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TII 16.09
9 Welding, steel struc
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ction

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Table of
o conten
nts
1

General ................................ ................................................ .................................... 4

1.1
1.2
1.3
1.4

Purpose ................................ ................................................ .................................... 4

Scope .................................... ................................................ .................................... 4
Definition
ns and abb
breviations ................................................ .................................... 4
Applicablle documents ........... ................................................ .................................... 4

1.4.1

Ordinan
nces, standards and direcctives ................................................. ............................................ 4

Basic ma
aterial req
quirements
s .............................................. .................................... 5

2.1
2.2
2.3
2.4
2.5

General ................................. ................................................ .................................... 5

Terms of delivery .................. ................................................ .................................... 5
Material test
t
certific
cates ........ ................................................ .................................... 5
Material marking
m
................... ................................................ .................................... 5
Additiona
al testing on the basicc material................................. .................................... 5

Manufac
cturing req
quirementts.............................................. .................................... 6

3.1
3.2
3.3
3.4

General ................................. ................................................ .................................... 6

Execution
n class ..................... ................................................ .................................... 6
Degree of
o preparatiion ........... ................................................ .................................... 6
Tolerance
e classes ................. ................................................ .................................... 6

Supplierr requirem
ments ........ ................................................ .................................... 7

4.1
4.2

Welding requiremen
r
nts ........... ................................................ .................................... 7
Welding personnel
p
................ ................................................ .................................... 7

4.2.1
4.2.2
4.2.3
4.2.4
4.2.5

Welding
g supervisor (WS) ...................................................................... ............................................ 7
Welderss ................................................................................................. ............................................ 7
Operato
ors for fully mechanised
m
o
or automated
d processes .................... ............................................ 7
Welding
g instructions
s (WPS) .................................................................. ............................................ 7
Operatin
ng equipmen
nt ............................................................................ ............................................ 7

Welding work....................... ................................................ .................................... 9

5.1
5.2
5.3
5.4

Design ................................... ................................................ .................................... 9

Welding seam
s
prep
paration .... ................................................ .................................... 9
Pre-heatiing ........................... ................................................ .................................... 9
Welding ................................. ................................................ .................................... 9

5.4.1
5.4.2
5.4.3
5.4.4

Welding
g processes ................................................................................ ............................................ 9
Welding
g additives .................................................................................. .......................................... 10
........................................................... .......................................... 10
Hot-dip galvanised components.
c
er protection ................................................................................ .......................................... 10
Weathe

5.5

Adjustme
ent work ................... ................................................ .................................. 10

Welding seam testing ......... ................................................ .................................. 11

6.1.1
6.1.2
6.1.3
6.1.4

General ................................................................................................. .......................................... 11

Visual in
nspection of welding sea
ams ..................................................... .......................................... 11
Non-desstructive testting (NDT) .............................................................. .......................................... 11
Non-desstructive testting of highlyy stressed we
elding seams
s .................. .......................................... 11

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TII 16.09
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Optiona
al joints in ste
eel structurall engineering
g ...................................... .......................................... 11
Correctiing of defective weld join
nts ....................................................... .......................................... 11

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Genera
al

1.1

Purpose

TII 16.09
9 Welding, steel struc
cture, meta l
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ction

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In the pla
anning, ma
anufacture and installlation of stteel and m
metal consttructions, th
hese
Technical Implementtation Instru
uctions (TII)) are design
ned to guarrantee a co
onsistent qu
uality
of the weld
ding work.

1.2

Scope
This TII iss binding forr all Sub-su
uppliers of Hitachi
H
Zose
en Inova AG
G and the Sub-contrac
S
ctors
for their sccope of delivery and se
ervices.

1.3

Definitions and abbrevia

ations
Table 1: Definitions
D
an
nd abbreviatiions
Abbrevia
ation

De
efinition

HZI

Hiitachi Zosen Inova AG

Supplier

Su
ub-contracto
or of HZI

Sub-conttractor

Su
uppliers of ap
pparatus and plant comp
ponents whoo are not sup
ppliers to HZI

TII

HZ
ZI Technical Implementa
ation Instruction

EN

Eu
uropean stan
ndard

DIN

Ge
erman Institu
ute for Stand
dards

1.4

Applica
able docu
uments

1.4.1

Ordinanc
ces, stand
dards and directives
s
Generally, TII 16.02 "Regulation
"
ns and Stan
ndards" applies with itss references
s to the rele
evant
regulations (laws, ord
dinances, ttrade assoc
ciation regulations, reccommendations, directives,
standardss etc.).
For this TII,
T the EN 1090-1, -2
2 standard and all sta
andards meentioned therein regarrding
welding arre to be follo
owed.

