Ground mount array welding the sch 40 pipe instead of using connectors like snap-n-rack or tamarack offers. Any code restrictions?

Ground mount array welding the sch 40 pipe instead of using connectors like snap-n-rack or tamarack offers. Any code restrictions? I figured why not I’ve got the time and it’s going on my property. It will be built under code of course and the my structural engineers recommendations. What do you think?

I cannot think of any better way of doing it than welding.
I also can’t imagine it not “meeting code” if you are using structural members that exceed live load plus dead load numbers along with the wind loading and uplift characteristics for your locale.

Idk, welding may need to be certified.
Galvanized? Csreful of the fumes.

I would think the engineer would need to take welding into consideration during the design?

The main reason I can think of for not welding, would be the welding would burn off any finish or galvanized coating and you can't galvanize the parts after it is built, so you would need to paint it.

Bolting stuff together is faster.

Supervstech said:

welding may need to be certified

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that didn’t occur to me.
I’d be happy with painted hot-rolled steel though.

Then again I’m a competent welder- just not certified on any process. I’ve welded on heavy trailers, hitches on 30k trucks, built trailers, heavily modified jeeps and other vehicles, do frame and sheet metal welding. I just assumed OP is a competent welder though AHJ I suppose might be paperwork aggressive.

Depends a little on the specific weld you will have to make. Sometimes a bolted connection is better than a welded connection. Lots of variables like how much alternating stresses there will be, how much weld area you will need.

If you’ve never used or seen a welded connection in an arrangement like you are thinking of doing, (unless someone you trust says they’ve done it) I’d find someone who knows what they are doing.

Use a slip fitting, get your bead all the way around, and paint it. It doesn't get more structural than that.

Just weld the bolts and threads in a position that they appear bolted together!

Q-Dog said:

I would think the engineer would need to take welding into consideration during the design?

The main reason I can think of for not welding, would be the welding would burn off any finish or galvanized coating and you can't galvanize the parts after it is built, so you would need to paint it.

Bolting stuff together is faster.

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There are cold galvanizing sprays one can use after welding. I'd use them there as well as on the cut ends of any galvanized pipe or steel members. And paint can be applied afterwards too. There may be some structural/longevity issues with using plain steel in concrete (or buried), ask your engineer. Best protection would probably be galvanized steel, if welding take the zinc off near the welds, and coat with cold galvanizing spray after welding and on all cut ends. Painting would add some protection (and looks).

Steve777 said:

may be some structural/longevity issues with using plain steel in concrete (or buried)

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In this scenario you pour concrete with hefty (oversized) galvanized threaded studs / rods and bolt the framework to that.

Think about all the bridges, towers, and above-ground fuel tank racks, etc. that were constructed with plain welded steel that have a ~40-50-year-plus service life. If you are 40 years old or more whatever you do is going to exceed your own personal service life so it really is a non-issue imho.

The consideration for me personally is cost: with all the sorta nice ‘bolt together’ aluminum racking with “standard” engineering sheets available for permitting at a not terrible price compared with the cost of standard steel lengths plus your time it might be “less costly” to just buy aluminum. That seems to be the case for roof mounts, whereas building / welding ground mounts from steel are way more labor efficient than rooftop and may make sense.

A splice with self tapping screws is what ironridge requires. It's hard to beat the simplicity of that. Welding is feasible but you would want to bevel the ends, ensure complete joint penetration so the weld doesn't become the failure point, and then do something like cold galv like suggested above.

It is possible that your AHJ will want compliance to a code such as AWS D1.1 (structural steel welding code).

If that is the case, you will need qualified procedures for the welding, you will need to be qualified as a welder to that procedure, you will need a Certified Welding Inspector to inspect the welds, etc.

I doubt it will get to that point, but if they want a properly engineered system, it could happen.

I used ground screws and 2" steel pipe to support ironridge racking. It made permitting a breeze. They do all the designing/engineering and spit out the build requirements.

If you do decide to weld it yourself, use ER70S-2 wire. It has lower silica content and is less problematic when welding galvanized (porosity).

12VoltInstalls said:

Think about all the bridges, towers, and above-ground fuel tank racks, etc. that were constructed with plain welded steel that have a ~40-50-year-plus service life. If you are 40 years old or more whatever you do is going to exceed your own personal service life so it really is a non-issue imho.

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When I accidentally poured some plain steel anchors into concrete outside I asked someone I know who's been in steel construction a long time about it and he confirmed this opinion and said shoot some "spray galv" on and forget about it, it will last your lifetime. I'll still use hot dip galvanized hardware in the future though.

The hurdle would be engineering. The pre engineered plans are pre engineered for the connectors. You could engineer it yourself with welds, but that's more work or money and building departments are gonna look at you funny when you submit self engineered.

But if no permits needed, no problem.

Q-Dog said:

I would think the engineer would need to take welding into consideration during the design?

The main reason I can think of for not welding, would be the welding would burn off any finish or galvanized coating and you can't galvanize the parts after it is built, so you would need to paint it.

Bolting stuff together is faster.

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Yes, I do think it would be a little efficient to use connectors I was trying to explore all methods and costs before deciding on one.