Pipeline brochure (1)

STRENGTH THROUGH COOPERATION
Pipeline product catalogue
Consumables for pipeline welding
1044248_Catalogus Pipeline.indd 1 16-08-12 08:01

Understanding the
challenges
The ESAB range of welding consumables for pipeline
welding has evolved over the years and has earned a
reputation in countless projects globally. With many
recent addtions, it is a modern range of products
dedicated to pipeline welding.
Quality, the environment and safety are three key
areas of focus. ESAB is the one single welding
company to have achieved ISO 14001 and OHSAS
18001 standards in Environmental, Health & Safety
Management Systems across all our global
manufacturing facilities.
With ESAB, you are assured of a partner who
understands the challenges of pipeline welding and
responds with innovative solutions for both onshore
and offshore applications.
www.esab.com
STRENGTH THROUGH COOPERATION

3
Contents
World leader in welding and cutting technology systems 4
ESAB & the pipeline industry 7
Overview ESAB consumables for pipeline welding 8
The Pipeweld range of cellulosic electrodes 10
Basic low-hydrogen electrodes for up- and downhill welding 13
Low-hydrogen electrodes always guaranteed with VacPac 16
Flux cored wires for pipeline welding 17
Gas shielded flux-cored wires 18
Self shielded flux-cored wires 19
Solid MAG wires 20
Submerged arc welding for double jointing 22
Storage and handling recommodations for consumables 25
SAW welding automation 27
AC/DC inverter power source for efficient submerged arc welding 29
R&D and Central laboratories 30
Welding Process Centre 30
Production facility certificates 31
Product documents 31
Page
DISCLAIMER
Whilst all reasonable efforts
have been made to ensure
the accuracy of the
information contained in this
handbook at the time of
going to press, ESAB gives
no warranty with regard to its
accuracy or completeness. It
is the responsibility of the
reader to check the accuracy
of the information contained
in this handbook, read
product labels and equipment
instructions and comply with
current regulations. If the
reader is in any doubt with
regard to the proper use of
any technology they should
contact the manufacturer or
obtain alternative expert
advice. ESAB accepts no
responsibility or liability for
any injury, loss or damage
incurred as a result of any
use or reliance upon the
information contained in this
handbook.

4
Welding consumables
• Globally available, vast range of high
productivity welding consumables covering all
applications.
• Consistent high quality.
• Productive, environmentally-friendly packaging
solutions.
• A wide range of pipe welding tested
low-hydrogen consumables.
• Most of the range produced in house: own
development, metallurgy skills, QA.
• Production standards rigorously proved and
tested to meet customer requirements.
Multinational manufacturing, local
representation and an international
network of independent distributors bring
the benefits of ESAB quality and unrivalled
expertise in materials and processes within
reach of all our customers, wherever they
are located.
ESAB operates at the forefront of
welding and cutting technology. Over one
hundred years of continuous
improvement in products and processes
enables us to meet the challenges of
technological advances in every sector in
which ESAB operates.
Quality and environment standards
Quality, the environment and safety are three
key areas of focus. ESAB is one of a few
international companies to have achieved
the ISO 14001 and OHSAS 18001
standards in Environmental, Health Safety
Management Systems across all our global
manufacturing facilities.
At ESAB, quality is an ongoing process that
is at the heart of all our production
processes and facilities worldwide.
World leader in welding and
cutting technology systems

5
Equipment
• Large variety of equipment designed for
demanding applications.
• Designed for semi-automation and
automation. High- and low-end
mechanised semi-automation.
• Various degrees of freedom to adjust
optimum process.
• User-friendly controls.
• Reduced energy consumption.
• Smart welding processes such as
SuperPulse™.
• Smart technology for consistent quality,
long product life (durability).
Automation robotics
integration
• Complete welding solutions for different
customer needs.
• Full range of processes from MIG/ MAG
to SAW.
• Customised heavy duty submerged arc
solutions.
• Reduced downtime in production due to
smart designs.
• Full range of positioners, manipulators
and column booms.

6
Cutting
• Cutting machines from 2
to 36m machine width.
• Filter systems.
• Cutting tables.
• Plasma system solutions
from 1 to 120mm
cutting thickness.
• Specialised cutting
software and easy to
operate CNC controls.
• High-duty oxyfuel cutting
equipment.
• Tools for automated
weld-edge preparation.
World leader in welding and
cutting technology systems
Personal
protection
equipment
• Full range of personal
protection equipment.
• Complying to and
exceeding the relevant
standards.
• Specifications of
welding glasses fulfil
advanced optical
requirements.
• UV and IR filtering.

7
ESAB the pipeline industry
For over 100 years, ESAB has been
powered by innovation and uncompromising
standards – and by the will to continuously
seek new and improved ways of serving our
customers. This has made ESAB a world
leader in welding products.
Every day countless kilometres of steel
pipelines are installed worldwide for the
most varied civil and industrial uses. They
form real networks comparable to a system
of road networks, which, although not so
obvious, are definitely much more intricate
and carry fluids and gases that have
become essential for us.
To comply with technical specifications and
fulfil the necessary safety requisites, special
materials and welding processes which have
evolved with the sector have been
developed in recent years.
The main welding process used to install the
pipelines is manual welding with coated
electrode, which, thanks to its ease and
versatility, is still the most popular.
However, to limit costs and increase welding
productivity, particularly on long routes,
various constructors have adopted the
semi-automatic or completely automatic
welding process with solid and flux cored
wires.
However, still today, when more
sophisticated materials and more productive
and less expensive techniques are at the
users’ disposal, MMA welding remains a
favoured process to weld pipes.
Its easy use, capacity to reach positions of
difficult accessibility, the simplicity of the
welding machines or the fact of being able
to use motor generators as network power
is not always available on installation sites,
the fact that protective gases can be difficult
to find in certain countries, necessary in
welding with solid or cored wires, are not
required, all these and others are the
reasons for this choice.
ESAB’s history in stick electrode welding
can be traced back to 1903 and in fact the
founder of ESAB was the pioneer of the
modern day stick electrode.
The Pipeweld range of cellulosic and basic
electrodes have been specially designed to
meet the requirements of the applicable
grade of steel used to manufacture
pipelines and the safety specifications laid
down by standards, but also to equip the
user i.e. welders with versatile products
created for this specific purpose.
The global shortage of skilled welders and
the requirement to achieve welds of the
highest quality has encouraged the
development and use of welding “bugs”.
Although these machines still require a
welder to operate them, they have in turn
substantially decreased pipeline construction
times and in many cases enabled the welds
to be deposited to a higher standard than
manual welding. ESAB has a complete
range of solid and flux cored wire
products that have been
developed to supply this segment
of the pipeline industry.
The creation of the Pipeweld range
has created an identifiable,
complete range of consumables,
tried and tested to meet all the
requirements of even the most
stringent pipeline mechanical
testing criteria.
The products come from a
manufacturer with a proven track
record in innovative welding
solutions and a history of
producing user friendly products.
Over the years ESAB has supplied
consumables to all the pipeline
sectors, cross country pipelines,
offshore Reel-lay, J-lay, S-lay and
double jointing.
We have contributed to the
welding of thousands of miles of
pipelines globally and will continue
to develop our products to match
the advancing requirements of the
pipeline industry.

