AS/NZS 1554.3:2002

1 - AS/NZS 1554.3:2002 STRUCTURAL STEEL WELDING - WELDING OF REINFORCING STEEL
4 - PREFACE
5 - CONTENTS
7 - SECTION 1 SCOPE AND GENERAL
7 - 1.1 SCOPE
7 - 1.2 INNOVATION
7 - 1.3 REFERENCED DOCUMENTS
7 - 1.4 DEFINITIONS
7 - 1.4.1 Approved
8 - 1.4.2 Designer
8 - 1.4.3 Fabricator
8 - 1.4.4 Inspecting authority
8 - 1.4.5 Inspector
8 - 1.4.6 Loadbearing welded joints
8 - 1.4.7 May
8 - 1.4.8 Non-loadbearing welded joints
8 - 1.4.9 Principal
8 - 1.4.10 Reinforcing steel
8 - 1.4.11 Shall
8 - 1.4.12 Should
8 - 1.4.13 Supervising engineer
8 - 1.4.14 Tack welds
8 - 1.4.15 Types of splice
9 - 1.4.16 Welded joints
9 - 1.5 WELD CATEGORY
9 - 1.6 WELDING OF REINFORCING STEEL
9 - 1.6.1 Approval
9 - 1.6.2 Limitations
10 - 1.6.3 Welding different grades
10 - 1.7 BASIC WELDING REQUIREMENTS
10 - 1.8 JOINING REINFORCING STEEL TO STRUCTURES
10 - 1.9 SAFETY PRECAUTIONS
10 - 1.9.1 Welding safety
10 - 1.9.2 Welding equipment
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
11 - 2.3.2 Storage of welding consumables
11 - 2.3.3 Shielding gas
12 - SECTION 3 DETAILS OF FUSION-WELDED CONNECTIONS
12 - 3.1 GENERAL
12 - 3.1.1 Permissible weld types
12 - 3.1.2 Non-symmetric connections
12 - 3.1.3 Size of welds
12 - 3.1.4 Design throat thickness
12 - 3.1.5 Effective length
12 - 3.1.6 Effective area
12 - 3.1.7 Finished width
12 - 3.1.8 Welding consumable strength
12 - 3.2 LOADBEARING WELDED JOINTS
12 - 3.2.1 Butt splices
13 - 3.2.2 Lap splices
13 - 3.2.3 Anchorage splices
14 - 3.3 NON-LOADBEARING WELDED JOINTS (TACK WELDS)
14 - 3.3.1 Number
14 - 3.3.2 Size
14 - 3.3.3 Lifting loads
14 - 3.3.4 Locational tack welds
16 - SECTION 4 QUALIFICATION OF WELDING PROCEDURES AND WELDING PERSONNEL FOR FUSION WELDING
16 - 4.1 QUALIFICATION OF WELDING PROCEDURE
16 - 4.2 METHODS FOR QUALIFICATION OF WELDING PROCEDURE
16 - 4.3 PREQUALIFIED WELDING PROCEDURES
16 - 4.4 PREQUALIFIED JOINT PREPARATIONS
16 - 4.4.1 General
17 - 4.4.2 Prequalified butt splices
17 - 4.4.3 Prequalified anchorage splices
17 - 4.4.4 Prequalified lap splices
17 - 4.5 QUALIFICATION OF WELDING CONSUMABLES
17 - 4.5.1 Prequalified welding consumables
17 - 4.5.2 Qualification of welding consumables by testing
18 - 4.6 EXTENSION OF QUALIFICATION
18 - 4.7 COMBINATION OF PROCESSES
18 - 4.8 RECORDS OF TESTS
18 - 4.9 REQUALIFICATION OF FUSION WELDING PROCEDURES
20 - 4.10 QUALIFICATION OF WELDING PERSONNEL
20 - 4.10.1 Welding supervisor
21 - 4.10.2 Welders
22 - 4.11 WORKMANSHIP
22 - 4.11.1 Preparation of material for welding
22 - 4.11.2 Assembly
23 - 4.11.3 Gouging
23 - 4.11.4 Positioning of work
23 - 4.11.5 Welding in adverse weather conditions
23 - 4.11.6 Preheat and interrun temperature
24 - 4.11.7 Arc strikes
24 - 4.11.8 Correction of defective welds
26 - SECTION 5 FLASH BUTT WELDING
26 - 5.1 GENERAL
26 - 5.2 SIZES
26 - 5.3 BAR PREPARATION
26 - 5.4 ALIGNMENT
26 - 5.5 CLEANLINESS
26 - 5.6 WORKMANSHIP
26 - 5.6.1 Overhang or projection from the dies
26 - 5.6.2 Clamping force
26 - 5.6.3 Preheating
27 - 5.6.4 Flashing
27 - 5.6.5 Upsetting
27 - 5.7 EQUIPMENT
27 - 5.7.1 General
27 - 5.7.2 Machine controls
27 - 5.7.3 Flash guards
27 - 5.7.4 Cleanliness of machine
28 - 5.8 QUALIFICATION OF WELDING PROCEDURE
28 - 5.8.1 General
28 - 5.8.2 Method of qualification of welding procedure
28 - 5.8.3 Requalification of flash butt welding procedure
28 - 5.9 PRODUCTION CONTROL TESTS
28 - 5.9.1 General production control tests
28 - 5.9.2 Frequency of tests
29 - 5.10 DEFECTIVE WELDS
30 - SECTION 6 FLAME PRESSURE WELDING
30 - 6.1 GENERAL
30 - 6.2 SIZES
30 - 6.3 BAR PREPARATION
30 - 6.4 ALIGNMENT
30 - 6.5 CLEANLINESS
30 - 6.6 WORKMANSHIP
30 - 6.6.1 Positioning
30 - 6.6.2 Clamping force
30 - 6.6.3 Upset
30 - 6.7 QUALIFICATION OF WELDING PROCEDURE
30 - 6.7.1 General
31 - 6.7.2 Method of qualification of welding procedure
31 - 6.7.3 Requalification of gas pressure welding procedures
31 - 6.8 PRODUCTION CONTROL TESTS
31 - 6.9 DEFECTIVE WELDS
32 - SECTION 7 QUALIFICATION OF WELDING PROCEDURE BY TESTING
32 - 7.1 APPLICATION
32 - 7.2 METHOD
32 - 7.3 TESTS
32 - 7.3.1 Macro test
32 - 7.3.2 Tensile test
32 - 7.3.3 Bend test
32 - 7.4 RETESTS
34 - SECTION 8 TESTS
34 - 8.1 PRODUCTION CONTROL TEST
34 - 8.2 MACRO TEST
34 - 8.3 TENSILE TEST
34 - 8.4 BEND TEST
35 - SECTION 9 QUALITY OF WELDS
35 - 9.1 CATEGORY OF WELD QUALITY
35 - 9.2 METHODS OF INSPECTION AND PERMISSIBLE LEVELS OF IMPERFECTIONS
35 - 9.2.1 Methods of inspection of welds
35 - 9.2.2 Permissible level of imperfections
35 - 9.3 MAGNETIC PARTICLE EXAMINATION
35 - 9.4 LIQUID PENETRANT EXAMINATION
35 - 9.5 INSPECTION AFTER WELD REPAIR
37 - SECTION 10 INSPECTION
37 - 10.1 GENERAL
37 - 10.2 QUALIFICATIONS OF INSPECTORS
37 - 10.3 INSPECTION OF WORK
37 - 10.3.1 Inspection
37 - 10.3.2 Inspection after welding
38 - 10.3.3 Non-destructive examination other than visual
39 - APPENDIX A - REFERENCED DOCUMENTS
41 - APPENDIX B - RECOMMENDED TACK WELDS FOR LOCATIONAL PURPOSES
43 - APPENDIX C - LOCATIONAL TACK WELDS-TEST METHODS AND PERFORMANCE REQUIREMENTS
43 - C1 GENERAL
43 - C2 CHEMICAL COMPOSITION
43 - C3 TEST SPECIMENS
44 - C4 TESTING AND PERFORMANCE REQUIREMENTS
44 - C4.1 General
44 - C4.2 Tensile test
44 - C4.3 Bend test
44 - C5 EXTENT OF TESTING
45 - C6 EVALUATION OF TEST RESULTS
45 - C6.1 General
45 - C6.2 Tensile test
45 - C6.3 Bend test
45 - C7 EXTENSION OF TEST RESULTS
46 - APPENDIX D - TYPICAL WELDING PROCEDURE SHEET, SUITABLE FOR USEAS A PQR OR A WPS
47 - APPENDIX E - MATTERS FOR RESOLUTION
48 - APPENDIX F - WELDED JOINT AND PROCESS IDENTIFICATION
48 - F1 NOTATION FOR JOINT IDENTIFICATION
48 - F2 NOTATION FOR DIMENSIONS, POSITIONS AND BACKING MATERIAL
49 - F3 NOTATION FOR PROCESSES
62 - AMENDMENT CONTROL SHEET

