Requirments

ECE Global
Your Global Partner in Engineering, Quality and Safety Compliance

Design Fabrication Inspection Certification
Slide: 1 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
ECE Global
We are ISO 9001:2008 Certified

We deliver engineering verification services, new and in-service equipment assessments and inspections, compliance assessments
Construction Surveillance
As-built & In-Service Inspections
Railcar Condition Inspection
Monitor Repair Programs
Vendor Support Services
CWI, IWE, EWE

Visual Inspections (VT)
UT, Phased Array UT, UTT
Surface Flaw Detection (MT, PT)
Positive Material ID Check (PMI)
PQR / WPS Approvals

Welder Qualifications / Training
Welding Coordinator Service
Welding Management Systems
Failure Assessments
Inspection &
Approvals
NDT Services
Welding Services
ASNT, AWS, API, EN, ISO,
ASME, AWS, API, EN, ISO,
Approval & Certification Services

AAR Rules (e.g. M-1003, ISO, ...)
European Rules (CE, EN, ISO, ...)
Product Compliance Assessments
Pre-Certification/Consulting Services
EN 15085 Welding of Rail Vehicle

ISO 3834 Quality System
CE Marking
EN 473 NDE Testing
Compliance Assessments
AAR Assessments (e.g. Sect. J )

Inspections (e.g. AAR Rule 88.B.2)
Truck / Brake Assessment
Rail Car Fabrication Consultation
Quality System Implementation
Compliance
For Europe
For North America
ASME, AWS, EN, ISO, GOST,
EU Directives, EN, ISO,
ASME, AWS, API, ISO,
1256 Remington Rd. - Schaumburg, IL 60173 - USA

+1 (847) 250-5240 (P) - +1 (847) 713-4860 (F)
infoece@eceglobal.com - www.eceglobal.com
American-European Working Group

for Welding Rail Vehicles (AEWRV)
rail@eceglobal.com
Helping with clientele success, nationally / globally, with cost-effective pricing, excellent service and a quick turnaround is our policy.
ECE Global
Common name
Official name
Slide: 2 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085Accession
Population
Area (km)
Area (miles)
1-Jan-95
8,340,924
83,871
32,383
Vienna
Kingdom of Belgium
25-Mar-57
10,666,866
30,528
11,787
Brussels
Republic of Bulgaria
1-Jan-07
7,640,238
110,910
42,823
Sofia
4 Cyprus
Republic of Cyprus
1-May-04
778,700
9,251
3,572
Nicosia
5 Czech Republic
Czech Republic
1-May-04
10,403,100
78,866
30,450
Prague
6 Denmark
Kingdom of Denmark
1-Jan-73
5,511,451
43,094
16,639
Copenhagen
7 Estonia
Republic of Estonia
1-May-04
1,340,935
45,226
17,462
Tallinn
8 Finland
Republic of Finland
1-Jan-95
5,312,415
338,145
130,559
Helsinki
9 France
French Republic
25-Mar-57
64,473,140
674,843
260,558
Paris
10 Germany
Federal Republic of Germany
25-Mar-57
82,218,000
357,050
137,858
Berlin
11 Greece
Hellenic Republic
1-Jan-81
11,125,179
131,990
50,962
Athens
12 Hungary
Republic of Hungary
1-May-04
10,036,000
93,030
35,919
Budapest
13 Iceland
Republic of Iceland
---
316,252
103,125
39,770
Reykjavk
14 Ireland
Ireland
1-Jan-73
4,501,000
70,273
27,133
Dublin
15 Italy
Italian Republic
25-Mar-57
59,619,290
301,318
116,340
Rome
16 Latvia
Republic of Latvia
1-May-04
2,266,000
64,589
24,938
Riga
17 Lithuania
Republic of Lithuania
1-May-04
3,357,873
65,303
25,214
Vilnius
18 Luxembourg
Grand Duchy of Luxembourg
25-Mar-57
483,800
2,586
998
Luxembourg
19 Malta
Republic of Malta
1-May-04
407,810
316
122
Valletta
20 Netherlands
Kingdom of the Netherlands[t 6]
25-Mar-57
16,471,968
41,526
16,033
21 Norway
Reich Commissariat of Norway
---
4,954,000
385,252
148,746
Oslo
22 Poland
Republic of Poland
1-May-04
38,115,641
312,683
120,728
Warsaw
23 Portugal
Portuguese Republic
1-Jan-86
10,599,095
92,391
35,672
Lisbon
24 Romania
Romania
1-Jan-07
21,498,616
238,391
92,043
Bucharest
25 Slovakia
Slovak Republic
1-May-04
5,400,998
49,037
18,933
Bratislava
26 Slovenia
Republic of Slovenia
1-May-04
2,025,866
20,273
7,827
Ljubljana
27 Spain
Kingdom of Spain
1-Jan-86
46,661,950
506,030
195,379
Madrid
28 Sweden
Kingdom of Sweden
1-Jan-95
9,253,675
449,964
173,732
Stockholm
29 Switzerland
Swiss Confederation
30 United Kingdom
United Kingdom of Great Britain
1 Austria
Republic of Austria
2 Belgium
3 Bulgaria
Capital
Amsterdam
---
7,785,600
41,285
15,940
Bern
1-Jan-73
61,003,875
244,820
94,526
London
EU-27
European Union total
499,514,405
4,456,304
1,720,590
North America
Canada, USA, Mexico
528,720,588
24,709,000
9,540,000
Washington
16,150,331
19,723,034
7,614,954
Difference
ECE Global
Slide: 3 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
Population
Area (km)
Area (miles)
European Union total
512,570,257
4,985,966
1,925,046
North America
528,720,588
24,709,000
9,540,000
16,150,331
19,723,034
7,614,954
34,482,779
9,984,670
3,855,103
Official name
Canada (2011)
ECE Global
Business in Europe
-EN 15085-
The goal of harmonization:

Harmonization within the European Union
* Freedom
* Trade: Unification and mutual requirements
* Common safety requirements; e.g.:
Public health and safety
Workers protection and safety
Plant & facility safety
Product safety
Slide: 4 of 45
Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
Certification for Europe

Many requirements apply when designing, fabricating and operating rail vehicles in Europe
CE Marking, etc
certification of pressure equipment, electrical equipment, EMC,

fire protection, operating in tunnel, and more
EN 15085
EN 12663
etc.
new building and repair work of rail vehicle and components

Structural requirements of railway vehicle bodies
.
Derailment Safety
Operational Safety, Side wind
Stress Safety (Active and Passive)
Control Systems, Safety Technology, Software
Brake System
Vehicle Profile / Clearance
Fire Safety, Environmental Protection
Workers Protection
Vehicle Accessories / Equipment
ECE Global
Business in Europe
-EN 15085-
What does it take for a fabricator of

Welded Rail Vehicles and Components
to sell products in Europe?
Slide: 7 of 45
Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085-
EN 15085 and AWS D15.1
We will focus on
EN 15085 Welding of Rail Vehicles and Components
Part 1: General
Part 2: Quality requirements and certification of welding manufacturer
Part 3: Design requirements

Part 4: Production requirements
Part 5: Inspection, testing and documentation
And focus on
AWS D15.1 Railroad Welding Specification for Cars and

Locomotives
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Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085-
Slide: 9 of 45
Date: 2012 Edition
Thomas Schmidt
American-European Working Group for Welding Rail Vehicles

(AEWRV) rail@eceglobal.com
Did you know:
Over 300 companies in China are certified per EN 15085 by 2012 ending
Canada roughly 5 Companies
USA roughly 15 Companies
Mexico roughly 0 Companies are certified per EN 15085!
That Quality Assurance / Quality Control Programs combined with some

approvals is an investment with an incredible ROI?
ECE Global
Business in Europe
-EN 15085-
Country
company
CA
Advance Manufacturing Technologies Inc. (DIN EN 15085-2)
CA
Alloy Welding Centre Limited (DIN EN 15085-2)
CA
China Steel Inc. (DIN EN 15085-2) open audit process
CA
Phillips & Temro Industries LTD (DIN EN 15085-2)
CA
Recreational & Industrial Products Corp. (DIN EN 15085-2)
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Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt

The intent of the workgroup is:
To represent the interest of the North American Railroaders with focus on
exporting its products to EU countries and other global destinations (e.g. S.A.).
Our meeting outcome will provide insights, input and advice to Technical
Committees for the development of e.g. AWS D15.1 and EN 15085.
Even though these standards are addressing the same industry and same
companies, the overall scope and approach is different.
ECE Global
Business in Europe
-EN 15085-
Slide: 12 of 45
Date: 2012 Edition
Thomas Schmidt
EN 15085
EN 15085 Scope
applies to
manufacturers of welded rail vehicles and components
outlines
certification and quality requirements
covers
new building and repair work of rail vehicle and components.
covers
steel and aluminum (principles apply to other materials equally)
ECE Global
Slide:
of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

Europe changed ..
From a Country by Country Approval Scheme
to the New European Approach!
Non regulated /
voluntary /
market oriented
initiatives
Product Liability;
Declaration
of Conformity,
EU Representation
Business Excellence &

European Competitiveness
Quality Policy System/Personnel
Global Approach
New Approach
regulated /
mandatory /
initiatives
Old Approach
80
83
85
89
90
94
95
96
00
01
02
ECE Global
Business in Europe
-EN 15085-
Slide: 14 of 45
Date: 2012 Edition
Thomas Schmidt
EN 15085-2: Definition of certification levels