API 5L pipe steel grade Minimum yield strength Minimum tensile strength Cellulosic electrodes Basic electrodes
X52 360 MPa (52200 psi) 460 MPa (66700 psi)
Root Pipeweld 6010P/PLUS Pipeweld 7016
Hot pass Pipeweld 6010P/PLUS Pipeweld 7016
Fill cap Pipeweld 6010P/PLUS Pipeweld 7016
X60 415 MPa (60200psi) 520 MPa (75400 psi)
Hot pass Pipeweld 7010 PLUS Pipeweld 7016
Fill cap Pipeweld 7010 PLUS Pipeweld 7016
X65 450 MPa (65300psi) 535 MPa (77600 psi)
X70 485 MPa (70300 psi) 570 MPa (82700 psi)
X80 555 MPa (80500psi ) 625 MPa (90600 psi)
Fill cap N.a. Pipeweld 10018
N.a. : not applicable
Overview ESAB consumables
for pipeline welding
NOTE:
Under certain circumstances it may be needed to select a higher strength consumable than recommended in this catalogue e.g. with
high input applications, strain based design or when high strength overmatching is required.
All flux wire combinations for the SAW welding of pipeline grades are available, see page 24. Actual consumables selection depends
on requirements and welding procedure.

Basic electrodes vertical down Flux cored wires gas-shielded Flux cored wires self-shielded Solid wires
N.a N.a. N.a. Pipeweld 70S-6/Plus
Pipeweld 80 DH Pipeweld 71T-1 Pipeweld 8Ni1-H5 Pipeweld 70S-6/Plus
N.a. N.a. N.a. Pipeweld 70S-6/Plus
Pipeweld 90 DH Pipeweld 101T-1 N.a. Pipeweld 70S-6/Plus
Pipeweld 90 DH Pipeweld 101T-1 N.a. Pipeweld 70S-6/Plus
Pipeweld 100 DH Pipeweld 111T-1 N.a. Pipeweld 100S
Pipeweld 100 DH Pipeweld 111T-1 N.a. Pipeweld 100S

The Pipeweld range of cellulosic
electrodes
10
API 5L pipe steel grade Cellulosic electrodes
X52
Root Pipeweld 6010P/PLUS
Hot pass Pipeweld 6010P/PLUS
Fill cap Pipeweld 6010P/PLUS
X60
Hot pass Pipeweld 7010 PLUS
Fill cap Pipeweld 7010 PLUS
X65
X70
X80
Fill cap N.a.
ESAB cellulosic electrodes for pipeline welding
Cellulosic electrodes have been used for many years for welding
pipelines worldwide. This is due to both easy application of the
root run and the speed of weld metal deposition. The ESAB range
of cellulosic electrodes deposits high quality weld metal for pipeline
steels up to X70 for filling and for root pass welding for all grades.
It is standard practice that the root run is done with E6010
electrodes because of the excellent arc force control that these
electrodes give, resulting in fewer fusion defects and good rein-
forcement.
The Pipeweld 6010 PLUS is best suited for welding on negative
polarity (DCEN) in order to optimise the reinforcement on the
inside of the root. Using DCEN also reduces the risk of internal
undercut, cracking as well as hollow beads. Pipeweld 6010
PLUS has excellent welding properties both in vertical up and
vertical down progression.
If it is necessary to use DCEP for the root, it is advisable to use
another electrode, the Pipeweld 6010P.
For the hot pass, fill and cap with E7010, E8010 and E9010,
ESAB has a complete range of cellulosic electrodes for welding
up to X70 pipe. These electrodes give excellent performance in
both the vertical up and down position on DCEP.
Although ESAB cellulosic electrodes are designed to produce
high integrity welds and excellent mechanical properties, care
must be taken when selecting electrodes of this type on thicker
pipe sections.
Due to the high hydrogen content of cellulosic electrode depos-
ited weld metal, there may be an increased risk of hydrogen
induced cracking and limitations may be achieved with regards
to mechanical testing results.

11
Pipeweld 6010P Typical all weld metal composition % Typical all weld metal mechanical Ø x l Current Welding
properties AW (mm) (A) positions
AWS E6010 C Si Mn Re/Rp0.2 (MPa) Rm (MPa) 2.5 (3/32) 50-70 1 2 3 4 5 6
Cellulosic coated 0.01 0.15 0.35 410 (59,450 psi) 495 (71,775 psi) 3.2 (1/8) 65-120 1 2 3 4 5 6
Polarity CVN -20˚C (J) A5 (%) 4.0 (5/32) 90-180 1 2 3 4 5 6
DC+, AC 60 (-4˚F, 44 ft-lb) 22 5.0 (3/16) 150-240 1 2 3 4 5 6
A cellolosic electrode designed for DC+
and AC welding only. This electrode
performs particularly well in uphill
welding.
Pipeweld 6010 PLUS Typical all weld metal composition % Typical all weld metal mechanical Ø x l Current Welding
AWS E6010 C Si Mn Re/Rp0.2 (MPa) Rm (MPa) 2.5 (3/32) 60-80 1 2 3 4 5 6
Cellulosic coated 0.1 0.2 0.45 430 (62,350 psi) 525 (76,125 psi) 3.2 (1/8) 75-130 1 2 3 4 5 6
Polarity CVN -30˚C (J) A5 (%) 4.0 (5/32) 100-190 1 2 3 4 5 6
DC+(-) 50 (-22˚F, 37 ft-lb) 23 5.0 (3/16) 160-240 1 2 3 4 5 6
Pipeweld 6010 PLUS has been
developed for rootpass welding on
electrode negative. This product offers
superior penetration and excellent root
profiles, it can be used either vertical
down or in an upwards progression.

AWS E7010-P1 C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 3.2 (1/8) 65-120 1 2 3 4 5 6
Cellulosic coated 0.8 0.13 0.45 0.38 465 (67,425 psi) 560 (81,200 psi) 4.0 (5/32) 90-180 1 2 3 4 5 6
Polarity CVN -30˚C (J) A5 (%) 5.0 (3/16) 150-240 1 2 3 4 5 6
DC+ 50 (-22˚F, 37 ft-lb) 23
A cellulosic electrode designed for
DC+ welding only. This electrode
performs well for filling and capping
on X52- X60 pipe materials in a
downward progression.

Actual mechanical properties in X60
Re/Rp0.2 (MPa) Rm (MPa)
421 (62,495 psi) 552 (80,040 psi)
CVN -30˚C (J) A5 (%)
53 (-22˚F, 39 ft-lb) 23

12
The Pipeweld range of cellulosic
electrodes
Cellulosic coated 0.07 0.13 0.65 0.75 530 (76,850 psi) 625 (90,625 psi) 4.0 (5/32) 90-180 1 2 3 4 5 6
Polarity CVN -30˚C (J) A5 (%) 5.0 (3/16) 150-240 1 2 3 4 5 6
DC+ 70 (-22˚F, 52 ft-lb) 22
A cellolosic electrode designed for
on X60- X70 pipe materials in a
downward progression.
569 (82,505 psi) 632 (91,640 psi)
CVN -40˚C (J) A5 (%)
41 (-40˚F, 30 ft-lb) 22
Cellulosic coated 0.1 0.2 1 0.9 620 (89,900 psi) 700 (101,500 psi) 4.0 (5/32) 90-180 1 2 3 4 5 6
Polarity CVN -30˚C (J) A5 (%) 5.0 (3/16) 150-240 1 2 3 4 5 6
DC+ 35 (-22˚F, 26 ft-lb) 22
A cellolosic electrode designed for
on X70 and X80 hot passing and
light wall applications (9.5mm)
556 (80,620 psi) 634 (91,930 psi)
CVN -30˚C (J) A5 (%)
40 (-22˚F, 30 ft-lb) 21

