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AS
AS/NZS 1554.5:2004

AS/NZS 1554.5:2004

Superseded

Superseded

A superseded Standard is one, which is fully replaced by another Standard, which is a new edition of the same Standard.

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Structural steel welding Welding of steel structures subject to high levels of fatigue loading

Available format(s)

Hardcopy , PDF 1 User , PDF 3 Users , PDF 5 Users , PDF 9 Users

Superseded date

07-03-2023

Superseded by

AS/NZS 1554.5:2011

Language(s)

English

Published date

24-03-2004

Publisher

Standards Australia

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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.

Committee
WD-003
DocumentType
Standard
ISBN
0 7337 5735 9
Pages
77
PublisherName
Standards Australia
Status
Superseded
SupersededBy
Supersedes
UnderRevision

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.

AS/NZS 1167.2:1999 Welding and brazing - Filler metals Filler metal for welding
AS/NZS 1554.4:2004 Structural steel welding - Welding of high strength quenched and tempered steels
AS 1470-1986 Health and safety at work - Principles and practices
AS 2203.1-1990 Cored electrodes for arc-welding Ferritic steel electrodes
AS 2214-2004 Certification of welding supervisors - Structural steel welding
AS 2074-2003 Cast steels
AS 4100-1998 Steel structures (Reconfirmed 2016)
AS 1101.3-2005 Graphical symbols for general engineering Welding and non-destructive examination
AS 2205.7.1-2003 Methods for destructive testing of welds in metal Charpy V-notch impact fracture toughness test
AS 2812-2005 Welding, brazing and cutting of metals - Glossary of terms (Reconfirmed 2018)
AS 2812-1985 Welding, brazing and cutting of metals - Glossary of terms
AS/NZS 1336:1997 Recommended practices for occupational eye protection
AS/NZS 1553.1:1995 Covered electrodes for welding - Low carbon steel electrodes for manual metal-arc welding of carbon steels and carbon-manganese steels
AS/NZS 1553.2:1999 Covered electrodes for welding - Low and intermediate alloy steel electrodes for manual metal-arc welding of carbon steels and low and intermediate alloy steels
AS 1817.1-2003 Metallic materials - Vickers hardness test Test method (ISO 6507-1:1997, MOD)
AS 3545-1988 Welding positions
AS/NZS 2717.1:1996 Welding - Electrodes - Gas metal arc - Ferritic steel electrodes
AS/NZS 4360:2004 Risk management
AS/NZS 4360:1999 Risk management
AS 2205.2.1-2003 Methods for destructive testing of welds in metal Transverse butt tensile test
AS 1817.3-2002 Metallic materials - Vickers hardness test Calibration of reference blocks
AS 2207-1994 Non-destructive testing - Ultrasonic testing of fusion welded joints in carbon and low alloy steel
AS/NZS ISO 3834.3:1999 Quality requirements for welding - Fusion welding of metallic materials Standards quality requirements
AS/NZS ISO 3834.2:1999 Quality requirements for welding - Fusion welding of metallic materials Comprehensive quality requirements
AS 1966.2-1985 Electric arc welding power sources - Rotary type
AS 1817.2-2002 Metallic materials - Vickers hardness test Verification of testing machines
AS 2205.3.1-2003 Methods for destructive testing of welds in metal Transverse guided bend test (Reconfirmed 2018)
AS 3990-1993 Mechanical equipment - Steelwork (Reconfirmed 2016)
AS/NZS 3678:1996 Structural steel - Hot-rolled plates, floorplates and slabs
AS/NZS 1554.5:1995 Structural steel welding Welding of steel structures subject to high levels of fatigue loading
AS/NZS 1595:1998 Cold-rolled, unalloyed, steel sheet and strip (Reconfirmed 2016)
AS/NZS 2865:2001 Safe working in a confined space
AS 3545-2004 Welding positions
AS 1858.1-2003 Electrodes and fluxes for submerged-arc welding Carbon steels and carbon-manganese steels
AS 1450-1983 Steel tubes for mechanical purposes
AS 1858.2-1989 Electrodes and fluxes for submerged-arc welding - Low and intermediate alloy steels
AS 1674.2-2007 Safety in welding and allied processes Electrical (Reconfirmed 2018)
AS 1966.1-1985 Electric arc welding power sources - Transformer type
AS 2207-2007 Non-destructive testing - Ultrasonic testing of fusion welded joints in carbon and low alloy steel (Reconfirmed 2017)
AS/NZS 3992:1998 Pressure equipment - Welding and brazing qualification
AS 2980-1987 Qualification of arc-welders for welding of steels
AS 1101.3-1987 Graphical symbols for general engineering - Welding and non-destructive examination
AS 1450-2007 Steel tubes for mechanical purposes (Reconfirmed 2017)
AS 1674.1-1997 Safety in welding and allied processes Fire precautions (Reconfirmed 2016)
AS 1397-2001 Steel sheet and strip - Hot-dipped zinc-coated or aluminium/zinc-coated
AS/NZS 3679.1:1996 Structural steel Hot-rolled bars and sections
AS/NZS 1338.1:1992 Filters for eye protectors Filters for protection against radiation generated in welding and allied operations
AS 1796-2001 Certification of welders and welding supervisors (Reconfirmed 2016)
AS ISO 13916-2003 Welding - Guide on the measurement of preheating temperature, interpass temperature and preheat maintenance temperature
AS 1674.2-2003 Safety in welding and allied processes - Electrical
AS 2205.6.1-2003 Methods for destructive testing of welds in metal Weld joint hardness test
AS/NZS 3679.2:1996 Structural steel Welded I sections
AS 4882-2003 Shielding gases for welding
AS/NZS 1995:2003 Welding cables (Reconfirmed 2017)
AS 2177.1-1994 Non-destructive testing - Radiography of welded butt joints in metal Methods of test
AS/NZS 1594:2002 Hot-rolled steel flat products (Reconfirmed 2016)
AS 2205.5.1-2003 Methods for destructive testing of welds in metal Macro metallographic test for cross-section examination (Reconfirmed 2018)
AS 4458-1997 Pressure equipment - Manufacture (Reconfirmed 2016)
AS/NZS ISO 3834.4:1999 Quality requirements for welding - Fusion welding of metallic materials Elementary quality requirements
AS 1171-1998 Non-destructive testing - Magnetic particle testing of ferromagnetic products, components and structures (Reconfirmed 2022)
AS/NZS 2980:2007 Qualification of welders for fusion welding of steels
AS 2799-1992 Resistance welding equipment - Single-phase a.c. transformer type
AS 1163-1991 Structural steel hollow sections
AS 2177.2-1982 Radiography of welded butt joints in metal - Image quality indicators (IQI) and recommendations for their use
AS/NZS ISO 3834.1:1999 Quality requirements for welding - Fusion welding of metallic materials Guidelines for selection and use
AS 1548-1995 Steel plates for pressure equipment
AS 4037-1999 Pressure equipment - Examination and testing (Reconfirmed 2016)
AS/NZS 1337:1992 Eye protectors for industrial applications