Annex A (informative)
Possible allocation of parts and subassemblies of rail vehicles to the certification levels
Certification Parts classification
level
Level CL 1
New build, conversion and repair of rail vehicles and their components Examples for components: bogies (headstocks, solebars, cross bearers,
bogie frames) under-frames (extensions, solebars, cross bearers, assembly) vehicle body (front walls, side walls, roof) draw and buffing gear
supporting frames for external equipment parts (e. g. tanks, electrical, air-conditioning and compressed air containers) wheel set mountings, axle
boxes, spring supports, shock absorbers, vibration dampers brake equipment (magnetic track brake, brake rods, brake triangles, brake cylinders,
brake cross beams) supporting frames for heavy duty vehicles including road/rail vehicles welded components for drag transmission from bogie
to vehicle (bolster) fuel tanks of vehicles finishing welding of castings within components indicated above pressure gas tanks, tanks and tank
containers of rail vehicles with test pressure a containers for dangerous materials a.
Level CL 1
New build, conversion and repair of rail vehicles and their components, depending on the weld performance class (CL 1 only for CP A, CP B or CP C1),
or
e.g.: entrance doors, end doors self-supporting equipment boxes and underfloor containers (fresh water and waste-water containers) external
Level CL 2
machine equipment parts (transformer, engine, transmission suspension) roof construction (pantograph, paneling) machine room equipment
(transformer casing, transformer suspension, engine suspension, transmission suspension, attachment for traction motor, instrument racks)
power transmission parts (traction coupling, cardan shafts) traverses (i.e. car wagon) turning and tipping equipment obstacle deflectors
stanchions and lashing rings compressed-air reservoirs for rail vehicles a pressurized pipes.
Level CL 2
New build, conversion and repair of non-pressurized containers without special test pressure, e.g.: payload container for non-dangerous materials
other transport containers. New build, conversion and repair of structural parts for rail vehicles, e.g.: internal parts of passenger coaches
(partitions, walls, doors, paneling) supporting frame for internal parts (electrical, air-conditioning and compressed air installations) driving cab
equipment lavatory parts and water containers with installations sliding doors in vehicles including runways fastenings for brake pipes nonself-supporting equipment boxes underneath the base frame (without supporting frame) gearboxes and consoles for hand brake operation
steps, hand rails (including handrails in entry areas) and railings external to the vehicle.
Level CL 3
New build, conversion and repair production of simple attached parts for rail vehicles, e.g: cranks and levers for various operations striking plates
equipment boxes and switch cabinets in rail vehicles (including gearboxes and consoles for hand brake operation, without supporting frame)
holders for index plates wheel scotches covers for freight wagons (heat protection on tank wagons) steps, handrails, railings on rail vehicles.
New build, conversion and repair of parts or trade supply parts for rail vehicles, for instance: seating frames window frames ventilation grilles.
Level CL 4
This certification level is valid for manufacturers that do not carry out their own welding fabrication if welded components and parts are: designed
bought and assembled.
a The requirements of this standard will be superseded by specific product standards, e.g. EN 286, air reservoirs.
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
CL 1: New build, conversion and

repair of rail vehicles and their
components Examples for
components:
CL 1 / 2: New build, conversion

and repair of rail vehicles and
their components, depending
on the weld performance class
(CL 1 only for CP A, CP B or CP
C1), e.g.:
CL 2: New build, conversion and

repair of non-pressurized
containers without special test
pressure, e.g.:
bogies (headstocks, solebars,

cross bearers, bogie frames)
entrance doors, end doors
payload container for nondangerous materials

other transport containers.
New build, conversion and
repair of structural parts for
rail vehicles, e.g.:
internal parts of passenger
coaches (partitions, walls,
doors, paneling)
supporting frame for internal
parts (electrical, airconditioning and compressed
air installations)
driving cab equipment
lavatory parts and water
containers with installations
underframes (extensions,
solebars, cross bearers,
assembly)
vehicle body (front walls, side
walls, roof)
draw and buffing gear
supporting frames for
external equipment parts (e.
g. tanks, electrical, airconditioning and compressed
air containers)
wheel-set mountings, axle
boxes, spring supports, shock
absorbers, vibration dampers
self-supporting equipment
boxes and underfloor
containers (fresh water and
waste-water containers)
external machine equipment
parts (transformer, engine,
transmission suspension)
roof construction
(pantograph, paneling)
machine room equipment
(transformer casing,
transformer suspension,
engine suspension,
transmission suspension,
attachment for traction
motor, instrument racks)
ECE Global
Slide: 16 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
EN 15085 Essential
provides
an essential link
between
performance requirements during design (e.g. static / dynamic safety)
and
achieving appropriate weld quality during production or repair
and
inspection requirements during production and in-service maintenance

The same applies to CE Marking
Knowing engineering / fabrication / inspection /

and certification principles is key
for fabrication supervisory
ECE Global
Business in Europe
-EN 15085-
Slide: 17 of 45
Date: 2012 Edition
Thomas Schmidt
How can the cost for doing business with Europe be estimated?
Internal sales experience?
Calls to service providers?
Negotiation of customer requirements to what is standard practice?
Other .
Would you believe me, if I would state that:
defining cost saving questions for a customer is tough!
negotiating standard practice processes costs more time and money
than complying with EU requirements!
calling service providers may end up with a surprise!