13
Basic low-hydrogen electrodes for
up- and downhill welding
ESAB basic electrodes for pipeline welding
With the introduction of modern pipeline steels with
elevated strength levels, the development of
suitable cellulosic downhill electrodes appears to
be stretched beyond it possibilities. Very often, the
high weld metal hydrogen content and limited low-
temperature toughness are found to offer
insufficient guarantees for sound welds.
Low-hydrogen basic electrodes provide a
technologically and economically sound alternative,
providing the required combination of high weld
metal strength and good low-temperature
toughness and, morover, a sharply reduced risk of
hydrogen induced cracking. Depending on the
steel quality, preheat temperatures can be reduced
or even be omitted in the case of many thermo-
mechanically treated steel grades, bringing savings
through better efficiency. Basic electrodes are used
for pipe steel grades as from X70, especially with
higher wall thickness and low-temperature weld
metal toughness requirements.
The ESAB range of basic electrodes for pipeline
welding features LMA (Low Moisture Absorption)
types for uphill and downhill welding; named
Pipeweld and Pipeweld DH respectively.
Uphill types can be used for the root pass and for
filling and capping and weaving is generally applied.
This gives a good weld penetration, but care must
be taken to control the heat input to avoid loss of
mechanical properties in the HAZ and weld metal.
A disadvantage is that the uphill technique is
relatively slow compared with downhill welding.
Downhill types are used exclusively for filling and
capping in combination with cellulosic types for root
hot pass or basic uphill types for the root. The
front-end laying speed, a decisive factor in pipeline
construction, can be retained at economically
attractive levels. In addition, stringer bead welding at
high travel speed results in a relatively low heat input
and consequently in good mechanical properties of HAZ and weld
metal, including good low-temperature toughness.
A generally recognised disadvantage of basic downhill electrodes is
start porosity, which is not removed by subsequent passes,
because of the low heat input. ESAB has solved this problem with
its patented innovative solution, causing a higher current density
and greater weld penetration when starting. This effectively
counteracts start porosity. An advantage of our onnovation over
types with a conical start end is that the coating does not so easily
chip off at the start end.
ESAB basic electrodes for pipeline welding are supplied exclusively
in VacPac vacuum packaging preserving the low-moisture condition
until the moment of opening the VacPac. Thereafter, the LMA
properties of the electrodes guarantee safe exposure for 12 hours
when the foil is left in place.
API 5L pipe steel grade Basic electrodes uphill Basic electrodes downhill
X52
Root Pipeweld 7016 N.a
Hot pass Pipeweld 7016 Pipeweld 80 DH
Fill cap Pipeweld 7016 Pipeweld 80 DH
X60
X65
X70
Root Pipeweld 7016 N.a.
X80

14
Pipeweld 7016 Typical all weld metal composition % Typical all weld metal mechanical Ø x l Current Welding
AWS E7016-1
Basic coated
Polarity
AC/DC +/-
Recovery
100%
HDM
5.0ml/100g
C Si Mn Re/Rp0.2 (MPa) Rm (MPa) 3.2 (1/8) 80-140 1 2 3 4 6
0.06 0.5 1.3 482 (69.890 psi) 575 (83,375 psi) 4.0 (5/32) 110-180 1 2 3 4 6
CVN -40˚C (J) A5 (%) 1 2 3 4 6
221 (-40˚F,163 ft-lb) 22
Basic thin coated AC/DC electrode
Providing excellent mechanical
properties. This electrode ensures
fully penetrated root passes, even in
adverse conditions.
524 (75,980 psi) 610 (88,450 psi)
CVN -20˚C (J) A5 (%)
77 (-4˚F, 57 ft-lb) 25
AWS E8016-G
Basic coated
Polarity
AC/DC+/-
Recovery
100%
HDM
5.0ml/100g
C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 3.2 (1/8) 80-140 1 2 3 4 6
0.06 0.3 1.8 0.9 660 (95,700 psi) 740 (107,300 psi) 4.0 (5/32) 110-170 1 2 3 4 6
CVN -60˚C (J) A5 (%)
102 (-40˚F, 52 ft-lb) 30
All positional basic electrode that
offers good CVN toughness at low
temperatures. Can be used up to X80.
624 (90,480 psi) 692 (100,340 psi)
CVN -25˚C (J) A5 (%)
140 (-13˚F, 103 ft-lb) 26
uphill welding
AWS E10018-D2
Basic coated
Polarity
AC/DC+/-
Recovery
120%
HDM
5.0ml/100g
C Si Mn Mo Ni Re/Rp0.2 (MPa) Rm (MPa) 2.5 (3/32) 65-105 1 2 3 4 6
0.07 0.6 1.8 0.4 0.7 670 (97,150 psi) 740 (107.300 psi) 3.2 (1/8) 80-140 1 2 3 4 6
CVN -40˚C (J) A5 (%) 4.0 (5/32) 95-200 1 2 3 4 6
40 (-40˚F, 29 ft-lb) 26
Pipeweld 10018 is a high strength
all positional electrode for pipe
applications. This electrode can be
used on X80 (strain based) and X100.
764 (110,780 psi) 820 (118,900 psi)
CVN -20˚C (J) A5 (%)
65 (-40˚F, 50 ft-lb) 24

15
Pipeweld 80DH Typical all weld metal composition % Typical all weld metal mechanical Ø x l Current Welding
AWS E8045-P2 H4R
Basic coated
Polarity
DC+
HDM
4.0ml/100g
C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 2.5 (3/32) 60-90 1 2 3 4 5 6
0.07 0.5 1.2 0.1 530 (76,850 psi) 615 (89,175 psi) 3.2 (1/8) 110-150 1 2 3 4 5 6
CVN -30˚C (J) A5 (%) 4.0 (5/32) 180-220 1 2 3 4 5 6
80 (-22˚F, 59 ft-lb) 27 4.5 (3/16) 180-280 1 2 3 4 5 6
A low hydrogen electrode for downhill
welding of circumferential joints. This
electrode has been specially designed
to provide exellent striking properties.
Production is much higher than
conventional vertical up electrodes.
Can be used on applications up to
X70.
512 (74,240 psi) 612 (88,740 psi)
CVN -30˚C (J) A5 (%)
69 (-22˚F, 51 ft-lb) 23
AWS E9045-P2 H4R
Basic coated
Polarity
DC+
HDM
4.0ml/100g
C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 3.2 (1/8) 110-150 1 2 3 4 5 6
0.06 0.55 1.6 0.9 610 (88,450 psi) 695 (100,775 psi) 4.0 (5/32) 180-220 1 2 3 4 5 6
CVN -30˚C (J) A5 (%) 4.5 (3/16) 210-270 1 2 3 4 5 6
80 (-22˚F, 59 ft-lb) 24
A low hydrogen electrode for downhill
Can be used on applications X70
and X80.
570 (82,650 psi) 668 (96,860 psi)
CVN -30˚C (J) A5 (%)
86 (-22˚F, 64 ft-lb) 20
AWS E10018-G H4R C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 3.2 (1/8) 110-150 1 2 3 4 5 6
0.6 0.45 1.85 1.75 690 (100,050 psi) 760 (110,200 psi) 4.0 (5/32) 180-220 1 2 3 4 5 6
Basic coated CVN -30˚C (J) A5 (%) 4.5 (3/16) 230-270 1 2 3 4 5 6
Polarity 110 (-22˚F, 81 ft-lb) 27
DC+
HDM
4.0ml/100g A low hydrogen electrode for downhill
Can be used on X80.
652 (94,540 psi) 732 (106,140 psi)
CVN -40˚C (J) A5 (%)
57 (-40˚F, 42 ft-lb) 22
downhill welding