AS/NZS 1554.1:2004 Structural steel welding Welding of steel structures
AS 2159-1995 Piling - Design and installation
AS 5047-2005 Hydraulic shoring and trench lining equipment
AS EN 12079.1-2010 Offshore containers and associated lifting sets Offshore containers - Design, manufacture and marking (EN 12079-1:2006, MOD)
AS 2214-2004 Certification of welding supervisors - Structural steel welding
AS/NZS 4677:2010 Steel utility services poles
AS/NZS 1554.2:2003 Structural steel welding Stud welding (steel studs to steel)
AS/NZS 1554.7:2006 Structural steel welding Welding of sheet steel structures
AS/NZS 4600:2005 Cold-formed steel structures
AS 3990-1993 Mechanical equipment - Steelwork (Reconfirmed 2016)
AS 3533.4.3-2007 Amusement rides and devices Specific requirements - Roller coasters
AS 4722-2009 Passenger ropeways and passenger conveyors
AS EN 12079.2-2010 Offshore containers and associated lifting sets Lifting sets - Design, manufacture and marking (EN 12079-2:2006, MOD)
AS 3785.8-1994 Underground mining - Shaft equipment Personnel conveyances in other than vertical shafts
AS 1692-2006 Steel tanks for flammable and combustible liquids (Reconfirmed 2016)
AS 4324.1-1995 Mobile equipment for continuous handling of bulk materials - General requirements for the design of steel structures
AS 2809.5-2001 Road tank vehicles for dangerous goods Tankers for bitumen-based products
AS 2809.2-1999 Road tank vehicles for dangerous goods - Tankers for flammable liquids
AS 1418.1-2002 Cranes, hoists and winches General requirements
AS 5100.6-2004 Bridge design Steel and composite construction
AS 4100-1998 Steel structures (Reconfirmed 2016)
AS 4457.1-2007 Earth-moving machinery - Off-the-road wheels, rims and tyres - Maintenance and repair Wheel assemblies and rim assemblies
AS 4991-2004 Lifting devices
AS 2809.4-2001 Road tank vehicles for dangerous goods - Tankers for toxic and corrosive cargoes
AS 2809.2-2008 Road tank vehicles for dangerous goods Road tank vehicles for flammable liquids
AS 3533.1-2009 Amusement rides and devices Design and construction
AS 2980-2004 Qualification of welders for fusion welding of steels
AS/NZS 3785.4:2002 Underground mining - Shaft equipment Conveyances for vertical shafts
AS 1448-2007 Carbon steel and carbon-manganese steels - Forgings (ruling section 300 mm maximum)
AS 2550.1-2002 Cranes, hoists and winches - Safe use General requirements
AS EN 12079.3-2010 Offshore containers and associated lifting sets Periodic inspection, examination and testing (EN 12079-3:2006, MOD)
AS/NZS 2980:2007 Qualification of welders for fusion welding of steels
AS 3785.7-2006 Underground mining - Shaft equipment Sheaves (Reconfirmed 2023)
AS/NZS 1554.1:2011 Structural steel welding Welding of steel structures
AS 2359.1-1995 Powered industrial trucks - General requirements

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