As 1554 Part 3 - Welding Reinforcing Steel

AS 1554, Part 3—1983

Australian Standard® SAA STRUCTURAL STEEL WELDING CODE Part 3—WELDING OF REINFORCING STEEL

This Australian standard was prepared by Committee WD/3, Welding of Structures. It was approved on behalf of the Council of the Standards Association of Australia on 28 June 1983 and published on 8 August 1983.

The following interests are represented on Committee WD/3: Aluminium Development Council Association of Consulting Engineers Australia Australian Chamber of Commerce Australian Institute of Steel Construction Ltd Australian Welding Institute Australian Welding Research Association Bureau Bureau of Steel Manufac Manufacturer turerss of Australia Australia Confederation of Australian Industry Department of Defence Department of Housing and Construction Electricity Electricity Supply Supply Association Association of Australia Australia Institution Institution of Enginee Engineers rs Australia Australia Metal Metal Trades Industry Industry Association Association of Australia National National Association Association of Australian Australian State Road Authorities Authorities Railways Railways of Australia Committee Committee Snowy Mountains Engineering Corporation Steel Reinforcement Promotion Group University of Sydney

 Review of Austr alia n Standa rds. To keep abreast abreast of progress progress in industry, industry, Australian Australian Standards Standards are subject  subject  to periodic periodic review review and are are kept up to date by the issue of amendments amendments or new editions as necessar necessary. y. It is important therefore therefore that Standards Standards users users ensure ensure that they are in possess possession ion of the latest edition, and any amendments amendments thereto. thereto. Full details of all Australian Australian Standards Standards and related publications will be found in t he Standards Standards Australia Catalogue of Publications; this information is supplemented each month by the magazine ‘The Australian Standard’, Standard’, which subscribing subscribing m embers embers receive, receive, and which gives details of new publications, publications, new editi ons and amendments, amendments, and of withdrawn Standards. Standards. Suggestions Suggestions for improvements improvements t o Australian Australian Standards, Standards, addressed addressed to the head offi ce of Standard Standardss Australia, Australia, are welcomed. Notification of any inaccuracy or ambiguity found in an Australian Standard should be made without delay in order that the matter may be investigated and appropriate appropriate action taken.

This Standard Standard was issued in draft form for comment comment as DR 82154 82154.. ..

AS 1554, Part 3—1983

Australian Standard® STRUCTURAL STEEL WELDING known as the SAA STRUCTURAL STEEL WELDING CODE Part 3—WELDING OF REINFORCING STEEL

Firs Firstt publ publish ished ed . . . . . . . . . . . . . . . . . . . . . . . . Seco Second nd edition edition . . . . . . . . . . . . . . . . . . . . . . . .

1974 1974 1983 1983

PUBLISHED BY ST AND ANDARDS ARDS AUSTRALIA (STANDARDS (STANDARDS ASSOCIATION ASSOCIATION OF AUSTRALIA) AUSTRALIA) 1 THE CRESCENT, HOMEBUSH, NSW 2140 ISBN 0 7262 3063 4

AS 1554, Part 3—1983

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PREFACE This edition of this standard was prepared prepared by the Association’s Association’s Committee on on Wel ding of Structures to supersede AS 1554, Part 3—1974. It establishes requirements for the welding welding of reinforcem reinforcement ent intende intended d to form part of concre concrete te structures structures designed designed and construc constructed ted in accordan accordance ce with AS 1480, 1480, SAA Concrete Concrete St ructures ructures Code. An important important differenc differencee between between this edition edition and the 1974 edition is that it applies applies to the welding of reinforcing bars of Grade 410Y to AS 1302. As the welda weldabi bility lity of Grade rade 410Y 410Y had had not not been been fully fully deter determin mined ed prior prior to the the publicati publication on of AS 1302—19 1302—1982 82,, an amendme amendment nt to AS 1302 1302 was subseque subsequently ntly issued issued involving involving t he lowering of the carbon equivalent equivalent value for Grade Grade 410Y from 0.60 to 0.39 for the purpose of ensuring ease in weldability. Requirements for steel material with carbon equivalent value greater than 0.39 are incorporated in this edition. It is intended that welding operations, other than flash butt welding and name pressure welding, welding, will be carried carried out under under t he supervision supervision of a person person certified certified i n accordanc accordancee with AS 2214, SAA Structural Steel Welding Supervisors Certification Code.

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CONTENTS Page

SECTION SECTION 1. SCOPE SCOPE AND GENERAL GENERAL 1. 1 1. 2 1.3 1. 4 1. 5 1.6 1.6 1.7 1.8 1.9

Sc op ope . . . . . . . . . . . . . . . . . . . . . Ap pl pli ca cat io io n . . . . . . . . . . . . . . . . . Refere eferen nced ced Doc Docume uments nts . . . . . . . . De fi fin it iti on ons . . . . . . . . . . . . . . . . . We ld ldi ng ng Sy Sy mb mbols . . . . . . . . . . . . Weldi We lding ng of Rei Reinf nforc orcin ing g Steel Steel . . . . Joining Joining Reinforcing Reinforcing Steel Steel to to Struct tructu ures res . . . . . . . . . . . . . . . . . . Weldin elding g Proc Proces esse sess . . . . . . . . . . . . Weldin elding g Equ Equiipmen pmentt . . . . . . . . . . .

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SECTION SECTION 2. MATERIA MATERIALS LS OF OF CONSTRUCTIO CONSTRUCTION N 2.1 2.2 2.3

Parent arent Ma Mater terial ial . . . . . . . . . . . . . . . Back acking ing Mater Material ial . . . . . . . . . . . . . . Weldin elding g Con Conssumab umablles . . . . . . . . . .

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SECTION SECTION 3. DETAILS DETAILS OF FUSION FUSION WELDED CONNECTIONS 3. 1 3. 2 3. 3 3. 4

Gener al al . . . . Bu tt tt Sp Spl ic ice s . La p S pl pli ce ces . Ta ck ck We Wel ds ds .

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SECTION SECTION 4. QUALIFICA QUALIFICATION TION OF OF WELDING WELDING PROCEDURES AND WELDING PERSONNEL FOR FUSION WELDING 4.1 4.1 4.2 4.2 4.3 4.4 4.4 4.5 4.5 4.6 4.6 4.7 4.7 4. 8

Qual Qualific ificaation tion of Weldin elding g Proce Procedu dure re 8 Metho Method d of of Qua Qualific lificati ation on of WeldWelding Proc Proced edu ure . . . . . . . . . . . . . . . . 8 Prequa requallified ified We Weld ldiing Proc Proceedur dures . . 8 Prequ Prequal alifie ified d Joint Joint Prepa Prepara rati tion onss . . . . 8 Qual Qualifica ification tion of of Weldin Welding g Consu Consuma mable bless 8 Requa Requalifi lificat cation ion of Fusion Fusion WeldWelding Proc Proced edu ures res . . . . . . . . . . . . . . . 8 Qual Qualific ificaation tion of Weldin elding g Perso Personn nnel el . 8 Wo rk rkma ns nshi p . . . . . . . . . . . . . . . . 9

Gener al al . . . . . . . Si ze zes . . . . . . . . . Ba r P re re pa par at ati on on . . Al ig ignm en ent . . . . . Cl ea eanl in in es es s . . . . . Wo rk rkma ns nshi p . . .

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Eq ui uipm en ent . . . . . . . . . . . . . . . . . Qual Qualific ificaation tion of Weldin elding g Proce Procedu dure re Produ roductio ction n Con Control trol Tests ests . . . . . . . Defe efecti ctive We Wellds . . . . . . . . . . . . .

SECTION SECTION 6. FLAME FLAME PRESSURE WELDING WELDING 6. 1 6. 2 6. 3 6. 4 6. 5 6. 6 6.7 6.7 6.8 6. 9

Gener al al . . . . . . . . . . . . . . . . . . . Si ze zes . . . . . . . . . . . . . . . . . . . . . Ba r P re re pa par at ati on on . . . . . . . . . . . . . . Al ig ignm en ent . . . . . . . . . . . . . . . . . Cl ea eanl in in es es s . . . . . . . . . . . . . . . . . Wo rk rkma ns nshi p . . . . . . . . . . . . . . . Qual Qualific ificaation tion of Weldin elding g Proce Procedu dure re Produ roductio ction n Con Control trol Tests ests . . . . . . . Def ect iv e W eld s

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SECTION SECTION 7. QUALIFICA QUALIFICATION TION OF OF WELDING WELDING PROCEDURE BY TESTING 7. 1 7.2 7.2 7. 3 7. 4

Gener al al . . . . . . . . . . . Meth Method od of of Qual Qualific ificati ation on Te st sts . . . . . . . . . . . . . Re te test s . . . . . . . . . . . .

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A A Chec Check k List List of Matt Matter erss for for Disc Discus ussi sion on B Recommen Recommended ded Method Method for Joint and Proce Process ss Ide Identi ntific ficat ation ion . . . . . . . . . . . C A Suitable Suitable Form of Welding Welding Proce du dur e S he heet . . . . . . . . . . . . . . . . .

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ANNEX. ANNEX. LIST OF REFERENCED REFERENCED DO CU CUME NT NT S . . . . . . . . . . . . . .

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SECTION SECTION 8. TEST REQUIREMENT REQUIREMENTS S 8.1 8.1

Product Production ion Control Control Test Test Requ equireme irement ntss . . . . . . . . . . 8.2 8.2 Macr Macro o Test Requ Require ireme ment ntss . . 8.3 8.3 Tens Tensile ile Test Test Requ Require ireme ment ntss . 8.4 Bend end Test Test Requ Require ireme men nts . .

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SECTION SECTION 9. INSPECT INSPECTION ION 9.1 9.2 9.2 9.3 9.4 9.5 9.6

Exam Examin inaation tion of of We Weld ldiing . . . Qual Qualific ificaations tions of of Ins Inspe pect ctor orss . Privile rivilege gess of Insp Inspec ecto tors rs . . . . Insp nspect ection ion of Weld Welder erss . . . . . Insp nspect ection ion of Work Work . . . . . . . Insp nspect ection ion after after We Weld ldiing . . .

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APPENDICES

SECTION SECTION 5. FLASH FLASH BUTT BUTT WELDING WELDING 5. 1 5. 2 5. 3 5. 4 5. 5 5. 6

5. 7 5.8 5.8 5.9 5.10 .10

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STANDARDS ASSOCIATION OF AUSTRALIA Australian Standard for STRUCTURAL STRUCTURAL STEEL STEEL WELDING WELDING PART 3—WELDING OF REIN REINFORCING FORCING STEEL SECTION SECTION 1. SCOPE SCOPE AND GENERAL GENERAL 1.1 SCOPE. This standard sets out requirements for mate aterials rials of cons onstruct truction ion,, preq requalif ualified ied weld eld preparations, methods for the qualification of welding proc procedu edures res and and weldin welding g perso personn nnel el,, togeth together er with workm workman ansh ship ip and and inspe inspecti ction on require requireme ments nts for the weldin welding g of reinfor reinforcing cing steel steel in concr concrete ete structu structures res designed designed and constructed in accordance accordance with AS 1480 and AS 1481.

