What is the correct action when a weld defect is detected during inspection?

• A. Stop welding, document, diagnose root cause, correct defect per WPS, and re-weld.
• B. Continue welding and ignore defect.
• C. Grind out defect and repaint.
• D. Leave it and proceed to next joint.

Answer: (A)

When a weld defect is found during inspection, the priority is to halt work and bring the joint under controlled repair. Stop welding, document the defect with details like location, type, and welding parameters, then start a root-cause assessment to determine why the defect occurred. Once you understand the cause, correct the defect using the Welding Procedure Specification and any approved repair procedures, and then re-weld the joint. After repair, the joint should be re-inspected or re-tested per the applicable code to confirm it meets acceptance criteria. This approach protects safety, ensures structural integrity, and keeps the process compliant with approved procedures.

Continuing to weld without addressing the defect can hide structural problems and violate code requirements. Cosmetic grinding and repainting may not satisfy repair criteria unless the WPS allows it for that defect, and even then it typically requires proper verification. Leaving the defect and moving on risks failure and liability.