Other .
Let me try to plant a suggestion ..
ECE Global
Business in Europe
-EN 15085-
A pound of Canadian feathers

cradles as much as
A pound of European feathers
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Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
Stress categories and Safety categories
Weld performance class CP A through CP D set the rules for
Quality System Requirements

Personnel Qualification Requirements
Process Approval Requirements
Cost for Certification!

Assessing and defining Weld Performance Requirements is a fundamental need,
regardless if the products operates in Europe or Canada or North America or
Stress category
High
Medium
Low
Safety categories
High
CP A a
CP B b
CP C1 d
Medium
CP B c
CP C2
CP C3
Low
CP C2
CP C3
CP D
ECE Global
Slide: 20 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
Back to the roots! definitions breakdown ..

certification level CL
weld performance class CP

weld inspection class CT
some default CL EN 15085-2, Annex A
stress category
stress factor
EN 15085-3 Table 1
safety category
The safety categories are differentiated as follows:
high
Failure of the welded joint leads to consequential events with

personal injuries and breakdown of the overall function.
medium
Failure of the welded joint leads to an impairment of the overall

function or can lead to consequential events with personal injuries.
low
Failure of the welded joint does not lead to any direct impairment of
the overall function. Consequential events with personal injuries
are unlikely.
ECE Global
Business in Europe
-EN 15085-
Slide: 21 of 45
Date: 2012 Edition
Thomas Schmidt
Rely on what you know .

Adopt what is global practice .
Build bridges, do not reinvent the wheel
ECE Global
Slide: 22 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

EN 15085-3: Design Requirements

Stress
category
Safety
category
Weld
Quality levels
performanc
for
e class
imperfections
EN ISO 5817
EN ISO 10042
Inspection
class
Volumetric
tests
RT or UT
Surface tests
MT or PT
Visual
examination
VT
High
High
CP A
see Table 5 or
Table 6
CT 1
100%
100%
100%
High
Medium
CP B
CT 2
10%
10%
100%
Medium
High
CP B
CT 2
10%
10%
100%
Low
High
CP C1
CT 2
10%
10%
100%
High
Low
CP C2
CT 3
Not required
Not required
100%
Medium
Medium
CP C2
CT 3
Not required
Not required
100%
Medium
Low
CP C3
CT 4
Not required
Not required
100%
Low
Medium
CP C3
CT 4
Not required
Not required
100%
Low
Low
CP D
CT4
Not required
Not required
100%
ECE Global
EN 15085-3: Design Requirements
Slide: 23 of 45
Date: 2012 Edition
EN 15085-3 (Table 5)
Weld performance classes Thomas Schmidt
Business
Imperfections in Europe
according to
-EN 15085Weld performance classes
EN ISO 5817 (Steel)
CP A
CP B CP C1 / CP C2 / CP C3 CP D
1.1 to 1.6, 1.13, 1.15,

1.18, 1.19, 1.22, 2.1,
2.7, 2.8, 2.11 to 2.13,
1,7, 1.8, 1.9, 1.11,

1.14, 1.17, 1.23, 2.2,
2.3 to 2.6, 2.9, 2.10,
3.1
Not permitted
Not applicable
1.10, 1.16, 1.20,

1.21, 3.2
1.12 a, 4.1, 4.2
a For CPA, see also 7.3.15.
These imperfections are not assessed
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Date: 2012 Edition
Thomas Schmidt
ECE Global
Business in Europe
-EN 15085How should the inspection class be introduced to fabrication?
Inspection shall be very well
trained and familiar with
inspection / validation
requirements!
Imperfections
according to
Weld performance
classes
EN ISO 5817 (Steel)
1.1 to 1.6, 1.13, 1.15,
1.18, 1.19, 1.22, 2.1,
2.7, 2.8, 2.11 to 2.13,
EN 15085-3 (Table 5)
Weld performance classes
CP A
CP B
CP C1 / CP C2 /
CP D
CP C3
C
Welder / Operator
must perform on
highest acceptance
level.
cost control: fabrication, inspection, repair, estimation, parts
Engineering must be very familiar

with the codes and requirements!
Engineering must produce sound and

informative drawings!
ECE Global
Business in Europe
-EN 15085-
Slide: 25 of 45
Date: 2012 Edition
Thomas Schmidt
lets summarize!
CL
CP
determined by weld performance class CP

stress category approved calculations & drawings
safety category risk assessment / engineering
engineering welding coordinator inspection
sales / purchasing
Fabrication
CT
PQR / welder / welding operator

inspector
CL mandates inspection scope
technology can demand deviation from rules
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
AWS D15.1: Brief Background on AWS Welding of Railroad Components

