent or purchase, studs, welding accessories, and our own welding technicians expert advice.

Stud Welding Products

Modern stud welding products already offer some of the most efficient systems for installing quick, powerful connection points and fastening technology. However, fabricators and manufacturing companies are still working to increase the range of those capabilities.

Setting Standards

Two major industries are setting sustainability and cost-saving guidelines for the rest of those who use stud welding on a large or heavy-duty scale. Power plants and shipbuilders have both researched and found ways to improve their use of studs with less waste and for longer use.

Power plants:

Most power plants use studs installed in operating furnaces to act as heat transfers into boiler tubes. These studs are typically made of 430 stainless steel with a refractory coating, and they have to be fully replaced about once a year. The replacement of these studs requires a large factory shutdown, which is both expensive and time-consuming. Some newer kinds of studs made from an iron and aluminum alloy have shown to last three to four times longer than 430 stainless steel studs. This new stud technology runs colder than older studs, transfers heat better, and forms anticorrosive aluminum oxide when exposed to furnace temperatures of 1,600-1,800ºF.

Shipbuilders:

Shipbuilders, especially those manufacturing naval vessels, have also found a way to eliminate cost and improve sustainable designs. A study released in 2012 showed that newer studs welding equipment with lower energy consumption during idle (between welds) could reduce shipbuilding costs on large vessels by $0.128 to $0.154 per stud. For shipyards that build destroyers and other navy warships, that could mean a reduction in cost of $589,000 to $708,000 in energy alone.

Newer technology across industries using stud welding products will only continue to prove how much more efficient and sustainable they can be. To learn more about the newest stud welding machines and the other products we offer, contact NFS at (651) 730-7770 or request a quote online.

Heavy-Duty Construction Equipment Built with Arc Stud Welding

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Stud welding is used to build ships, infrastructure, commercial, residential, and industrial buildings, electrical equipment, food production equipment, and much more. Another industry where drawn arc and capacitor discharge stud welding operations are used extensively is vehicle manufacturing. Personal cars, commercial vehicles, and many types of industrial vehicles are all built with stud welding at multiple points on production lines. No matter what type of vehicle or other equipment you’re manufacturing, Northland Fastening Systems has the tools, studs, accessories, and any other equipment you may need. We also offer a repair and service program for most tool models and the advice of our own expert technicians. Both capacitor discharge (CD) and drawn arc stud welding operations have their use in vehicle production, and we offer a comprehensive range of supplies for both.

Arc Stud Welding

Heavy-duty vehicles for the construction industry in particular utilize arc stud welding more prevalently than any other stud operation. Drawn arc studs have larger dimensions, use stronger materials, and are, overall, more powerful than the lightweight applications of CD welding. For the high-stress loads that construction equipment and vehicles handle, drawn arc fastening systems are ideal.

Main Categories

Some main categories of heavy-duty construction vehicles that are built with drawn arc welding operations include:

Excavation:

There are many kinds of excavators built with stud welding connections. For the construction industry, excavator vehicles are critical. Trenchers, dredgers, power shovels, reclaimers, dragline excavators, long-reach excavators, and even mini excavators like backhoes and front loaders all have stud-welded connection points on multiple areas of their bodies, booms, housing, and other components.

Loaders:

Similar to excavators, construction loaders are key in the removal of demolition debris, earth, and other building materials. Generally, loaders are smaller vehicles than excavators, built with stud welding to move materials quickly between construction sites and secondary removal systems.

Paving:

For infrastructure purposes, paving vehicles are very important systems. They build roads, expressways, parking lots, driveways, and even bridges. Some pavers that are made with arc studs include asphalt layers and pavers, compactors, rollers, milling and planing equipment, curing rigs, and more.

Handlers:

Lifting, reaching, moving, and controlling heavy materials in various ways is done with construction handlers. These vehicles range in format, but some common types include cranes, forklifts, truck-mounted boom loaders, cherry pickers, lifts, and straddle carriers.

