NZ Welding Standards, the latest update, &

seismic behaviour video

Principal Sponsor 13-15 November 2018Rotorua, NZ

seismic behaviour video

Dr Michail KarpenkoAlan McClintock

NZ Welding Centre, HERA

HERANZ Heavy Engineering Research Association

•Not-for-profit •Industry-owned•Member driven –with over 600

Principal Sponsor 13-15 November 2018Rotorua, NZ

with over 600 companies•Strong national and international links

HERA structure

HERA CEODr Troy Coyle

Industry DevelopmentSeeking new business opportunities for members

HERA Executive

Principal Sponsor 13-15 November 2018Rotorua, NZ

Secretariat

NZ Stainless Steel Development Association (NZSSDA)

members

NZ Welding CentreMaterial performance when weldedFatigue in welded structuresProductivity improvementAdvice and consultancyTraining – welding supervisor, inspectors

Structural SystemsExpertise in steel construction

Steel Construction NZ (SCNZ)

Metals New Zealand

HERAStandards development

Principal Sponsor 13-15 November 2018Rotorua, NZ

Standards development

NZWC: Standards development

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Who needs standards; can’t we just trust the welder?

Principal Sponsor 13-15 November 2018Rotorua, NZ

What can go wrong?

• Design

• Welder skill

• Welding procedure

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• Welding procedure

• Welding supervision

• Inspection

Poor design

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Wrong design and wrong procedure

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Example of early quality control for welding -“Welds shall be made in a workmanlike manner, free from gross defects…”

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Quality Management in Welding Fabrication - Basics

Welding is a special process as quality of welding cannot be fully verified by final

inspection.

The quality cannot be inspected into the

Principal Sponsor 13-15 November 2018Rotorua, NZ

The quality cannot be inspected into the product it has to be built into it.

It requires Control over all relevant inputs e.g. design, qualifications, welding

procedures as defined in AS/NZS ISO 3834

Principal Sponsor 13-15 November 2018Rotorua, NZ

Standards aim to produce welded steel structures which are economical to fabricate and are serviceable for the intended application

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Principles of welding standards

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How standards apply to structural steelwork for buildings

NZS 3404.1 Design Standard

Building Act - applies to new and existing buildings

AS/NZS 5131 Structural steelwork – Fabrication and erection

Principal Sponsor 13-15 November 2018Rotorua, NZ

AS/NZS 1554 Welding Standard

AS/NZS 2980 and AS/NZS ISO 9606.1Welder Qualification Standards

AS/NZS 5131 Structural steelwork – Fabrication and erection

AS/NZS 5131:2016

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Principal Sponsor 13-15 November 2018Rotorua, NZ

WELDLOK

Steel Fabricator Certification Framework

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NZWC: Standards development -

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NZWC: Standards development -Welder qualification standards

Examples of variations in welder skill

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…. same settings, same welding equipment, 3 different welders

Welder qualification(Welder performance qualification or “ticket”)

Assessment of a welder’s ability to:

• Manually manipulate the electrode/welding torch

• Follow a welding procedure

Principal Sponsor 13-15 November 2018Rotorua, NZ

While a welder qualification test:

• it is not intended to be a guide for welding during actual construction

• it cannot guarantee that an individual perform to the required standard on the job.

Ref: American Welding Society, AS/NZS 2980

Shop vs. site welding

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AS/NZS ISO 9606.1:2017ISO 9606-1:2012 IDT

AS/NZS 2980:2018

Changes to welder qualification standards

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AS/NZS ISO 9606.1:2017ISO 9606-1:2012 IDT

AS/NZS 2980:2018

Use this except for:

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except for:• Testing standards• Weld acceptance

levels• Stainless steel tube

Welder qualification to AS/NZS 2980:2018

For stainless steeltube

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AS/NZS ISO 9606.1 - The essential variables:

• welding process• plate or pipe• butt or fillet weld• filler material group• Weld metal thickness, pipe diameter• welding position (vertical separate)

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• welding position (vertical separate)• weld detail(s):• Backing

• single side welding• both side welding• single layer, multi-layer

Welder cert – new Revalidation (requalification) options – by the employer or examining body

1. Retest every 3 years.2. Every 2 years revalidation based on NDT test

results.

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results.

3. The welder qualification lasts indefinitely where the fabricator has a ISO 3834-2 or ISO 3834-3 quality programme e.g. SFC scheme

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Not everyone can be an examiner

Type of weld – range of qualification

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Range of qualification – butt welds and fillet weldsButt welds qualify fillet welds with supplementary fillet weld test piece.

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NZ Welding Centre: Seismic Research

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PACIFIC TOWER Building, Christchurch

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23 levels 86 metres Source: Prof. Charles Clifton

Active link fracture

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Wrong location of the stud

Low impact toughness of the material ~12J@0 C

Crack initiation site at the toe of the stud weld

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Credit: Milo V. Karl et al. 2013

L0 Steel used instead of S0 specified steel used

Moment Resisting Frame

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PlasticHinges

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Principal Sponsor 13-15 November 2018Rotorua, NZ 37

Principal Sponsor 13-15 November 2018Rotorua, NZ

Seismic research- full size beam-to-column test

Principal Sponsor 13-15 November 2018Rotorua, NZ

Principal Sponsor 13-15 November 2018Rotorua, NZ

Principal Sponsor 13-15 November 2018Rotorua, NZ

Summary

Standards• Structural steel ; Clients, designers and local authorities expect steel fabricators to do-it-right, and to be able to document that it has been done right.

Principal Sponsor 13-15 November 2018Rotorua, NZ

right.• Welder qualification; move to ISO standardsResearch into the performance of structural steel continues with the aim of cost effective, fit-for-purpose weld details.