Sometimes repairing a non-compliant weld can lead to more problems than the repair solves. Defects in the metal around the weld not previously distressed may develop cracks due to the localised heat input of the repair. Lamellar cracking in column flanges has sometimes occurred where thick complete penetration welds connecting steel girders to the columns have been repaired.
Sometimes repairing a weld is also economically prohibitive or technically or logistically very difficult.
So what criteria can be used to determine if a particular weld should in fact be repaired? This is where a fitness for purpose assessment is required. Put simply: will the weld in its current condition perform as required for the design life of the structure?