Purpose of Standard
- A single comprehensive document of welding data,

applicable throughout the railroad industry
- Contribution to improvements in welding quality and
performance
Committee Members
Experts from all segments of the industry

- Users
- Suppliers
- General Public
- Representatives of the Association of American Railroads (AAR)
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
General Scope Information

This document includes data from
- AWS D1.1/D1.1M, Structural Welding CodeSteel
- AWS D1.2/D1.2M, Structural Welding Code Aluminum
- AWS D1.3/D1.3M, Structural Welding CodeSheet Steel
- AWS D1.6/D1.6M, Structural Welding CodeStainless Steel
Material Thickness 1/8 in [3 mm]
Clauses 1 through 17: General requirements for welded construction for metal
components 1/8 in [3 mm] or greater, in thickness
Material Thickness Less 1/8 in [3 mm]

Clauses 18 through 23: Welding of base metals less than 1/8 in [3 mm] in thickness 11
gauge (0.1196 in [3.04 mm]) material may be considered 1/8 in [3 mm] plate or sheet
steel
ECE Global
Business in Europe
-EN 15085-
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Date: 2012 Edition
Thomas Schmidt
AWS D15.1:
- Pragmatic
- Based on experience
Not included:
Product
Classification
and Quality
System
Requirements
No reference to
i.e. M-1003
- Focused on essential tasks and disciplines related to welding

- Details requirements for welding process qualifications
- Addresses welding personnel qualification
- Partially addresses inspection personnel qualification
- Defines acceptance criteria for weld quality
- Highlights requirements certain product
ECE Global
Slide: 29 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

AWS D15.1 - Content:
AWS D15.1
Does not include
information / requirements
concerning
PRODUCT CERTIFICATION
QUALITY SYSTEMS
Inspection /
Acceptance
Welding
Requirements
Welding
Personnel
Qualification
Technique and
Workmanship
Procedure
Qualification
Prequalified
WPS
General
Qualification
Requirements
Only a limited comparison between AWS D15.1 and EN 15085 is currently possible!
However, similarities in PHILOSOPHIES can be recognized!
ECE Global
Slide:
of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

Product Liability;
Declaration
of Conformity,
EU Representation
Quality Assurance / Control System

Certification Tool to Compliance
Non regulated /
voluntary /
market oriented
initiatives
Business Excellence &

European Competitiveness
Quality Policy System/Personnel
Global Approach
New Approach
regulated /
mandatory /
initiatives
Old Approach
80
83
85
89
90
94
95
96
00
01
02
ECE Global
Slide: 31 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
EN 15085-2: Quality requirements and certification of welding manufacturer

Definition of requirements for welding manufacturer
Certification levels
Level CL 1
Manufacturer Certification
Weld performance class
Quality requirements b
Required
CP A to CP D
EN ISO 3834-2
Required
(CP C1) a , CP C2 to CP D
EN ISO 3834-3
Level CL 3
Not required
CP D
EN ISO 3834-4
Welding coordinator
Level A
Level B or C
No requirement
Deputy of the welding coordinator

Welders and operators
Level CL 2
Level CL 4
Required
CP A to CP D
EN ISO 3834-3
For:
level 1 welding work: Level A
level 2 welding work: Level B or C
Deputy: Level A c Further

Deputy: Level C
No requirement
No requirement
deputies: Level B or C d
Depending on the welding process and material group, qualified welders or welding operators
are required according to EN 287-1 (for steels), EN ISO 9606-2 (for aluminum) or EN 1418 (for Not relevant
welding operators).
Testing personnel
- Testing personnel for welding quality tests

- Testing supervisors for welding quality tests: responsible welding coordinator (not for CL 3)
- Non-destructive testing personnel: level 1 according to EN 473
- Testing evaluator for non-destructive testing: level 2 according to EN 473.
Not relevant
Welding instruction
WPS according to the relevant parts of EN ISO 15609 or EN ISO 14555 or EN ISO 15620
Not relevant
Welding instruction
WPS qualified by WPQR the relevant parts of EN ISO 15610,