16
Area to note date and time
of opening the VacPac
Ducted plastic box and
aluminium foil can be
separated for disposal and
recycling.
The plastic box only
produces carbon dioxide and
water when incinerated.
Plastic box protects the
electrodes. It can be
re-sealed for further use within
the time intervals specified for
ESAB VacPac electrodes.
Complete product
information on label.
Low-hydrogen electrodes always
guaranteed with VacPac
No re-baking, no holding ovens,
no quivers.
MMA electrodes from VacPac can be
used straight from the package without
the need to re-bake them and store them
temporarily in holding ovens and quivers.
Upon opening, fresh and dry electrodes are
guaranteed when the vacuum is maintained.
Electrodes of low moisture absorption type
(LMA, classified as H4 or H5), re-absorb
moisture slowly from the air. The safe
exposure time for this type of electrode is
12 hours* after opening the VacPac with the
foil left in place.
* Valid at standard AWS test conditions of
26.7°C and 80% RH.
How to handle VacPac
To protect the vacuum foil, avoid using
a knife or any other sharp object when
opening the outer package. Keep the
electrodes inside the package and do not
take out more than one electrode at a time.
Low moisture absorption type electrodes
(LMA) that have been exposed to the
atmosphere in an opened VacPac for more
than 12 hours (26.7°C and 80% RH) should
be discarded or re-dried.
VacPac is available in various packaging
sizes to suit fabricators’ individual
consumption of MMA electrodes.
Without VacPac With VacPac
Central store
max.50°C
Shop store
max.50°C
Welding
Central store
Baking
Remaining
electrodes
Shop store
Quiver
Welding
Greatly simplified storage and
handling for major savings

17
Flux cored wires for pipeline
welding
The Pipeweld family consists of all
positional rutile, low-hydrogen
flux-cored wires for applications involving
the welding of pipe and pipe components
with impact toughness requirements down
to –60°C.
The wires are extremely “welder friendly”
wire with a soft, spatter-free arc that always
operates in the spray arc mode. It is easy
to obtain flat welds with a good penetration
and smooth wetting onto the pipe edges.
The brittle slag is easily removed leaving
behind a smooth rutile weld appearance.
Typical positional welding defects such
as lack of fusion and slag inclusions are
avoided, due to the spray arc operation.
The wires have a good tolerance to poor
joint preparation.
The wire formulation provides a fast freezing
slag that supports the weld pool well in
positional welding, enabling deposition
rates which cannot be equalled by stick
electrodes or solid wires. Deposition rates
in vertical up welding can reach up to 4 kg/h
(100% duty cycle), making it the most
productive consumable available for manual
welding in this position. Diffusible hydrogen
satisfies the AWS H4 class.
Pipeweld 8Ni1 H5
This self-shielded flux-cored wire is a product especially
developed for the offshore industry. It is unique in the sense that
it features a diffusible hydrogen content below 5ml/100g
deposited weld metal making it ideal for critical steel applications
where cold-cracking resistance is required. It is welder-friendly
and has excellent all-positional welding operability, including
downhill welding to suit for a wider range of WPS requirements.
Pipeweld 8Ni1 H5 provides good low-temperature CVN
toughness down to -40°C.
API 5L pipe steel grade Flux cored wires gas-shielded Flux cored wires self-shielded
X52
Root N.a. N.a.
Hot pass Pipeweld 71T-1 Pipeweld 8Ni1-H5
Fill cap Pipeweld 71T-1 Pipeweld 8Ni1-H5
X60
Root N.a. N.a.
X65
Root N.a. N.a.
X70
Root N.a. N.a.
Hot pass Pipeweld 101T-1 N.a.
Fill cap Pipeweld 101T-1 N.a.
X80
Root N.a. N.a.
Hot pass Pipeweld 111T-1 N.a.
Fill cap Pipeweld 111T-1 N.a.

18
Gas shielded flux-cored wires
Pipeweld Typical all weld metal composition % Typical all weld metal Ø x l Current Voltage Welding
71 T1 mechanical properties (mm) (A) (V) positions
AWS E71T-1M H8
Gas shielded
Rutile flux cored
DC+
C Si Mn Re/Rp0.2 (MPa) Rm (MPa) 1.2 (.047”) 150-350 35 max 1 2 3 4 6
0.06 0.6 1.33 535 (77,575 psi) 601 (87,145 psi)
CVN -20˚C (J) A5 (%)
54 (-4˚F, 41 ft-lb) 22
Pipeweld 71T1 is an all positionable
rutile flux cored wire that can be used
with either Ar CO2
or CO2
shielding
gases. This product is suitable for up
to X52 pipe.
545 (79,025 psi) 639 (92,655 psi)
CVN -30˚C (J) A5 (%)
42 (-22˚F, 31 ft-lb) 21
AWS E91T1-G
Gas shielded
Rutile flux cored
DC+
0.05 0.37 1.25 604 (87,580 psi) 670 (97,150 psi)
CVN -40˚C (J) A5 (%)
92 (-40˚F, 68 ft-lb) 27
Flux cored wire that is used with Ar-CO2
shielding gas.This wire offers excellent
weldability This product is suitable for
up to X65 pipe.
569 (82,505 psi) 632 (91,640 psi)
CVN -40˚C (J) A5 (%)
43 (-40˚F, 32 ft-lb) 22
AWS E101T-G
Gas shielded
Rutile flux cored
DC+
0.06 0.4 1.54 654 (94,830 psi) 709 (102,805 psi)
CVN -40˚C (J) A5 (%)
70 (-40˚F, 52 ft-lb) 26
rutile flux cored wire that is used with
Ar-CO2
shielding gas.This wire offers
excellent weldability This product is
suitable for up to X70 pipe.
580 (84,100 psi) 691 (100,195 psi)
CVN -30˚C (J) A5 (%)
42 (-22˚F, 31 ft-lb) 21

19
Self shielded flux-cored wires
Pipeweld 8 Typical all weld metal composition % Typical all weld metal Ø x l Current Voltage Welding
Ni1H5 mechanical properties (mm) (A) (V) positions
AWS E71T-8Ni1J
Self shielded
DC-
HDM
5.0ml/100g
C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 1.6 (1/16”) 120-245 17-22 1 2 3 4 6
0.03 0.3 1.4 1.0 447 (59,450 psi) 536 (77,720 psi) 2.0 (5/64”) 120-280 18-23 1 2 3 4 6
CVN -29˚C (J) A5 (%)
150 (-20˚F,110 ft-lb) 30
Pipeweld 8Ni1H5 is a self-shielded flux-
cored wire designed to produce welds
with low diffusible hydrogen and robust
mechanical properties.It is welder
friendly and has excellent all positionable
welding operability. It operates on
electrode negative (DC-ve) and produces
sound welds either vertical up or down.

