as 1554 part 3 - welding reinforcing steel

AS 1554, Part 3—1983

Australian Standard

SAA STRUCTURAL STEELWELDING CODE

Part 3—WELDING OFREINFORCING STEEL

This Australian standard was prepared by Committee WD/3, Welding of Structures. Itwas approved on behalf of the Council of the Standards Association of Australia on28 June 1983 and published on 8 August 1983.

The following interests are represented on Committee WD/3:

Aluminium Development Council

Association of Consulting Engineers Australia

Australian Chamber of Commerce

Australian Institute of Steel Construction Ltd

Australian Welding Institute

Australian Welding Research Association

Bureau of Steel Manufacturers of Australia

Confederation of Australian Industry

Department of Defence

Department of Housing and Construction

Electricity Supply Association of Australia

Institution of Engineers Australia

Metal Trades Industry Association of Australia

National Association of Australian State Road Authorities

Railways of Australia Committee

Snowy Mountains Engineering Corporation

Steel Reinforcement Promotion Group

University of Sydney

Review of Australian Standards.To keep abreast of progress in industry, Australian Standards are subjectto periodic review and are kept up to date by the issue of amendments or new editions as necessary. It isimportant therefore that Standards users ensure that they are in possession of the latest edition, and anyamendments thereto.

Full details of all Australian Standards and related publications will be found in the Standards AustraliaCatalogue of Publications; this information is supplemented each month by the magazine ‘The AustralianStandard’, which subscribing members receive, and which gives details of new publications, new editionsand amendments, and of withdrawn Standards.

Suggestions for improvements to Australian Standards, addressed to the head office of Standards Australia,are welcomed. Noti fication of any inaccuracy or ambiguity found in an Australian Standard should be madewithout delay in order that the matter may be investigated and appropriate action taken.

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

AS 1554, Part 3—1983

Australian Standard

STRUCTURAL STEEL WELDINGknown as theSAA STRUCTURAL STEELWELDING CODE

Part 3—WELDING OFREINFORCING STEEL

First published . . . . . . . . . . . . . . . . . . . . . . . . 1974Second edition . . . . . . . . . . . . . . . . . . . . . . . . 1983

PUBLISHED BY STANDARDS AUSTRALIA(STANDARDS ASSOCIATION OF AUSTRALIA)1 THE CRESCENT, HOMEBUSH, NSW 2140

ISBN 0 7262 3063 4

AS 1554, Part 3—1983 2

PREFACE

This edition of this standard was prepared by the Association’s Committee on Weldingof Structures to supersede AS 1554, Part 3—1974. It establishes requirements for thewelding of reinforcement intended to form part of concrete structures designed andconstructed in accordance with AS 1480, SAA Concrete Structures Code.

An important difference between this edition and the 1974 edition is that it applies tothe welding of reinforcing bars of Grade 410Y to AS 1302.

As the weldability of Grade 410Y had not been fully determined prior to thepublication of AS 1302—1982, an amendment to AS 1302 was subsequently issuedinvolving the lowering of the carbon equivalent value for Grade 410Y from 0.60 to0.39 for the purpose of ensuring ease in weldability. Requirements for steel materialwith carbon equivalent value greater than 0.39 are incorporated in this edition.

It is intended that welding operations, other than flash butt welding and name pressurewelding, will be carried out under the supervision of a person certified in accordancewith AS 2214, SAA Structural Steel Welding Supervisors Certification Code.

Copyright STANDARDS AUSTRALIA

Users of Standards are reminded that copyright subsists in all Standards Australia publications and software. Except where theCopyright Act allows and except where provided for below no publications or software produced by Standards Australia may bereproduced, stored in a retrieval system in any form or transmitted by any means without prior permission in wri ting fromStandards Australia. Permission may be conditional on an appropriate royalty payment. Requests for permission and information oncommercial software royalties should be directed to the head off ice of Standards Australia.

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Care should be taken to ensure that material used is from the current edition of the Standard and that it is updated whenever theStandard is amended or revised. The number and date of the Standard should therefore be clearly identif ied.

The use of material in print form or in computer software programs to be used commercially, with or without payment, or incommercial contracts is subject to the payment of a royalty. This policy may be varied by Standards Australia at any time.

3 AS 1554, Part 3—1983

CONTENTS

Page

SECTION 1. SCOPE AND GENERAL

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . 41.2 Application . . . . . . . . . . . . . . . . . . 41.3 Referenced Documents . . . . . . . . . 41.4 Definitions . . . . . . . . . . . . . . . . . . 41.5 Welding Symbols . . . . . . . . . . . . . 41.6 Welding of Reinforcing Steel . . . . . 41.7 Joining Reinforcing Steel to

Structures . . . . . . . . . . . . . . . . . . . 51.8 Welding Processes . . . . . . . . . . . . . 51.9 Welding Equipment . . . . . . . . . . . . 5

SECTION 2. MATERIALS OF CONSTRUCTION

2.1 Parent Material . . . . . . . . . . . . . . . 62.2 Backing Material . . . . . . . . . . . . . . 62.3 Welding Consumables . . . . . . . . . . 6

SECTION 3. DETAILS OF FUSION WELDEDCONNECTIONS

3.1 General . . . . . . . . . . . . . . . . . . . . 73.2 Butt Splices . . . . . . . . . . . . . . . . . 73.3 Lap Splices . . . . . . . . . . . . . . . . . 73.4 Tack Welds . . . . . . . . . . . . . . . . . 7

SECTION 4. QUALIFICATION OF WELDINGPROCEDURES AND WELDINGPERSONNEL FOR FUSIONWELDING

4.1 Qualification of Welding Procedure 84.2 Method of Qualification of Weld-

ing Procedure . . . . . . . . . . . . . . . . 84.3 Prequalified Welding Procedures . . 84.4 Prequalified Joint Preparations . . . . 84.5 Qualification of Welding Consumables 84.6 Requalification of Fusion Weld-

ing Procedures . . . . . . . . . . . . . . . 84.7 Qualification of Welding Personnel . 84.8 Workmanship . . . . . . . . . . . . . . . . 9

SECTION 5. FLASH BUTT WELDING

5.1 General . . . . . . . . . . . . . . . . . . . 185.2 Sizes . . . . . . . . . . . . . . . . . . . . . 185.3 Bar Preparation . . . . . . . . . . . . . . 185.4 Alignment . . . . . . . . . . . . . . . . . 185.5 Cleanliness . . . . . . . . . . . . . . . . . 185.6 Workmanship . . . . . . . . . . . . . . . 18

Page5.7 Equipment . . . . . . . . . . . . . . . . . 185.8 Qualification of Welding Procedure 185.9 Production Control Tests . . . . . . . 195.10 Defective Welds . . . . . . . . . . . . . 19

SECTION 6. FLAME PRESSURE WELDING

6.1 General . . . . . . . . . . . . . . . . . . . 206.2 Sizes . . . . . . . . . . . . . . . . . . . . . 206.3 Bar Preparation . . . . . . . . . . . . . . 206.4 Alignment . . . . . . . . . . . . . . . . . 206.5 Cleanliness . . . . . . . . . . . . . . . . . 206.6 Workmanship . . . . . . . . . . . . . . . 206.7 Qualification of Welding Procedure 206.8 Production Control Tests . . . . . . . 206.9 Defective Welds 20