Trucks:

Trucks are ubiquitous in the construction world, from pickups to dump trucks. All modern trucks of any size are built with drawn arc stud fastening systems, and many also use CD fasteners in computer systems and other electronics.

While there are many high-powered, earth-moving vehicles used in the construction industry, these are just a few of the industrial tools built with arc stud welding operations. To learn more about stud welding for construction equipment, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online

Why the Stud Welding Process Speeds Up Production

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Welding operations of all kinds are used across industries in many capacities, from forge welding to plastic welding. While there are four to seven main types of metal welding, depending on the application and industry, within those groups there are many more variations. In the category of stud welding, there are at least three main types of operations: drawn arc, capacitor discharge (CD), and short cycle. Stud welding is a highly valuable operation for many manufacturers because it provides several benefits in addition to the powerful connections it can form. Not only is stud welding used in multiple industries to connect studs for fastening systems and support structures; it’s also used in composite construction to attach concrete and steel or provide shear strength in infrastructure. No matter what industry you work in, you can find the supplies you need at Northland Fastening Systems. We provide a comprehensive range of studs, tools, accessories, and anything else needed for your stud welding process.

Fastening Systems

Drawn arc, short cycle, and CD stud welding each offer a unique solution for fastening systems. Short cycle and CD stud welding are generally used in automated or quick welds for smaller stud diameters or pins. These operations are ideal for clean, strong connection points. Drawn arc stud welding is used for larger diameter studs, bar anchors, and shear connectors.

Stud Welding Process

All of these operations are part of a stud welding process that can speed up your production line much better than any other fastening system. The main reasons why stud welding can increase manufacturing speeds include:

No secondary operations:

Stud welding can often be performed without grinding or polishing surfaces. Some stud welds can even be attached over paint and other surface treatments. There is no need to drill or tap holes or use rivets, bolts, nuts, or washers. This also eliminates the cost of secondary equipment needed to perform all of these operations.

Rapid weld time:

In many cases, welds can be performed up to 30 times a minute. In the most rapid cases on automated production lines, up to 1,800 studs can be installed per hour.

Single-person task:

Handheld stud welding tools and automated stud welding machines can often be operated successfully by just one worker. The equipment needed to stud weld is also typically lightweight, portable, and easy to operate when following manual directions.

Adaptable to many metals:

While the main materials used for studs and welding surfaces are different kinds of steel, most kinds of metal can be adapted to the stud welding process. Stud welders use metals of all kinds in various applications, including aluminum, mild and stainless steel, brass, copper, titanium, and even Inconel.

In addition to the speed benefits that stud welding provides, these operations also offer precision, uniformity, reliability, and a generally failsafe connection point. To learn more about the stud welding process and the supplies and services we provide, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online

Building Complex Sanitary Conveyor Systems with Food Grade Welding

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The global food industry is one of the largest economic systems in the world. Its success relies on intricate webs of distribution lines. With a world population of almost 8 billion people, the demands on the food industry to support access to everything from safe, nutritious foods to international delicacies are immense. When it comes to the industrial equipment used throughout the food industry, reliability and hygiene are some of the most important factors that engineers and fabricators should build into any design. For many kinds of automated food production equipment used in factory settings, stud welding provides strong, clean fastening systems without risk of harborage or corrosion. If you are working with food grade welding studs to build your food production equipment designs, Northland Fastening Systems has the tools and supplies you need. We provide a complete range of welding tools, studs, and accessories, as well as repair services and the advice of our own welding technicians.

Food Production Equipment

There are many different purposes that various types of food production equipment serve. One of the most essential systems in an automated facility is the conveyor belt operations. To prevent the risk of contamination in the complex parts of a conveyor belt, food grade welding with stainless-steel studs is used to build many components on an automated production line.