1.4.7 Indirect butt splice—a splice—a splice between two bars of reinfo reinforce rceme ment nt whose whose axes axes are appro approxim ximat ately ely coline colinear ar wherein wherein the bars are are welde welded d to a comm common on splice member by either single or double bevel welds, the cross-section of the bars where they butt together remain remaining ing unweld unwelded ed.. The splice splice memb member er may be plat plate, e, angle angle,, bar bar or other other shap shapee appr approv oved ed by the Supervising Engineer.

It i s intend intended ed for the welding welding of reinforc reinforcing ing steel steel complying with AS 1302, AS 1303 and AS 1304, but applie ppliess also lso to the the weld welding ing of steel steel conn connec ectio tion n devices, devices, inserts, anchors and anchor details, including pref prefabr abric icate ated d asse assemb mblie liess requi required red in rein reinfo force rced d concret concretee and precast precast concre concrete te construc constructions tions,, in t he fabrication shop and in the field.

1.4.8 1.4.8 Principal Principal— —the purc purch haser aser or own owner of the structure being fabricated or erected, or his nominated representative.

NOTE: NOTE: Appe Append ndix ix A gives gives a list list of matters matters of a cont contract ractual ual nature nature which which might need need to be finalized finalized between between t he principal principal and the contractor.

1.2 APPLICATION. This standard applies primarily to t he weldin welding g of reinfo reinforci rcing ng steel steel and other steel steel devi devices ces intend intended ed for use use in rein reinfor forced ced conc concret retee construction complying with AS 1480 and AS 1481. 1.3 REFERENCED REFERENCED DOCUMENTS. DOCUMENTS. A list with titles of t he docume documents nts referred referred to in this standa standard rd is given in the Annex. 1.4 DEFINITIONS. For the purpose of this standard, the welding welding symb symbol olss and and terms terms given given in AS 1101, 1101, Part 3 and AS Z5 apply, together with the following definitions:

—material complying complying with 1.4.9 1.4.9 Reinforcin Reinforcing g steel steel—material AS 1302, AS 1303 or AS 1304, as appropriate. —a joint joint cons consist isting ing of a 1.4. 1.4.10 10 Single Single lap splice splice—a single weld deposited in the groove formed between two bars in contact where only one side is accessible. 1.4.11 Specification—the Specification—the specification forming part of the documents in which is set out the work to be executed. th e En gi gi ne ne er er 1.4 1.4.12 .12 Super Supervis visin ing g Engine Engineeer— th responsible responsible for the supervision of the construction. construction. 1.4.13 1.4.13 Tack weld—a weld—a short weld used used for assembly assembly and fixing purposes only. 1.5 WELDING WELDING SYMBOLS. Welding symbols shown on drawings drawings shall comply comply with AS 1101, 1101, Part 3. 1.6 WELDING OF REINFORCING STEEL.

1.4.1 Approved—except Approved—except as may be otherwise stated, appro pprove ved d by the the Princi Principal pal,, the the Desig Designe nerr or the Supervising Engineer, as appropriate. appropriate.

1.6.1 1.6.1 Approval Approval and Type of Welding. Welding. Welding of  reinforcing steel shall not be carried out unless it is shown hown on the drawi drawings ngs,, or in other other appr approp opria riate te documents, documents, or is otherwise approved.

— t he he per so son, per s ons or 1.4. 1.4.2 2 Contr Contrac actor tor— organization responsible for executing the work.

Welding Welding of reinforci reinforcing ng steel steel shall comply with the requirements of this standard.

1.4.3 Contract drawings—the drawings—the drawings forming part of the documents in which is set out the work to be executed.

following g 1.6. 1.6.2 2 Limi Limitat tation ionss on Weldi Welding. ng. The followin limitations limitations on welding welding shall shall apply: apply:

1.4.4 Designer—the Designer—the person, persons or organization responsible for the design of the structure. 1.4.5 Direct butt splice—a splice—a splice between two bars of r einforcin einforcing g steel whose whose axes axes are approxi approximately mately colinear, the bars having been joined by a butt weld mad e fr om om b ot ot h s id id es es o r f ro ro m o ne ne si de de w it it h permanent or temporary backing and having complete pene penetra trati tion on and and fusi fusion on of weld weld and and base base meta metall througho throughout ut the depth of the splice. 1.4.6 1.4.6 Double Double lap splice—a splice—a joint joint cons consistin isting g of two welds, welds, deposit deposited ed in the t wo grooves grooves formed formed between between two bars in contact.

(a) Where Where tack welds are are not not shown on the drawings drawings but but are required to maintain maintain the reinforci reinforcing ng steel in i ts correct correct position, position, only only approved approved tack welds that comply with the requirements of Clause 3.4 shall be made. (b) Except Except where tack welding welding of main bars bars into the corners corners of fitments fitments is approved, approved, welding welding shall shall not not be carrie carried d out out withi within n 75 mm of any any bent bent port portion ion of a bar bar whic which h has has or had a bend bend of  internal radius less than 6 times the bar size. 1.6. 1.6.3 3 Welding Welding Differe Different nt Grade Gradess of Reinfo Reinforci rcing ng Steels. It shal shalll be permis permissib sible le to weld weld togeth together er

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diff differe erent nt gra grades des and and types types of rein reinfor forci cing ng ste steels prov provide ided d that that the appr approp opriate riate requi requireme rement ntss of this standard are complied with for each grade. 1.7 J OI OIN IN IN G R EI EIN FO FO RC RCI NG NG S TE TE EL EL TO Where reinfo reinforc rcing ing steel steel is to be STRUCTURES. Where  joi ned to st eel plate , rolled ro lled secti ons or hollo w section ectionss by butt butt or fillet fillet welds welds,, the the welds welds shal shalll comply with the requirements for structural welding given in AS 1554, Part 1. Interconnection of precast concrete members by way of reinforcing steel projecting from the concrete may be mad made by fus fusion ion welds elds comp compllying ying with with this standard. Weld lding ing shall shall be 1.8 WELDING WELDING PROCESSES. PROCESSES. We perfo performe rmed d using using manu manual al metal-a metal-arc rc welding welding,, semisemiautom automatic atic or autom automatic atic gas-sh gas-shield ielded ed or flux cored cored metal metal-a -arc rc weld weldin ing, g, flash flash butt butt weldin elding, g, or flame flame pressure pressure welding. welding. O ther welding processes processes may be approved approved following satisfactory procedure procedure testing.

1.9 WELDING EQUIPMENT. plant 1.9.1 1.9.1 Compliance Compliance with Standards. Standards. Welding plant and equipment equipment for metal-arc and flash butt butt welding welding shall shall comply with relevant relevant standards standards issued issued by the Standar Standards ds Associ Association ation of Austral Australia ia and and with any requ equireme irement ntss of the Statu Statuttory ory Auth Autho ority. rity. The electrical equipment equipment of the machine shall shall comply with the appropriate requirements of AS 3000. Applic Applicab able le standa standards rds are AS 1966 1966,, AS 1995 1995 and AS C301. 1.9. 1.9.2 2 Safety Safety Precau Precautions tions.. The requi requirem remen ents ts of  AS 1336, AS 1337, AS 1338, AS 1470, AS 1674 and AS CC5, CC5, as appr approp opri riate ate,, shal shalll be comp compli lied ed with during welding. Suitable welding screens shall be provided to protect welders welders or other persons persons in the i mmediate mmediate vicinity vicinity of  welding. NOTE: NOTE: AWRA Technic Technical al Note Note 7 also gives guidance guidance in safe safe practices to be employed.

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SECTION SECTION 2. MATERIA MATERIALS LS OF CONSTR CONSTRUCT UCTION ION Parent material material shall shall 2.1 2.1 PARENT PARENT MATERIA MATERIAL. L. Parent incl include ude steel steel rein reinfor force ceme ment nt,, stee steell plat plates, es, rolle rolled d sectio sections ns and and hollow hollow secti sections ons (inclu (includin ding g tubes tubes), ), comp omplyi lying with AS 1163 163, AS 1204 1204,, AS 1205, 205, AS 1302, AS 1303 and AS 1304, as appropriate. Other Other steels steels shall shall be used only only after after the weldin welding g procedures procedures have been established and approved. NOTE: This standard applies also to repairs and alterations to existing existing buildings where where care should should be taken taken to i dentify steel in existing existing structures structures and speci special al care should be taken to ensure that that the electr electrode odess and and weldi welding ng proce procedu dures res selec selected ted are appropr appropriate iate to the parent parent material material to be welded.

2.2 BACKING MATERIAL. Steel backing material to be fus fused in the the weldin elding g proc proceess shal hall hav have weldability not less than that of the parent material. 2.3 WELDING CONSUMABLES. 2.3.1 Electrodes and Filler Wires. Electrodes for the welding of the parent material specified in Clause 2.1 shall shall comply comply with the following: following: (a) For manua manuall metal-ar metal-arcc weldi welding ng

. . . . AS 1553. 1553.

(b) (b) For For proce processses ses other other than than manu manuaal meta metal-a l-arc rc welding elding . . . . . . . . . . AS 1588 1588 and AS AS 2203. 2203. Other electrodes may be used provided that they are qualifi qualified ed in accor accordan dance ce with t he require requiremen ments ts of  Clause 4.5.2. 2.3.2 Storage of Welding Consumables. Electrodes shall be stored in their original packets or cartons in a dry place, adequately protected from the effects of  weather. Where special protection during storage and use is recomme recommende nded d by the manufact manufacturer, urer, they they shall shall be stored tored in acco accorda rdanc ncee with with the reco recomm mmen ende ded d conditions. conditions. Fi ller metals shall be dry, smooth smooth and free from corrosion corrosion or other matter deleterious deleterious either either to satisfa satisfact ctory ory opera operation tion or to the weld metal. metal. If t he electrodes or filler metals are coated, coated, the coating shall be con continu tinuo ous and firml firmly y adhe dheren rent. Whe Where the manu manufac factur turer er make makess speci specific fic recom recommen menda dation tionss covering conditioning and pre-treatment of electrodes prior to use, such recommendations shall be followed. NOTE: AWRA Technical Technical Note 3 contains contains recommendations recommendations for the storage and conditioning of electrodes.