SECTION 7. QUALIFICATION OF WELDINGPROCEDURE BY TESTING

7.1 General . . . . . . . . . . . . . . . . . . . 217.2 Method of Qualification . . . . . . . . 217.3 Tests . . . . . . . . . . . . . . . . . . . . . 217.4 Retests . . . . . . . . . . . . . . . . . . . . 21

SECTION 8. TEST REQUIREMENTS

8.1 Production Control TestRequirements . . . . . . . . . . . . . . . 22

8.2 Macro Test Requirements . . . . . . . 228.3 Tensile Test Requirements . . . . . . 228.4 Bend Test Requirements . . . . . . . 22

SECTION 9. INSPECTION

9.1 Examination of Welding . . . . . . . 239.2 Qualifications of Inspectors . . . . . 239.3 Privileges of Inspectors . . . . . . . . 239.4 Inspection of Welders . . . . . . . . . 239.5 Inspection of Work . . . . . . . . . . . 239.6 Inspection after Welding . . . . . . . 23

APPENDICES

A A Check List of Matters for Discussion 24B Recommended Method for Joint and

Process Identification . . . . . . . . . . . 25C A Suitable Form of Welding Pro-

cedure Sheet . . . . . . . . . . . . . . . . . 26

ANNEX. LIST OF REFERENCEDDOCUMENTS . . . . . . . . . . . . . . 27

AS 1554, Part 3—1983 4

STANDARDS ASSOCIATION OF AUSTRALIA

Australian Standard

for

STRUCTURAL STEEL WELDING

PART 3—WELDING OF REINFORCING STEEL

SECTION 1. SCOPE AND GENERAL

1.1 SCOPE.This standard sets out requirements formaterials of construction, prequalified weldpreparations, methods for the qualification of weldingprocedures and welding personnel, together withworkmanship and inspection requirements for thewelding of reinforcing steel in concrete structuresdesigned and constructed in accordance with AS 1480and AS 1481.

It is intended for the welding of reinforcing steelcomplying with AS 1302, AS 1303 and AS 1304, butapplies also to the welding of steel connectiondevices, inserts, anchors and anchor details, includingprefabricated assemblies required in reinforcedconcrete and precast concrete constructions, in thefabrication shop and in the field.

NOTE: Appendix A gives a list of matters of a contractualnature which might need to be finalized between the principaland the contractor.

1.2 APPLICATION. This standard applies primarilyto the welding of reinforcing steel and other steeldevices intended for use in reinforced concreteconstruction complying with AS 1480 and AS 1481.

1.3 REFERENCED DOCUMENTS.A list with titlesof the documents referred to in this standard is givenin the Annex.

1.4 DEFINITIONS. For the purpose of this standard,the welding symbols and terms given in AS 1101,Part 3 and AS Z5 apply, together with the followingdefinitions:

1.4.1 Approved—except as may be otherwise stated,approved by the Principal, the Designer or theSupervising Engineer, as appropriate.

1.4.2 Contractor—the person, persons ororganization responsible for executing the work.

1.4.3 Contract drawings—the drawings forming partof the documents in which is set out the work to beexecuted.

1.4.4 Designer—the person, persons or organizationresponsible for the design of the structure.

1.4.5 Direct butt splice—a splice between two barsof reinforcing steel whose axes are approximatelycolinear, the bars having been joined by a butt weldmade from both sides or from one side withpermanent or temporary backing and having completepenetration and fusion of weld and base metalthroughout the depth of the splice.

1.4.6 Double lap splice—a joint consisting of twowelds, deposited in the two grooves formed betweentwo bars in contact.

1.4.7 Indirect butt splice—a splice between two barsof reinforcement whose axes are approximatelycolinear wherein the bars are welded to a commonsplice member by either single or double bevel welds,the cross-section of the bars where they butt togetherremaining unwelded. The splice member may beplate, angle, bar or other shape approved by theSupervising Engineer.

1.4.8 Principal—the purchaser or owner of thestructure being fabricated or erected, or his nominatedrepresentative.

1.4.9 Reinforcing steel—material complying withAS 1302, AS 1303 or AS 1304, as appropriate.

1.4.10 Single lap splice—a joint consisting of asingle weld deposited in the groove formed betweentwo bars in contact where only one side is accessible.

1.4.11 Specification—the specification forming partof the documents in which is set out the work to beexecuted.

1.4.12 Supervising Engineer—the Engineerresponsible for the supervision of the construction.

1.4.13 Tack weld—a short weld used for assemblyand fixing purposes only.

1.5 WELDING SYMBOLS. Welding symbols shownon drawings shall comply with AS 1101, Part 3.

1.6 WELDING OF REINFORCING STEEL.

1.6.1 Approval and Type of Welding. Welding ofreinforcing steel shall not be carried out unless it isshown on the drawings, or in other appropriatedocuments, or is otherwise approved.

Welding of reinforcing steel shall comply with therequirements of this standard.

1.6.2 Limitations on Welding. The followinglimitations on welding shall apply:

(a) Where tack welds are not shown on the drawingsbut are required to maintain the reinforcing steelin its correct position, only approved tack weldsthat comply with the requirements of Clause 3.4shall be made.

(b) Except where tack welding of main bars into thecorners of fitments is approved, welding shallnot be carried out within 75 mm of any bentportion of a bar which has or had a bend ofinternal radius less than 6 times the bar size.

1.6.3 Welding Different Grades of ReinforcingSteels. It shall be permissible to weld together

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5 AS 1554, Part 3—1983

different grades and types of reinforcing steelsprovided that the appropriate requirements of thisstandard are complied with for each grade.

1.7 JOINING REINFORCING STEEL TOSTRUCTURES. Where reinforcing steel is to bejoined to steel plate, rolled sections or hollowsections by butt or fillet welds, the welds shallcomply with the requirements for structural weldinggiven in AS 1554, Part 1.

Interconnection of precast concrete members by wayof reinforcing steel projecting from the concrete maybe made by fusion welds complying with thisstandard.

1.8 WELDING PROCESSES. Welding shall beperformed using manual metal-arc welding, semi-automatic or automatic gas-shielded or flux coredmetal-arc welding, flash butt welding, or flamepressure welding. Other welding processes may beapproved following satisfactory procedure testing.

1.9 WELDING EQUIPMENT.

1.9.1 Compliance with Standards.Welding plantand equipment for metal-arc and flash butt weldingshall comply with relevant standards issued by theStandards Association of Australia and with anyrequirements of the Statutory Authority. Theelectrical equipment of the machine shall comply withthe appropriate requirements of AS 3000.

Applicable standards are AS 1966, AS 1995 andAS C301.

1.9.2 Safety Precautions. The requirements ofAS 1336, AS 1337, AS 1338, AS 1470, AS 1674 andAS CC5, as appropriate, shall be complied withduring welding.

Suitable welding screens shall be provided to protectwelders or other persons in the immediate vicinity ofwelding.

NOTE: AWRA Technical Note 7 also gives guidance in safepractices to be employed.

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AS 1554, Part 3—1983 6

SECTION 2. MATERIALS OF CONSTRUCTION

2.1 PARENT MATERIAL. Parent material shallinclude steel reinforcement, steel plates, rolledsections and hollow sections (including tubes),complying with AS 1163, AS 1204, AS 1205,AS 1302, AS 1303 and AS 1304, as appropriate.