Conveyor Belt Systems

Conveyor belt systems meet a wide range of automated food production needs. In the process of moving goods from one operation to the next, most facilities need to maintain precise control over the product quality and load. Some aspects of a conveyor system built with sanitary stud welding include:

Laning and sorting:

Products moving downstream from operation to operation need to be accurately sorted into lanes or sections of a conveyor system. This keeps the production line running smoothly and prevents cross contamination, damage, or unnecessary loss of goods.

Stacking:

In many parts of processing in the food industry, products need to be handled in multiples. For the packaging industry in particular, food items often need to be stacked on top of each other while they move seamlessly through a factory. With sanitary automated stackers, production lines can reduce human error and contamination.

Transfers:

Like sorting systems, transfers also need to occur as products are moved on a conveyor system between different stages. Transfers built into an automated conveyor system keep the process running quickly through lateral or multi-level moves.

Rejection:

Most factories today are incorporating intelligent rejection systems to remove damaged or misshapen goods. These reject systems use laser measurements, weight, imaging, and other smart technologies to determine if goods meet the correct specifications and remove flawed products from the production line. With a reject system on a conveyor, automation can continue through that stage of processing.

Food grade welding contributes to the sanitation and quality of many operations that can be incorporated into a conveyor belt system and an automated production line in general. To learn more, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online.

 

Types of Ferrules and Their Applications with Drawn Arc Welding

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As a broad category of manufacturing operations, stud welding has many applications. Even within the stud welding classification, there are various kinds of operations with specific applications and capabilities. Capacitor discharge stud welding, for example, is a rapid, lightweight weld best for studs with diameters under 3/8”. However, CD welding is extremely useful for quick, clean, and strong welds of smaller studs for a greater range of materials than other types of stud welding. Drawn arc welding, on the other hand, uses larger diameter studs for heavy industrial purposes and composite construction. No matter what kind of studs and applications you work with, Northland Fastening Systems has the tools, studs, accessories, and any other supplies you need. We also provide tool repair and maintenance for most models, and our own stud welding technicians offer expert advice for any project.

Drawn Arc Welding

If you’re working with drawn arc welding operations, you’re likely using ceramic ferrules. Ferrules are attached around the tip of the stud and control the flow of molten metal as the weld is performed. When a successful weld is completed, ferrules are quickly and cleanly removed with a hammer.

Ferrules

These ferrules are critical components of drawn arc stud fastening systems. Some common types of ferrules include:

  • Flat ferrule: These ferrules are some of the most commonly used standard ferrule types. They are used when welding to a horizontal, flat surface such as sheet metal and beams. Standard flat ferrules come in a range of diameters, thread specifications, profiles, and fillets.
  • Vertical ferrule: Vertical ferrules are another standard ferrule type with specifications that are similar to flat ferrules. The main difference is that these are used when welding on a vertical surface. A vertical ferrule has a ring of half-teeth and half-solid ceramics to prevent molten metal from spilling through the teeth on the bottom while the weld is being performed.
  • Inside angle ferrule: Angled ferrules are used to install studs at varying angles, determined by the ferrule shape. Standard inside angle ferrules are typically used to install studs at a 90º angle.
  • Outside angle ferrule: These ferrules are used to contain molten metal and install studs on the opposite side of inside angle ferrules.
  • Side angle ferrule: Like inside angle ferrules, side angle ferrules are used to install studs at specific degrees. Side angles are almost always used to install studs at 45º.
  • Thru-hole decking ferrule: Studs that will be installed through decking to a steel beam use thru-hole decking ferrules with teeth wider than most standard ferrules. The wider space between ferrule teeth allows for more shielding gas and atmospheric exposure to create a hotter weld.
  • Specialty ferrules: There are many types of specialty ferrules, from aluminum welding ferrules to hydraulic port ferrules. A variety of more frequently-used specialty ferrules include radius, reduced base, thru-bore, rectangular, and square ferrules.

To learn more about ferrules and drawn arc welding, contact Northland Fastening Systems at (651) 730-7770 or request a quote online to get started with us today.

