HI-LO Welding Gauge Cat 1 Usage Guide

HI-LO Welding Gauge • Cat # 1 • Gauge Overview
The HI-LO Welding Gauge, from the G.A.L. Parts of the Gauge
Gage Company, is an essential tool for pipe
and weld inspection. It can perform the INTERNAL
following functions: ALIGNMENT
37½° STOPS
• Internal Misalignment DEGREE
• Pipe Wall Thickness BEVEL
• Leg Length for a Fillet Weld
• Crown Height
EXTENSION
& SLIDING
There are two go no-go features of this
gauge which are used to verify that the BODY
beveled angle is the required 37-1/2
degrees and that the required gap after fit-
up is no larger than 3/32nd. Scribe lines on
the feet can be used to calculate the
required 1/16th gap after fit-up for socket MATERIAL
welds; if one of our patented GAP-A-LETS THICKNESS
is not used. For added versatility, this SCALE
gauge comes in standard (inches) and
metric (millimeters).
Scales Overview
LOCKING
There are three scales on this gauge. The
SCREW
Material Thickness Scale measures in
16ths. The Internal Alignment Scale
measures in 3/32nds and the Scales for the INTERNAL
Scribe Lines measures in 16ths. ALIGNMENT
SCALES
CAUTION: The metal strips that connect
the Internal Alignment Stops to the 37-1/2°
bevel can be bent when removing from the
pipe after a measurement. Use care and
caution when extracting from a pipe to GAUGE FEET / LEGS & SCALE FOR
prevent damaging your gauge. SCRIBE LINES TO CHECK PIPE FIT-UP
Page 1 of 5
G.A.L. Gage Company

Phone: (269) 465-5750 ● Fax: (269) 465-6385 ● www.galgage.com
2953 Hinchman Road, Bridgman, Michigan 49106-9501
Identifying the Zero Position
Figure #1
The versatility of the gauge requires that after a
measurement is taken and another one is needed
the gauge must be returned to Zero Position before
a new measurement is taken. Zero Position for the
gauge is achieved when the Internal Alignment
Scales and the Alignment Stops mirror each other.
Also, the Right Edge of the Extension & Sliding
Body should be just below the Zero Mark on the
Material Thickness Scale (See Figure 1).
Figure #2
How to Measure the Fit-Up Gap
The Alignment Stops are milled with exact precision

to have 3/32nd and 1/16th measurements. The
3/32nd is the width of the lower portion of the Stops
(left edge in photo) and 1/16th is the width at the top
of the Stops (right edge in photo) -- See Figure 2.
Gauge should be in Zero Position. Turn the gauge
90 degrees and insert the tip of the Stops into the Figure #3
gap. If the Stops will not fit into the gap then the
gap measures less than 1/16th. If the Stops fit
partially then the gap measures in-between 1/16th
and 3/32nd. If the Stops move freely in the gap
then the measurement is wider than 3/32nd (See
Figure 3).
How to Check for 37-1/2 Degree Bevel

Figure #4

90 degrees and lower the Alignment Stops into the
gap of the pipe until the top edge of the Beveled
Angle touches the pipe. Turn the gauge back to the
original position. Turn the locking screw and lower
the Sliding Body until the top edge of the extension
touches the surface of the pipe. Square the
shoulders of the beveled angle by moving the legs
of the gauge (See Figure 4).
Page 2 of 5
G.A.L. Gage Company

How to Measure Crown Height of a Butt Weld
Figure #5
Gauge should be in Zero Position. Loosen the
locking screw and raise the leg that is on the same
side of the weld. Position the gauge on the
horizontal member so that one foot is on the
horizontal member and the other is raised above the
weld. Lower the raised foot by pushing down gently
on the raised Alignment Stop until the bottom of the
foot touches the top of the weld (See Figure 5).
Read the measurement from the 32nd scale (See

