TN11-18

Weld Australia Technical Note 11:

Commentary on the
Structural Steel Welding
Standard AS/NZS 1554

This Technical Note:
• Is a minor revision of the 2016 edition of this
Technical Note and includes comment on the
editions of AS/NZS 1554 Parts 1 to 7 current at the
date of publication;
• Is intended to complement the Standards and is
referenced by them;
• Presents background material which could not be
included in the Standards;
• Discusses the requirements of the Standards, with
particular emphasis on new or revised clauses;
• Endeavours to explain the application of the
Standards to welding in steel construction;
• Emphasises the need for the principal, design
engineer, fabricator and inspecting authority to rely
on the provisions of the Standard to achieve the
required weld quality;
• Serves as an educational text for students of
engineering;
• Has been prepared by Weld Australia in
conjunction with Standards Australia Committee
WD-003.
Future Revisions
This Technical Note will be revised from time to time
and comments aimed at improving its value will be
welcomed.
This publication is copyright and extracts from this
publication shall not be re-printed or published without
the Publisher’s express consent.
Acknowledgments
The editors wish to thank Mr M Fletcher from
BlueScope, Mr E Derwort from Bradken, Mr A Syam
from OneSteel Tube Mills, Mr S Munter from the Steel
Reinforcement Institute of Australia and Mr A Williams
from Stud Welding NZ for their assistance in the
preparation of the 2016 edition of the commentary,
and Dr Michail Karpenko and the staff of the Heavy
Engineering Research Association (HERA) for review
of the New Zealand specific contents.
Technical amendments arising since the publication of
2016 edition are marked with a vertical bar in the left
margin.
Disclaimer
While every effort has been made and all reasonable
care taken to ensure the accuracy of the material
contained herein, the authors, editors and publishers
of this publication shall not be held to be liable or
responsible in any way whatsoever and expressly
disclaim any liability or responsibility for any loss or
damage costs or expenses howsoever caused incurred
by any person whether the purchaser of this work or
otherwise including but without in any way limiting any
loss or damage costs or expenses incurred as a result
of or in connection with the reliance whether whole or
partial by any person as aforesaid upon any part of the
contents of this Technical Note.
Should expert assistance be required, the services of a
competent professional person should be sought.
Editor
Mr B. Cannon
Technical Publications Manager
Weld Australia
National Library of Australia card number and ISBN
978-0-9946359-0-7.

2 | Weld Australia Technical Note 11 | © 2018

About
Weld Australia
Who We Are
Weld Australia represents the welding profession in
Australia. Our members are made up of individual
welding professionals and companies of all sizes. Weld
Australia members are involved almost every facet of
Australian industry and make a significant contribution
to the nation’s economy.
Our primary goal is to ensure that the Australian
welding industry remains both locally and globally
competitive, both now and into the future.
A not-for-profit, membership-based organisation, Weld
Australia is dedicated to providing our members with
a competitive advantage through access to industry,
research, education, certification, government, and the
wider industrial community.
Weld Australia is the Australian representative member
of the International Institute of Welding (IIW).
Our Mission
Our mission is to represent the interests of members
and safeguard the public by ensuring the integrity of
in-service welds, and to promote the use of best
practice technology and quality systems.
Value Proposition
Weld Australia generates revenue through its
commercial activities which is then reinvested back into
the welding community for the benefit of members.
Weld Australia brings individual and company
members together to deliver:
• A forum for the exchange of ideas and the sharing
of resources
Commentary on the Structural Steel Welding Standard AS/NZS 1554
• A voice to promote the interests of the welding
community and shape the market for welding
services
• Specialist technical problem solving and a conduit
between industry and research organisations
• A pathway for learning and career development
and the opportunity to benchmark against world’s
best practice
Services
Weld Australia provides:
• Events and Seminars
• Technical Publications
• Technical Support and Advisory Services
• Project Management
• Professional Development
• Qualification and Certification
Real Solutions to Real Problems…
Weld Australia has a team of highly qualified welding
engineers and technologists available to provide expert
advisory services on all welding related matters. With
expertise in a wide range of industries, ranging from
biotechnology to heavy engineering we have a unique
capability to solve your welding problems.