Highlighting Our Video Resources for Stud Welding Equipment

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Northland Fastening Systems provides a complete supply of stud welding equipment to the construction and industrial markets, including tools for rent or purchase, studs in a wide range of dimensions, custom stud options, welding accessories, maintenance and repairs, and the expert advice of our own welding technicians.

Stud Welding Equipment

To provide some technical support and highlight tools and operations, we produce a variety of stud welding equipment media content. This includes the following videos that can be found on the NFS YouTube channel:

Stud gun check:

This video demonstrates checking a standard type of welding gun to determine if cleaning or other services are required. If you do require tool maintenance, take advantage of our services for most stud welding gun models.

Studs welded on top of each other:

This video showcases shooting 3/4” x 6 and 3/16” studs onto a weld surface and then welding an additional stud directly on top of the first, both using drawn arc welding systems.

CD stud welding quality:

This video shows the inspection of a CD welding unit, cable set, and weld results for quality control. Visual and mechanical diagnostics are done to show the strength of the weld.

CDi 502 demo:

This video demonstrates using a CDi welding unit, including covering the strength, pressure, sizing, time, release, and cost.

KARE11 commercial:

In 2019, NFS was featured in a North American Banking Company commercial. The commercial highlights NFS as a family-owned, long-standing business offering services and supplies to a global industry.

Automation stud welding:

This video demonstrates the versatility of the automation tool QUICK BOY and the rapid operations it allows.

NFS Stud Welding Automation:

This stylized video shows the power and speed our automated systems can provide on a production line.

HBS Visar 650 with 150’ of cable:

This video shows that the HBS VISAR 650 can be used effectively with cable lengths upwards of 150 feet on a fabrication site.

HBS VISAR 650 highlight:

This video further demonstrates the specifications, features, and operation of the VISAR 650 drawn arc welding unit.

Headed anchor stud welding:

This video shows an example of how headed bar anchors can be attached quickly with strong results.

Automated CD stud welding:

  • This video demonstrates the speed and precision of an automated CD machine with a VBZ-3 stud feeder.

Stud welding nameplate studs:

This video shows an example of a break-off nameplate stud and how those specialty studs are attached easily and quickly with CD welders.

Weld thru–deck stud welding:

This video shows an operator performing thru-decking fastening of studs with a drawn arc tool.

NFS CD stud welding:

This video demonstrates CD stud welding with a chuck and collet system using an HBS CDi 1502 unit.

For more information about the content shown in these videos, our team, or about our stud welding equipment, contact Northland Fastening Systems at (651) 730-7770, or request a quote online to get started with us today.

Thru-Decking Procedures for Structural Steel Welding

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Drawn arc stud welding operations are used extensively in the construction industry. Not only do drawn arc studs function as fastening systems for sheet metal fabrication, construction equipment manufacturing, and structural steel manufacturing, they are also used to build large-scale infrastructure with composite building. With drawn arc shear connectors, bar anchors, and other studs, manufacturers can build composite materials. Stud welding offers a rapid, clean operation that results in a connection stronger than the stud or the welding surface. At Northland Fastening Systems, we provide a complete selection of drawn arc welding tools, studs, and accessories. We also provide repairs and service for most welding tool models, and our expert welding technicians can give guidance and advice on any project. If you’re working with drawn arc structural steel welding, NFS is your one-stop-shop for supplies.

Structural Steel Welding

One of the most important uses of drawn arc operations for structural steel welding is the thru-deck installation process. Weld thru-decking (studs abbreviated WTD) fastens decking material to steel beams. Building with decking welded to beams is a common construction practice, used to fabricate components in many types of buildings, from homes to skyscrapers.

In order to accurately attach studs through decking to the beam underneath, specific welding procedures should be followed.

