AS/NZS 1554.5:2011

1 - AS/NZS 1554.5:2011 STRUCTURAL STEEL WELDING - WELDING OF STEEL STRUCTURES SUBJECT TO HIGH LEVELS OF FATIGUE LOADING
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
8 - 1.5.1 Fabricator
8 - 1.5.2 Inspecting authority
8 - 1.5.3 Inspector
8 - 1.5.4 May
9 - 1.5.5 Principal
9 - 1.5.6 Shall
9 - 1.5.7 Should
9 - 1.6 MANAGEMENT OF QUALITY
9 - 1.6.1 Quality management
9 - 1.6.2 Basic welding requirements
9 - 1.7 SAFETY
9 - 1.7.1 Safety equipment and procedures
9 - 1.7.2 Welding equipment
9 - 1.7.3 Other hazards
10 - SECTION 2 MATERIALS OF CONSTRUCTION
10 - 2.1 PARENT MATERIAL
10 - 2.2 BACKING MATERIAL
10 - 2.3 WELDING CONSUMABLES
10 - 2.3.1 Electrodes and filler wires
11 - 2.3.2 Care of electrodes and filler wires
11 - 2.3.3 Flux
11 - 2.3.4 Shielding gas
12 - SECTION 3 DETAILS OF WELDED CONNECTIONS
12 - 3.1 GENERAL
12 - 3.1.1 Permissible weld types
12 - 3.1.2 Design stresses
12 - 3.1.3 Drawings
12 - 3.2 BUTT WELDS
12 - 3.2.1 Size of weld
12 - 3.2.2 Design throat thickness
13 - 3.2.3 Effective length
13 - 3.2.4 Effective area
13 - 3.2.5 Transition of thickness or width
13 - 3.3 FILLET WELDS
13 - 3.3.1 Size of weld
13 - 3.3.2 Design throat thickness
15 - 3.3.3 Effective length
15 - 3.3.4 Effective area
16 - 3.3.5 Minimum size of fillet welds
16 - 3.3.6 Maximum size of fillet welds along edges
18 - 3.4 COMPOUND WELDS
18 - 3.4.1 Description
18 - 3.4.2 Design throat thickness (DTT)
19 - SECTION 4 QUALIFICATION OF PROCEDURES AND PERSONNEL
19 - 4.1 QUALIFICATION OF WELDING PROCEDURE
19 - 4.1.1 General
19 - 4.1.2 Butt welds
20 - 4.1.3 Fillet welds
21 - 4.1.4 Qualification of multiple welding positions
21 - 4.2 METHODS FOR QUALIFYING A WELDING PROCEDURE
21 - 4.3 PREQUALIFIED WELDING PROCEDURES
22 - 4.4 PORTABILITY OF QUALIFIED WELDING PROCEDURES
22 - 4.5 PREQUALIFIED JOINT PREPARATIONS
22 - 4.5.1 General
22 - 4.5.2 Prequalified complete penetration butt welds
22 - 4.5.3 Prequalified incomplete penetration butt welds
22 - 4.5.4 Prequalified fillet welds
23 - 4.6 QUALIFICATION OF WELDING CONSUMABLES
23 - 4.6.1 Prequalified welding consumables
29 - 4.6.2 Qualification of welding consumables by testing
30 - 4.7 QUALIFICATION OF WELDING PROCEDURE BY TESTING
30 - 4.7.1 Method of qualification
32 - 4.7.2 Preparation of special test piece
33 - 4.7.3 Dimensions of test pieces
33 - 4.7.4 Macro tests
33 - 4.7.5 Transverse butt tensile tests
33 - 4.7.6 Bend tests
33 - 4.7.7 Charpy impact tests
33 - 4.7.8 Hardness comparison tests between parent metal and weld metal
33 - 4.7.9 Hardness tests for weld-heat-affected zones
34 - 4.7.10 Retests
34 - 4.8 EXTENSION OF QUALIFICATION
34 - 4.9 COMBINATION OF PROCESSES
34 - 4.10 RECORDS OF TESTS
34 - 4.11 REQUALIFICATION OF WELDING PROCEDURES
38 - 4.12 QUALIFICATION OF WELDING PERSONNEL
38 - 4.12.1 Welding supervisor
38 - 4.12.2 Welders
42 - SECTION 5 WORKMANSHIP
42 - 5.1 PREPARATION OF EDGES FOR WELDING
42 - 5.1.1 General
42 - 5.1.2 Thermal cutting
42 - 5.2 ASSEMBLY
42 - 5.2.1 General
42 - 5.2.2 Alignment of butt-welded joints
43 - 5.2.3 Alignment of fillet welds and incomplete penetration butt welds