Our advice can help you substantially increase the
operational life of your plant and equipment and thereby
reduce your maintenance and repair overheads.
Further Information
For further information about Weld Australia and how
we can help your business, please visit:
www.weldaustralia.com.au.
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Contents
Introduction __________________________ 8
Scope __________________________________ 10
Terminology __________________________ 11
Section A: Part 1 - Welding of Steel
Structures ____________________________ 12
A0 Guidance in the Use of Part 1 - Welding of
Steel Structures __________________________ 12
A0.1 Guidance for the Design Engineer _________
A0.1.1 General ____________________________
A0.1.2 Guidance in the Use of Part 1 for Typical
Applications _________________________
A0.2 Guidance for the Fabricator ______________
A0.3 Guidance for the Inspector ______________
A0.4 Guidance for the Welder _________________
A1 Scope and Application __________________ 21
A1.1 Scope _______________________________ 21
A1.2 Exclusions ___________________________ 22
A1.3 Innovation ____________________________ 24
A1.6 Weld Categories _______________________ 25
A1.7 Management of Quality _________________ 26
A1.7.1 Quality Management ___________ 26
A1.7.2 Basic Welding Requirements _____ 29
A1.8 Safety Recommendations _______________ 29
A2 Materials of Construction ________________ 29
A2.1 Parent Material _______________________
A2.2 Backing Material ______________________ 30
A2.3 Welding Consumables _________________ 32
A2.3.1 Electrodes and Filler Wires ______
A2.3.2 Care of Electrodes and Filler Wires
A2.3.3. Flux ________________________
A2.3.4 Shielding Gas _________________
A3 Details of Welded Connections ___________ 33
A3.1 General ______________________________
A3.1.2 Design Stresses _______________
A3.1.3 Drawings _____________________
A3.2 Butt Welds ____________________________
A3.2.1 Size of Weld __________________
A3.2.2. Design Throat Thickness ________
4 | Weld Australia Technical Note 11 | © 2018
A3.2.3 Effective Length ________________35
A3.2.5 Transition of Thickness or Width ___ 35
A3.3 Fillet Welds ___________________________ 36
A3.3.1 Size of Weld __________________ 36
A3.3.2 Design Throat Thickness _________37
A3.3.3 Effective Length ________________37
A3.3.5 Minimum Size of Fillet Welds _____ 38
A3.3.6 Maximum Size of Fillet Welds along
Edges _______________________ 38
A3.4 Compound Welds ______________________ 38
A3.6 Plug Welds ___________________________ 38
A3.7 Slot Welds ____________________________ 38
A3.8 Welds for the Purpose of Combining Rolled
12 Steel Sections _________________________38
12 A3.9 Provisions Not Included In Either
AS/NZS 1554.1, or the Design Standards ___ 39
13
18 A4 Qualification of Procedures and
19 Personnel ________________________________ 40
19
A4.1 Qualification of Welding Procedure _________ 40
A4.1.2 Butt Welds ____________________ 41
A4.1.3 Fillet Welds ___________________ 41
A4.1.4 Qualification of Multiple Welding
Positions _____________________ 41
A4.2 Method of Qualification of Welding
Procedure ____________________________ 41
A4.3 Prequalified Welding Procedure ___________ 43
A4.4 Portability of Qualified Welding Procedures __ 43
A4.5 Prequalified Joint Preparations ____________ 43
A4.6 Qualification of Welding Consumables ______ 44
A4.6.1 Prequalified Welding
Consumables _________________ 45
A4.6.2 Qualification of Welding
29 Consumables by Testing _________ 46
A4.7 Qualification of Welding Procedure by
Testing ______________________________ 46
32 A4.7.1 Method of Qualification __________ 46
A4.7.2 Preparation of Special Test Piece __ 46
32 A4.7.3 Dimensions of Test Pieces _______ 47