Surface Preparation

Both the surface of your decking material and the steel beams should be properly prepared for a weld. This means removing any paint, rust, mill scale, dirt, moisture, and other contaminants. Galvanized surfaces on beams should have the galvanization removed at the weld point. Moisture from rain or humidity should be dried with a heat gun at the weld point. Additionally, if you are welding in cold weather, the weld point should be warmed to the touch but not overheated.

Grounding

Finally, the decking and beam should be properly grounded to prevent loss of welding current. Using C-clamps or welding grounds attached to a beam flange where the surface has been ground to bare metal will prevent poor weld connections due to inadequate current.

Weld Specifications

Thru-deck welding requires currents typically between 1,500 to 1,900 amps. Your welding unit manual will specify the exact power source requirements determined by stud dimensions, decking thickness, and materials. Keep in mind that extensions of cables and changes to wire size can impact the current and compromise a weld. If you must run a long cable, you may need to run parallel cables to generate enough power for the weld site.

 

Thru-deck welding requires a special ceramic ferrule with wider gaps between teeth. These gaps allow for a hotter weld that can successfully fuse the stud through the decking to the steel beam. Most thru-decking welds will take between 0.8 to 1.6 seconds to fuse, and studs will plunge approximately 1/4″ to 1/2” depending on their length and decking thickness.

If you would like more information about drawn arc structural steel welding with thru-decking or need to order supplies, contact Northland Fastening Systems today at (651) 730-7770 or request a quote online.

Building Stainless Steel Furniture with Food Grade Welding

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One of the reasons why stud welding is such a prolific manufacturing operation is its versatility. Stud welding can be used to form powerful fastening systems for a variety of materials, including composite construction for bridges and other important infrastructure. Composite construction combines concrete and steel into a strong material that can resist enormous amounts of shear force, weight, and tension. Without the shear connectors and deformed bar anchors used in composite construction, we wouldn’t have the roads, bridges, multi-story buildings, and other large-scale structures that are key components of our modern world. The use of stud welding in composite construction is just the tip of the iceberg. Stud fastening systems are utilized across industries for anything from sheet metal construction to sanitary fabrication with food grade welding. No matter what industry you work in, you can find all you need for tools, supplies, and support with Northland Fastening Systems. NFS provides quality stud welding tools for rent or purchase, drawn arc, CD, and short cycle weld studs in a complete range of dimensions, custom stud options, welding accessories, and a repair program.

Food grade Welding

Stainless steel is a primary material used in food grade welding for many reasons, but, as a unique set of metal alloys, it can also be used for many other purposes when it comes to building furniture. Using stainless steel to construct various types of furniture with stud welding has many benefits. From aesthetics to practical purposes, manufacturers, artists, designers, and furniture companies build with stainless steel and stud welding to take advantage of their properties.

Sanitary:

For food service equipment, commercial and residential kitchen appliances, and other instances where good sanitation and hygiene are critical, stainless steel is a remarkable material. Because stainless steel has antiseptic properties and is highly cleanable, it pairs well with the smooth, crevice-free results that stud welding can achieve to build sanitary furniture and food grade equipment.

Anti-Rust:

Stainless steel also has corrosion resistant properties. The chromium content in stainless-steel alloys creates a passive film on the material’s surface. The presence of oxygen allows this film to self-heal when abrasions, cuts, and other damage occur. This means furniture made with stainless steel and stud welding operations can withstand corrosive environments and last longer than other metals.

Practical:

With its sanitary and anti-rust properties, stainless steel is already a practical material for building furniture of all kinds. Its durability, strength, and flexibility only add to its value as a furniture building material. Compared to many other materials used to build furniture, stainless steel is one of the strongest and most practical.

Aesthetics:

For design purposes, stainless steel offers a great range of finishes, from the lustrous sheen of a polished, bare surface to the vibrancy and color ranges that annealing, plating, and other finishing treatments can yield.

If you are working with food grade welding or other operations for furniture and equipment building with stud fastening systems, contact Northland Fastening Systems at (651) 730-7770 or request a quote online today.