Figure 6).
Figure #6
How to Measure Leg of a Fillet Weld

Figure #7
Gauge should be in Zero Position. Loosen the
locking screw and raise the leg that is on the same
side of the weld. Position the gauge on the
horizontal member so that one foot is on the
horizontal member and the other is raised above the
weld (See Figure 7).
Lower the raised foot by pushing down gently on the

raised Alignment Stop until the bottom of the foot
touches the toe of the weld. Read the measurement
from the 32nd scale (See Figure 8).
Figure #8
Page 3 of 5
G.A.L. Gage Company

How to Measure Pipe Wall Thickness
Gauge should be in Zero Position. Turn the gauge 90

degrees and lower the Alignment Stops into the gap of
the pipe. Turn the gauge back to original position. Figures #9 & #11
Stop when the tip of the bevel touches the gap.
Loosen the locking screw and lower the extension until
the top edge touches the surface of the pipe. Pull the
leg, on the same side of the pipe whose thickness
needs to be measured, until the Alignment Stop
touches the interior of the pipe (See Figure 9). Read
the measurement from the 16th scale (See Figure 10).
Figure #10
How to Measure Internal Misalignment

Figure #12
90 degrees and lower the Alignment Stops into the
gap of the pipe. Turn the gauge back to original
position. Stop when the tip of the bevel touches the
gap. Loosen the locking screw and lower the
extension until the top edge touches the surface of
the pipe. Pull one leg up until the Alignment Stop
touches the interior of the pipe (See Figure 11). Pull
the other leg up until the Alignment Stop touches the
interior of the pipe. Both Alignment Stops should be
in contact with the interior of the pipe (See Figure
12). Read the measurement from the 32nd scale
(See Figure 13).
Figure #13
Page 4 of 5
G.A.L. Gage Company

How to Use the Hi-Lo Gauge to Create a 1/16th Gap Figure #14
for Socket Welds
According to A.W.S. Standards Socket Welds

require a minimum of 1/16th gap between the pipe
and the bottom of the socket.
If you do not have one of our patented GAP-A-LETS

you can use the Hi-Lo Gauge to determine the
1/16th gap for socket welds. This scale is in 16ths.
Use the method below.
Gauge should be in Zero Position. Use the scribe

lines, on the feet of the gauge, to make a 1/2 inch Figure #15
reference line from the face of the socket (See

Figure 14).
Bottom out the pipe by pushing the pipe all the way
into the socket.
Use the scribe lines on the gauge to draw another Figure #16
line 3/4 of an inch, onto the pipe, from the face of the
socket weld. Using the 3/4 inch mark and the scribe
lines of the gauge, pull the pipe out from the socket
weld 1/8 of an inch (See Figure 15).
Tack the pipe to the socket. The measurement

between the 1/2 inch reference line and the 3/4 inch
mark, after movement, should be 1-5/16th (See
Figure 16). This measurement ensures the 1/16th
gap required by A.W.S. Standards.
Important Note: Figure 16 does not show actual

measurement. Also, the distance from the 1-5/16th
implies that tacking has occurred which will naturally
draw the pipe into the socket.
Page 5 of 5
G.A.L. Gage Company


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HI-LO Welding Gauge • Cat # 1 • Gauge Overview

G.A.L. Gage Company

How to Measure the Fit-Up Gap

The Alignment Stops are milled with exact precision

How to Check for 37-1/2 Degree Bevel

Gauge should be in Zero Position. Turn the gauge

G.A.L. Gage Company

Read the measurement from the 32nd scale (See

How to Measure Leg of a Fillet Weld

Lower the raised foot by pushing down gently on the

G.A.L. Gage Company

Gauge should be in Zero Position. Turn the gauge 90

How to Measure Internal Misalignment

G.A.L. Gage Company

for Socket Welds

According to A.W.S. Standards Socket Welds

If you do not have one of our patented GAP-A-LETS

Gauge should be in Zero Position. Use the scribe

reference line from the face of the socket (See

Tack the pipe to the socket. The measurement

Important Note: Figure 16 does not show actual

G.A.L. Gage Company

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