Other steels shall be used only after the weldingprocedures have been established and approved.

NOTE: This standard applies also to repairs and alterations toexisting buildings where care should be taken to identify steel inexisting structures and special care should be taken to ensurethat the electrodes and welding procedures selected areappropriate to the parent material to be welded.

2.2 BACKING MATERIAL. Steel backing materialto be fused in the welding process shall haveweldability not less than that of the parent material.

2.3 WELDING CONSUMABLES.

2.3.1 Electrodes and Filler Wires.Electrodes for thewelding of the parent material specified in Clause 2.1shall comply with the following:

(a) For manual metal-arc welding . . . . AS 1553.

(b) For processes other than manual metal-arcwelding . . . . . . . . . . AS 1588 and AS 2203.

Other electrodes may be used provided that they arequalified in accordance with the requirements ofClause 4.5.2.

2.3.2 Storage of Welding Consumables.Electrodesshall be stored in their original packets or cartons ina dry place, adequately protected from the effects ofweather. Where special protection during storage anduse is recommended by the manufacturer, they shallbe stored in accordance with the recommendedconditions. Filler metals shall be dry, smooth and freefrom corrosion or other matter deleterious either tosatisfactory operation or to the weld metal. If theelectrodes or filler metals are coated, the coating shallbe continuous and firmly adherent. Where themanufacturer makes specific recommendationscovering conditioning and pre-treatment of electrodesprior to use, such recommendations shall be followed.

NOTE: AWRA Technical Note 3 contains recommendations forthe storage and condit ioning of electrodes.

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7 AS 1554, Part 3—1983

SECTION 3. DETAILS OF FUSION WELDED CONNECTIONS

3.1 GENERAL.

3.1.1 Types of Fusion Welded Connections.Afusion welded connection shall be a butt splice, a lapsplice, or a tack weld.

3.1.2 Design Throat Thickness. For stresscalculations, the design throat thickness shall be thethroat size of the weld (see Fig. 3.1).

3.1.3 Throat Size of Weld.The throat size of a weldS shall be as follows:

(a) For an indirect butt splice and a lap splice. . . . . not less than 0.25 times the size of the

smaller bar joined.

(b) For a direct butt splice ..... the size of thesmaller bar joined.

3.1.4 Effective Length. The effective length of anindirect butt splice or of a lap splice shall be taken tobe the length of the weld that is of the specified sizethroughout.

3.1.5 Finished Width.The width of a finished weldof an indirect butt splice or of a lap splice shall benot less than 0.45 times the size of the smaller barjoined.

3.1.6 Effective Area.The effective area of a weld foran indirect butt splice or a lap splice shall be taken asthe sum of the products of the effective length andthe applicable design throat thickness.

The effective area of a weld for a direct butt spliceshall be taken as the area of the smaller bar joined.

3.2 BUTT SPLICES.

3.2.1 Direct Butt Splices.Direct butt splices shallcomply with Table 4.1.

NOTE: Double-V and double-bevel butt splices may havepreparations unequal in depth.

3.2.2 Indirect Butt Splices.Indirect butt splices shallcomply with Table 4.2 and the followingrequirements:

(a) Welding of reinforcement to the splice plate orangle shall be by means of fillet welds, or to thesplice sleeve by means of end fillet welds.

(b) As applicable, the splice plate, angle, sleeve andattaching welds should have sections ofsufficient strength to meet the requirements ofAS 1480.

3.3 LAP SPLICES. Lap splices shall comply withTable 4.3. The width of a finished weld of a lapsplice shall be not less than 0.45 times the size of thesmaller bar joined.

3.4 TACK WELDS.

3.4.1 Limitations on Tack Welds. The number oftack welds shall be kept to the minimum necessary tolocate the reinforcing steel during erection andplacement of concrete.

Tack welds shall not substantially reduce thecross-section of the reinforcing steel nor adverselyaffect its strength.

3.4.2 Size of a Tack Weld.Tack welds shall—

(a) have a throat thickness not less than 4 mm;

(b) have a length not less than the size of thesmaller bar; and

(c) comply with the preheat requirements given inTable 4.7.

*W = width of weld.

Fig. 3.1. DESIGN THROAT THICKNESS AND EFFECTIVE LENGTH

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AS 1554, Part 3—1983 8

SECTION 4. QUALIFICATION OF WELDING PROCEDURESAND WELDING PERSONNEL FOR FUSION WELDING

4.1 QUA L I FI C A TI ON OF W E L DI N GPROCEDURE. The welding procedure, i.e. the jointpreparation, the welding consumables and the weldingparameters, shall be qualified before weldingcommences.

The Contractor shall establish a welding procedureand shall list the applicable parameters in a documentknown as the ‘welding procedure sheet’. A suitabletype of welding procedure sheet is shown inAppendix C.

4.2 METHOD OF QUALIFICATION OFWELDING PROCEDURE. A welding procedureshall be qualified by one of the following methods:

(a) A procedure prequalified in accordance withClause 4.3.

(b) Production of documentary evidence of relevantprior experience by the Contractor.NOTE: A completed welding procedure sheet such as thatshown in Appendix C, together with records of any testscarr ied out, including suitable photographs of the test pieces,consti tutes documentary evidence of prior experience.

(c) Preparation of a test piece which simulates asclosely as practicable the weld preparation, thegrade, type and size of the reinforcement and thewelding conditions to be used in production. Thetest piece shall be tested in accordance with therequirements of Section 7.

4.3 PREQUALIFIED WELDING PROCEDURES.Welding procedures shall be deemed to beprequalified where—

(a) the joint preparations are prequalified inaccordance with Clause 4.4;

(b) the consnmables are prequalified in accordancewith Clause 4.5;

(c) the workmanship and welding techniques,including the preheat and interrun temperaturerequirements, comply with the requirements ofthis standard; and

(d) where required, documentary evidence isavailable of a satisfactory macro test inaccordance with Clause 7.3.

4.4 PREQUALIFIED JOINT PREPARATIONS.

4.4.1 General.The joint preparations prescribed inClauses 4.4.2 and 4.4.3 shall be deemed to beprequalified provided that the welding processes andconsumables used are in welding positionsrecommended by the electrode manufacturer.

4.4.2 Prequalified Butt Splices.Joint preparationsconforming to the dimensions given for the processesindicated in Tables 4.1 and 4.2 shall be deemed to beprequalified.

All butt splices that are to be welded from both sidesusing these prequalified preparations shall have theback of the first run gouged out by suitable means tosound metal before welding is started on the secondside, unless evidence is produced by macroetchingthat complete fusion can be obtained without suchgouging.

4.4.3 Prequalified Lap Spl ices.Joint preparationscomplying with Table 4.3 shall be deemed to beprequalified for all processes.

4.5 QU AL I F I C AT I ON OF W E L D IN GCONSUMABLES.

4.5.1 Prequalified Welding Consumables.Wherewelding consumables are matched with the steel type inaccordance with the requirements of Table 4.4 andcomply with the other relevant requirements of thisstandard and provided that they are used in thepositions recommended by the manufacturer, suchwelding consumables shall be deemed to beprequalified and shall not require qualification testing.