33 A4.7.4 Macro Test ___________________ 47
A4.7.5 Transverse Butt Tensile Test ______ 47
A4.7.6 Bend Test _____________________47
A4.7.7 Charpy Impact Test _____________ 47
33 A4.7.8 Hardness Comparison Test - Parent
33 Metal and Weld Metal ___________ 48
33 A4.7.9 Hardness Test - HAZ ____________ 48
34 A4.8 Extension of Qualification ________________ 48
34 A4.9 Combination of Processes _______________ 48
35 A4.10 Record of Tests _______________________ 48
A4.11 Re-qualification of Welding Procedures ____ 49
A4.11.1 Changes in Essential Variables
Requiring Re-qualification of Examination ___________________ 75
Welding Procedure ____________ 49
A4.12 Qualification of Welding Personnel ________ 51
A4.12.1 Welding Supervisor ____________ 51
A4.12.2 Welders _____________________ 53
A5 Workmanship __________________________ 54
A5.1 Preparation of Edges for Welding __________ 54
A5.1.1 General ______________________ 54
A5.1.2 Thermal Cutting ________________ 55
A5.2 Assembly _____________________________ 55
A5.2.1 General ______________________ 55
A5.2.2 Alignment of Butt Welded Joints ___ 55
A5.2.3 Alignment of Fillet Welds and Consumable Classification System ___________ 78
Incomplete Penetration Butt Welds _ 55
A5.2.4 Separation of a Backing Material __ 55
A5.3 Preheating and Interrun Control ___________ 55
A5.3.5 Inter run temperature control
Heat input limits ________________ 60
A5.4 Welding Under Adverse Weather Conditions _ 60
A5.5 Tack Welds ___________________________ 60
A5.6 Weld Depth-To-Width Ratio _______________ 61
A5.7 Control of Distortion and Residual Stress ____ 61
A5.7.1 General ______________________ 61
A5.7.2 Welding and Cutting Under Stress _ 61
A5.7.3 Peening ______________________ 63
A5.7.4 Correction of Distortion __________ 64
A5.8 Backgouging and Repair of Defects in Welds _ 64
A5.8.1. General ______________________ 64
A5.8.2 Removal of Weld Metal __________ 65
A5.8.3 Grinding ______________________ 65
A5.8.4 Stop Starts ____________________ 65
A5.9 Temporary Attachments __________________ 65
A5.10 Arc Strikes ___________________________ 65
A6 Quality of Welds _______________________ 65
A6.1 Categories of Welds ____________________ 65
A6.2 Methods of Inspection and Permissible Levels
of Imperfections ________________________ 66
A6.2.0 General ______________________ 66
A6.2.1 Methods of Inspection of Completed
Welds ________________________ 67
A6.2.2 Permissible Levels of Imperfection _ 68
A6.3 Radiography __________________________ 70
A6.4 Ultrasonic Examination _________________ 70
A6.7 Weld Defects _________________________ 71
A7 Inspection ____________________________ 72
A7.1 General ______________________________ 72
A7.2 Qualifications of Inspectors _______________ 73
A7.3 Visual Inspection of Work ________________ 74
A7.4 Non-Destructive Examination Other Than
Visual _______________________________ 74
Commentary on the Structural Steel Welding Standard AS/NZS 1554
A7.4.1 Qualification of Personnel ________ 74
A7.4.2 Extent of Non-Destructive
AB Appendix B Brittle Fracture ______________ 76
AC Appendix C Typical Forms for Welding
Procedures ______________________________ 77
AD Appendix D Matters for Resolution _______ 77
AE Appendix E Weld Joint and Process
Identification _____________________________ 78
AF Appendix F Weld Procedure Requirements
Associated with Changes to the Welding
AG Appendix G Typical Material Groups for
Common Steels ___________________________ 78
AH Appendix H Selection of Materials for the
Avoidance of Lamellar Tearing ______________ 78
Section B: Part 2 - Stud Welding
(Steel Studs to Steel) ________________ 79
B0 Introduction ___________________________ 79
B0.1 General ______________________________ 79
