AS/NZS 1554.1:2011

1 - AS/NZS 1554.1:2011 STRUCTURAL STEEL WELDING - WELDING OF STEEL STRUCTURES
4 - PREFACE
5 - CONTENTS
7 - SECTION 1 SCOPE AND GENERAL
7 - 1.1 SCOPE
8 - 1.2 EXCLUSIONS
8 - 1.3 INNOVATION
8 - 1.4 NORMATIVE REFERENCES
8 - 1.5 DEFINITIONS AND SYMBOLS
8 - 1.5.1 Definitions
9 - 1.5.2 Symbols
9 - 1.6 WELD CATEGORIES
9 - 1.7 MANAGEMENT OF QUALITY
9 - 1.7.1 Quality management
10 - 1.7.2 Basic welding requirements
10 - 1.8 SAFETY
10 - 1.8.1 Safety equipment and procedures
10 - 1.8.2 Welding equipment
10 - 1.8.3 Other hazards
11 - SECTION 2 MATERIALS OF CONSTRUCTION
11 - 2.1 PARENT MATERIAL
11 - 2.2 BACKING MATERIAL
11 - 2.3 WELDING CONSUMABLES
11 - 2.3.1 Electrodes and filler wires
12 - 2.3.2 Care of electrodes and filler wires
12 - 2.3.3 Flux
12 - 2.3.4 Shielding gas
13 - SECTION 3 DETAILS OF WELDED CONNECTIONS
13 - 3.1 GENERAL
13 - 3.1.1 Permissible weld types
13 - 3.1.2 Design stresses
13 - 3.1.3 Drawings
13 - 3.2 BUTT WELDS
13 - 3.2.1 Size of weld
13 - 3.2.2 Design throat thickness
14 - 3.2.3 Effective length
14 - 3.2.4 Effective area
14 - 3.2.5 Transition of thickness or width
14 - 3.3 FILLET WELDS
14 - 3.3.1 Size of weld
14 - 3.3.2 Design throat thickness
15 - 3.3.3 Effective length
15 - 3.3.4 Effective area
15 - 3.3.5 Minimum size of fillet welds
15 - 3.3.6 Maximum size of fillet welds along edges
18 - 3.4 COMPOUND WELDS
18 - 3.4.1 Description
19 - 3.4.2 Design throat thickness (DTT)
19 - 3.5 SEAL WELDS
20 - 3.6 PLUG WELDS
20 - 3.7 SLOT WELDS
20 - 3.8 COMBINING STEEL SECTIONS
22 - SECTION 4 QUALIFICATION OF PROCEDURES AND PERSONNEL
22 - 4.1 QUALIFICATION OF WELDING PROCEDURE
22 - 4.1.1 General
22 - 4.1.2 Butt welds
23 - 4.1.3 Fillet welds
24 - 4.1.4 Qualification of multiple welding positions
24 - 4.2 METHODS FOR QUALIFYING A WELDING PROCEDURE
24 - 4.3 PREQUALIFIED WELDING PROCEDURES
25 - 4.4 PORTABILITY OF QUALIFIED WELDING PROCEDURES
25 - 4.5 PREQUALIFIED JOINT PREPARATIONS
25 - 4.5.1 General
25 - 4.5.2 Prequalified complete penetration butt welds
25 - 4.5.3 Prequalified incomplete penetration butt welds
25 - 4.5.4 Prequalified fillet welds
26 - 4.5.5 Additional requirements for welds in hollow section members
32 - 4.6 QUALIFICATION OF WELDING CONSUMABLES
32 - 4.6.1 Prequalified welding consumables
39 - 4.6.2 Qualification of welding consumables by testing
40 - 4.7 QUALIFICATION OF WELDING PROCEDURE BY TESTING
40 - 4.7.1 Method of qualification
41 - 4.7.2 Preparation of special test piece
41 - 4.7.3 Dimensions of test pieces
41 - 4.7.4 Macro test
41 - 4.7.5 Transverse butt tensile test
44 - 4.7.6 Bend test
44 - 4.7.7 Charpy impact test
44 - 4.7.8 Hardness comparison test for parent metal and weld metal
44 - 4.7.9 Hardness test for weld-heat-affected zones
44 - 4.7.10 Retests
44 - 4.8 EXTENSION OF QUALIFICATION
45 - 4.9 COMBINATION OF PROCESSES
45 - 4.10 RECORDS OF TESTS
45 - 4.11 REQUALIFICATION OF WELDING PROCEDURES
49 - 4.12 QUALIFICATION OF WELDING PERSONNEL
49 - 4.12.1 Welding supervisor
49 - 4.12.2 Welders
53 - SECTION 5 WORKMANSHIP
53 - 5.1 PREPARATION OF EDGES FOR WELDING
53 - 5.1.1 General