EN ISO 15611, EN ISO 15612, EN ISO 15613, EN ISO 15614 e
WPS qualified by WPQR only if
or EN ISO 14555 or EN ISO 15620 (for details see EN 15085-4)
Not relevant
specified in the contract
For CP D, only if specified in the contract.
a
b
c
d
e
CL 1 when CT 1
The requirements of the relevant part of EN ISO 3834 shall be met, but no certification according to EN ISO 3834 is required.
Level A deputy is not required for small welding manufacturers with a single welding shop.
For welding manufacturers with several welding shops an additional deputy, Level C, is required for each welding shop.
For railway applications, only EN ISO 15614-1, EN ISO 15614-2, prEN ISO 15614-3, EN ISO 15614-4, EN ISO 15614-7, EN ISO 15614-11, EN ISO 15614-12 and
EN ISO 15614-13 are relevant.
ECE Global
EN 15085-2: Quality Assurance / Control
ISO 3834 Similar to ISO 9000

BUT SPECIFIC for Welding Shops
Audits
Continuous
Improvement
Customer
Satisfaction
Product
Realization /
Fabrication
Customer
Service
Sales & Projects
Engineering /
Product
Development
Control od Documents & Records
Development
Control of NonConforming
Product/Process
Test
Equipment
Maintenance
Material
Management
Procurement
Communication
Customer
Communication
Communication
Customer Requirements
Recourse
Management
Slide:
of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
ECE Global
Slide: 33 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

Welding Coordination A Key Function within the System

Level CL 1
Level CL 2
Level CL 3
Manufacturer Certification
Required
Required
Weld performance class
CP A to CP D
(CP C1) a) , CP C2 to CP D CP D
Quality requirements b)
EN ISO 3834-2
EN ISO 3834-3
EN ISO 3834-4
Welding coordinator
Level A
Level B or C
No requirement
Deputy of the welding

coordinator
Deputy: Level A c)
additional deputies:
Level B or C d)
Deputy: Level C
No requirement
a)
b)
c)
d)
Not required
CL 1 when CT 1
The requirements of the relevant part of EN ISO 3834 shall be met, but no certification according to EN
ISO 3834 is required.
Level A deputy is not required for small welding manufacturers with a single welding shop.
For welding manufacturers with several welding shops an additional deputy, Level C, is required for each
welding shop.
95
ECE Global
Slide: 34 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
Welding Coordination A Key Function within the System

welding coordinators are an essential link
- design requirements
(e.g. static / dynamic safety)
purchasing
engineering
- weld quality
(production or repair)
- inspection requirements
(production / maintenance)
sales
welding
coordinator
welding
fabrication
quality
ECE Global
certification level CL based on a weld!

The European Standard Focus on
design requirements
Business in Europe
-EN 15085-
Slide: 35 of 45
Date: 2012 Edition
Thomas Schmidt
Later: CL definition acc to EN 15085-2
Material
Suitability for
Welding/Fab.
infrastructure conditions
This is not
new
-Design
Design
-Production
Requirements
This
is
now
part
of
an
approval/certification
-In-Service
weld performance
Weldability
process
.
material suitability
Of
Components
Attention
SALES !
The
pragmatic
approach is going
to be replaced
Attention PURCHASING !
with a new approach
e.g. low temperature
inspectability
- new construction
- in-service
- maintenance
Inspection
Testing
Validation
ECE Global
Business in Europe
-EN 15085-
Slide: 36 of 45
Date: 2012 Edition
Thomas Schmidt
Sectioned close to center stiffener
A216 WCC
A588
ECE Global
Slide: 37 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

ASTM A588 Chemical Composition

Grade
A
The Element Max (%)

C
Mn
0.19
0.80-1.25 0.04 0.05
Si
Cu
0.30-0.65
Ni
0.25-0.40 0.40
Cr
Mo
Nb
0.40-0.65
0.02-0.10
0.01
..
Carbon Equivalent: CEV [max]: 0.60

CET [max]: 0.38
(CET: acc. Uwer and Hoehne)
CET = C +((Mn+Mo)/10)+((Cr+Cu)/20)+Ni/40
ASTM A216 Chemical Composition

Grade
WCC
The Element Max (%)

C [max]
0.25
Mn [max] P [max] S [max] Si [max] Cu [max] Ni [max]

1.20
0.04
0.045
0.60
0.30
0.50
Cr [max] Mo [max] V [max] Rest

0.50
0.20
Carbon Equivalent: CEV [max]: 0.55

CET [max]: 0.44
(CET: acc. Uwer and Hoehne)
CET = C +((Mn+Mo)/10)+((Cr+Cu)/20)+Ni/40
0.03
1.00
..
ECE Global
Slide: 38 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-