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SECTION SECTION 3. DETAILS DETAILS OF FUSION WELDED CONNECTI CONNECTIONS ONS 3.1 GENERAL. 3.1. 3.1.1 1 Types Types of Fusion Fusion Welded Welded Connec Connection tions. s. A fusion fusion welded welded connec connection tion shall shall be a butt butt splice, a lap splice, or a tack weld. tre ss ss 3.1. .1.2 Desi Desig gn Throa hroat Thickn hicknes esss. Fo r s tr calculations, the design throat thickness shall be the throat size of the weld (see Fig. 3.1). 3.1.3 Throat Size of Weld. The throat size of a weld S  shall be as follows: (a) For an indire ndirect ct butt butt splic splicee and and a lap spli plice . . . . . not not less less than than 0.25 0.25 times times the size size of the smaller smaller bar joined. joined. (b) For a direc irectt butt splice plice .... .... the the size size of the smaller smaller bar joined. joined. effective length length of an 3.1.4 3.1.4 Effective Effective Length. Length. The effective indirect butt splice or of a lap splice shall be taken to be the length of the weld that is of the specified size throughout. 3.1.5 Finished Width. The width of a finished weld of an indirect butt splice or of a lap splice shall be not not less less t han han 0.45 0.45 times times the size size of the smaller smaller bar bar  joi ned. 3.1.6 Effective Area. The effective effective area of a weld for an indirect butt splice or a lap splice shall be taken as the sum of the products of the effective length and the applicable design throat thickness. The effective area of a weld for a direct butt splice shall be taken as the area of the smaller bar joined. 3.2 BUTT SPLICES. 3.2.1 3.2.1 Direct Direct Butt Splices. Direct butt splices shall comply with Table 4.1.

NOTE: NOTE: Double Double-V -V and and doub doublele-bev bevel el butt butt splic splices es may have have preparations unequal in depth.

3.2.2 3.2.2 Indirect Indirect Butt Splices. Splices. Indirect butt splices shall compl y w it it h Ta bl ble 4. 2 and th e f ol oll ow owing requirements: (a) Welding Welding of reinfo reinforce rcemen mentt to the splice splice plate plate or angle angle shall shall be by means of fillet welds, welds, or to the splice sleeve by means of end fillet welds. (b) As applicabl applicable, e, the splice plate, plate, angle, angle, sleeve and and at ta tach in in g w el eld s s ho houl d h av ave se ct cti on ons o f   sufficient sufficient strength strength to meet the requirements requirements of  AS 1480. comply with 3.3 LAP SPLICES. Lap splices shall comply Tabl Tablee 4.3. 4.3. The width width of a finishe finished d weld weld of a lap splice splice shall be not not less than 0.45 times the size of the smaller smaller bar joined. joined. 3.4 TACK WELDS. number of  3.4.1 3.4.1 Limitations Limitations on Tack Welds. The number tack welds shall be kept to the minimum necessary to loca locate te the rein reinfor forcin cing g ste steel durin during g erecti erection on and placement of concrete. Tack ack weld weldss shall hall not not subst ubstaanti ntially ally redu educe the the cross-sec cross-section tion of the reinforcing reinforcing steel steel nor adversel adversely y affect affect its strength. strength. 3.4.2 Size of a Tack Weld. Tack welds shall— (a) have have a throat thickn thickness ess not less less than 4 mm; (b) have a len length not not less ess than han the the size size of the smaller bar; and (c) compl comply y with the prehea preheatt requir requireme ements nts given given in Table 4.7.

*W  = width of weld.

Fig. Fig. 3.1 3.1.. DESIGN THROAT THROAT THICKNESS THICKNESS AND EFFECTIVE EFFECTIVE LENGTH LENGTH

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SECTION SECTION 4. QUALIFICAT QUALIFICATION ION OF WELDING WELDING PROCE PROCEDURES DURES AND WELDING PERSONNEL FOR FUSION WELDING 4 .1 .1 Q UA UA L I F I CA C A TI T I ON ON OF W E L DI D I NG NG PROCEDURE. The welding procedure, i.e. the joint preparation, the welding consumables consumables and the welding para aramet meters, ers, shal shalll be qua qualifie lified d befo beforre weld weldiing commences. The Contracto Contractorr shall establish a welding welding procedur proceduree and shall list the applicable parameters in a document known known as the ‘welding ‘welding procedu procedure re sheet’. sheet’. A suitable suitable type ype of wel welding ding proc proceedure dure she sheet is show shown n in Appendix Appendix C . 4.2 ME TH THOD OF QUA LI LIF IC IC AT ATI ON ON OF WELDING WELDING PROCEDURE. PROCEDURE. A welding welding procedu procedure re shall be qualified by one of the following methods: (a) A proce procedur duree prequ prequalifi alified ed in accor accorda dance nce with Clause 4.3. (b) Production Production of documentary documentary evidence evidence of relevant relevant prior experienc experiencee by the Contractor. Contractor. NOTE: NOTE: A completed completed welding welding procedure procedure sheet sheet such such as that shown shown in Appendix Appendix C, together together with records of any tests tests carried out, including suitable photographs of the test pieces, constitutes constitutes documentary evidence evidence of prior experience.

(c) Prepara Preparatio tion n of a test test piece piece which which simula simulates tes as closely closely as practicab practicable le the weld preparat preparation, ion, the grade, type and size of the reinforcement and the welding conditions to be used in production. The test piece shall be tested in accordance with the requirements of Section 7. 4.3 PREQUALIFIED WELDING PROCEDURES. We ld ldi ng ng pr oc ocedur es es s ha hall be dee me med t o be prequalified where— (a) the join jointt prep prepaaratio ration ns are accordance accordance with Clause 4.4;

pre prequal qualiified fied

in

(b) the consnma consnmables bles are prequalified prequalified in accordan accordance ce with Clause 4.5; (c) (c) the the workma workmans nship hip and and weldi welding ng tech techn nique iques, s, including including the preheat preheat and interrun interrun temperatur temperaturee requireme requirements, nts, comply comply with the requireme requirements nts of  this standard; and

preparations 4.4. 4.4.3 3 Prequ Prequalifi alified ed Lap Splices Splices.. Joint preparations comp comply lyin ing g with with Table Table 4.3 4.3 shal shalll be deem deemed ed to be prequalified for all processes. 4 .5 .5 Q U A L I F I C AT AT I O N CONSUMABLES.

OF

W EL DIN G

4.5.1 4.5.1 Prequalif Prequalified ied Welding Welding Consumabl Consumables. es. Where welding consumables are matched with the steel type in accor accorda danc ncee with t he requi requirem remen ents ts of Table Table 4.4 4.4 and and compl comply y with the other other relev relevan antt requi requirem remen ents ts of this stand tandar ard d and and prov provid ided ed that that they they are are used used in the the posi positi tions ons recom recomme mend nded ed by the manuf manufac actu turer rer,, such such weldi lding con consumables les shall be dee deemed to be prequalified and shall not require qualification testing. 4.5. 4.5.2 2 Quali Qualifica ficatio tion n of Welding Welding Consu Consumab mable less by Wheree weldi elding ng cons onsuma umables les are are not not Testing. Wher prequalified in accordance with Clause 4.5.1, they may be qualif qualified ied in conjunc conjunction tion with with a welding procedure procedure qualification test in accordance with Section 7. 4.6 REQUALIFICATION OF FUSION WELDING PROCEDURES. 4.6.1 4.6.1 Changes Changes in Essential Essential Variab Variables les Necess Necessitati itating ng R eq eq ua u a l i f ic ic a att iio o n of W eell di d i n g P rro o ce ce d ur u r e. e. Requa Requalif lific icati ation on of a fusio fusion n weldi welding ng proce procedu dure re by testing in accordance with Section 7 shall be required where changes in the essential variables for the welding procedure exceed the limits given in Table 4.5. 4.6.2 Minor Changes Necess Necessitating itating Requalification Requalification of  Requalification of  Welding Welding Procedu Procedure re by Macro Macro Test. Test. Requalification the welding procedure procedure by a macro test taken either from a product production ion splice or from a special special splice welded welded for the the purp purpos osee shal shalll be requ require ired d where where change changess in the essential essential variables for the welding procedure procedure exceed the limits given in Table 4.6. 4 .7 .7 Q U A L I F I C AT AT I O N PERSONNEL.

OF

W EL DIN G

4.4 PREQUALIFIED JOINT PREPARATIONS.

4.7.1 4.7.1 Welding Welding Superviso Supervisor. r. Welding Welding shall shall be carried out out unde underr the supe superv rvisi ision on of a weldi welding ng super supervi viso sorr empl employ oyed ed by the Contr Contrac acto tor. r. The funct functio ion n of the welding supervisor shall be to ensure that all welding is ca rr rrie d out as specifie d in the plans and specif specification icationss or other other docume documents nts in accorda accordance nce with the requiremen requirements ts of this standard. standard. Such Such a supervi supervisor sor shall be a person who—

preparationss prescribed prescribed in 4.4.1 General. General. The joint preparation Clause lausess 4.4. 4.4.2 2 and and 4.4. 4.4.3 3 shal shalll be deem deemed ed to be prequalified provided that the welding processes and co ns nsu ma mable s u se sed ar e i n w el eld in ing p os osi t io io ns ns recommended recommended by the electrode manufacturer.

(a) (a) holds holds an Austral Australia ian n Welding Welding Insti Institute tute welding welding supervisor’s certificate in structural steel welding in accor accorda danc ncee with with AS 2214 2214,, or has equi equiva valen lentt qual qualif ifica icatio tions ns acce accept ptab able le to the Supe Superv rvis isin ing g Engineer;

4.4.2 4.4.2 Prequalified Prequalified Butt Splices. Joint preparations conforming to the dimensions given for the processes indicated in Tables 4.1 and 4.2 shall be deemed to be prequalified.

(b) (b) has has serve served d an appr appren entic ticesh eship ip in an appr approp opria riate te metal metal trade and during or subsequ subsequent ent thereto thereto has had had 5 year years’ s’ expe experi rien ence ce in the fabri fabrica cati tion on of  welded steel structures, and is able to satisfy the Supervis Supervising ing Enginee Engineerr that he is suitable for the work upon which he will be employed;

(d) wher wheree requ requiired, red, docu ocumen mentary tary evide viden nce ava il il ab abl e o f a s aatti sf sf ac act or ory m ac acr o te st st accordance accordance with Clause 7.3.

is in

All butt splices that are to be welded from both sides using using these prequal prequalified ified preparations preparations shall shall have the back back of t he first run gouged gouged out out by suitable means means to sound metal before welding is started on the second side, side, unless unless evidence evidence is produc produced ed by macroetching macroetching that complete complete fusion fusion can be obtained obtained without without such such gouging.