B0.2 Stud Welding Equipment and Process ______ 79
B0.2.1 Power Sources and Controls _____ 79
B0.2.2 Stud Welding Guns _____________ 79
B0.2.3 Connecting Cables _____________ 80
B0.2.4 Welding Sequence _____________ 80
B0.3 Rationale of Part 2 ______________________ 80
B0.4 Changes to Part 2 ______________________ 81
B1 Scope and General ______________________ 81
B1.4 Definitions ____________________________ 82
B1.6 Safety Precautions _____________________ 82
B2 Materials of Construction ________________ 82
B2.1 General Requirements for Studs ___________ 82
B2.1.1 Stud Design ___________________ 82
B2.1.2 Ferrule _____________________________ 82
B2.1.3 Flux _________________________ 83
B2.1.4 Stud Bases ___________________ 83
B2.1.5 Manufacture ___________________ 83
B2.2 Stud Material __________________________ 83
B2.2.1 Manufacture ___________________ 83
B2.2.2 Mechanical Properties ___________ 83
B2.2.3 Certification ___________________ 83
B2.3 Parent Material __________________ 83
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Contents (cont.)
B3 Stud Application Qualification ______________ 84
B3.1 General ______________________________ 84
B3.2 Preparation of Test Specimens ____________ 84
B3.3 Testing _______________________________ 84
B3.3.1 General ______________________ 84
B3.3.2 Bend Test _____________________ 85
B3.3.3 Tension Test ___________________ 85
B3.4 Test Data _____________________________ 85
B4 Procedural Control ______________________ 85
B4.1 Preproduction Testing ___________________ 85
B4.1.2 For a stud Welding Machine Which C1.4.15 Types of Splice _______________
Does Not Record Weld Cycle Parameters 85
B4.1.2.1 Daily Tests __________________ 85
B4.1.2.2 Retests _____________________ 86
B4.2 Production Welding _____________________ 86
B4.3 Stud-Welding Operator Qualification ________ 86
B5 Production Technique and
Workmanship _____________________________ 88
B5.0 General ______________________________ 88
B5.1 Preparation Before Welding ______________ 88
B5.1.1 Studs ________________________ 88
B5.1.2 Stud Base ____________________ 88
B5.1.3 Ferrules ______________________ 88
B5.1.4 Parent Material ________________ 88
B5.2 Welding ______________________________ 88
B5.2.1 General ______________________ 88
B5.2.2 Adverse Weather _______________ 90
B5.2.3 Alternative Welding Processes ____ 90
B5.3 Stud Spacing __________________________ 90
B5.4 Finished Welds ________________________ 90
B5.5 Stud Welding Through Sheet Metal ________ 90
B5.6 Workmanship __________________________ 91
B5.6.1 General ______________________ 91
B5.6.2 Replacement of Unacceptable
Welds _____________________________ 93
B6 Testing of Finished Welds ________________ 93
B6.0 General ______________________________ 93
B6.1 Non-Threaded Studs ____________________ 93
B6.2 Threaded Studs ________________________ 93
B6.3 Use of Tested Studs ____________________ 93
B6.4 Additional Testing For Studs Welded to Beams
with Adverse Surface Conditions ___________ 94
B6.5 Unsatisfactory Welds ____________________ 94
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BA Appendix A Matters for Resolution ________ 94
BC Appendix C Manufacturer’s Stud Base
Qualification Requirements _________________ 94
Section C: Part 3 - Welding of
Reinforcing Steel _____________________ 95
C0 Introduction ___________________________ 95
C1 Scope and General ______________________ 95
C1.1 Scope _______________________________ 95
95
C1.4.16 Welded Joints ________________ 96
C1.6.2 Limitations of Welding ___________ 96
C1.8 Joining Reinforcing Steel to Structures ______ 96
C2 Materials of Construction ________________ 96
C3 Details of Fusion Welded Connections _____ 96
C3.2.1.2 Indirect Butt Splices ___________ 97