Tp = 697 X CET + 160 X tanh (d/35) + 62 X HD 0 35 +(53 X CET- 32) X Q - 328 (C) i ii iii
Weldment: ASTM A588-A Plate with ASTM A216-WCC Casting
Material: ASTM A588-A
WPS BT002-1 (with Backing)
HD: 1/Q: Root
HD: 1/Q: Intermediate HD: 5/Q: Root
Tp
58.22863
Tp
56.09383
Tp
105.1295
Factor 1
697
Factor 1
697
Factor 1
697
CET
0.38
CET
0.38
CET
0.38
Factor 2
160
Factor 2
160
Factor 2
160
d
14
d
14
d
14
35
35
35
tanh(d/35) 0.379949
tanh(d/35) 0.379949
tanh(d/35) 0.379949
Factor 3
62
Factor 3
62
Factor 3
62
HD
1
HD
1
HD
5
HD: 5/Q: Intermediate

Tp
102.9947
Factor 1
697
CET
0.38
Factor 2
160
d
14
35
tanh(d/35) 0.379949
Factor 3
62
HD
5
HD 0.35
Factor 4
CET
Factor 5
Q
Factor 6
HD 0.35
Factor 4
CET
Factor 5
Q
Factor 6
1
53
0.38
32
0.12
328
HD 0.35
Factor 4
CET
Factor 5
Q
Factor 6
1
53
0.38
32
0.30
328
HD 0.35
Factor 4
CET
Factor 5
Q
Factor 6
1.756465
53
0.38
32
0.12
328
1.756465
53
0.38
32
0.30
328
1. i Determination
the lowest
preheat
temperature
for cold cracking I per
sate welding
of steels. Authors Uwer D, Hoehne H, IIW. Do c IXAWS
D15.1 ofdoes
not
require
pre-heating
default.
1631 - 91.
If2.the
weld ofismethods
in a high
stressed
area, pre-heating
shouldAuthors
be reviewed!
ii Comparison
for determining
weld procedures
for the avoidance of requirements
hydrogen cracking in fabrication.
Hart
3.
P.H.M, Pargetter R.J, Wright M.D, IIW. Doc IX- 1602-90

iii Industry standards
ECE Global
Business in Europe
-EN 15085-
Slide: 39 of 45
Date: 2012 Edition
Thomas Schmidt
Welding Coordination
AWS D15.1, Clause 4.7:
Fabricator Engineer is responsible for interpretations related to approval needs
If so agreed, same responsibility applies to Owners Engineer
When both engineers are assigned, the references assigned to only one entity
shall apply to both entities
Note: Engineers are often degreed mechanical or civil engineers
EN 15085-2, Annex B: Competence of Welding Coordinator
Welding coordinator a comparable educational program as outlined in EN
15085-2, Sect 512 and EN ISO 14731 is not available in AWS D15.1
AWS D15.1 requires the company to employ suitably educated employees
ECE Global
Business in Europe
-EN 15085-
Slide: 40 of 45
Date: 2012 Edition
Thomas Schmidt
EN 15085-2 and AWS D15.1

inspection
sales
customer
purchasing
national safety authority

engineering
fabrication
ECE Global
Business in Europe
-EN 15085-
Slide: 41 of 45
Date: 2012 Edition
Thomas Schmidt
Summary
1) Manufacturers of welded products will have to be certified according to the
Certification Level (CL) and Weld Performance Class (CP)
2) Front End Loading standard knowledge and engineering / fabrication
requirements safes time, cost and increases confidence
3) Quality System approval per EN 15085-2 with compliance to ISO 3834 is a
FUNDAMENTAL MILESTONE
4) Personnel with suitable qualifications are essential
a. Welding Coordinator Technology and Standards
b. NDE Personnel Qualification per EN 473/ISO 9712 depends on CP Class

5) Approved welding procedure per EN / ISO
6) Welder / Welding Operator approval per EN / ISO
7) Contractual agreements shall include technology requirements
ECE Global
Slide: 42 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
Summary --- Estimated Time Frames for Companies with QA Systems

Assess the Weldment for
Classification
X days, depending on
complexity
Quality System an
Fabrication Performance
1 to 2 days, Gap Audit
Welding Procedure and

Welder Approvals
X days, plus Time for

Testing Lab
Personnel Training for

Welding Coordination
X days, including Test
Personnel Training for

Inspection / NDE
X days, depending on
current status
ECE Global
Business in Europe
-EN 15085-
Slide: 43 of 45
Date: 2012 Edition
Thomas Schmidt
Implementation Support and Duration, as well as

Certification Audit and Cost need to be added!
What does it take to become AAR Section J, M-1003

Certified?
ECE Global
Business in Europe
-EN 15085-
Slide: 44 of 45
Date: 2012 Edition
Thomas Schmidt

Maybe in the near future, the score card looks like this?
Over 300 companies in China that are certified per EN 15085 by 2012 ending
Canada roughly 55+ Companies
USA roughly 55+ Companies
Mexico roughly 55+ Companies are certified per EN 15085!
That Quality Assurance / Quality Control Programs combined with some

approvals is an investment with an incredible ROI?
ECE Global
Business in Europe
-EN 15085-
Please stay on track!