(c) has had had at least ast 7 year ears’ exp experience in the fabr fabric icat atio ion n of reinfo reinforc rcing ing stee steell and and is able able to satisfy the Supervising Engineer that he is suitable for the work upon which he will be employed; or

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AS 1554, Part 3—1983 3—1983

9

(d) (d) is the the hold holder er of a dipl diplom omaa or a cert certif ific icat atee in Engineering or Metallurgy of an approved technical coll colleege or is a grad gradua uate te in Engi Engine neeering ring or Metal etallu lurg rgy y of a reco recog gnize nized d univ univer erssity ity and and subsequent to obtaining his diploma, certificate or deg degree ree has had had 3 yea years’ rs’ expe experi rieence nce in the the fabrication of welded steel structures. 4.7.2 Welders. The following requirements shall apply to the qualification of welders: (a) All welders welders shall shall be suitably suitably qualifie qualified d to carry carry out the the weld weldin ing g proc proced edur ures es on whic which h they they will will be employed. The Contractor shall provide satisfactory evidence that welders are suitably qualified. (b) (b) A weld welder er not not alre alread ady y qual qualif ifie ied d for for the the weld weldin ing g proces processs requir required ed by the weldin welding g proced procedure uress on which which he is to be employed employed shall shall be required required to demo demons nstr trat atee his abil abilit ity y to comp comply ly with ith the the appropriate appropriate requirements requirements of this standard standard by means of a macro test. (c) A person person operat operating ing automa automatic tic or semi-a semi-auto utomat matic ic equipment and qualified to use a particular process with with an approv approved ed consum consumabl ablee or combin combinati ation on of  consumable consumabless shall be considered considered qualified qualified to use other other approv approved ed consum consumabl ables es or combin combinati ations ons of  consumables with the same process. (d) Qualifi Qualificat cation ionss establ establish ished ed under under this this Clause Clause with with any one of the steels covered by this standard shall be considered as qualification to weld any other of  the steels covered by this standard. (e) (e) Wher Wheree a weld welder er repe repeat ated edly ly prod produc uces es weld weldss not not complying with the requirements of this standard, welding welding by the welder welder shall be discontinue discontinued d until additional tests are carried out by the welder and the welds so produced comply with this standard. (f)

The names names of all welder welderss qualifi qualified ed in accord accordanc ancee with with this this Clause Clause together together with with partic particula ulars rs of any tests tests passed passed by each, each, shall be record recorded ed and made made avai availa labl blee for for peru perusa sall by the the Insp Inspec ecto torr for for the the duration of the job.

4.8 WORKMANSHIP. 4.8. 4.8.1 1 Prep Prepar arat atio ion n of Mate Materi rial al for for Weld Weldin ing. g. The surfaces to be welded shall be free of defects, and from heavy heavy scale, scale, moistu moisture, re, slag, slag, rust, rust, oil, oil, paint, paint, cement cement or any other foreign foreign material material likely to to affect adversely adversely the quality of the weld. If preparation or cutting of the fusion face is necessary, this should be carried out by a method approved by the Supervising Engineer. Wheree rein reinfo forc rcin ing g stee steell is to be 4.8.2 Assembly. Assembly. Wher assemb assembled led prior to weldin welding, g, it shall shall comply comply with the following requirements: (a) (a) Bars Bars to be weld welded ed shal shalll be held held in the the corr correc ectt posi positi tion on unti untill weld weldin ing g has has been been comp comple lete ted. d. Fastening Fastening devices devices shall be adequate adequate to ensure ensure safety during welding operations. operations. Suitable allowances allowances for warpag warpagee and shrink shrinkage age shall shall be made. made. Each joint joint shall have adequate adequate clearance for accessibi accessibility lity to make the weld. (b) Before the welding of a butt splice, the the surfaces surfaces of  bars bars of equa equall size size shal shalll not not be out out of alig alignm nmen entt with one another by more than 0.10 times the size of the bars or 3 mm, whichever is the lesser.

The The surf surfac aces es of bars bars of uneq unequa uall size size shal shalll lie lie wholly wholly within within the projection projection of the surface surface of the thicker bar in the joint. (c) (c) Parts Parts to be lap lap spli splice ced d shal shalll be brou brough ghtt into as close lose a conta ontact ct as pra practic cticaable ble to mini minimi mizze distor distortio tion. n. The gap due to faulty workmans workmanship hip or incorre incorrect ct fit-up fit-up shall shall not be more more than than 0.25 0.25 times the the size size of the bar bar or 3 mm, mm, whic whiche heve verr is the the lesser lesser.. If separa separatio tion n occurs occurs locall locally, y, the effecti effective ve throat thickness of the weld shall be maintained. (d) All tack tack welds, whether whether to be consumed consumed ultimately ultimately or not, not, shal shalll be subj subjec ecte ted d to the the same same init initia iall treatment (preheating) as for the final welds. Tack  welds welds that are to be consum consumed ed in the final final weld weld shall be cleaned of slag before being fused into the weld. Defective, cracked or broken welds shall be removed before the final welding. 4.8.3 Gouging. In all butt splices that are to be welded from from both both side sides, s, the the back back of the the firs firstt run run shal shalll be gouged gouged out by suitab suitable le means to clean clean metal metal before before weld weldin ing g is star starte ted d on that that side side,, unle unless ss evid eviden ence ce is produced produced that the welding welding procedure procedure employed employed is such that complete fusion is obtained without such gouging. 4.8.4 Positioning of Work. The work should, whenever prac practi tica cabl ble, e, be posi positi tion oned ed for for weld weldin ing g in the the flat flat position. 4.8. 4.8.5 5 Weld Weldin ing g in Adve Advers rsee Weat Weathe herr Cond Conditi ition ons. s. Weld We ldin ing g shal shalll not not be carr carrie ied d out out in the the foll follow owin ing g conditions: (a) Where the temperature temperature of the parent parent metal is below 0°C unless unless preheating preheating is carried carried out in accordanc accordancee with Clause 4.8.6 to a minimum of 20° C. (b) Where welding welding surfaces surfaces are wet from condensa condensation, tion, rain, snow or ice. (c) Where Where rain rain or snow snow is fallin falling g on the surfaces surfaces to be welded. (d) During periods periods of high wind, wind, unless unless the welder welder and the work are properly protected. Preheat temperatures temperatures and 4.8.6 Preheat Temperature. Preheat electrode electrode sizes for the fusion fusion welding of reinforceme reinforcement nt shall be in accordance with Table 4.7. 4.8.7 Correction of Defective Welds. Where a weld is found found to be defect defective ive,, the Contra Contracto ctorr shall shall repair repair the weld, or, if required by the Supervising Engineer, shall remove the weld and then reweld the splice. Repairing or rewelding shall be carried out in accordance with this standard, and the Supervising Engineer shall be advised of all such repairs or rewelds. The removal of weld metal or portions of the base metal shall shall be effect effected ed by machin machining ing,, grindi grinding, ng, chippi chipping, ng, oxygen oxygen gouging, gouging, or air/carbon-a air/carbon-arc rc gouging. gouging. It shall be done in a manner that ensures that the remaining weld metal or base metal is not nicked or undercut. Defective port portio ions ns of the the weld weld shall hall be remo remove ved d with withou outt substantial removal of the base metal. The surfaces shall be cleaned thoroughly before rewelding. Defe Defect ctiv ivee unde underc rcut utti ting ng shal shalll be made made good good by the the deposition of additional weld metal to comply with the requir requireme ements nts of Clause Clause 8.1 or by the removal removal of the undercut undercut by grinding grinding provided that this complies complies with the requirements of Clause 8.1.

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AS 1554, Part 3—1983

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TABLE 4.1 PREQUALIFIED DIRECT BUTT SPLICE PREPARATIONS NOTATION: d b = bar size G = root gap F r = root face θ = included angle of preparation, degrees F: flat, flat, H: horizo horizonta ntal, l, OH: ove overhe rhead, ad, V: verti vertical cal NOTE: All linear dimensions are in millimetres.

Joint identification (See Appendix Appendix B)

B D- 2 a

Preparation detail

Joint type

( a)

S in gl e- V b ut t spli ce (w el ded bo th sides)

Manual metal-arc

Flux-cored arc, self-shielded and gasshielded

Gas-shielded Gas-shielded metal-arc Spray transfer

Dip transfer

d b

All

All

All

All

Posn G F r θ

All 3.5 1.5 60

See θ 3 3 50-F,H,OH 60-V

F 0 4 50

See θ 3 0 50-F,H,OH 60-V

d b

All

All

All

All

Posn G F r

All 3.5 1.5 45

See θ 3 1.5 50-F,H,OF 60-V

F and H 1.5 4 50

See θ 4 0 50-F,H,OH 60-V

Where the root is root is accessible for back-gouging and application of a sealing run (see Clause 4.4.2)

B D- 4

( b) b)

S in gl e- bevel b ut t s pl ic e ( un un equal bars ) (welded both sides)

θ

Where the root is accessible accessible for back-gouging and application of a sealing run (see Clause 4.4.2)

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B D- 2 b

( c)

S in gl e- V b ut t spli ce ce wi th spli t p ip e b acki ng

d b Posn G F r θ

All See θ See θ 0 20-F,OH:G=12

All See θ 6 0 30-F,H,OH 45-V

All F 3 1.5 30

All See θ 6 0 30-F,H,OH 45-V

All See θ 3 3 50-F,H,OH 60-V

All F 0 3 50

All See θ 4 0 50-F,H,OH 60-V

30-F,OH:G=9 45-A11:G=6

W he he re re a cc cc es ess t o t he he r oo oo t of th e we ld ld i s u nnobtaina obtainable ble.. Alterna Alternativ tivel ely, y, a remova removable ble copp copper er backing bar may be used in place of the permanent backing shown B D- 3 a

( d)

D oubl e- V butt spli ce

d b Posn G F r θ

All All 3.5 1.5 60

Horizontal bars should be welded in the flat position wherever practicable practicable

ALLOWABLE JOINT TOLERANCES  Di mensi on

Root Ro ot not gouged

(root gap withou withoutt backi backing) ng) G (root (roott gap with with back backing ing)) . . G (roo θ (ang (angle le of prepa prepara ratio tion) n) . . . . (root face face)) . . . . . . . . . . . F r (root

. . . .

. . . .

. ±1.5 1.5 mm . . . . . . . . . +6, -1.5 -1.5 mm . . . . . . . +10, +10, -5 degre degrees es . . . . ±0.5 0.5 mm . . . . . . . .

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Root Ro ot gouged 

+1. +1.5, -3 mm mm Not app appli licab cable le +10, +10, -5 degre degrees es No upp upper er limi limit, t, -0 -0

AS 1554, Part 3—1983

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B D- 2 b

( c)

S in gl e- V b ut t spli ce ce wi th spli t p ip e b acki ng

All See θ See θ 0 20-F,OH:G=12

d b Posn G F r θ

All See θ 6 0 30-F,H,OH 45-V

All F 3 1.5 30

All See θ 6 0 30-F,H,OH 45-V

All See θ 3 3 50-F,H,OH 60-V

All F 0 3 50

All See θ 4 0 50-F,H,OH 60-V

30-F,OH:G=9 45-A11:G=6

W he he re re a cc cc es ess t o t he he r oo oo t of th e we ld ld i s u nnobtaina obtainable ble.. Alterna Alternativ tivel ely, y, a remova removable ble copp copper er backing bar may be used in place of the permanent backing shown B D- 3 a

( d)

D oubl e- V butt spli ce

All All 3.5 1.5 60

d b Posn G F r θ

Horizontal bars should be welded in the flat position wherever practicable practicable

ALLOWABLE JOINT TOLERANCES  Di mensi on

Root Ro ot not gouged

(root gap withou withoutt backi backing) ng) G (root (roott gap with with back backing ing)) . . G (roo θ (ang (angle le of prepa prepara ratio tion) n) . . . . (root face face)) . . . . . . . . . . . F r (root

. . . .

. . . .

. ±1.5 1.5 mm . . . . . . . . . +6, -1.5 -1.5 mm . . . . . . . +10, +10, -5 degre degrees es . . . . ±0.5 0.5 mm . . . . . . . .