493 (71,485 psi) 580 (84,100 psi)
CVN -20˚C (J) A5 (%)
117 (-4˚F, 86 ft-lb) 22.5
AWS E111 T1 K3MJ-H4 C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 1.2 (.047”) 100-300 32 max 1 2 3 4 6
Gas shielded 0.06 0.39 1.2 2.8 761 (110, 345 psi) 840 (121,800 psi)
Rutile flux cored CVN -40˚C (J) A5 (%)
DC+ 72 (-40˚F, 53 ft-lb) 18
rutile flux cored wire that is used with
Ar-CO2
shielding gas.This wire offers
excellent weldability This product is
suitable for up to X100 pipe.
670 (97,150 psi) 721 (104,545 psi)
CVN -20˚C (J) A5 (%)
83 (-4˚F, 61 ft-lb) 21

20
Solid MAG wires
API 5L pipe steel grade Solid wires
X52
Root Pipeweld 70S-6/Plus
Hot pass Pipeweld 70S-6/Plus
Fill cap Pipeweld 70S-6/Plus
X60
X65
X70
X80
Hot pass Pipeweld 100 S
Fill cap Pipeweld 100 S
Pipeweld MAG wires - premium quality copper-coated wire
ESAB’s Pipeweld premium quality copper-coated MAG welding wire
feature a carefully controlled wire surface condition and cleanliness, in
combination with a continuous copper-layer with optimum thickness.
They bring reduced contamination of the feeding system with copper
flakes and guarantee longer periods of problem-free feeding, arc
stability, low spatter and excellent weld quality.The chemistry of the
wire is carefully controlled for consistently high mechanical properties
of the weld. They are successfully applied for manual and mechanised
welding in the pipeline construction industry. They can be welded with
Ar/CO2
mixed shielding gas or with pure CO2
.
Pipeweld Plus MAG wires – non copper-coated wires with ASC
The Pipeweld Plus wires are non copper coated wires with ASC
(Advanced Surface Characteristics). These wires do not contaminate
wire feeders, liners, torches and contact tips with copper particles.
This results in trouble-free feeding, a high process stability, reduced
consumption of wear parts and superior welding properties.
With Pipeweld Plus you gain a higher productivity, improved weld
quality, a cleaner work environment and reduced overall welding costs.
They are successfully applied for manual and mechanised welding in
the pipeline construction industry. They can be welded with Ar/CO2
mixed shielding gas or with pure CO2
.

Pipeweld and Pipeweld Plus wires are always layer-wound on all
spools to ensure wire pay-off without entanglement. Spools are sealed
in foil with moisture absorbing paper included, for a long shelf life
without the formation of rust.
Pipeweld Plus features summarised are:
• Consistent welding performance
• Stable arc with low feeding force
• Excellent arc ignition
• High current operability
• Extremely low overall spatter
• Trouble-free feedability, even at high wire feed speeds and
lengthy feed distances
• Low fume emission
• Improved resistance against corrosion of the wire

21
Pipeweld 100S Typical chemical composition wire (%) Typical all weld metal Ø x l Current Voltage Welding
mechanical properties (mm) (A) (V) positions
AWS A5.28 C Si Mn Ni Re/Rp0.2 (MPa) Rm (MPa) 0.9mm (.035) 60-250 33 max 1 2 3 4 5 6
ER 100S-G 0.08 0.6 1.8 1.0 620 (89,900 psi) 700 (101,500 psi) 1.0mm (.040”) 80-300 33 max 1 2 3 4 5 6
Polarity CVN -20˚C (J) A5 (%) 1.2mm (.047) 100-360 33 max 1 2 3 4 5 6
DC+ 130 (-4˚F, 96 ft-lb) 20
Shielding gas
A copper coated wire electrode
especialy designed for downhill welding
of pipe. This high strength wire can be
used on applications up to X100.
Actual mechanical properties in X80*
721 (104,545 psi) 835 (121,075 psi)
CVN -40˚C (J) A5 (%)
208 (-40˚F, 153 ft-lb) 20
Pipeweld 70S-6 Typical chemical composition wire (%) Typical all weld metal Ø x l Current Voltage Welding
mechanical properties (mm) (A) (V) positions
AWS A5.18 C Si Mn Re/Rp0.2 (MPa) Rm (MPa) 0.9mm (.035) 60-250 33 max 1 2 3 4 5 6
ER 70S-6 0.09 1.0 1.7 535 (77,575 psi) 600 (87,000 psi) 1.0mm (.040”) 80-300 33 max 1 2 3 4 5 6
DC+ 100 (-4˚F, 74 ft-lb) 26
A copper coated wire electrode
especialy designed for downhill welding
of pipe. The chemistry of this product is
carefully controlled to give outstanding
mechanical properties. This product can
be used up to X70 or X80 on narrow
gap applications.
661 (95,845 psi) 728 (105,560 psi)
CVN -20˚C (J) A5 (%)
147 (-4˚F, 108 ft-lb) 25
Pipeweld Typical chemical composition wire (%) Typical all weld metal Ø x l Current Voltage Welding
ER70S 6 Plus mechanical properties (mm) (A) (V) positions
AWS A5.18 C Si Mn Re/Rp0.2 (MPa) Rm (MPa) 0.9mm (.035) 60-250 33 max 1 2 3 4 5 6
ER 70S-6 0.09 1.0 1.7 535 (77,575 psi) 600 (87,000 psi) 1.0mm (.040) 80-300 33 max 1 2 3 4 5 6
DC+ 100 (-4˚F, 74 ft-lb) 26
A copper free wire electrode especialy
designed for superior feeding qualities
and low surface deposits to reduce
cleaning.The chemistry of this product is
carefully controlled to give outstanding
mechanical properties. This product can
be used up to X70 or X80 on narrow
gap applications.
619 (89,755 psi) 682 (98,890 psi)
CVN -40˚C (J) A5 (%)
56 (-40˚F, 41 ft-lb) 23
* Denotes a narrow gap joint

22
Submerged arc welding
for double jointing
For pipe grades up to X70, double jointing
presents few problems. The pipe itself is
likely to have been manufactured using the
submerged arc process for its seam weld,
and consumables to do this are readily
available.
Tubular wires can offer a productivity
improvement of about 25% compared with
solid wires, and have been used where
double jointing had to keep up with a fast-
moving lay barge.
However the mechanical properties
required for example on strain based
designed X80 materials can present
problems.
The submerged arc welding process is, by
default a high heat input process resulting
in high dilution levels. Consumables and
welding techniques have to be carefully
selected and controlled to meet the
applicable acceptance criteria.
ESAB offers a full range of submerged arc
welding consumables and equipment to
meet these demands.
Submerged arc welding of pipelines
When a pipeline is laid using sections of
pipe 12 m in length, it advances by 1 km for
every 83 joints made on the line. Some pipe
mills can make pipe in 18 m lengths, so for
the same welding productivity, the speed of
advance increases by 50%. In pursuit of
even greater speeds of advance, and where
access permits, it has become common
practice to join pairs of pipe sections off line.
This practice is known as double jointing. In
offshore applications, groups of up to four
pipe sections may be welded together at a
time.
Generally for cross country pipelines the
pipes being joined can be rotated so that
welding is carried out in the down hand
position, allowing for the use of high
deposition rate processes such as
submerged arc welding.
For offshore pipeline construction, double
jointing has become very common, and it
will have an important part to play where
large distances have to be crossed.