Specifies requirements for the welding of reinforcing steel used in concrete structures that are designed and constructed in accordance with AS 3600 or NZS 3101.1, as well as other Standards that may be appropriate. It also applies to the welding of steel connection devices, inserts, anchors and anchor details, including prefabricated assemblies required in reinforced and precast concrete constructions.

This Standard specifies requirements for the welding of reinforcing steel used in concrete structures that are designed and constructed in accordance with AS 3600 or NZS 3101.1, as well as other Standards that may be appropriate, by the following processes:(a) Manual metal-arc welding (MMAW).(b) Gas metal-arc welding (GMAW).(c) Flux-cored arc welding (FCAW).(d) Flash butt welding.(e) Flame-pressure welding or other processes approved by the principal.The Standard applies specifically to the welding of reinforcing steels complying with AS/NZS 4671, but other steels may be used as provided for in Clause 2.1. It also applies to the welding of steel connection devices, inserts, anchors and anchor details, including prefabricated assemblies required in reinforced and precast concrete constructions.NOTES: 1 Specific approval remains the prerogative of the supervising engineer.2 Further information is given in WTIA Technical Note 11.

First published as AS CA8.3-1970.
Revised and redesignated as AS 1554.3-1974.
Second edition 1983.
Jointly revised and designated as AS/NZS 1554.3:2002.