Root Ro ot gouged 

+1. +1.5, -3 mm mm Not app appli licab cable le +10, +10, -5 degre degrees es No upp upper er limi limit, t, -0 -0

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TABLE TABLE 4.1 4.1 (continued )

Joint identification (See Appendix Appendix B) B D- 3 b

Joint type

( e) e)

D ou bl e- V bu tt spli ce ce ( un equal b ar s)

Preparation detail

Manual metal-arc

Flux-cored Flux-cored arc, arc, self-shielded and gas-shielded

Gas-shielded Gas-shielded metal-arc Spray transfer

Dip transfer

d b Posn G F r

All All 3.5 1.5 60

All See θ 3 3 50-F,H,OH 60-V

All F 0 4 50

All See θ 4 0 50-F,H,OH 60-V

d b Posn G F r

All All 3.5 1.5 45

All See θ 1.5 1.5 50-F,H,OH 60-V

All F 0 3 50

All See θ 4 0 50-F,H,OH 60-V

θ

Horizontal bars should be welded in the flat position wherever practicable

B D- 5

( f) f)

Do D ou bl e- bevel b ut t s pl ic e ( ba bars vert ic ic al )

θ

ALLOWABLE JOINT TOLERANCES: See page 11.

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TABLE TABLE 4.1 4.1 (continued )

Joint identification (See Appendix Appendix B) B D- 3 b

Preparation detail

Joint type

( e) e)

D ou bl e- V bu tt spli ce ce ( un equal b ar s)

Manual metal-arc

Flux-cored Flux-cored arc, arc, self-shielded and gas-shielded

Gas-shielded Gas-shielded metal-arc Spray transfer

Dip transfer

d b Posn G F r

All All 3.5 1.5 60

All See θ 3 3 50-F,H,OH 60-V

All F 0 4 50

All See θ 4 0 50-F,H,OH 60-V

d b Posn G F r

All All 3.5 1.5 45

All See θ 1.5 1.5 50-F,H,OH 60-V

All F 0 3 50

All See θ 4 0 50-F,H,OH 60-V

θ

Horizontal bars should be welded in the flat position wherever practicable

B D- 5

( f) f)

Do D ou bl e- bevel b ut t s pl ic e ( ba bars vert ic ic al )

θ

ALLOWABLE JOINT TOLERANCES: See page 11.

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TABLE TABLE 4.2 4.2 PREQUALIFIED INDIRECT BUTT SPLICE PREPARATIONS NOTATION: d b = bar size G = root gap W  = width of weld S  = size of weld F: flat. NOTE: All linear dimensions are in millimetres.

Joint identification (See Appendix Appendix B)

Joint type

Preparation detail

Manual metal-arc

Flux-cored arc, self-shielded and gas-shielded

Gas-shielded metal-arc Spra Spray y tra transfe nsferr

Dip Dip tra transfe nsferr

B I- 1a 1a

( a)

I nd nd ir ec ect butt spl ic e wi th fl at at b acki ng

d n Posn G

All F 20 max.

All F 20 max.

All F 20 max.

All F 20 max.

B I- 1b 1b

( b)

In Ind ir ec ect butt spl ic e wi th angl e b acki ng

d n Posn G

All F 20 max.

All F 20 max.

All F 20 max.

All F 20 max.

B I- 1 c

( c)

I nd ir ect butt spl ic e wi th sl eeve

d n Posn G

All All 20 max.

All All 20 max.

All All 20 max.

All All 20 max.

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TABLE TABLE 4.2 4.2 PREQUALIFIED INDIRECT BUTT SPLICE PREPARATIONS NOTATION: d b = bar size G = root gap W  = width of weld S  = size of weld F: flat. NOTE: All linear dimensions are in millimetres.

Joint identification (See Appendix Appendix B)

Preparation detail

Joint type

Manual metal-arc

Flux-cored arc, self-shielded and gas-shielded

Gas-shielded metal-arc Spra Spray y tra transfe nsferr

Dip Dip tra transfe nsferr

B I- 1a 1a

( a)

I nd nd ir ec ect butt spl ic e wi th fl at at b acki ng

d n Posn G

All F 20 max.

All F 20 max.

All F 20 max.

All F 20 max.

B I- 1b 1b

( b)

In Ind ir ec ect butt spl ic e wi th angl e b acki ng

d n Posn G

All F 20 max.

All F 20 max.

All F 20 max.

All F 20 max.

B I- 1 c

( c)

I nd ir ect butt spl ic e wi th sl eeve

d n Posn G

All All 20 max.

All All 20 max.

All All 20 max.

All All 20 max.

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TABLE TABLE 4.3 4.3 PREQUALIFIED LAP-SPLICE PREPARATIONS NOTATION: d b = bar size W  = width of weld S  = size of weld F: flat, H: horizontal, horizontal, OH: overhead, overhead, V: vertical NOTE: All linear dimensions are in millimetres.

Joint identification (See Appendix Appendix B)

Joint type

Preparation detail

Manual metal-arc

Gas-shielded metal-arc

Flux-cored Flux-cored arc, arc, self-shielded and gas-shielded

Spra Spray y tra transfe nsferr

Dip Dip tra transfe nsferr

L -( a) a)

( a)

D oubl e l ap spl ic e ( bar sup er im po sed)

d b Posn

All H

All H

All H

All H

L -( b) b)

( b)

Do D oubl e l ap spl ic e ( bars si de by si de)

d b Posn

All F,OH

All F,OH

All F,OH

All F,OH

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TABLE TABLE 4.3 4.3 PREQUALIFIED LAP-SPLICE PREPARATIONS NOTATION: d b = bar size W  = width of weld S  = size of weld F: flat, H: horizontal, horizontal, OH: overhead, overhead, V: vertical NOTE: All linear dimensions are in millimetres.

Joint identification (See Appendix Appendix B)

Joint type

Preparation detail

Manual metal-arc

Gas-shielded metal-arc

Flux-cored Flux-cored arc, arc, self-shielded and gas-shielded

Spra Spray y tra transfe nsferr

Dip Dip tra transfe nsferr

L -( a) a)

( a)

D oubl e l ap spl ic e ( bar sup er im po sed)

d b Posn

All H

All H

All H

All H

L -( b) b)

( b)

Do D oubl e l ap spl ic e ( bars si de by si de)

d b Posn

All F,OH

All F,OH

All F,OH

All F,OH

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L -( c) c)

( c)

D ou bl e l ap spl ic e ( bars vert ic al )

d b Posn

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All V, OH

All V,OH

All V,OH

All V,OH

AS 1554, Part 3—1983

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L -( c) c)

( c)

D ou bl e l ap spl ic e ( bars vert ic al )

d b Posn

All V, OH

All V,OH

All V,OH

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TABLE 4.4 PREQUALIFIED WELDING CONSUMABLES St ee eel g rade

Ma nu nual me ta ta l arc (AS 1553)

230S 230R 410C 450W 410Y (CE≤0.39) Bars not complying with AS 1302 or where CE > 0.39

E41XX, E48XX E41XX, E48XX E4816, E4818 E4816, E4818 E48XX E4816, E4818

Flux-cored Flux-cored arc (AS 2203) W40X, W50X W40X, W50X W50X W50X W50X W50X

NOTE: Where X is shown in a classification, any number is acceptable.

TABLE 4.5 CHANGES IN ESSENTIAL VARIABLES NECESSITATING REQUALIFICATION Nature of change (a ) A c hang e fr om on e p ro cess to a noth er (b) A change change from a low-hydrog low-hydrogen en type electrode electrode to a non-lownon-lowhydr og en t yp e e le ct ro de (c ) A c hang e in e le ct ro de/f lu x/ shie ld in g gas comb in at io n (d ) A c hang e fr om om on e g as as or gas m ix ix tu tu re re to a no th er er g as or g as mi xt xt ur ur e (e) A chang changee of more than than ±7 percent of the specified mean arc voltage of the electrode used for automatic arc welding processes, or more than ±15 percent for manual metal-arc welding (f) A chan change ge of more than than ±10 percent percent of the specified specified mean welding current for the electrode used for automatic arc welding processes,

Applicability MM AW AW GM AW AW FC AW AW X X X X — —

— X X

— X X

X

X

X

X

X

X

All V,OH

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TABLE 4.4 PREQUALIFIED WELDING CONSUMABLES St ee eel g rade

Ma nu nual me ta ta l arc (AS 1553)

230S 230R 410C 450W 410Y (CE≤0.39) Bars not complying with AS 1302 or where CE > 0.39

E41XX, E48XX E41XX, E48XX E4816, E4818 E4816, E4818 E48XX E4816, E4818

Flux-cored Flux-cored arc (AS 2203) W40X, W50X W40X, W50X W50X W50X W50X W50X

NOTE: Where X is shown in a classification, any number is acceptable.

TABLE 4.5 CHANGES IN ESSENTIAL VARIABLES NECESSITATING REQUALIFICATION Nature of change (a ) A c hang e fr om on e p ro cess to a noth er (b) A change change from a low-hydrog low-hydrogen en type electrode electrode to a non-lownon-lowhydr og en t yp e e le ct ro de (c ) A c hang e in e le ct ro de/f lu x/ shie ld in g gas comb in at io n (d ) A c hang e fr om om on e g as as or gas m ix ix tu tu re re to a no th er er g as or g as mi xt xt ur ur e (e) A chang changee of more than than ±7 percent of the specified mean arc voltage of the electrode used for automatic arc welding processes, or more than ±15 percent for manual metal-arc welding (f) A chan change ge of more than than ±10 percent percent of the specified specified mean welding current for the electrode used for automatic arc welding processes, or more than ± 15 percent for manual metal-arc welding (g) A chang changee of more than than ±25 percent percent in the specif specified ied number number of runs. If the cross-se cross-section ctional al area of t he preparation preparation is increase increased, d, it i s also permissib permissible le to increase increase the number number of runs in proportion to the in cr eased a re a (h) An increase increase of 25 percent percent or more, or a decr decrease ease of 10 percent percent or mo re i n f lo w ra te o f shie ld in g gas (j) A change change in the position position in which which welding welding is done or a change change i n di re ct io n f or a v er ti cal we ld (k) A change change in welding welding current current from a.c. to d.c. d.c. and vice versa versa or a ch an ge i n d. c. pola ri ri ty ty or a c hange i n me ta l t rraa ns nsfe r a cr os oss th e a rc (l) A decrease decrease of more than 20 K in the minimum minimum specif specified ied preheat preheat and in te rr un te mp er at ur e (m) A change change in material thickn thicknes esss outside outside the r ange ange 0.75 to 1.5 times ma te ri al th ic kn ess

Applicability MM AW AW GM AW AW FC AW AW X X X X — —

— X X

— X X

X

X

X

X

X

X

—

X

X

—

X

X

X

X

X

—

X

X

X

X

X

—

X

X

X indicates applicability.