23
-0,2
0,0
0,2
0,4
0,6
0,8
1,0
0,05 0,10 0,15 0,20 0,25 0,30
-1,0
-0,2
-0,6
0,2
0,6
1,0
1,4
1,8
0,5 1,0 1,5 2,0
% Si in wire
% Si pick-up
from flux
% Mn in wire
% Mn pick-up
from flux
450 A
750 A
450 A
750 A
-0,2
0,0
0,2
0,4
0,6
0,8
1,0
0,05 0,10 0,15 0,20 0,25 0,30
-1,0
-0,2
-0,6
0,2
0,6
1,0
1,4
1,8
0,5 1,0 1,5 2,0
% Si in wire
% Si pick-up
from flux
% Mn in wire
% Mn pick-up
from flux
450 A
750 A
450 A
750 A
Single wire, ø 4.0 mm, DC+, 30 V, 60 cm/ min
Classification flux Basicity index Density Grain size
EN 760: SA FB 1 55 AC H5 3.2 ~ 1.1 kg/ dm3
0.2 - 1.6 mm
Slag type Polarity Alloy transfer Hydrogen
Fluoride-basic DC+ / AC No Si or Mn alloying ≤ 5 HDM
Flux consumption
kg flux / kg wire
Voltage DC+ AC
26 0.7 0.6
30 1.0 0.9
34 1.3 1.2
38 1.6 1.4
Classification
Wire Weld metal
OK Autrod EN / AWS EN / AW AWS / AW AWS / PWHT
12.22 S2Si / EM12K S 38 5 FB S2Si A5.17: F7A8-EM12K A5.17: F6P8-EM12K
12.24 S2Mo; S Mo / EA2 S 46 4 FB S2Mo A5.23: F8A6-EA2-A2 A5.23: F7P6-EA2-A2
12.32 S3Si / EH12K S 46 6 FB S3Si A5.17: F7A8-EH12K A5.17: F7P8-EH12K
12.34 S3Mo; S MnMo / EA4 S 50 4 FB S3Mo A5.23: F8A6-EA4-A4 A5.23: F8P6-EA4-A4
12.44 S4Mo / EA3 S 50 5 FB S4Mo A5.23: F9A8-EA3-A3 A5.23: F9P8-EA3-A3
13.24 S3Ni1Mo0.2 / EG S 50 6 FB S3Ni1Mo0.2 A5.23: F8A10-EG-G A5.23: F8P8-EG-G
13.27 S2Ni2 / ENi2 S 46 7 FB S2Ni2 A5.23: F8A10-ENi2-Ni2 A5.23: F8P10-ENi2-Ni2
13.40 S3Ni1Mo / EG S 62 6 FB S3Ni1Mo A5.23: F10A8-EG-F3 A5.23: F9P6-EG-F3
13.43 S3Ni2,5CrMo / EG S 69 6 FB S3Ni2,5CrMo A5.23: F11A8-EG-G A5.23: F11P8-EG-G
13.44 S3Ni1.5CrMo / EG S 62 5 FB S3Ni1.5CrMo A5.23: F9A8-EG-G
OK Tubrod
15.24S A5.23: F8A6-EC-G
15.25S A5.23: F7A8-EC-Ni2
15.27S A5.23: F11A8-EC-G
Spoolarc
100 EF5 A5.23: F12A6-EF5-G
120 EM4 A5.23: F11A6-EM4-M4
OK Flux 10.62 is an
agglomerated, high-basic flux
for submerged arc welding. It is
used for multi-run welding of
thick section materials. When
high demands on impact
toughness values are required,
OK Flux 10.62 is the flux to use.
The flux is neutral on Si and Mn
alloying.
It can be used for single and
multi-wire procedures, for butt
and fillet welds and works
equally well on DC and AC
current. Since no alloying takes
place, it is perfect for multi-
layer welding of unlimited plate
thickness. OK Flux 10.62 is
especially suited for narrow gap
welding due to good slag
detachability and smooth
sidewall blending. It operates
optimally at the lower end of
the voltage range. The weld
metal produced has a low-
oxygen content; approx.
300ppm and hydrogen levels
lower than 5ml/100g.
OK Flux 10.62 - high impact flux
for critical applications

24
Typical weld metal chemical composition (%), DC+
C Si Mn Cr Ni Mo Other
With OK Autrod
12.22 0.07 0.3 1.0
12.24 0.07 0.2 1.0 0.5
12.32 0.10 0.3 1.6
12.34 0.10 0.2 1.4 0.5
12.44 0.08 0.2 1.9 0.5
13.24 0.08 0.3 1.4 0.9 0.2
13.27 0.06 0.2 1.0 2.1
13.40 0.07 0.2 1.5 0.9 0.5
13.43 0.11 0.2 1.5 0.6 2.2 0.5
13.44 0.08 0.2 1.4 0.2 1.6 0.4
13.49 0.06 0.2 1.0 3.1
With OK Tubrod
15.00S 0.05 0.4 1.4
15.24S 0.06 0.3 1.6 0.8
15.25S 0.05 0.4 1.3 2.3
15.27S 0.06 0.3 1.6 2.3 0.2
With Spoolarc
100 0.09 0.3 1.7 0.3 2.4 0.5 Cu: 0.3
120 0.07 0.3 1.5 0.3 2.3 0.5
Typical weld metal mechanical properties, DC+
ReL / Rp0.2
(MPa)
Rm
(MPa)
A4 / A5
(%)
CVN
(J at °C)
AW/
SR
Remarks
With OK Autrod -40 -50 -60 -73
12.22 410 500 33 90 70 40 AW
12.24 500 580 25 60 45 AW
12.32 475 560 28 110 75 AW
12.34 540 620 24 115 45 AW
12.40 530 620 26 50 40 AW
12.44 600 700 27 80 65 55 AW
13.21 470 560 28 70 60 AW
13.24 530 620 25 120 110 70 50 AW
13.27 490 570 27 110 80 50 AW CVN at -70°C: 60 J
13.40 650 730 23 70 60 AW CVN at -62°C: 50 J
13.43 700 800 21 75 65 55 AW CVN at -62°C: 50 J
13.44 610 700 22 55 AW CVN at -62°C: 40 J
With OK Tubrod
15.24S 540 630 29 150 130 AW
15.25S 490 580 29 100 AW
15.27S 690 770 17 AW CVN at -60ºC: 69J
With Spoolarc
100 855 925 20 AW CVN at -51ºC: 70J
120 760 825 20 AW CVN at -51ºC: 89J
With OK Autrod
12.22 360 480 34 130 75 40 SR
12.24 470 530 26 55 40 SR
12.32 410 510 28 110 65 SR
12.34 540 620 25 70 40 SR
12.40 460 560 26 45 35 SR
12.44 590 690 26 75 55 45 SR
13.24 500 590 27 120 100 70 SR
13.27 490 580 29 100 90 40 SR
13.40 610 690 24 60 45 SR
13.43 695 790 21 60 50 SR CVN at – 62°C: 40 J
13.49 510 570 29 85 SR CVN at – 101°C: 50 J
OK Flux 10.62 is used when
high demands on low-
temperature toughness,
strength and CTOD-values are
required. Many offshore
constructions, drilling rigs,
platforms, etc. are welded with
OK Flux 10.62. It is used for all
kinds of pressure vessel
productions, including those for
nuclear applications. In power
generation it can be welded
with applicable wires on creep
resistant steels. Other
applications include
shipbuilding steels up to EH69
with various wires and
approvals. It is also used on
multi-run welded pipes, e.g. for
special applications at low
temperatures, or on high
strength steels, structural
steels, and fine-grained steels,
including in civil construction
and transport industries.
OK Flux 10.62 has passed CTOD
tests with the following wires:
OK Autrod 12.32 at -10°C and -15°C,
OK Autrod 13.24 at -10°C and -15°C,
OK Autrod 13.27 at -10°C,
OK Autrod 13.40 at -10°C.
OK Flux 10.62 - high impact flux
for critical applications

