Are you enforcing AWS D1.1 Table 6.1 as-written for isolated porosity, or grinding everything on client request? As a CWI, I flagged a 3/8 in fillet on A36 with three pores around 1/32–1/16 in clustered within about an inch on the second pass; we repaired to meet criteria, but the GC pushed for full removal — how are you aligning expectations with code and the WPS before NDT?
When a GC wants stricter than “Table 6.1,” I bake the porosity limits and disposition into the ITP/weld map before NDT and get them to initial at kickoff, so a 3/8 A36 fillet with a 1/32–1/16 cluster only gets blended if it exceeds the mapped limit — not ground out by default. If they still push for full removal, I tag it as client-directed repair on the RFI so schedule/cost track back to them. Did your PO spell out acceptance beyond D1.1 or was it just a verbal ask?