4.5.2 Qualification of Welding Consumables byTesting. Where welding consumables are notprequalified in accordance with Clause 4.5.1, they maybe qualified in conjunction with a welding procedurequalification test in accordance with Section 7.

4.6 REQUALIFICATION OF FUSION WELDINGPROCEDURES.

4.6.1 Changes in Essential Variables NecessitatingRequal i f icat ion of Weld in g Proced ure.Requalification of a fusion welding procedure bytesting in accordance with Section 7 shall be requiredwhere changes in the essential variables for the weldingprocedure exceed the limits given in Table 4.5.

4.6.2 Minor Changes Necessitating Requalification ofWelding Procedure by Macro Test.Requalification ofthe welding procedure by a macro test taken either froma production splice or from a special splice welded forthe purpose shall be required where changes in theessential variables for the welding procedure exceed thelimits given in Table 4.6.

4.7 QU AL I F I C AT I ON OF W E L D IN GPERSONNEL.

4.7.1 Welding Supervisor.Welding shall be carriedout under the supervision of a welding supervisoremployed by the Contractor. The function of thewelding supervisor shall be to ensure that all weldingis carried out as specified in the plans andspecifications or other documents in accordance withthe requirements of this standard. Such a supervisorshall be a person who—

(a) holds an Australian Welding Institute weldingsupervisor’s certificate in structural steel weldingin accordance with AS 2214, or has equivalentqualifications acceptable to the SupervisingEngineer;

(b) has served an apprenticeship in an appropriatemetal trade and during or subsequent thereto hashad 5 years’ experience in the fabrication ofwelded steel structures, and is able to satisfy theSupervising Engineer that he is suitable for thework upon which he will be employed;

(c) has had at least 7 years’ experience in thefabrication of reinforcing steel and is able tosatisfy the Supervising Engineer that he is suitablefor the work upon which he will be employed; or

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9 AS 1554, Part 3—1983

(d) is the holder of a diploma or a certificate inEngineering or Metallurgy of an approved technicalcollege or is a graduate in Engineering orMetallurgy of a recognized university andsubsequent to obtaining his diploma, certificate ordegree has had 3 years’ experience in thefabrication of welded steel structures.

4.7.2 Welders.The following requirements shall applyto the qualification of welders:

(a) All welders shall be suitably qualified to carry outthe welding procedures on which they will beemployed. The Contractor shall provide satisfactoryevidence that welders are suitably qualified.

(b) A welder not already qualified for the weldingprocess required by the welding procedures onwhich he is to be employed shall be required todemonstrate his ability to comply with theappropriate requirements of this standard by meansof a macro test.

(c) A person operating automatic or semi-automaticequipment and qualified to use a particular processwith an approved consumable or combination ofconsumables shall be considered qualified to useother approved consumables or combinations ofconsumables with the same process.

(d) Qualifications established under this Clause withany one of the steels covered by this standard shallbe considered as qualification to weld any other ofthe steels covered by this standard.

(e) Where a welder repeatedly produces welds notcomplying with the requirements of this standard,welding by the welder shall be discontinued untiladditional tests are carried out by the welder andthe welds so produced comply with this standard.

(f) The names of all welders qualified in accordancewith this Clause together with particulars of anytests passed by each, shall be recorded and madeavailable for perusal by the Inspector for theduration of the job.

4.8 WORKMANSHIP.

4.8.1 Preparation of Material for Welding. Thesurfaces to be welded shall be free of defects, and fromheavy scale, moisture, slag, rust, oil, paint, cement orany other foreign material likely to affect adversely thequality of the weld.

If preparation or cutting of the fusion face is necessary,this should be carried out by a method approved by theSupervising Engineer.

4.8.2 Assembly. Where reinforcing steel is to beassembled prior to welding, it shall comply with thefollowing requirements:

(a) Bars to be welded shall be held in the correctposition until welding has been completed.Fastening devices shall be adequate to ensure safetyduring welding operations. Suitable allowances forwarpage and shrinkage shall be made. Each jointshall have adequate clearance for accessibility tomake the weld.

(b) Before the welding of a butt splice, the surfaces ofbars of equal size shall not be out of alignmentwith one another by more than 0.10 times the sizeof the bars or 3 mm, whichever is the lesser.

The surfaces of bars of unequal size shall liewholly within the projection of the surface of thethicker bar in the joint.

(c) Parts to be lap spliced shall be brought into asclose a contact as practicable to minimizedistortion. The gap due to faulty workmanship orincorrect fit-up shall not be more than 0.25 timesthe size of the bar or 3 mm, whichever is thelesser. If separation occurs locally, the effectivethroat thickness of the weld shall be maintained.

(d) All tack welds, whether to be consumed ultimatelyor not, shall be subjected to the same initialtreatment (preheating) as for the final welds. Tackwelds that are to be consumed in the final weldshall be cleaned of slag before being fused into theweld. Defective, cracked or broken welds shall beremoved before the final welding.

4.8.3 Gouging.In all butt splices that are to be weldedfrom both sides, the back of the first run shall begouged out by suitable means to clean metal beforewelding is started on that side, unless evidence isproduced that the welding procedure employed is suchthat complete fusion is obtained without such gouging.

4.8.4 Positioning of Work.The work should, wheneverpracticable, be positioned for welding in the flatposition.

4.8.5 Welding in Adverse Weather Conditions.Welding shall not be carried out in the followingconditions:

(a) Where the temperature of the parent metal is below0°C unless preheating is carried out in accordancewith Clause 4.8.6 to a minimum of 20° C.

(b) Where welding surfaces are wet from condensation,rain, snow or ice.

(c) Where rain or snow is falling on the surfaces to bewelded.

(d) During periods of high wind, unless the welder andthe work are properly protected.

4.8.6 Preheat Temperature.Preheat temperatures andelectrode sizes for the fusion welding of reinforcementshall be in accordance with Table 4.7.

4.8.7 Correction of Defective Welds.Where a weld isfound to be defective, the Contractor shall repair theweld, or, if required by the Supervising Engineer, shallremove the weld and then reweld the splice. Repairingor rewelding shall be carried out in accordance with thisstandard, and the Supervising Engineer shall be advisedof all such repairs or rewelds.

The removal of weld metal or portions of the base metalshall be effected by machining, grinding, chipping,oxygen gouging, or air/carbon-arc gouging. It shall bedone in a manner that ensures that the remaining weldmetal or base metal is not nicked or undercut. Defectiveportions of the weld shall be removed withoutsubstantial removal of the base metal. The surfaces shallbe cleaned thoroughly before rewelding.

Defective undercutting shall be made good by thedeposition of additional weld metal to comply with therequirements of Clause 8.1 or by the removal of theundercut by grinding provided that this complies withthe requirements of Clause 8.1.

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AS 1554, Part 3—1983 10

TABLE 4.1PREQUALIFIED DIRECT BUTT SPLICE PREPARATIONS

NOTATION: db = bar size G = root gap Fr = root face θ = included angle of preparation, degreesF: flat, H: horizontal, OH: overhead, V: vertical

NOTE: All l inear dimensions are in mil limetres.

