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    AS/NZS 1554.5:2004

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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    Superseded date:  07-03-2023

    Language(s):  English

    Published date:  24-03-2004

    Publisher:  Standards Australia

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    Table of Contents - (Show below) - (Hide below)

    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

    Abstract - (Show below) - (Hide below)

    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.

    Scope - (Show below) - (Hide below)

    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.

    General Product Information - (Show below) - (Hide below)

    Committee WD-003
    Document Type Standard
    Publisher Standards Australia
    Status Superseded
    Superseded By
    Supersedes
    Under Revision

    Standards Referenced By This Book - (Show below) - (Hide below)

    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

    Standards Referencing This Book - (Show below) - (Hide below)

    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
    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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