25
ESAB fluxes, agglomerated and fused, have
a guaranteed as-manufactured moisture
content from production. This moisture
content is controlled by internal ESAB
specifications. Before transport, each pallet
is shrink wrapped in plastic foil. This
precautionary action is done in order to
maintain the as-manufactured moisture
content for as long as possible. Flux should
never be exposed to wet conditions, such
as rain or snow.
Storage
• Unopened flux bags must be stored in
maintained storage conditions as follows:
Temperature: 20 +/- 10°C
Relative humidity: As low as possible - not
exceeding 60%.
• Fluxes shall not be stored longer than 3
years.
• The content of unprotected flux hoppers
must, after an 8 hours shift, be placed in a
drying cabinet or heated flux hopper at a
temperature of 150 +/- 25°C.
• Remaining flux from opened bags must be
placed at a temperature of 150 +/- 25°C.
Re-cycling
• Moisture and oil must be removed from
the compressed air used in the re-cycling
system.
• Addition of new flux must be done with
the proportion of at least one part new
flux to three parts re-cycled flux.
• Foreign material, such as millscale and
slag, must be removed by a suitable
system, such as sieving.
Re-drying
• When handled and stored as above, the
ESAB fluxes can normally be used straight
away.
• In severe applications, stipulated by the
applicable material specification, re-drying
of the flux is recommended.
• Furthermore, if the flux has somehow
picked up moisture, re-drying can return
the flux to its original moisture content.
• Re-drying shall be performed as follows:
Agglomerated fluxes: 300 +/- 25°C for
about 2-4 hours.
Fused fluxes: 200 +/- 50°C for about
2-4 hours.
• Redrying must be done either in
equipment that turns the flux so that the
moisture can evaporate easily or in an
oven on shallow plates with a flux height
not exceeding 5 cm.
• Re-dried flux, not immediately used, must
be kept at 150 +/- 25°C before use.
Disposal
• Discard any product, residue, disposable
container or liner in an environmentally
acceptable manner, in full compliance with
federal and local regulations.
• Please address your local disposal
company for prescribed disposal.
• Information on product and residues are
given in the Safety Data Sheets available
through www.esab.com.
Easy and efficient storage and
handling of fluxes
JK 50 Powder Dryer
- Redries flux at max. 500°C for
about 3 hours
- Then automatically drops tem-
perature to pre-set value (max.
200°C) and stores flux
- Capacity: 50 l
- Supply voltage: 400V, 3 phase;
output: 3.7 kW
JS 200 Flux storage silo
- Keeps flux dry and clean
- Adjustable temperature
between 100 and 300°C
- Capacity: 200 l
- Supply voltage: 220V, 1
phase; output: 2 kW
Equipment for storage and re-drying

26
Storage and handling
recommodations for consumables
Pipeweld MMA electrodes
ESAB Pipeweld basic stick electrodes are always packed
in VacPac - ESAB’s easy to use vacuum packaging. For
recommendations on storage and handling see page 16 of
this catalogue.
Pipeweld Pipeweld Plus MAG wires and cored
wires, should be stored in dry conditions in original sealed
undamaged packaging as supplied. Contact with water or
moisture should be avoided. This could take the form of
rain or the condensation of moisture on a cold wire. To
avoid condensation, keep the wire in the original packaging
and, if necessary, leave the wire to warm up to at least the
ambient temperature before opening the package. Other
hydrogen-containing substances, like oil, grease and
corrosion or substances that could absorb moisture must
also be avoided on the surface of the wires. Wires should
not be left on welding machines or out of the store for
prolonged periods, especially overnight, since
condensation of moisture from the air may lead to rapid
surface deterioration. Partly used spools should be
replaced in the original packaging for storage to prevent
surface contamination. Wire should be stored at ambient
conditions of temperature and humidity, and dusty areas
should be avoided when wire is not enclosed in some type
of dust-protecting packaging or equipment.
Cored wires that are rusty, have suffered from serious
water and moisture contamination, or have been exposed
to the atmosphere over long periods of time cannot be
restored in their original condition and should be discarded.
Recommended conditions of storage
for all solid wires are minimum temperature of 15°C and
humidity of maximum 60% RH.
ESAB submerged arc fluxes have a guaranteed
as-manufactured moisture content from production. This
moisture content is controlled by internal ESAB
speciﬁcations. Before transport, each pallet is shrink
wrapped in plastic foil. This precautionary action is done in
order to maintain the as-manufactured moisture content for
as long as possible. Flux should never be exposed to wet
conditions, such as rain or snow.
Storage
• Unopened flux bags must be stored in maintained
storage conditions as follows:
Temperature: 20 +/- 10°C Relative humidity: as low as
possible – not exceeding 60%.
• Fluxes delivered in aluminium lined BigBags can be
stored under more severe climatic conditions, because
the packaging protects the flux reliably from moisture
pick-up, as long as it is unopened and undamaged.
• The content of unprotected flux hoppers must, after an 8
hours shift, be placed in a drying cabinet or heated flux
hopper at a temperature of 150 +/- 25°C.
• Remaining flux from opened bags must be placed at a
temperature of 150 +/- 25°C.
Re-cycling
• Moisture and oil must be removed from the compressed
air used in the re-cycling system.
• Addition of new flux must be done with the proportion of
at least one part new flux to three
parts re-cycled flux.
• Foreign material, such as millscale and slag, must be
removed by a suitable system,
such as sieving.
Re-drying
• When handled and stored as above, the ESAB fluxes
can normally be used straight away.

27
A2 S Mini Master
The A2 S Mini Master represents an automatic
welding system designed with the emphasis on
low weight, compactness and flexible use. The
system is built around basic units. The degree of
automation and process orientation of the basic
unit you choose can be expanded or modified as
required, depending on the application.
Appropriate welding heads can be combined with
suitable manipulators, which results in a total
solution to a specific welding problem.
Single SAW Twin SAW Single GMAW
Max load at 100%
duty cycle, A
800 800 600
Wire feed, m/ min 0.2-9 0.2-9 0.2-16
A6 S Compact
The A6 S Compact 300/ 500/ 700 are three reliable
members of the A6 family for the efficient, high-
productivity SAW method. These welding heads make it
possible to build highly efficient stations for the internal
welding of butt joints inside tubes in different versions for
tubes down to diameter 300 mm. TV-monitoring
equipment can be integrated into the system, thereby
enabling the operator to supervise and adjust the head
position from the outside via the
TV screen.
A6 S Compact
Max load at 100% duty cycle, A 800
Wire diameter, mm 2.5, 3.0, 4.0
Wire feed, m/ min 0.4-8.0
SAW welding automation
Welding heads