Jointidentif ication

(See Appendix B)Joint type Preparation

detailManual

metal-arc

Flux-coredarc,

self-shieldedand gas-shielded

Gas-shielded metal-arc

Spraytransfer Dip transfer

BD-2a (a) Single-V butt splice (welded bothsides)

db

PosnGFr

θ

All

All3.51.560

All

Seeθ3350-F,H,OH60-V

All

F0450

All


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

BD-4 (b) Single-bevel butt splice (unequal bars)(welded both sides)

db

PosnGFr

θ

All

All3.51.545

All

Seeθ31.550-F,H,OF60-V

All

F and H1.5450

All


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

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11 AS 1554, Part 3—1983

BD-2b (c) Single-V butt splice with spli t pipe backing dbPosnGFr

θ

AllSeeθSeeθ020-F,OH:G=12

30-F,OH:G=945-A11:G=6

AllSeeθ6030-F,H,OH45-V

AllF31.530


Where access to the root of the weld is un-obtainable. Alternatively, a removable copperbacking bar may be used in place of the permanentbacking shown

BD-3a (d) Double-V butt splice dbPosnGFr

θ

AllAll3.51.560


AllF0350


Horizontal bars should be welded in the flatposit ion wherever practicable

ALLOWABLE JOINT TOLERANCES

Dimension Root not gouged Root gouged

G (root gap without backing) . . .±1.5 mm . . . . . . . . +1.5, -3 mmG (root gap with backing) . . . . . +6, -1.5 mm . . . . . . Not applicableθ (angle of preparation) . . . . . . . +10, -5 degrees . . . +10, -5 degreesFr (root face) . . . . . . . . . . . . . .±0.5 mm . . . . . . . . No upper limit, -0

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AS 1554, Part 3—1983 12

TABLE 4.1 (continued)



detailManual

metal-arc

Flux-cored arc,self-shielded

and gas-shielded


Spraytransfer Dip transfer

BD-3b (e) Double-V butt splice (unequal bars) db

PosnGFr

θ

AllAll3.51.560


AllF0450


Horizontal bars should be welded in the flat positionwherever practicable

BD-5 (f) Double-bevel butt splice (bars vert ical) dbPosnGFr

θ

AllAll3.51.545

AllSeeθ1.51.550-F,H,OH60-V

AllF0350


ALLOWABLE JOINT TOLERANCES: See page 11.

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13 AS 1554, Part 3—1983

TABLE 4.2PREQUALIFIED INDIRECT BUTT SPLICE PREPARATIONS

NOTATION: db = bar size G = root gap W = width of weld S = size of weldF: flat.




detailManual

metal-arc


and gas-shielded


Spray transfer Dip transfer

BI-1a (a) Indirect butt splice with flat backing dn

PosnG

AllF20 max.

AllF20 max.

AllF20 max.

AllF20 max.

BI-1b (b) Indirect butt splice with angle backing dnPosnG

AllF20 max.

AllF20 max.

AllF20 max.

AllF20 max.

BI-1c (c) Indirect butt splice with sleeve dn

PosnG

AllAll20 max.

AllAll20 max.

AllAll20 max.

AllAll20 max.

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AS 1554, Part 3—1983 14

TABLE 4.3PREQUALIFIED LAP-SPLICE PREPARATIONS

NOTATION: db = bar size W = width of weld S = size of weldF: flat, H: horizontal, OH: overhead, V: vertical




detailManual

metal-arc


and gas-shielded


Spray transfer Dip transfer

L-(a) (a) Double lap splice (bar superimposed) db

PosnAllH

AllH

AllH

AllH

L-(b) (b) Double lap splice (bars side by side) db

PosnAllF,OH

AllF,OH

AllF,OH

AllF,OH

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15 AS 1554, Part 3—1983

L-(c) (c) Double lap splice (bars vert ical) db

PosnAllV, OH

AllV,OH

AllV,OH

AllV,OH

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AS 1554, Part 3—1983 16

TABLE 4.4

PREQUALIFIED WELDING CONSUMABLESSteel grade Manual metal arc

(AS 1553)Flux-cored arc

(AS 2203)230S230R410C450W410Y (CE≤0.39)Bars not complyingwith AS 1302 orwhere CE > 0.39

E41XX, E48XXE41XX, E48XXE4816, E4818E4816, E4818E48XXE4816, E4818

W40X, W50XW40X, W50XW50XW50XW50XW50X

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

TABLE 4.5

CHANGES IN ESSENTIAL VARIABLES NECESSITATINGREQUALIFICATION

Nature of changeApplicabil ity

MMAW GMAW FCAW(a) A change from one process to another X X X(b) A change from a low-hydrogen type electrode to a non-low-

hydrogen type electrode X — —(c) A change in electrode/f lux/shielding gas combination — X X(d) A change from one gas or gas mixture to another gas or gas mixture — X X(e) A change of more than±7 percent of the specified mean arc voltage

of the electrode used for automatic arc welding processes, or morethan ±15 percent for manual metal-arc welding

X X X

(f ) A change of more than±10 percent of the specified mean weldingcurrent for the electrode used for automatic arc welding processes,or more than±15 percent for manual metal-arc welding

X X X

(g) A change of more than±25 percent in the specified number of runs.If the cross-sectional area of the preparation is increased, it is alsopermissible to increase the number of runs in proport ion to theincreased area — X X

(h) An increase of 25 percent or more, or a decrease of 10 percent ormore in flow rate of shielding gas — X X

(j ) A change in the posit ion in which welding is done or a change indirection for a vertical weld X X X

(k) A change in welding current from a.c. to d.c. and vice versa or achange in d.c. polari ty or a change in metal transfer across the arc — X X

(l ) A decrease of more than 20 K in the minimum specified preheat andinterrun temperature X X X

(m) A change in material thickness outside the range 0.75 to 1.5 timesmaterial thickness — X X

X indicates applicabil ity.

TABLE 4.6

MINOR CHANGES IN ESSENTIAL VARIABLES NECESSITATINGREQUALIFICATION OF WELDING PROCEDURES BY MACRO TEST

Nature of changeApplicabil ity

MMAW GMAW FCAW(a) An increase in the diameter of the electrode(b) A change in the shape of any one type of joint preparation—

(i ) a decrease in the included angle of the joint preparation(ii ) a decrease in the root gap of the joint preparation

(i ii ) an increase in the root face of the joint preparation(iv) the omission or inclusion of backing material

X

XXXX

X

XXXX

X

XXXX

X indicates applicabil ity.

