AS/NZS 1554.5:2004

1 - AS/NZS 1554.5:2004 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 REFERENCED DOCUMENTS
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
8 - 1.5.5 Principal
9 - 1.5.6 Shall
9 - 1.5.7 Should
9 - 1.6 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
15 - 3.3.5 Minimum size of fillet welds
15 - 3.3.6 Maximum size of fillet welds along edges
17 - 3.4 COMPOUND WELDS
17 - 3.4.1 Description
17 - 3.4.2 Design throat thickness (DTT)
18 - SECTION 4 QUALIFICATION OF PROCEDURES AND PERSONNEL
18 - 4.1 QUALIFICATION OF WELDING PROCEDURE
18 - 4.1.1 General
18 - 4.1.2 Butt welds
19 - 4.1.3 Fillet welds
19 - 4.1.4 Qualification of multiple welding positions
19 - 4.2 METHODS FOR QUALIFYING A WELDING PROCEDURE
20 - 4.3 PREQUALIFIED WELDING PROCEDURES
20 - 4.4 PORTABILITY OF QUALIFIED WELDING PROCEDURES
20 - 4.5 PREQUALIFIED JOINT PREPARATIONS
20 - 4.5.1 General
20 - 4.5.2 Prequalified complete penetration butt welds
21 - 4.5.3 Prequalified incomplete penetration butt welds
21 - 4.5.4 Prequalified fillet welds
21 - 4.6 QUALIFICATION OF WELDING CONSUMABLES
21 - 4.6.1 Prequalified welding consumables
26 - 4.6.2 Qualification of welding consumables by testing
27 - 4.7 QUALIFICATION OF WELDING PROCEDURE BY TESTING
27 - 4.7.1 Method of qualification
27 - 4.7.2 Preparation of special test piece
27 - 4.7.3 Dimensions of test pieces
27 - 4.7.4 Macro tests
27 - 4.7.5 Transverse butt tensile tests
29 - 4.7.6 Bend tests
30 - 4.7.7 Charpy impact tests
30 - 4.7.8 Hardness comparison tests between parent metal and weld metal
30 - 4.7.9 Hardness tests for weld-heat°affected zones
30 - 4.7.10 Retests
30 - 4.8 EXTENSION OF QUALIFICATION
31 - 4.9 COMBINATION OF PROCESSES
31 - 4.10 RECORDS OF TESTS
31 - 4.11 REQUALIFICATION OF WELDING PROCEDURES
34 - 4.12 QUALIFICATION OF WELDING PERSONNEL
34 - 4.12.1 Welding supervisor
35 - 4.12.2 Welders
38 - SECTION 5 WORKMANSHIP
38 - 5.1 PREPARATION OF EDGES FOR WELDING
38 - 5.1.1 General
38 - 5.1.2 Thermal cutting
38 - 5.2 ASSEMBLY
38 - 5.2.1 General
38 - 5.2.2 Alignment of butt-welded joints
39 - 5.2.3 Alignment of fillet welds and incomplete penetration butt welds
39 - 5.3 PREHEATING AND INTER-RUN CONTROL
39 - 5.3.1 General
39 - 5.3.2 Need for preheating
39 - 5.3.3 Extent of preheating and cooling after welding
40 - 5.3.4 Determination of preheating temperature
41 - 5.4 WELDING UNDER ADVERSE WEATHER CONDITIONS
41 - 5.5 TACK WELDS
41 - 5.6 WELD DEPTH°TO°WIDTH RATIO
42 - 5.7 CONTROL OF DISTORTION AND RESIDUAL STRESS
42 - 5.7.1 General
42 - 5.7.2 Stressed parts
44 - 5.7.3 Peening
44 - 5.7.4 Correction of distortion
47 - 5.8 BACKGOUGING AND REPAIR OF DEFECTS IN WELDS
47 - 5.8.1 General
47 - 5.8.2 Removal of weld metal
47 - 5.8.3 Grinding
48 - 5.8.4 Stop/Starts
48 - 5.9 TEMPORARY ATTACHMENTS
48 - 5.10 ARC STRIKES
48 - 5.11 CLEANING OF FINISHED WELDS
48 - 5.12 DRESSING OF BUTT WELDS
49 - SECTION 6 QUALITY OF WELDS
49 - 6.1 METHODS OF INSPECTION AND PERMISSIBLE LEVELS OF IMPERFECTIONS
49 - 6.1.1 Methods of inspection of completed welds
49 - 6.1.2 Permissible levels of imperfection
49 - 6.1.3 Adjacent imperfections
49 - 6.1.4 Interpretation of tests
49 - 6.2 RADIOGRAPHY
49 - 6.2.1 Method
50 - 6.2.2 IQI sensitivity
50 - 6.2.3 Acceptance limits
50 - 6.3 ULTRASONIC EXAMINATION
50 - 6.3.1 Method
51 - 6.3.2 Evaluation
51 - 6.3.3 Acceptance limits
51 - 6.4 MAGNETIC PARTICLE EXAMINATION
51 - 6.5 WELD DEFECTS
51 - 6.6 REPORTING
56 - SECTION 7 INSPECTION
56 - 7.1 GENERAL
56 - 7.2 QUALIFICATIONS OF INSPECTORS
56 - 7.3 VISUAL INSPECTION OF WORK
56 - 7.4 NON°DESTRUCTIVE EXAMINATION OTHER THAN VISUAL
58 - APPENDIX A - REFERENCED DOCUMENTS
61 - APPENDIX B - BRITTLE FRACTURE
61 - B1 METHODS
61 - B2 NOTCH°DUCTILE RANGE METHOD
61 - B3 DESIGN SERVICE TEMPERATURE
61 - B3.1 General
61 - B3.2 Basic design temperature
61 - B3.3 Modifications to the basic design temperature
62 - B4 MATERIAL SELECTION
62 - B4.1 Selection of steel type
62 - B4.2 Limitations
62 - B4.3 Modification for certain applications
63 - B5 FRACTURE ASSESSMENT
66 - APPENDIX C - TYPICAL FORMS FOR WELDING PROCEDURES
69 - APPENDIX D - CHECK LIST OF MATTERS FOR DISCUSSION
70 - APPENDIX E - WELDED JOINT AND PROCESS IDENTIFICATION
70 - E1 NOTATION FOR JOINT IDENTIFICATION
70 - E2 NOTATION FOR DIMENSIONS, POSITIONS AND BACKING MATERIAL
71 - E3 NOTATION FOR PROCESSES
71 - E4 EXAMPLE