TABLE 4.6 MINOR CHANGES IN ESSENTIAL VARIABLES NECESSITATING REQUALIFICATION OF WELDING PROCEDURES BY MACRO TEST Nature of change (a) (b)

An increas increasee in the the diamet diameter er of the electrode electrode A change change in the shap shapee of any any one type type of joint joint prepar preparation— ation— (i) a decr decrease ease in the included included angle angle of the joint prepa preparation ration (ii) a decr decreas easee in the root gap gap of the joint joint prep prepara aration tion (iii) an increas increasee in the the root root face of the the joint joint prepara preparation tion (iv) the omission omission or inclus inclusion ion of backing backing material material

X indicates applicability.

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MM AW AW X X X X X

Applicability GM AW AW FC AW X X X X X X

X X X X

AS 1554, Part 3—1983 3—1983

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TABLE 4.7 MINIMUM PREHEAT TEMPERATURES (a) Hydrogen Controlled Electrodes (EXXX15,EXX16,EXX18,EXXX28) Semi-Automatic and Automatic Welding Processes Steel Steel desi designa gnatio tion n

Rang Rangee of  bar sizes mm

Minimum preheat preheat temperature, °C Electrode sizes, mm 3. 15 4 5 6. 3 Arc energy energy (semi-automatic process processes) es),, kJ/mm kJ/mm >1 ≤1.5 >1.5 ≤ 2. 5 >2.5 ≤ 3. 5 >3.5 Pr eheat n ot re qu ir ed

230 S

≤2 4

230 R

>24 ≤ 3 6

75

410 C

>36 ≤ 5 0

100

75

450 W

>50

100

10 0

410 Y (where CE ≤ 0.39) Bars not complying with AS 1302 or where CE>0.39

Pr eheat n ot re qu ir ed

Al l ≤2 4 >24 ≤ 3 6 >36 ≤ 5 0 >50

N/ R

N/ R

75

N/ R

Pr eheat n ot re qu ir ed 75 125 150 175

10 0 12 5 15 0

Pr eheat n ot re qu ir ed N/ R N/ R 10 0 N/ R 12 5 100

(b) Non-hydrogen Controlled Electrodes EXX10,EXX11,EXX12,EXX13, EXX14,EXX20,EXX24,EXX27 Minimum preheat preheat temperature, Steel Steel desi designa gnatio tion n

3. 15

4

230 S

Rang Rangee of  bar sizes mm ≤2 4

100

230 R

°C

Electrode sizes, mm 5

6. 3

50

N/ R

N/ R N/ R

>24 ≤ 3 6

125

10 0

50

410 C

>36 ≤ 5 0

125

10 0

10 0

50

450 W

>50

125

10 0

10 0

50

410 Y (where CE ≤ 0.39) Bars not complying with AS 1302 or where CE>0.39

Al l

Pr eheat n ot re qu ir ed

Al l

We ld in g not perm it te d

NOTES: 1. 2.

N/R indicates indicates preheat preheat not not required. required. CE indica indicates tes carbo carbon n equival equivalent ent of eleme elements: nts:

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SECTION SECTION 5. FLASH FLASH BUTT BUTT WELDING WELDING 5.1 5.1 GENERA GENERAL. L. T he he f la lash but t weldi ng ng of   reinfo einforrceme cemen nt shal shalll comp comply ly with the relev elevaant requireme requirements nts of other S ections ections of this standard standard and the specific requirements of this Section. 5.2 SIZES. The size of the bar to be welded shall be with within in the the machin machinee capac capacity ity as speci pecifi fied ed by the machine manufacturer and shall be confirmed in the procedure qualification test (see Clause 5.8). 5.3 BAR PREPARATION. The ends of bars to be welded shall be prepared in a way that will facilitate the starting of flashing (see Note). The face areas in contact during welding shall be approximately approximately equal and the difference difference in size of the contac contactt faces faces shall shall not exceed 15 percent of the smaller face. NOTE: NOTE: Shearing, Shearing, cropping, cropping, flame cutting cutting and saw saw cutting cutting are acceptable acceptable methods. A smooth smooth machined face, normal to the axis of the bar, is not recommended.

5.4 ALIGNMENT. The bars to be welded shall be set set in the machine machine so that that the axes axes are coincid coinciden ent. t. The The axes xes of the bars bars at the weld weld shal shalll be in line line within 10 percent of the size or 3 mm, whichever is the lesser. The bar bar ends ends and and adja adjace cent nt 5.5 CLEANLINE CLEANLINESS. SS. The materia material, l, and and parts parts of the bar in the region region of the clamping dies shall be free from insulating material, ru st st, p ai ai nt nt, g re rease or o th th er er fo re rei gn gn m at at te te r, r, immediately prior to welding. The dies shall be kept clean clean and any any adher adhering ing spatter spatter shall shall be remov removed ed before each weld. 5.6 WORKMANSHIP. 5.6.1 5.6.1 Overhan Overhang g or Projection Projection from from the Dies. Th e two bars to be welded shall be clamped so that the overh overhan ang g of each each is equa equal. l. The overh overhan ang g shall shall not not exceed twice the size of the bar. 5.6.2 5.6.2 Clamping Clamping Force. Force. The clamping force exerted by the clamping dies on the bars being welded shall be suff suffici icient ent to preve prevent nt move moveme ment nt of the the bars bars in relation to the clamps during the upsetting operation but not enough to deform the bars. 5.6.3 Preheating. Preheating shall be as follows: (a) Hot-rolled bars. For hot-rolled bars it shall be permis permissib sible le to shorte shorten n the flashi flashing ng cycl cyclee by preheating. (b) Cold-worked bars. Cold-w Cold-work orked ed bars bars shall shall be welde welded d without without prehe preheat ating. ing. Once Once the flashin flashing g action has been initiated, it should be maintained by matc atching hing the the feed feed rate rate with the the rate rate of  burnoff. 5.6.4 Flashing. The speed speed of advance advance of the moving moving platen and the value of the welding current shall be regulated regulated to ensure that t he flashing is continuou continuouss througho throughout ut the cycle, and that the welding operation operation does not freeze up or the platen stops moving. The flashing flashing shall shall be smoo smooth, th, cont continuo inuous us,, and and be maintaine maintained d until upset upset takes place. place. The current shall be maintained at least until upset has started. 5.6.5 Upsetting. The value of the upset force required to weld steel bars of different quality depends upon

the temperature temperature gradient gradient in the plastic plastic zone and the compressive strength of the steel at high temperature. The length of upset shall be sufficient to ensure the closing of all voids and the expulsion of oxide and molten molten metal from t he weld. It shall not be enough enough to cause distortion of the weld or excessive expulsion of  plastic metal. 5.7 EQUIPMENT. 5.7.1 General. An automatic or semi-automatic flash butt butt welding welding machine machine shall be used for all welding, welding, except except that that a manual manual machine machine may be used where it can be established that the welding complies with the requirements of this standard. The mach machin inee shal shalll be 5.7. 5.7.2 2 Machine Machine Controls Controls.. The equipped with control gear which, after the bars have been been clam clampe ped d in the the dies, dies, perfo perform rmss at leas leastt the following cycle of operations in the sequence given: (a) (a) Maintai aintains ns the the flash flashin ing g cycl cyclee for the the desi desire red d period of time and length of stroke. (b) Upsets Upsets the bars bars to complete complete the weld. (c ) Cu ts ts o ff ff th e c ur ur re re nt nt t o t he he b ar ar s a ft ft er er t he he commencement commencement of upsetting. NOTE: The following cycling operations are normally under the control of the operator: (i) Closi Closing ng t he electr electrical ical circuit circuit and and bringing bringing t he bars bars into initial contact. contact. (ii) Establi Establishing shing the prehea preheating ting cycle cycle (where (where applicable). applicable). (iii) Initiating Initiating flashing. flashing.

5.7.3 Flash Guards. Flash guards shall be placed at such uch a dist distan ancce fro from the the clam lamped ped bars bars as will will mini minimiz mizee the the pos possibili sibility ty of parti particl cles es throw thrown n off  during the flashing period rebounding into the weld. 5.7.4 Cleanliness of Machine. The welding machine and particularly the die faces shall be kept free from spatter, and the contact faces shall be cleaned of oil, grease, oxide oxide or metallic dust and globules globules after every weld. 5 .8 .8 Q UA U A L IF I F IC I C A T IO IO N PROCEDURE.

OF

W E LD LD I N G

welding ng proc proced edur uree shall shall be 5.8.1 5.8.1 General. General. The weldi qua li li f ie ie d b ef efo re re p ro ro du duct io io n we ld ld in ing of t he he reinforcement reinforcement commences. commences. The Contractor Contractor shall shall establish establish a welding welding procedur proceduree and shall list the applicable machine settings for each type, grade and size of reinforcement in a document known known as a ‘welding procedure procedure sheet’. 5.8 .2 .2 Me th th o od d of Qu a all if ifi ca cat iio o n of W eelld iin ng Procedure. When acceptable machine settings have been obtained, a welding procedure shall be qualified by producing producing a set of test splices splices of reinforce reinforcement ment in accordance with the material specification to be used in production and subjecting these splices to the tests specified in Section 7. 5.8. .8.3 Requa Requali lific ficat atiion of Flash lash Bu Butt tt Weldi Welding ng Procedure. Requalification of the flash butt welding proc procedu edure re by testing in acco accord rdanc ancee with Sectio Section n 7 shall be required where—

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(a) there there is a chan change ge in— (i)

materia materiall specific specificati ation, on, grad gradee or type; type;

(ii) (ii)

bar bar size size;;

(iii) joint prepara preparation; tion; or (iv) significan significantt machine compo componen nent; t; or (b) there are consistent failures in produc production tion contr ol tests. 5.9 PRODUCTION CONTROL TESTS. 5.9.1 5.9.1 General General Production Production Control Control Tests. Tests. During prod roduct uction, ion, in orde orderr to ensu ensurre that that the splice plicess continue to comply with the quality requirements of  Section 8, bend tests and tensile tests shall be carried out in accordance with the frequency requirements of  Clause 5.9.2. 5.9.2 Frequency of Tests. Test joints shall be made at the following times: (a) Comme test Commenc ncem ement ent of produ producti ction on run. run. Two test  joi nts shall be made at the commenceme comm enceme nt of 

each production run of each welding procedure: one to be subjected to the bend test and one to be subjected to the tensile test. (b) During production run. Test joints shall be made in a cc ccor da danc e w it ith one o f th e fo ll llo wi wi ng ng procedures: (i) Where Where more more than than 100 joints joints are are made made in in a product production ion run, for each each 100 100 joints joints or part th er ere of of aft er er t he he fi rs rst 100 j oi oin ts ts an additio dditiona nall test test join jointt shal shalll be made made and and bend-tested bend-tested in accordance with Clause 7.3.3 and and an additional additional test joint joint shall be made and tensil tensilee-tes tested ted in acco accorda rdanc ncee with with Clause 7.3.2. (i i ) Wh er ere 100 j oi oi nt nt s o r l es ess a re re m a de de i n a product production ion run, at l east one additional additional test  joi nt shall be made and bend-t ested est ed in accordance accordance with Clause 7.3.3. 5.10 DEFECTIVE WELDS. Production Production welds welds that fail to comply comply with the requi requireme rements nts of Clause Clause 9.5 9.5 shall be removed and a new weld made.