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17 AS 1554, Part 3—1983

TABLE 4.7

MINIMUM PREHEAT TEMPERATURES

(a) Hydrogen Controlled Electrodes (EXXX15,EXX16,EXX18,EXXX28)Semi-Automatic and Automatic Welding Processes

Steel designation Range ofbar sizes

Minimum preheat temperature, °CElectrode sizes, mm

3.15 4 5 6.3Arc energy (semi-automatic processes), kJ/mm

mm >1≤1.5 >1.5≤2.5 >2.5≤3.5 >3.5230 S ≤24 Preheat not required

230 R >24≤36 75 Preheat not required

410 C >36≤50 100 75 N/R N/R

450 W >50 100 100 75 N/R

410 Y (whereCE≤0.39)

All Preheat not required

Bars not complyingwith AS 1302 orwhere CE>0.39

≤24 75 Preheat not required>24≤36 125 100 N/R N/R>36≤50 150 125 100 N/R>50 175 150 125 100

(b) Non-hydrogen Controlled Electrodes EXX10,EXX11,EXX12,EXX13,EXX14,EXX20,EXX24,EXX27

Steel designation Range ofbar sizes

mm

Minimum preheat temperature, °CElectrode sizes, mm

3.15 4 5 6.3

230 S ≤24 100 50 N/R N/R230 R >24≤36 125 100 50 N/R410 C >36≤50 125 100 100 50450 W >50 125 100 100 50

410 Y (whereCE≤0.39)

All Preheat not required

Bars not complyingwith AS 1302 orwhere CE>0.39

All Welding not permit ted

NOTES:1. N/R indicates preheat not required.2. CE indicates carbon equivalent of elements:

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AS 1554, Part 3—1983 18

SECTION 5. FLASH BUTT WELDING

5.1 GENERAL. The flash butt welding ofreinforcement shall comply with the relevantrequirements of other Sections of this standard andthe specific requirements of this Section.

5.2 SIZES.The size of the bar to be welded shall bewithin the machine capacity as specified by themachine manufacturer and shall be confirmed in theprocedure qualification test (see Clause 5.8).

5.3 BAR PREPARATION. The ends of bars to bewelded shall be prepared in a way that will facilitatethe starting of flashing (see Note). The face areas incontact during welding shall be approximately equaland the difference in size of the contact faces shallnot exceed 15 percent of the smaller face.

NOTE: Shearing, cropping, flame cutting and saw cutt ing areacceptable methods. A smooth machined face, normal to the axisof the bar, is not recommended.

5.4 ALIGNMENT. The bars to be welded shall beset in the machine so that the axes are coincident.The axes of the bars at the weld shall be in linewithin 10 percent of the size or 3 mm, whichever isthe lesser.

5.5 CLEANLINESS. The bar ends and adjacentmaterial, and parts of the bar in the region of theclamping dies shall be free from insulating material,rust, paint, grease or other foreign matter,immediately prior to welding. The dies shall be keptclean and any adhering spatter shall be removedbefore each weld.

5.6 WORKMANSHIP.

5.6.1 Overhang or Projection from the Dies.Thetwo bars to be welded shall be clamped so that theoverhang of each is equal. The overhang shall notexceed twice the size of the bar.

5.6.2 Clamping Force.The clamping force exertedby the clamping dies on the bars being welded shallbe sufficient to prevent movement of the bars inrelation to the clamps during the upsetting operationbut not enough to deform the bars.

5.6.3 Preheating.Preheating shall be as follows:

(a) Hot-rolled bars. For hot-rolled bars it shall bepermissible to shorten the flashing cycle bypreheating.

(b) Cold-worked bars.Cold-worked bars shall bewelded without preheating. Once the flashingaction has been initiated, it should be maintainedby matching the feed rate with the rate ofburnoff.

5.6.4 Flashing.The speed of advance of the movingplaten and the value of the welding current shall beregulated to ensure that the flashing is continuousthroughout the cycle, and that the welding operationdoes not freeze up or the platen stops moving.

The flashing shall be smooth, continuous, and bemaintained until upset takes place. The current shallbe maintained at least until upset has started.

5.6.5 Upsetting.The value of the upset force requiredto weld steel bars of different quality depends upon

the temperature gradient in the plastic zone and thecompressive strength of the steel at high temperature.The length of upset shall be sufficient to ensure theclosing of all voids and the expulsion of oxide andmolten metal from the weld. It shall not be enough tocause distortion of the weld or excessive expulsion ofplastic metal.

5.7 EQUIPMENT.

5.7.1 General.An automatic or semi-automatic flashbutt welding machine shall be used for all welding,except that a manual machine may be used where itcan be established that the welding complies with therequirements of this standard.

5.7.2 Machine Controls. The machine shall beequipped with control gear which, after the bars havebeen clamped in the dies, performs at least thefollowing cycle of operations in the sequence given:

(a) Maintains the flashing cycle for the desiredperiod of time and length of stroke.

(b) Upsets the bars to complete the weld.

(c) Cuts off the current to the bars after thecommencement of upsetting.

NOTE: The following cycling operations are normally under thecontrol of the operator:(i ) Closing the electrical circuit and bringing the bars into

init ial contact.(i i) Establishing the preheating cycle (where applicable).(i ii ) Init iating flashing.

5.7.3 Flash Guards.Flash guards shall be placed atsuch a distance from the clamped bars as willminimize the possibility of particles thrown offduring the flashing period rebounding into the weld.

5.7.4 Cleanliness of Machine.The welding machineand particularly the die faces shall be kept free fromspatter, and the contact faces shall be cleaned of oil,grease, oxide or metallic dust and globules after everyweld.

5.8 QU AL I F IC A T ION OF W E LD I N GPROCEDURE.

5.8.1 General. The welding procedure shall bequalified before production welding of thereinforcement commences.

The Contractor shall establish a welding procedureand shall list the applicable machine settings for eachtype, grade and size of reinforcement in a documentknown as a ‘welding procedure sheet’.

5.8.2 Method of Qualification of WeldingProcedure. When acceptable machine settings havebeen obtained, a welding procedure shall be qualifiedby producing a set of test splices of reinforcement inaccordance with the material specification to be usedin production and subjecting these splices to the testsspecified in Section 7.

5.8.3 Requalification of Flash Butt WeldingProcedure. Requalification of the flash butt weldingprocedure by testing in accordance with Section 7shall be required where—

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19 AS 1554, Part 3—1983

(a) there is a change in—

(i) material specification, grade or type;

(ii) bar size;

(iii) joint preparation; or

(iv) significant machine component; or

(b) there are consistent failures in production controltests.

5.9 PRODUCTION CONTROL TESTS.

5.9.1 General Production Control Tests.Duringproduction, in order to ensure that the splicescontinue to comply with the quality requirements ofSection 8, bend tests and tensile tests shall be carriedout in accordance with the frequency requirements ofClause 5.9.2.

5.9.2 Frequency of Tests.Test joints shall be madeat the following times:

(a) Commencement of production run.Two testjoints shall be made at the commencement of

each production run of each welding procedure:one to be subjected to the bend test and one tobe subjected to the tensile test.

(b) During production run.Test joints shall be madein accordance with one of the followingprocedures:(i) Where more than 100 joints are made in a

production run, for each 100 joints or partthereof after the first 100 joints anadditional test joint shall be made andbend-tested in accordance with Clause 7.3.3and an additional test joint shall be madeand tensile-tested in accordance withClause 7.3.2.

(ii) Where 100 joints or less are made in aproduction run, at least one additional testjoint shall be made and bend-tested inaccordance with Clause 7.3.3.

5.10 DEFECTIVE WELDS. Production welds thatfail to comply with the requirements of Clause 9.5shall be removed and a new weld made.

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AS 1554, Part 3—1983 20

SECTION 6. FLAME PRESSURE WELDING

6.1 GENERAL. Flame pressure welding ofreinforcement shall comply with the relevantrequirements of other Sections of this standard andthe specific requirements of this Section.

6.2 SIZES.The size of the bar to be welded shall bewithin the equipment capacity as specified by theequipment manufacturer and shall be confirmed in theprocedure qualification test (see Clause 6.7).