Thank you for you attention!
Slide: 45 of 45
Date: 2012 Edition
Thomas Schmidt
ECE Global
Slide: 46 of 45
Date: 2012 Edition
Thomas Schmidt
Business in Europe
-EN 15085-
ECE Global
We are ISO 9001:2008 Certified

We deliver engineering verification services, new and in-service equipment assessments and inspections, compliance assessments
Construction Surveillance
As-built & In-Service Inspections
Railcar Condition Inspection
Monitor Repair Programs
Vendor Support Services
CWI, IWE, EWE

Visual Inspections (VT)
UT, Phased Array UT, UTT
Surface Flaw Detection (MT, PT)
Positive Material ID Check (PMI)
PQR / WPS Approvals

Welder Qualifications / Training
Welding Coordinator Service
Welding Management Systems
Failure Assessments
Inspection &
Approvals
NDT Services
Welding Services
ASNT, AWS, API, EN, ISO,
ASME, AWS, API, EN, ISO,
Approval & Certification Services

AAR Rules (e.g. M-1003, ISO, ...)
European Rules (CE, EN, ISO, ...)
Product Compliance Assessments
Pre-Certification/Consulting Services
EN 15085 Welding of Rail Vehicle

ISO 3834 Quality System
CE Marking
EN 473 NDE Testing
Compliance Assessments
AAR Assessments (e.g. Sect. J )

Inspections (e.g. AAR Rule 88.B.2)
Truck / Brake Assessment
Rail Car Fabrication Consultation
Quality System Implementation
Compliance
For Europe
For North America
ASME, AWS, EN, ISO, GOST,
EU Directives, EN, ISO,
ASME, AWS, API, ISO,
1256 Remington Rd. - Schaumburg, IL 60173 - USA

+1 (847) 250-5240 (P) - +1 (847) 713-4860 (F)
infoece@eceglobal.com - www.eceglobal.com
American-European Working Group

for Welding Rail Vehicles (AEWRV)
rail@eceglobal.com
Helping with clientele success, nationally / globally, with cost-effective pricing, excellent service and a quick turnaround is our policy.
ECE Global
Business in Europe
-EN 15085-
Slide: 47 of 45
Date: 2012 Edition
Thomas Schmidt

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ECE Global

Your Global Partner in Engineering, Quality and Safety Compliance

We are ISO 9001:2008 Certified

Design Fabrication Inspection Certification

CWI, IWE, EWE

PQR / WPS Approvals

ASNT, AWS, API, EN, ISO,

ASME, AWS, API, EN, ISO,

Approval & Certification Services

EN 15085 Welding of Rail Vehicle

AAR Assessments (e.g. Sect. J )

For North America

ASME, AWS, EN, ISO, GOST,

EU Directives, EN, ISO,

ASME, AWS, API, ISO,

1256 Remington Rd. - Schaumburg, IL 60173 - USA

American-European Working Group

Federal Republic of Germany

Grand Duchy of Luxembourg

Kingdom of the Netherlands[t 6]

Reich Commissariat of Norway

United Kingdom of Great Britain

European Union total

Canada, USA, Mexico

European Union total

The goal of harmonization:

Certification for Europe

certification of pressure equipment, electrical equipment, EMC,

new building and repair work of rail vehicle and components

What does it take for a fabricator of

EN 15085 and AWS D15.1

EN 15085 Welding of Rail Vehicles and Components

Part 3: Design requirements

AWS D15.1 Railroad Welding Specification for Cars and

American-European Working Group for Welding Rail Vehicles

That Quality Assurance / Quality Control Programs combined with some

Advance Manufacturing Technologies Inc. (DIN EN 15085-2)

Alloy Welding Centre Limited (DIN EN 15085-2)

China Steel Inc. (DIN EN 15085-2) open audit process

Phillips & Temro Industries LTD (DIN EN 15085-2)

Recreational & Industrial Products Corp. (DIN EN 15085-2)

American-European Working Group for Welding Rail Vehicles

manufacturers of welded rail vehicles and components

certification and quality requirements

new building and repair work of rail vehicle and components.

steel and aluminum (principles apply to other materials equally)

Your Global Partner in Engineering, Quality and Safety Compliance

Business Excellence &

EN 15085-2: Definition of certification levels

CL 1: New build, conversion and

CL 1 / 2: New build, conversion

CL 2: New build, conversion and

bogies (headstocks, solebars,

entrance doors, end doors

payload container for nondangerous materials

performance requirements during design (e.g. static / dynamic safety)

achieving appropriate weld quality during production or repair

inspection requirements during production and in-service maintenance

Knowing engineering / fabrication / inspection /

calling service providers may end up with a surprise!

Let me try to plant a suggestion ..

A pound of Canadian feathers

Stress categories and Safety categories