43 - 5.3 PREHEATING AND INTER-RUN CONTROL
43 - 5.3.1 General
43 - 5.3.2 Need for preheating
44 - 5.3.3 Extent of preheating and cooling after welding
44 - 5.3.4 Determination of preheating temperature
50 - 5.3.5 Inter-run temperature determination
50 - 5.4 WELDING UNDER ADVERSE WEATHER CONDITIONS
50 - 5.5 TACK WELDS
50 - 5.6 WELD DEPTH-TO-WIDTH RATIO
51 - 5.7 CONTROL OF DISTORTION AND RESIDUAL STRESS
51 - 5.7.1 General
51 - 5.7.2 Stressed parts
51 - 5.7.3 Peening
51 - 5.7.4 Correction of distortion
52 - 5.8 BACKGOUGING AND REPAIR OF DEFECTS IN WELDS
52 - 5.8.1 General
52 - 5.8.2 Removal of weld metal
52 - 5.8.3 Grinding
52 - 5.8.4 Stop/starts
53 - 5.9 TEMPORARY ATTACHMENTS
53 - 5.10 ARC STRIKES
53 - 5.11 CLEANING OF FINISHED WELDS
53 - 5.12 DRESSING OF BUTT WELDS
54 - SECTION 6 QUALITY OF WELDS
54 - 6.1 METHODS OF INSPECTION AND PERMISSIBLE LEVELS OF IMPERFECTIONS
54 - 6.1.1 Methods of inspection of completed welds
54 - 6.1.2 Permissible levels of imperfection
57 - 6.1.3 Adjacent imperfections
59 - 6.1.4 Interpretation of tests
59 - 6.2 RADIOGRAPHY
59 - 6.2.1 Method
59 - 6.2.2 Image quality indicator (IQI) sensitivity
59 - 6.2.3 Acceptance limits
60 - 6.3 ULTRASONIC EXAMINATION
60 - 6.3.1 Method
60 - 6.3.2 Evaluation
60 - 6.3.3 Acceptance limits
61 - 6.4 MAGNETIC PARTICLE EXAMINATION
61 - 6.5 WELD DEFECTS
61 - 6.6 REPORTING
62 - SECTION 7 INSPECTION
62 - 7.1 GENERAL
62 - 7.2 QUALIFICATIONS OF INSPECTORS
62 - 7.3 VISUAL INSPECTION OF WORK
63 - 7.4 NON-DESTRUCTIVE EXAMINATION OTHER THAN VISUAL
64 - APPENDIX A - NORMATIVE REFERENCED DOCUMENTS
67 - APPENDIX B - BRITTLE FRACTURE
67 - B1 METHODS
67 - B2 NOTCH-DUCTILE RANGE METHOD
67 - B3 DESIGN SERVICE TEMPERATURE
67 - B3.1 General
67 - B3.2 Basic design temperature
67 - B3.3 Modifications to the basic design temperature
68 - B4 MATERIAL SELECTION
68 - B4.1 Selection of steel type
68 - B4.2 Limitations
68 - B4.3 Modification for certain applications
69 - B5 FRACTURE ASSESSMENT
72 - APPENDIX C - TYPICAL FORMS FOR WELDING PROCEDURES
75 - APPENDIX D - CHECK LIST OF MATTERS FOR DISCUSSION
76 - APPENDIX E - WELDED JOINT AND PROCESS IDENTIFICATION
76 - E1 NOTATION FOR JOINT IDENTIFICATION
76 - E2 NOTATION FOR DIMENSIONS, POSITIONS AND BACKING MATERIAL
77 - E3 NOTATION FOR PROCESSES
77 - E4 EXAMPLE
90 - APPENDIX F - WELD PROCEDURE REQUIREMENTS ASSOCIATED WITH CHANGES TO THE WELDING CONSUMABLE CLASSIFCATION SYSTEM
90 - F1 GENERAL
90 - F2 SYSTEM CHANGES
90 - F2.1 Strength
91 - F2.2 Impact resistance
91 - F2.3 Flux designations (MMAW)
91 - F2.4 Usability designations (FCAW)
91 - F2.5 Positional designations
91 - F2.6 Weld metal hydrogen
92 - F3 EXTENSION OF WELD PROCEDURE QUALIFICATION
92 - F4 OTHER PROCESSES
94 - 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, by the MMAW, SAW, GMAW, GTAW or TIG, FCAW, ESW and EGW processes. The Standard is limited to the welding of steel parent material with a specified minimum yield strength not exceeding 500MPa.

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.

Originated in Australia as AS 1554.5-1989.
Originated in New Zealand as AS/NZS 1554.5:1995.
Previous edition 2004.
Fourth edition 2011.