6.3 BAR PREPARATION. The ends of bars to bewelded shall be prepared by either sawing or shearingapproximately normal to the axis of the bar so as tofacilitate welding.

6.4 ALIGNMENT. The bars to be welded shall beset in the equipment so that the axes are coincident.The axes of the portions of the welded bar shall be inline within 10 percent of the size or 3 mm, whicheveris the lesser.

6.5 CLEANLINESS. The bar ends and adjacentmaterial shall be free from rust, paint, grease, orother foreign matter, immediately prior to welding.

6.6 WORKMANSHIP.

6.6.1 Positioning.The two bars to be welded shall beclamped so that the overhang of each is equal and theweld interface is centrally located in the flame. Thegap between bars before welding shall not exceed3 mm.

6.6.2 Clamping Force.The clamping force exertedby the clamping dies on the bars being welded shallbe sufficient to prevent movement of the bars inrelation to the clamps during the upsetting operation,but not enough to deform the bars.

6.6.3 Upset.The diameter of the upset after weldingshall be not less than 1.3 times the size of the smallerbar, and shall be uniformly distributed around thecircumference of the bar.

6.7 QUA L I FI C A TI ON OF W E L DI N GPROCEDURE.

6.7.1 General. The welding procedure shall bequalified before production welding of the reinforcingbars commences.

The Contractor shall establish a welding procedureand shall list the applicable machine settings for each

type, grade and size of reinforcing bar in a documentknown as a ‘welding procedure sheet’.

This procedure shall include the following:

(a) Heating tip type.

(b) Gas pressures and preferably flows.

(c) Heating time.

(d) Upset pressure.

6.7.2 Method of Qualification of WeldingProcedure. When acceptable machine settings havebeen obtained, a welding procedure shall be qualifiedby producing a set of test splices of reinforcing barsin accordance with the material specification to beused in production and subjecting these splices to thetests specified in Section 7.

6.7.3 Requalification of Gas Pressure WeldingProcedures. Requalification of the flame pressurewelding procedure by testing in accordance withSection 7 shall be required where—

(a) there is a change in—

(i) material specification, grade or type;

(ii) bar size;

(iii) joint preparation; or

(iv) significant machine component; or

(b) there are consistent failures in productioncontrol tests.

6.8 PRODUCTION CONTROL TESTS. Duringproduction, in order to ensure that the splicescontinue to comply with the quality requirements ofSection 8, bend tests and tensile tests shall be carriedout in accordance with the following requirements:

(a) At the commencement of each production shifttwo welds shall be made by each welder: one tobe subject to a bend test (see Clause 7.3.3) andone to be subject to a tensile test (seeClause 7.3.2).

(b) During the shift, at least one further weld shallbe made by each welder and shall be subject toa tensile test.

6.9 DEFECTIVE WELDS. Production welds thatfail to comply with the requirements of Clause 9.5shall be removed and a new weld made.

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21 AS 1554, Part 3—1983

SECTION 7. QUALIFICATION OF WELDING PROCEDUREBY TESTING

7.1 GENERAL. This Section applies where thequalification of welding procedures by the testing ofa sample of spliced reinforcing steel is permitted byClause 4.2(c).

7.2 METHOD OF QUALIFICATION. The weldingprocedure shall be qualified by producing a set of testsplices by the applicable procedure and subjectingthese splices to the tests specified in Table 7.1.

Provided that the splice complies with the relevanttest requirements of Section 8, the welding procedureshall be accepted as qualified.

7.3 TESTS.

7.3.1 Macro Test.The macro test shall be carried outin accordance with AS 2205.5.1.

7.3.2 Tensile Test.The tensile test shall be carriedout in accordance with AS 2205.2.1.

7.3.3 Bend Test.The bend test shall be carried out inaccordance with AS 2205.3.1, using a former havinga diameter as specified in AS 1302, appropriate to thesize and grade of bar. The exposed section of the barshall be ground or machined smooth to the diameterof the bar, i.e. overall diameter includingdeformation.

NOTE: The bend test may be performed on a commercial barbending machine in the same way that normal bends are made.

7.4 RETESTS.Where any one specimen of all thosetested during a procedure qualification test fails tocomply with the test requirements, retests for thatparticular type of test specimen may be performedwith two specimens of the same type ofprocedure-qualification test piece. Both retests shallcomply with the test requirements. However, if anyfailure is due to cracking in the heat-affected zone orin the weld, the procedure shall be modified and anew procedure test splice shall be prepared andtested.

TABLE 7.1

TESTS REQUIRED FOR WELD PROCEDURE QUALIFICATION

Weldingprocess

Consumables Preparation

Tests requiredDirect butt splices Lap splices

and indirectbutt splices

Macro Tensile Bend MacroFusion Prequali fied in

accordance withTable 4.4

Prequali fied inaccordance withTables 4.1, 4.2 and 4.3

1 Nil Nil 1

Other preparations 1 1 1 1

Not pre-qualif ied

Prequali fied inaccordance withTables 4.1, 4.2 and 4.3

1 1 1 1

Other preparations 1 1 1 2Flash butt Not applicable All Nil 2 2 Not applicableFlame pressure Not applicable All Nil 2 2 Not applicable

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AS 1554, Part 3—1983 22

SECTION 8. TEST REQUIREMENTS

8.1 P R OD U C T I ON C O N T R O L T E S TREQUIREMENTS. Test splices shall comply withthe following requirements:

(a) Welds shall be sound and of full size throughoutexcept that imperfections such as undersizewelds, porosity, piping, undercut, slag inclusions,incomplete penetration, incomplete fusion andsimilar generally elongated imperfections may bedisregarded where they result in less than5 percent loss of effective cross-sectional area.

(b) Weld metal and adjacent parent metal shallcontain no cracks.

(c) Weld reinforcement shall not exceed 3 mm inheight, except for flame pressure welding.

8.2 MACRO TEST REQUIREMENTS. The testspecimen shall comply with the requirements ofClause 8.1(a).

8.3 TENSILE TEST REQUIREMENTS. The tensilestrength of a butt splice shall be not less than1.15 times (for 230 grade) and 1.05 times (for410 grade) the minimum specified yield strength ofthe reinforcing steel used in the splice.

8.4 BEND TEST REQUIREMENTS.On completionof the test, no crack or other imperfection in the weldor the heat-affected zone shall have a dimensiongreater than 3 mm measured in any direction at theouter surface of the test specimen.

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23 AS 1554, Part 3—1983

SECTION 9. INSPECTION

9.1 EXAMINATION OF WELDING. All weldingshall be subject to the examination of an Inspectorappointed by the Principal.

9.2 QUALIFICATIONS OF INSPECTORS. TheInspector shall have had suitable training andexperience in the fabrication and inspection of weldedstructures. He should have at least the qualificationsrequired for a welding supervisor. The holding of anAustralian Welding Institute Certificate either as aWelding Inspector or as a Structural WeldingSupervisor shall be accepted as evidence of thesequalifications.

9.3 PRIVILEGES OF INSPECTORS.An Inspectorshall have access at all reasonable times to the workand shall be provided with facilities for the inspectionthereof. He shall be notified in advance of anywelding operations.

He shall have access to a complete set of relevantdrawings showing size, length, type and dispositionof welds and any weld procedures which are to beused for the work.