C3.2.2 Lap Splices ___________________ 97
C3.2.3 Transverse End Plate Splices _____ 97
C3.3 Non-Loadbearing Welded Joints ___________ 97
C4 Qualification of Welding Procedures and
Personnel for Fusion Welding _______________ 98
C4.5.4 Prequalified Lap Splices _________ 98
C4.6 Prequalified Welding Consumables ________ 98
C4.7 Qualification of Welding Procedure by Testing 98
C4.7.3 Tensile Test Requirements _______ 98
C4.7.4 Bend Tests ____________________ 98
C4.12 Qualification of Welding Personnel ________ 98
5.3 Preheat and Inter run Control ______________ 98
C5.6 Tack Welds ___________________________ 99
C6 Quality of Welds ________________________ 99
C7 Inspection _____________________________ 99
CB Appendix B Flash Butt Welding and
Appendix C Flame Pressure Welding _________ 99
Section D: Part 4 - Welding of High
Strength Quenched and Tempered
Steels _________________________________ 100
D1 Scope and General ______________________ 100
D1.1 Scope _______________________________ 100
D1.6 Weld Categories _______________________ 101
D2 Materials of Construction __________________ 101
D2.1 Parent Material ________________________ 101
D3 Details of Welded Connections ___________ 101
D4 Qualification of Procedures and
Personnel _______________________________ 101
D4.6 Qualification of Welding Consumables ______ 101
D4.6.1 Prequalified Welding Consumables 101
D5 Workmanship __________________________ 102
D6 Quality of Welds ________________________ 102
DB Brittle Fracture _________________________ 102
Section E: Part 5 - Welding of Steel
Structures Subject to High Levels of
Fatigue Loading ______________________ 103
E1 Scope and General _____________________ 103
E2 Materials of Construction ________________ 103
E3 Details of Welded Connections ___________ 104
E4 Qualification of Procedures and
Personnel _______________________________ 104
E5 Workmanship __________________________ 104
E6 Quality of Welds _______________________ 104
E6.1 Methods of Inspection and Permissible Levels
of Imperfections ________________________ 104
E6.2 Radiography __________________________ 106
E6.3 Ultrasonic Examination __________________ 104
E7 Inspection _____________________________ 105
E7.4 Non-Destructive Examination Other Than
Visual _______________________________ 105
ED Matters for Resolution __________________ 105
Commentary on the Structural Steel Welding Standard AS/NZS 1554
Section F: Part 6 - Welding Stainless
Steels for Structural Purposes ______ 107
F1 Scope and General _____________________ 107
F2 Materials of Construction ________________ 107
F3 Details of Welded Connections ___________ 107
F4 Qualification of Procedures and
Personnel _______________________________ 107
F4.11 Requalification of Welding Procedures ____ 108
F5 Workmanship _________________________ 108
F6 Quality of Welds _______________________ 108
F7 Inspection ____________________________ 109
Section G: Part 7 - Welding of Sheet
Steel Structures ______________________ 110
G1 Scope and General ____________________ 110
G2 Materials of Construction _______________ 110
G3 Details of Welded Connections __________ 110
G4 Qualification of Procedures and
Personnel _______________________________ 110
G5 Workmanship _________________________ 110
G6 Quality of Welds _______________________ 111
G7 Inspection ____________________________ 111
G7.4 Non-Destructive Examination Other Than
Visual ______________________________ 111
References ___________________________ 112
R1 Standards ____________________________ 112
R2 Weld Australia Technical Notes __________ 115
R3 General References ____________________ 115
R4 Further Reading _______________________ 116
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