28
SAW welding automation
Handling equipment
Roller beds
Roller beds are designed to enable large round items
to be welded and handled during rotation welding for
example. ESAB offers a large range of roller beds of
different models and load possibilities. The range partly
consists of conventional roller beds, where the
operator manually and mechanically sets the distance
between the rollers to different diameters – and partly
self-adjusting roller beds, where the rollers
automatically adjust themselves to the diameter of the
workpiece. All roller beds are designed to be easily
combined with ESAB A2/ A6 programme and can be
controlled via a remote control unit or from the process
controller PEK.
CD 5-120 and CI 5-120, conventional roller beds with
rail bogie. Max. loading capacity from 2.5 – 60 tons/
section.
CD-30/ 60/ 100/ 120-DB and CI-300/ 100/ 120-IB,
conventional roller beds with rail bogie. Max. loading
capacity from 15 – 60 tons/ section.
FIR 35, 75 and 100, these units are part of a growing
line and used especially in wind tower production.
Max. loading capacity 35, 75 or 100 tons.
FIT 30, 60 and 100, conventional idler roller beds with
built-in hydraulic height adjustment. These units are
part of a growing line and used especially in wind
tower production. Max. loading capacity 15, 30 or 50
tons.
FUB 30, complete unit for ﬁt-up of section. One set of
FUB consist of one power and one idler roller bed 30T.
Four independently adjusted rollers to align the two
sections with each other. Max. loading capacity 30
tons.
SD 5-100 and SI 5-100, self-aligning roller beds.
Motorised and idler rail bogie versions. Max. loading
capacity 2.5 – 50 tons/ section.
SD 5-100 DB and SI 5-100 IB, self-aligning roller
beds. Motorised and idler rail bogie versions. Max.
loading capacity 2.5 – 50 tons/ section.
Suitable application areas: wind tower fabrication,
offshore, shipyards, pressure vessels and pipelines.
Versatile accessories: a wide range of accessories is
available for ESAB’s roller beds, which additionally
improve workpiece handling during welding.

29
AC/DC inverter power source for
efficient submerged arc welding
Power source Aristo®
1000 AC/DC SAW
• Based on unique and patent pending technologies to deliver
the best welding performance with the lowest power
consumption.
• Designed for use with the digital PEK controller and the
robust A2/ A6 feeder units.
• A global inverter - connect to a three phase mains supply
from 380 to 575 V, 50 or 60 Hz.
• Change between DC and AC ”on the fly”. Minimize
downtime and weld defects by the push of a button with the
patent pending ”on the fly” function.
• Long welding cables. The patent pending Cable Boost™
technology stores energy and instantly delivers up to 450%
additional energy when required. Cable Boost extends the
maximum usable weld cable length with more than a factor
two, without compromising the weld result.
• Cable Boost™ is also an energy saver. The inductive energy
generated in the welding cables is re-used in the welding
process instead of being wasted as heat and power losses.
• Designed for uninterrupted welding production. There are no
connectors or cables at any exposed positions. All cables are
connected behind a door in the front of the machine. Easily
accessible for service and well protected against damage.
Aristo®
1000 AC/DC SAW
Mains supply, 3 ph, V, Hz 3380-575, 50/ 60
Mains current (DC load), A / V 86 / 380
82 / 400
79 / 415
74 / 440
71 / 460
66 / 500
59 / 550
57 / 575
Mains fuse (slow), A / V 100 / 380
100 / 400
80 / 415
80 / 440
80 / 460
80 / 500
63 / 550
63 / 575
Maximum load at 100% duty cycle, A / V 1000 / 44
Open circuit voltage, V 130
Open circuit power, W 240
Efficiency at max rating 0.88
Power factor 0.93
Dimensions, LxWxH, mm (in.) 865x610x1320
(34x24x52)
Weight, kg (lbs) 330 (727.5
Enclosure class IP23
Certification CE-certified
Third party approvals ETL, CCC,
Ghost-R
The Aristo 1000 AC/DC power source, used in combination
with ESAB’s new three wire ICE SAW process, is the most
productive process available today for welding thick joints.
Please contact your local ESAB office for more details.
ICEBeyond belief
Submerged
arc welding
will never be
the same.

30
RD and Central Laboratories
The Process Centres are
innovative environments were
ESAB and its customers can
work in partnership to develop
total solutions for welding and
cutting challenges, pushing the
technological boundaries to
exciting new levels.
The facilities are state of the art
in equipment and apply best
practice in EHS. There are also
showrooms, with
comprehensive demonstration
facilities. A global network of
ESAB Process Centres has
been established to help our
customers to improve their
business performance and daily
operations. This support network embraces the full spectrum of
welding requirements, from customer support to process
development; training to operational services. The global network
uses the globally spread know-how within ESAB to maintain the
same service levels around the globe ensuring that a consistent,
high technology solution service is delivered.
ESAB Central Laboratories
The ESAB Central laboratories
in Gothenburg, Sweden,
together with the Process
Centre, form the technical heart
of ESAB worldwide. Equipped
with modern facilities, they
provide research services to the
development departments, to
production sites and to end
customers.
The several laboratories are:
• Metallographic laboratory
• Mechanical testing
• Chemical laboratory
• Welding laboratory
• Heat treatment laboratory
Principal activities are:
• Customer support:
Defects, properties, welding procedures,
failure analysis.
• Development support:
Microstructure and properties for
development and improvement of
products.
• Research:
Internal and external (universities,
institutes) research projects.
• Production support:
Verification of product quality and
production processes.
Welding Process Centre

31
Production facility certificates
REASON FOR ISSUE
Welding positions and EN classification updated
GENERAL
A low alloyed low hydrogen electrode of AWS 10018-G type specially designed for downhill welding
circumferential joints in pipelines API 5L ,X80.
The low hydrogen weld metal provides high notch toughness and excellent ductility to reduce the risk of
cracking.
The electrode has been specially designed to provide excellent striking properties and elimination of start
porosity.
Productivity is significantly higher than conventional low hydrogen electrodes for welding vertically up.
Polarity: DC+
Alloy Type: Low alloyed
Coating Type: Basic
Diff Hydrogen: 4.0 ml/100g
WELDING POSITIONS
1 2
9
CLASSIFICATIONS Electrode
EN 757
E 62 5 Z B 45 H5
SFA/AWS A5.5 E10018-G H4R
APPROVALS
Not applicable
CHEMICAL COMPOSITION
All Weld Metal (%)
C
Si
Mn
P
S
Cr
Ni
Mo
V
Nb
Cu
Min Max
0.04 0.08
0.25 0.60
1.60 2.10
0.015
0.015
0.1
1.50 2.00
0.1
0.04
0.04
0.1
Product Data Sheet Pipeweld 100DH
E 'Manual metal-arc welding'
ESAB AB Sweden
Signed by
Approved by
Reg no
Cancelling Reg date Page
P-O Oskarsson Tony Dray/Christos Skodras EN005310 EN005237 2010-11-02 1 (2)
All Pipeweld products are supported by core documen-
tation such as product data sheets (PDS) and safety data
sheets (SDS)
Product documents

World leader in welding and cutting
technology and systems
ESAB operates at the forefront of
welding and cutting technology. Over
one hundred years of continuous
improvement in products and
processes enables us to meet the
challenges of technological advance
in every sector in which ESAB
operates.
Quality and environment
standards
Quality, the environment and safety
are three key areas of focus. ESAB is
one of few international companies to
have achieved the ISO 14001 and
OHSAS 18001 standards in
Environmental, Health Safety
Management Systems across all our
global manufacturing facilities.
At ESAB, quality is an ongoing
process that is at the heart of all our
production processes and facilities
worldwide.
Multinational manufacturing, local
representation and an international
network of independent distributors
brings the benefits of ESAB quality
and unrivalled expertise in materials
and processes within reach of all our
customers, wherever they are located.
ESAB Sales and Support Offices worldwide
ESAB AB
Box 8004 S-402 77 Gothenburg, Sweden
Tel. +46 31 50 90 00. Fax. +46 31 50 93 90
www.esab.com
ESAB Process Centres provide specialist support
to the industry.
Reg.No:XA00161120082012

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