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SECTION SECTION 6. FLAME FLAME PRESSURE PRESSURE WELDING WELDING me p re re ss ssu re re w el eld in in g of   6.1 6.1 GENERA GENERAL. L. F llaa me reinfo einforrceme cemen nt shal shalll comp complly with the relev elevaant requireme requirements nts of other S ections ections of this standard standard and and the specific requirements of this Section. 6.2 SIZES. The size of the bar to be welded shall be within within the equip equipmen mentt capac capacity ity as speci specified fied by the equipment equipment manufacturer and shall be confirmed in the procedure qualification test (see Clause 6.7). 6.3 BAR PREPARATION. The ends of bars to be welded shall be prepared by either sawing or shearing approxi approximatel mately y normal normal to the axis of the bar bar so as to facilitate welding. 6.4 ALIGNMENT. The bars to be welded shall be set in the equipment so that the axes are coincident. The axes of the portions of the welded bar shall be in line within 10 percent of the size or 3 mm, whichever is the lesser. The bar bar ends ends and and adja adjace cent nt 6.5 CLEANLINE CLEANLINESS. SS. The materia materiall shall shall be free free from from rust, rust, paint, paint, greas grease, e, or other foreign matter, immediately prior to welding.

type, grade and size of reinforcing bar in a document known known as a ‘welding procedure procedure sheet’. This procedur proceduree shall shall include include the following: (a) Heat Heating ing tip tip type. type. (b) Gas pressu pressures res and preferab preferably ly flows. (c) Heat Heating ing time. time. (d) Upset Upset pressu pressure. re. 6.7 .2 .2 Me th th o od d of Qu a all if ifi ca cat iio o n of W eelld iin ng Procedure. When acceptable machine settings have been obtained, a welding procedure shall be qualified by producing a set of test splices of reinforcing bars in accordanc accordancee with the material material specification specification t o be used in production and subjecting these splices to the tests specified in Section 7. 6.7. 6.7.3 3 Requali Requalifica fication tion of Gas Press Pressure ure Welding Welding Requalification tion of the flame pressure pressure Procedures. Requalifica weldin welding g proce procedu dure re by testing testing in acco accorda rdanc ncee with Section 7 shall be required where— (a)

there there is a chan change ge in— in—

6.6 WORKMANSHIP.

(i)

material material spec specificati ification, on, grade or type; type;

6.6.1 Positioning. The two bars to be welded shall be clamped so that the overhang of each is equal and the weld interface is centrally located in the flame. The gap gap betwe between en bars bars befor beforee weldin welding g shall shall not not exce exceed ed 3 mm.

(ii) (ii)

bar bar size size;;

6.6.2 6.6.2 Clamping Clamping Force. Force. The clamping force exerted by the clamping dies on the bars being welded shall be suffi suffici cient ent to preve prevent nt movem movemen entt of the the bars bars in relation to the clamps during the upsetting operation, but not enough to deform the bars. 6.6.3 Upset. The diameter of the upset after welding shall shall be not not less than 1.3 times the size of t he smaller bar, bar, and shall be unifor uniformly mly distribu distributed ted around around the circumference circumference of the bar. 6 .7 .7 Q UA UA L I F I CA C A TI T I ON ON PROCEDURE.

OF

W E L DI D I NG NG

welding ing proce procedu dure re shall shall be 6.7.1 6.7.1 General. General. The weld qualified before production production welding of the reinforcing bars commences. The Contracto Contractorr shall establish establish a welding welding procedu procedure re and shall list the applicable machine settings for each

(iii) joint prepara preparation; tion; or (iv) significan significantt machine machine compon component; ent; or (b) (b)

there there are consis consisten tentt failures failures in produc production tion control tests.

6.8 6.8 PRODUC PRODUCTIO TION N CONTR CONTROL OL TESTS. TESTS. During prod roduct uction, ion, in orde orderr to ensu ensurre that that the spli plices ces continue to comply with the quality requirements of  Section 8, bend tests and tensile tests shall be carried out in accordance wit h the following requirements: (a) At the commen commence ceme ment nt of each each produ productio ction n shift shift two welds shall be made by each welder: one to be subject to a bend test (see Clause 7.3.3) 7.3.3) and one t o be s ub ubj ec ect to a t en ensi le le t es est ( se see Clause 7.3.2). (b) During During the shift, shift, at least least one further further weld weld shall shall be made by each welder and shall be subject to a tensile test. 6.9 DEFECTIVE WELDS. Production Production welds that fail to comp comply ly with the requirem requirement entss of Clause Clause 9.5 shall be removed and a new weld made.

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SECTION SECTION 7. QUALIFICAT QUALIFICATION ION OF WELDING WELDING PROCE PROCEDURE DURE BY TESTING This Sec Section tion appli applies es where where the 7.1 7.1 GENERAL GENERAL.. This qualifica qualification tion of welding procedures procedures by the testing testing of  a sample of spliced reinforcing steel is permitted by Clause 4.2(c). 7.2 METHOD OF QUALIFICATION. The welding procedure shall be qualified by producing a set of test splices splices by the applicable applicable procedur proceduree and subjecting subjecting these splices to the tests specified in Table 7.1. Provided Provided that t he splice splice complies complies with the relevant relevant test requirements of Section 8, the welding procedure shall be accepted as qualified. 7.3 7.3 TESTS. TESTS. 7.3.1 Macro Test. The macro test shall be carried out in accordance with AS 2205.5.1. 7.3.2 7.3.2 Tensile Test. The tensile test shall be carried out in accordance with AS 2205.2.1. 2205.2.1.

shall be carried out in 7.3.3 7.3.3 Bend Test. The bend t est shall accordance accordance with AS 2205.3.1, 2205.3.1, using a former having a diameter as specified in AS 1302, appropriate to the size and grade of bar. The exposed section of the bar shall shall be ground ground or machined machined smooth smooth to the diameter of t he he ba r, r, i .e .e. over al al l dia me met er er incl ud udi ng ng deformation. NOTE: NOTE: The bend bend test test may be performed on a commercia commerciall bar bending machine in the same way that normal bends are made.

7.4 RETESTS. Where any one specimen of all those tested tested during during a procedure procedure qualificat qualification ion t est fails to comp comply ly with the test requi requirem remen ents, ts, retests retests for that that particular particular type of t est specimen specimen may be performed performed wi t h t wo wo speci mens of th e s ame t yp ype of   procedu procedure-qu re-qualificat alification ion test piece. piece. Both retests shall shall comply with the test requirements. However, if any failure is due to cracking cracking in the heat-affec heat-affected ted zone or in the weld, weld, the proce procedu dure re shall shall be modified modified and a new new proce procedu dure re test test splic splicee shal shalll be prepa prepare red d and and tested.

TABLE TABLE 7.1 7.1 TESTS REQUIRED FOR WELD PROCEDURE QUALIFICATION Welding process Fu si on

Co ns nsum ab able s

Pr eq uali fi fi ed ed in accordance accordance wit h Table 4.4 Not prequalified

Fl ash b ut t Fl am e pr essure

No t a pp li cabl e No No t a pp li cabl e

Tests Tests required required Di rreect bu tt spl ic ic es es

Ma cro 1

Te nsil e Ni l

Be nd Ni l

Lap spli ccees and indirect butt splices Ma cro 1

1

1

1

1

1

1

1

1

1 Ni l Ni l

1 2 2

1 2 2

2 No t a pp li cabl e No t a pp li cabl e

Preparat io io n

Prequalified in accordance accordance wit h Tables 4.1, 4.2 and 4.3 Ot her p re para ti on s Prequalified in accordance accordance wit h Tables 4.1, 4.2 and 4.3 Ot her p re para ti on s Al Al l Al l

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SECTION SECTION 8. TEST REQUIREM REQUIREMENTS ENTS 8 . 1 P R OD O D U C TI T I ON ON C O N T R O L T E S T splices shall shall comply comply with REQUIREMENTS. Test splices the following requirements:

test 8.2 MACRO TEST REQUIREME REQUIREMENTS. NTS. The test spec specime imen n shal shalll compl comply y with the requi requirem rement entss of  Clause 8.1(a).

(a) Welds shall shall be sound sound and and of full size size througho throughout ut exce except pt that that imperfec imperfection tionss such such as unde undersiz rsizee welds, porosity, piping, undercut, slag inclusions, incomplet incompletee penetratio penetration, n, incomplet incompletee fusion fusion and similar generally generally elongated imperfections may be disr isrega egarded rded wher wheree they they resu result lt in less ess than han 5 percent percent loss loss of effective cross-sectiona cross-sectionall area. area.

8.3 TENSILE TENSILE TEST REQUIREMENTS. REQUIREMENTS. The tensile streng trengtth of a but butt splic splicee shal shalll be not less ess tha than 1.15 .15 times imes (for (for 230 230 gra grade) de) and and 1.05 1.05 times imes (for (for 410 410 gr ade) ade) the minimum specified specified yield yield strength strength of  the reinforcing steel used in the splice.

(b) (b) Weld Weld metal metal and and adja adjace cent nt pare parent nt metal metal shall hall contain no cracks.

8.4 BEND TEST REQUIREMENTS. REQUIREMENTS.On On completion of the test, no crack or other other imperfection imperfection in the weld or the heat-a heat-affec ffected ted zone zone shall shall have have a dimen dimensio sion n greater than 3 mm measured in any direction at the outer surface of the test specimen.

(c) Weld reinf reinfor orcem cemen entt shall shall not not excee exceed d 3 mm in height, height, except except for f lame pressure pressure welding. welding.

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SECTION ECTION 9. INSPEC INSPECTIO TION N 9.1 EXAMINATION OF WELDING. All welding shall shall be subject subject to the examina examination tion of an I nspecto nspectorr appointed by the Principal. 9.2 QUALIFICA QUALIFICATIONS TIONS OF INSPECTOR INSPECTORS. S. The Insp nspect ector shal shalll have ave had had suita suitabl blee train trainin ing g and and experience experience in the fabrication and inspection of welded structures structures.. He should should have have at l east the qualificat qualifications ions required for a welding supervisor. The holding of an Australian Australian W elding elding Institute Institute Certificate Certificate either either as a Weldin elding g Insp Inspeector ctor or as a Struct tructu ural ral Weldin Welding g Super Supervi visor sor shall shall be acce accept pted ed as evide evidence nce of these these qualifications. nspector 9.3 PRIVILEGES OF INSPECTORS. An I nspector shall have access at all reasonable times to the work  and shall be provided with facilities for the inspection ther thereof eof.. He shal shalll be noti notifie fied d in adva advanc ncee of any any welding operations. He shall have access to a complete set of relevant drawings drawings showing showing size, size, length, length, type and disposition disposition of welds and any any weld proce procedu dures res which which are to be used for the work. Where the the 9.4 9.4 INSPECT NSPECTIO ION N OF WELD WELDERS ERS.. Where quality of the work of a particular welder does not in the opin opiniion of the Insp nspect ector, or, comp omply with the the require requireme ments nts of this this stand standar ard, d, the Inspe Inspecto ctorr may may request that welder to undergo test(s) to show that he is capable of welding satisfactorily. 9.5 INSPECTION OF WORK. 9.5.1 9.5.1 Inspection Inspection Prior Prior To and During Welding. Welding. The Inspe Inspect ctor or shall shall inspec inspectt the the set-up set-up of the work and satisfy satisfy himself himself that— that—

(a) the shape shape and the size size of joints are in accor accordanc dancee with the approved design; (b ) th e w el el di din g is b ei ei ng ng c ar arr iiee d out w it ith t he he specified materials and suit able equipment; (c) correct correct welding welding condition conditionss at the work work are being being maintained; and (d) (d) the work work i s being being done done in acco accorda rdanc ncee with the requirements of this standard. He shall particularly particularly check check t hat hat thorough thorough f usion usion of  the weld, proper penetration and clean weld metal are being obtained. NOTE: It is recommended that if the type and nature of a defect consi consisten stently tly appear appearss in the welds welds performed performed by any particular particular welder, further welding be discontinued until additional tests are carri carried ed out out by the the weld welder er and and the weld weldss so produ produce ced d are are considered considered satisfactory. satisfactory.