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 500 Mpa.

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 specifically to the welding of steelwork in structures complying with AS 3990, AS 4100 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, where the stress range in the welded joint is greater than 80% of the permissible stress range for Category B of AS 3990, or exceeds the stress range permitted for detail Category 112 of AS 4100 or NZS 3404.1, but does not exceed the maximum stress ranges permitted for these categories. NOTE: Fillet welds and incomplete penetration butt welds may be used in AS 4100 or NZS 3404.1 detail Category 125, and in Category B fatigue applications of AS 3990 when the direction of the weld is parallel to the direction of the applied stress. In addition to the abovementioned structures, the Standard applies to the welding of bridges, cranes, hoists, other dynamically loaded structures and steelwork in applications other than structural. NOTES: 1 Further information on this Standard is given in WTIA Technical Note 11. 2 The Standard is basically in line with AS/NZS 1554.1; however, it specifically applies to welds subject to fatigue loading in excess of the range covered by AS/NZS 1554.1 and hence it should not be specified where AS/NZS 1554.1 is acceptable. 3 It is expected that welds covered by this Standard will not normally occur with structures such as buildings, tanks or silos, but only in certain classes of machinery and transport equipment. 4 The Standard requires that weld preparation, welding consumables and welding procedures be qualified before commencement of welding. Prequalified joint preparations, welding consumables and welding procedures are also given in the Standard.