Weld Inspection Checklist (Free, PDF/Excel)

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14 critical items still open - these are the highest-risk gaps.

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Documents and qualifications (before welding)

Approved WPS available at the work location and matches the jointCRITICALSupporting PQR referenced and covers thickness and materialCRITICALWelder qualification valid for process, position and materialCRITICALWelder continuity confirmed within code periodDrawing and weld symbols reviewed at current revisionMaterial certificates match the specification and heat numbers are recordedCRITICALFiller metal type, lot and storage condition verified

Fit-up and preparation

Joint type, angle, root gap and root face within WPS toleranceCRITICALEdges clean of oil, paint, rust, moisture and mill scaleHigh-low misalignment within limitCRITICALTack welds sound, made by qualified welder, and free of cracksBacking, purge or gouging arrangements as specifiedPreheat applied and measured before weldingCRITICALEquipment calibrated and in date (ammeter, voltmeter, temperature gauges)

In-process control

Interpass temperature within WPS maximumCRITICALCurrent, voltage, and travel speed within WPS rangeShielding gas type and flow rate correct, no draftsRoot pass inspected before filling where requiredCRITICALInterpass cleaning removes slag and spatterLow hydrogen electrodes kept in a heated holding ovenBead sequence and heat input consistent with procedure

Final visual inspection

No cracks on weld or heat affected zoneCRITICALNo lack of fusion or incomplete penetration visibleCRITICALUndercut within acceptance limitReinforcement height and weld profile within limitNo excessive spatter, arc strikes or surface porosityWeld size and leg length measured with gauge for filletsDimensional checks and distortion within drawing tolerance

NDT, repairs and records

NDT method and extent as specified (VT, MT, PT, UT, RT)CRITICALNDT personnel qualified for method and levelDefects recorded, repaired by approved procedure and re-inspectedCRITICALWeld map with welder IDs and weld numbers completedPWHT performed and recorded where requiredCRITICALInspection report signed and filed in the quality dossier

Any critical item that fails should stop the job until it is corrected. Acceptance criteria come from the applicable code or specification.

Digital inspection records

Optional: ask how checklists can be captured on the shop floor and linked to ERP orders.

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How to use the checklist

Work through the groups in order for each joint or weld lot. Tick items as they are verified and note exceptions. Critical items are flagged because failing them often means a rejected weld or unqualified work. Export the completed list to PDF to attach to the traveler or inspection record.

Run the first two groups before welding starts
Do in-process checks on the first joint of every shift
Keep the weld map beside the checklist
Use the acceptance level from your code

What each stage catches

Document checks prevent welding with the wrong procedure or an unqualified welder. Fit-up checks catch gap and alignment faults that cause lack of fusion and distortion. In-process checks control preheat, interpass and heat input, which drive cracking and toughness. Final inspection finds surface defects, and NDT finds the internal ones.

Acceptance criteria

This list does not give limits because they depend on the code, such as ISO 5817 quality levels, AWS D1.1 or ASME fabrication codes, and on service conditions. Pull the limits from your contract specification and write them on the inspection plan so every inspector uses the same numbers.

Common mistakes

Inspection is often reduced to a quick look at the finished bead. Common gaps are no check of the WPS at the workstation, no record of preheat temperature, welders assigned outside their qualification, and repairs welded without an approved repair procedure.

Inspecting only after welding is complete
No temperature measurement record
Repair without re-inspection
Missing welder identification on the weld map

Frequently Asked Questions

Is this checklist tied to a specific code?

No. It follows a general inspection flow common to ASME, AWS and ISO based work. Acceptance limits come from your code and contract, so add them to your inspection plan and customize the list for your product.

Who should perform weld inspection?

Qualified inspectors, for example certified to CSWIP, AWS CWI or equivalent, usually perform visual inspection. NDT must be done by personnel qualified to the method and level required, such as under ISO 9712 or SNT-TC-1A practice.

When should inspection happen?

Before, during, and after welding. Pre-weld checks prevent defects, in-process checks control temperature and parameters, and final checks verify the finished weld. Waiting until after welding only finds problems when repair is expensive.

How long should I keep inspection records?

Retention depends on contract, code and regulation. Pressure equipment, structural and nuclear work often need many years or the life of the asset. Follow your quality management system and customer requirements.

Netray can help turn inspection checklists into structured records in your ERP or quality system, linked to the work order and material lot.

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Weld Inspection Checklist for Fit-Up, In-Process and Final Inspection