9.6 INSPE INSPECTI CTION ON AFTER AFTER WELDI WELDIN NG. The Inspe Inspect ctor or shall shall ascer ascertain tain that that the size, size, length length and loca locatio tion n of all all welds elds comp comply ly with with the the plans plans and and specifica specifications. tions. A careful careful systematic systematic check check shall shall be made ade to ens ensure ure that that no wel weld calle called d for for on the the drawings drawings is omitted. omitted. The Contractor Contractor shall have the surface of the weld cleaned to the satisfaction of the Inspe Inspect ctor. or. Welds Welds shall shall be exam examine ined d caref carefully ully for cont contour our,, dimen dimensio sions ns,, surfac surfacee defec defects, ts, signif significan icantt undercutting and cracks in the weld or parent metal. Cont Contour our and dimen dimensio sions ns shall shall be checke checked d with a gauge gauge where where practicab practicable. le. The Inspector Inspector should should keep a complete complete record record of the position position of all corrections corrections made and the procedure that was used.

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APPENDI APPENDIX X A

CHECK LIST OF MATTERS FOR DISCUSSION Some matters of a contractual nature which may need discussion are listed below for reference and it is recommended that the Principal resolve these with the Contractor where practicable, before work is commenced: (a) Approval Approval f or welding welding to proceed proceed (Clause 1.6). 1.6). (b) Joining Joining reinforcing reinforcing steel steel (Clause (Clause 1.7). 1.7). (c) Limitation on on welding processes processes (Clause 1.8). 1.8). (d) Approval Approval of parent parent material material (Clause 2.1). 2.1). (e) Qualification Qualification of welding welding procedure procedure (Clauses (Clauses 4.1, 4.1, 4.2, 5.8, 6.7 and 7.2). (f) Qualification Qualification of welding welding personne personnell (Clause 4.7). 4.7). (g) Cutting fusion face face (Clause 4.8.1 4.8.1). ). (h) Correction Correction of defective defective welds (Clause (Clause 4.8.7). 4.8.7). (j)

Manua Manuall f lash butt butt welding welding (Clause (Clause 5.7.1) 5.7.1)..

(k) Availability Availability of records for perusal perusal by Inspector Inspector (Clause (Clause 9.3). (l)

Type and and extent of of inspection inspection (Clause (Clause 9.5).

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AS 1554, Part 3—1983 3—1983

APPENDI APPENDIX X B

RECOMMEND RECOMMENDED ED METHOD METHOD FOR JOINT AND PROCESS PROCESS IDENTIFICATION B1 PREQUALIFIED JOINT IDENTIFICATION. Weld preparations in Tables 4.1 to 4.3 are identified by the following letters and numbers: (a)

Joint type identification.

B—butt splice L—lap splice (b)

Penetration identification.

D—direct penetration I—indirect penetration (c)

Preparation identification (butt splices).

1—square 2—single-V 3—double-V 4—single-bevel 5—double-bevel The lower-case letters a, b, and c are used as suffixes to the numbers in (c) above, to distingui distinguish sh between between diagrams diagrams showing showing variations variations of the same prequali prequalified fied joint. joint. Welding processe processess are identified identified as follows: follows: B2 PROCESS IDENTIFICATION. Welding FCAW FCAW(N)* (N)* —flux —flux-c -cor ored ed arc weldi welding ng with withou outt gas gas shield shieldin ing g FCAW(C or M)* —flux-cor —flux-cored ed arc welding welding with gas shield shielding ing GMAW MAW —gas gas-shie -shield ldeed meta metall-arc -arc wel welding— ding—sp sprray and and dip dip transf ransfer er MMA W —m a nual m et a l- ar ar c wel di di ng B3 EXAMPLE. ‘BD-2 MMAW’ is a single-V single-V direct direct penetrati penetration on butt splice welded by manual manual me ta tal --aar c we ld ldi ng ng w hi hi ch ch c an an b e m ad ade ei th ther wi t ho hout a b ac ackin g bar (BD-2a MMAW) or with backing bars (BD-2b MMAW). *N r efers to no gas shielding shielding.. C refers to shielding with carbon dioxide. M refers to shielding with mixed gases.

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AS 1554, Part 3—1983

26

APPENDI APPENDIX X C

A SUITABLE FORM OF WELDING PROCEDURE SHEET (For use in detailing detailing prequalified prequalified welding welding procedures procedures and f or r ecording ecording qualified welding procedures procedures))

Welding elding Proce Procedur dure e No* No* . . . . . . . . . . . . .

Contrac ontracto torr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.

Welding elding proc proce ess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (or combinati combination, on, if used)

2.

Mate ateria riall sta standa ndard rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.

Bar siz size e . . . . .. . . . .. . . . .. . . . .. . . . . . .. . . . . .. . . . . . . .. . . . .. . . . .. . . . .. . . . .

4.

Joint oint design design (use (use ske sketc tch h if neces necess sary) ary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.

Filler iller me meta tall Stan tandar dard d ...... ....... ......... .......... ........ ....... ....... ....... Classi lassifficati ication on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Size ize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.

Sh i el el d in in g g as as Comp omposi ositi tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas flow flow rate rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.

Shieldi hielding ng flux flux (ty (type pe and size size)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.

Powe owerr source source chara characte cteri risti stics cs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (a.c. (a.c. or d.c. and polarity)

9.

Posi osition tion of weldin elding g ................................................. ..... (include direction of vertical welding)

10.

Numb umber er of runs runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.

Maxi aximum time time lapse lapse betw between een runs runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (if critical for preheat)

12.

Back gougi gouging ng meth ethod od . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.

Preheati reheatin ng and and interr interrun un tempe temperat ratur ure e ...... ....... ......... .......... ........ .

14.

Postwel ostweld d heat treat treatmen mentt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (method, (method, temperature, temperature, temperature temperature control methods, time at temperature, temperature, heating and cooling rate)

15.

Run det details ails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Run No

Electrode size

Welding current

Welding voltage

Travel speed

Electrical stick-out

Joint detail detail (include (include run sequence sequence where necessary) necessary)

Welder’ elder’s s nam name e .........................

Approv pprove ed by . . . . . . . . . . . . . . . . . . . . . . . . . .

.. .... .. ... .. ... .. ... ... ....

Da te te . . . . . . . . . . . . . . . . . . . . . . . . . . .

* This procedure procedure may vary owing to fabrication sequenc sequence, e, fit-up, material thickness, thickness, number of runs, etc within t he essential essential variables (see Clause 4.6).

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27

AS 1554, Part 3—1983 3—1983

ANNEX

LIST OF REFERENCED DOCUMENTS (a) Materials. AS AS AS AS AS AS

1163 1163 1204 1205 1302 1303 1304

Structural Structural Steel Hollow Hollow Sections Structural Structural S teels—Ordin teels—Ordinary ary Weldable Weldable Grades Grades Structural Structural S teels—Weath teels—Weather-res er-resistant istant Weldabl Weldablee Grades Steel Reinforc Reinforcing ing Bars for Concrete Concrete Hard-draw Hard-drawn n Steel Reinforci Reinforcing ng Wire for Concrete Concrete Hard-draw Hard-drawn n Steel Wire Reinforcin Reinforcing g Fabric for Concret Concretee

(b) Safety. AS 133 1336 Reco ecomme mmended nded Practi ractice cess for Eye Prote Protect ction ion in the the Indu ndustr strial ial Environment AS 1337 Eye Protectors Protectors for Industrial Industrial Application Applicationss AS 1338 1338 Filters Filters for for Eye Protect Protectors ors AS 1470 Code of General General Principles Principles for Safe Working Working in Industry Industry AS 1674 Fire Precaution Precautionss i n Cutting, Cutting, Heating Heating and Welding Operation Operationss AS CC5 Rules Rules for the Preventi Prevention on of Electric Electric Shock Shock to Arc Welde Welders rs AWRA Techn Technica icall Note Note 7—Health 7—Health and and Safety Safety in in Weldin Welding g (c) Electrodes . AS 1553 Covered Covered Electrodes Electrodes for Arc Welding Welding Part 1—Low Carbon Steel Electrodes for Manual Metal-arc Welding of  Carbon and Carbon-manganese Steels AS 1588 1588 Filler Filler Rods Rods for for Welding Welding AS 2203 Carbon Carbon Steel Electrode Electrodes, s, Cored (for Arc Welding) Welding) AWRA Technica Technicall Note 3—Care 3—Care of of M Manu anual al Arc-welding Arc-welding Steel Electrodes Electrodes (d) Other. AS 1101 Graphica Graphicall Symbols Symbols for Genera Generall Engineeri Engineering ng Part 3—Symbols for Welding AS 1480 1480 SAA Concre Concrete te Structures Structures Code AS 1481 1481 SAA Prestress Prestressed ed Concret Concretee Code AS 1554 1554 SAA Structural Structural Steel Welding Welding Code Code Part 1—Welding of Steel Structures AS 1966 Electric Electric Arc Welding Machine Machiness AS 1995 1995 Welding Welding Cabl Cables es AS 2205 Methods Methods of Destructive Destructive Testing Testing of Welds Welds in Metal Metal 2205.2 2205.2.1 .1 Part 2—Tensile T ests—Transv ests—Transvers ersee Butt Tensile Test 2205.3.1 Part 3—Bend Tests—Transverse Guided Bend Test 2205.5 2205.5.1 .1 Part 5—Metallogr 5—Metallographic aphic Tests—Macr Tests—Macro o Test—Cross-se Test—Cross-section ction Examination AS 2214 SAA Structural Structural Steel Welding Welding Supervisors Supervisors Certification Certification Code AS 3000 3000 SAA Wiring Wiring Rules Rules AS C301 Manua Manuall Arc-welding Arc-welding Electrode Electrode Holders Holders AS Z5 Gloss Glossar ary y of Met Metal al Weldi Welding ng Terms and and Definitio Definitions ns

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