9.4 INSPECTION OF WELDERS. Where thequality of the work of a particular welder does not inthe opinion of the Inspector, comply with therequirements of this standard, the Inspector mayrequest that welder to undergo test(s) to show that heis capable of welding satisfactorily.

9.5 INSPECTION OF WORK.

9.5.1 Inspection Prior To and During Welding.TheInspector shall inspect the set-up of the work andsatisfy himself that—

(a) the shape and the size of joints are in accordancewith the approved design;

(b) the welding is being carried out with thespecified materials and suitable equipment;

(c) correct welding conditions at the work are beingmaintained; and

(d) the work is being done in accordance with therequirements of this standard.

He shall particularly check that thorough fusion ofthe weld, proper penetration and clean weld metal arebeing obtained.

NOTE: It is recommended that if the type and nature of a defectconsistently appears in the welds performed by any part icularwelder, further welding be discontinued unti l additional tests arecarr ied out by the welder and the welds so produced areconsidered satisfactory.

9.6 INSPECTION AFTER WELDING. TheInspector shall ascertain that the size, length andlocation of all welds comply with the plans andspecifications. A careful systematic check shall bemade to ensure that no weld called for on thedrawings is omitted. The Contractor shall have thesurface of the weld cleaned to the satisfaction of theInspector. Welds shall be examined carefully forcontour, dimensions, surface defects, significantundercutting and cracks in the weld or parent metal.Contour and dimensions shall be checked with agauge where practicable. The Inspector should keepa complete record of the position of all correctionsmade and the procedure that was used.

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AS 1554, Part 3—1983 24

APPENDIX A

CHECK LIST OF MATTERS FOR DISCUSSION

Some matters of a contractual nature which may need discussion are listed below forreference and it is recommended that the Principal resolve these with the Contractorwhere practicable, before work is commenced:

(a) Approval for welding to proceed (Clause 1.6).

(b) Joining reinforcing steel (Clause 1.7).

(c) Limitation on welding processes (Clause 1.8).

(d) Approval of parent material (Clause 2.1).

(e) Qualification of welding procedure (Clauses 4.1, 4.2, 5.8, 6.7 and 7.2).

(f) Qualification of welding personnel (Clause 4.7).

(g) Cutting fusion face (Clause 4.8.1).

(h) Correction of defective welds (Clause 4.8.7).

(j) Manual flash butt welding (Clause 5.7.1).

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

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

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25 AS 1554, Part 3—1983

APPENDIX B

RECOMMENDED METHOD FOR JOINT AND PROCESSIDENTIFICATION

B1 PREQUALIFIED JOINT IDENTIFICATION. Weld preparations in Tables 4.1to 4.3 are identified by the following letters and numbers:

(a) Joint type identification.

B—butt spliceL—lap splice

(b) Penetration identification.

D—direct penetrationI—indirect penetration

(c) Preparation identification (butt splices).

1—square2—single-V3—double-V4—single-bevel5—double-bevel

The lower-case letters a, b, and c are used as suffixes to the numbers in (c) above, todistinguish between diagrams showing variations of the same prequalified joint.

B2 PROCESS IDENTIFICATION. Welding processes are identified as follows:

FCAW(N)* —flux-cored arc welding without gas shieldingFCAW(C or M)* —flux-cored arc welding with gas shieldingGMAW —gas-shielded metal-arc welding—spray and dip transferMMAW —manual metal-arc welding

B3 EXAMPLE.

‘BD-2 MMAW’ is a single-V direct penetration butt splice welded by manualmetal-arc welding which can be made either without a backing bar(BD-2a MMAW) or with backing bars (BD-2b MMAW).

*N refers to no gas shielding.C refers to shielding with carbon dioxide.M refers to shielding with mixed gases.

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AS 1554, Part 3—1983 26

APPENDIX C

A SUITABLE FORM OF WELDING PROCEDURE SHEET(For use in detailing prequalified welding procedures and for recording qualified welding procedures)

Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding Procedure No* . . . . . . . . . . . . .

1. Welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(or combination, if used)

2. Material standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Bar size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Joint design (use sketch if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Filler metalStandard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Shielding gasComposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Shielding flux (type and size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Power source characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(a.c. or d.c. and polarity)

9. Position of welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(include direction of vertical welding)

10. Number of runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Maximum time lapse between runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(if crit ical for preheat)

12. Back gouging method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. Preheating and interrun temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. Postweld heat treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(method, temperature, temperature control methods, time at temperature, heating and coolingrate)

15. Run details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RunNo

Electrodesize

Weldingcurrent

Weldingvoltage

Travelspeed

Electricalstick-out

Joint detail (include run sequencewhere necessary)

Welder’s name . . . . . . . . . . . . . . . . . . . . . . . . . Approved by . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . .

* This procedure may vary owing to fabrication sequence, fit -up, material thickness, number of runs, etc within the essentialvariables (see Clause 4.6).

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27 AS 1554, Part 3—1983

ANNEX

LIST OF REFERENCED DOCUMENTS

(a) Materials.

AS 1163 Structural Steel Hollow SectionsAS 1204 Structural Steels—Ordinary Weldable GradesAS 1205 Structural Steels—Weather-resistant Weldable GradesAS 1302 Steel Reinforcing Bars for ConcreteAS 1303 Hard-drawn Steel Reinforcing Wire for ConcreteAS 1304 Hard-drawn Steel Wire Reinforcing Fabric for Concrete

(b) Safety.

AS 1336 Recommended Practices for Eye Protection in the IndustrialEnvironment

AS 1337 Eye Protectors for Industrial ApplicationsAS 1338 Filters for Eye ProtectorsAS 1470 Code of General Principles for Safe Working in IndustryAS 1674 Fire Precautions in Cutting, Heating and Welding OperationsAS CC5 Rules for the Prevention of Electric Shock to Arc WeldersAWRA Technical Note 7—Health and Safety in Welding

(c) Electrodes.

AS 1553 Covered Electrodes for Arc WeldingPart 1—Low Carbon Steel Electrodes for Manual Metal-arc Welding of

Carbon and Carbon-manganese SteelsAS 1588 Filler Rods for WeldingAS 2203 Carbon Steel Electrodes, Cored (for Arc Welding)AWRA Technical Note 3—Care of Manual Arc-welding Steel Electrodes

(d) Other.

AS 1101 Graphical Symbols for General EngineeringPart 3—Symbols for Welding

AS 1480 SAA Concrete Structures CodeAS 1481 SAA Prestressed Concrete CodeAS 1554 SAA Structural Steel Welding Code

Part 1—Welding of Steel StructuresAS 1966 Electric Arc Welding MachinesAS 1995 Welding CablesAS 2205 Methods of Destructive Testing of Welds in Metal

2205.2.1 Part 2—Tensile Tests—Transverse Butt Tensile Test2205.3.1 Part 3—Bend Tests—Transverse Guided Bend Test2205.5.1 Part 5—Metallographic Tests—Macro Test—Cross-sectionExamination

AS 2214 SAA Structural Steel Welding Supervisors Certification CodeAS 3000 SAA Wiring RulesAS C301 Manual Arc-welding Electrode HoldersAS Z5 Glossary of Metal Welding Terms and Definitions

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