53 - 5.1.2 Thermal cutting
53 - 5.2 ASSEMBLY
53 - 5.2.1 General
53 - 5.2.2 Alignment of butt-welded joints
54 - 5.2.3 Alignment of fillet welds and incomplete penetration butt welds
54 - 5.2.4 Separation of a backing material
54 - 5.3 PREHEATING AND INTER-RUN CONTROL
54 - 5.3.1 General
54 - 5.3.2 Need for preheating
55 - 5.3.3 Extent of preheating and cooling after welding
55 - 5.3.4 Determination of preheating temperature
56 - 5.3.5 Inter-run temperature determination
61 - 5.4 WELDING UNDER ADVERSE WEATHER CONDITIONS
61 - 5.5 TACK WELDS
61 - 5.6 WELD DEPTH-TO-WIDTH RATIO
62 - 5.7 CONTROL OF DISTORTION AND RESIDUAL STRESS
62 - 5.7.1 General
62 - 5.7.2 Stressed parts
62 - 5.7.3 Peening
62 - 5.7.4 Correction of distortion
63 - 5.8 BACKGOUGING AND REPAIR OF DEFECTS IN WELDS
63 - 5.8.1 General
63 - 5.8.2 Removal of weld metal
63 - 5.8.3 Grinding
63 - 5.8.4 Stop starts
64 - 5.9 TEMPORARY ATTACHMENTS
64 - 5.10 ARC STRIKES
64 - 5.11 CLEANING OF FINISHED WELDS
64 - 5.12 DRESSING OF BUTT WELDS
65 - SECTION 6 QUALITY OF WELDS
65 - 6.1 CATEGORIES OF WELDS
65 - 6.2 METHODS OF INSPECTION AND PERMISSIBLE LEVELS OF IMPERFECTIONS
65 - 6.2.1 Methods of inspection of completed welds
65 - 6.2.2 Permissible levels of imperfection
65 - 6.2.3 Adjacent imperfections
65 - 6.2.4 Interpretation of tests
70 - 6.3 RADIOGRAPHY
70 - 6.3.1 Method
70 - 6.3.2 IQI sensitivity
70 - 6.3.3 Acceptance limits
71 - 6.4 ULTRASONIC EXAMINATION
71 - 6.4.1 Method
71 - 6.4.2 Evaluation
71 - 6.4.3 Acceptance limits
72 - 6.5 MAGNETIC PARTICLE EXAMINATION
72 - 6.6 LIQUID PENETRANT EXAMINATION
72 - 6.7 WELD DEFECTS
72 - 6.8 REPORTING
73 - SECTION 7 INSPECTION
73 - 7.1 GENERAL
73 - 7.2 QUALIFICATIONS OF INSPECTORS
73 - 7.3 VISUAL INSPECTION OF WORK
74 - 7.4 NON-DESTRUCTIVE EXAMINATION OTHER THAN VISUAL
75 - APPENDIX A - NORMATIVE REFERENCED DOCUMENTS
78 - APPENDIX B - BRITTLE FRACTURE
78 - B1 METHODS
78 - B2 NOTCH-DUCTILE RANGE METHOD
78 - B3 DESIGN SERVICE TEMPERATURE
78 - B3.1 General
78 - B3.2 Basic design temperature
78 - B3.3 Modifications to the basic design temperature
79 - B4 MATERIAL SELECTION
79 - B4.1 Selection of steel type
79 - B4.2 Limitations
79 - B4.3 Modification for certain applications
80 - B5 FRACTURE ASSESSMENT
83 - APPENDIX C - TYPICAL FORMS FOR WELDING PROCEDURES
86 - APPENDIX D - MATTERS FOR RESOLUTION
87 - APPENDIX E - WELDED JOINT AND PROCESS IDENTIFICATION
87 - E1 NOTATION FOR JOINT IDENTIFICATION
87 - E2 NOTATION FOR DIMENSIONS, POSITIONS AND BACKING MATERIAL
88 - E3 NOTATION FOR PROCESSES
88 - E4 EXAMPLE
106 - APPENDIX F - WELD PROCEDURE REQUIREMENTS ASSOCIATED WITH CHANGES TO THE WELDING CONSUMABLE CLASSIFCATION SYSTEM
106 - F1 GENERAL
106 - F2 SYSTEM CHANGES
106 - F2.1 Strength
107 - F2.2 Impact resistance
107 - F2.3 Flux designations (MMAW)
107 - F2.4 Usability designations (FCAW)
107 - F2.5 Positional designations
107 - F2.6 Weld metal hydrogen
108 - F3 EXTENSION OF WELD PROCEDURE QUALIFICATION
108 - F4 OTHER PROCESSES
110 - APPENDIX G - TYPICAL MATERIAL GROUPS FOR COMMON STEELS
112 - BIBLIOGRAPHY

Specifies requirements for the welding of steel structures made up of combinations of steel plate, sheet or sections, including hollow sections and built-up sections, or castings and forgings. It is limited to the welding of steel parent material with a specified minimum yield strength not exceeding 500MPa. It does not apply to oxyacetylene, friction, thermit or resistance welding processes or to the welding of pressure vessels or pressure piping.

This Standard specifies requirements for the welding of steel structures made up of combinations of steel plate, sheet or sections, including hollow sections and built-up sections, or castings and forgings, by the following processes:(a) Manual metal-arc welding (MMAW).(b) Submerged arc welding (SAW).(c) Gas metal-arc welding (GMAW or MIG), including pulsed mode.(d) Gas tungsten-arc welding (GTAW or TIG).(e) Flux-cored arc welding (FCAW).(f) Electroslag (including consumable guide) welding (ESW).(g) Electrogas welding (EGW).The Standard is limited to the welding of steel parent material with a specified minimum yield strength not exceeding 500 MPa.The Standard applies to the welding of steelwork in structures complying with AS 3990, AS 4100, AS/NZS 4600 or NZS 3404.1. Where welded joints in these structures are governed by dynamic loading conditions, the Standard applies only to those welded joints that comply with the fatigue provisions of AS 3990, AS 4100 or NZS 3404.1, as limited by Item (ii) below, or the directly equivalent fatigue provisions of other application Standards.Welded joints complying with the above are those that are - (i) not subject to fatigue conditions; or(ii) subject to fatigue conditions, where—(A) the stress range in the welded joint complies with the permissible stress range of stress categories C, D, E or F of AS 3990, or weld categories lower than or equal to detail category 112 of AS 4100 or NZS 3404.1; or(B) the stress range in the welded joint is not greater than 80% of the permissible stress range of stress category B of AS 3990.In addition to the abovementioned structures, the Standard applies to the welding of cranes, hoists and other dynamically loaded structures, the welding of road and pedestrian bridges and the welding of steelwork in applications other than structural.NOTE: Further information on this Standard, is given in WTIA Technical Note 11.

First published in Australia as AS CA8-1933.Second edition 1939.Revised and redesignated in part as AS Int 352-1952.AS Int 352-1952 and part of AS CA8-1939 revised, amalgamated and redesignated as AS CA8.1-1965.Revised and redesignated in part as AS 1554.1-1974.Second edition 1980. Third edition 1985.Fourth edition 1991.First published in New Zealand in part as NZS 4701:1981.NZS 4704 first published 1994.AS 1554.1-1991, NZS 4701:1981 and NZS 4704:1994 jointly revised, amalgamated and designated AS/NZS 1554.1:1995.Sixth edition 2000.Seventh edition 2004.Eighth edition 2011. Originated in Australia as AS CA8-1933. Originated in New Zealand, in part, as NZS 4701:1981. Previous edition AS/NZS 1554.1:2004. Eighth edition 2011.