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Basic materia
al requirrements
s

2.1

General

Hitachi Zosen
Z
Inova AG

The mate
erial qualitie
es named i n the appro
oved works
shop drawinngs and material
m
listss are
binding for the Supplier.

2.2

Terms of
o delive
ery
EN 10025 applies for the d
delivery of constructional steel.. For hot--dip galvan
nised
componen
nts the apprropriate matterial quality
y must be used.
u

2.3

Materia
al test certificates
s

2.4

Materia
al marking

2.5

Th
he materials
s used musst be verified
d with certifficates in acccordance with
w EN 102
204.
Fo
or constructtional steelss with a yie
eld point up to fy = 2355 N/mm2, the certificate of
co
ompliance with
w the orde
er 2.2 is req
quired.
Fo
or constructtional steelss with a yie
eld point of fy
f > 235 N//mm2, test certificate
c
3 is
3.1
re
equired.

Alll steel ele

ements with
h a yield point fy > 235 N/mm
m2, must be clearly and
pe
ermanently marked (e. g. with punched numbers).
Ap
ppropriate measures
m
m
must be tak
ken to ensu
ure that it iss possible to
t allocate steel
s
co
omponents clearly to th
he relevant test certifica
ates.

Additional testing on th
he basic material
m
Sheet me
etal of exec
cution classs according
g EN 1090
0-2, EXC3, which is stressed
s
in
n the
direction of
o the shee
et thicknesss (e.g. cros
ss and T-jo
oints) must meet qualiity class S1
1 for
internal inhomogeneiity accordin
ng EN 1016
60. The test must be doone by qua
alified perso
onnel
under the responsibility of a certtified stage--3 expert ac
ccording EN
N ISO 9712.

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Manufa
acturing
g requirrements
s

3.1

General

Hitachi Zosen
Z
Inova AG

Manufactu
uring must be
b done acccording EN 1090-2.

3.2

Executiion class
s

3.3

Degree of prepa
aration

3.4

Exxecution cla
ass 2 (EXC
C2) shall be used for general steeel and meta
al constructiions,
ass well as forr crane systtems of clas
ss S0.
Exxecution cla
ass EXC3 iss applicable
e to crane sy
ystems of cclass S1 to S9.
S
Co
omponents of executio
on class EX
XC3 are defined in the w
workshop drawings.
d

Fo
or corrosivitty categorie
es C2, C3 and
a C4, the degree of ppreparation
n P2 is requ
uired,
an
nd for corrosivity categ
gory C5, the
e degree of preparationn P3 is required in acc. with
standard EN ISO 8501-3
3.
Att least the corrosivity class of th
he compon
nents must be clearly defined in
n the
wo
orkshop dra
awings.

Toleran
nce class
ses

In general, th
he supplem
mental class 2 manufac
cturing tolerrances apply according
g EN
10
090-2. Anne
ex D2.
Sttricter manufacturing tolerance requiremen
nts must bbe clearly defined
d
on the
wo
orkshop dra
awings (e.g . boiler bea
aring or supp
port).

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Supplier requ
uirements
Welding work
w
may only be subccontracted with
w the wriitten permisssion of HZ
ZI. Howeverr, the
supplier iss always he
eld respons ible for com
mplying with the internaational stand
dards.

4.1

Welding
g require
ements
The Supp
plier must meet the welding re
equirements
s in accord
rding EN IS
SO 3834-3
3 for
execution class EXC2
2 or EN ISO
O 3834-2 fo
or execution class EXC
C3.

4.2

Welding
g person
nnel

4.2.1

Welding superviso
or (WS)

4.2.2

Welders

4.2.3

Th
he supplier has the solle responsib
bility regard
ding weldingg supervisio
on. The sup
pplier
must name at
a least one responsible
e welding supervisor w
who must be
e a professiional
we
elder traine
ed in accord
dance to DV
VS-IIW / EW
WF 1173 annd with exp
perience in steel
s
co
onstruction.
W
Welding
sup
pervision m
may be su
ub-contracte
ed. Howevver, compliiance with the
international standards sstill remains
s the respon
nsibility of thhe supplier..
Th
he welding supervisor ttasks are defined in EN
N ISO 147331.

Th
he plant must
m
have a sufficien
nt number of welderss with valid welding test
ce
ertificates according
a
to
o EN 287-1// ISO 9606-1.
Fo
or fillet weld
ds, welders must also have
h
a fillet welding tesst certificate
e.
W
Welders
who
o carry out i nstallation welding
w
must have a m
manual skills
s test certifiicate.

Operatorrs for fully

y mechaniised or au
utomated processes
p
s
For fully mechanised
d or autom
mated welding processes (e.g. ffully mech. MAG weld
ding,
submerge
ed arc welding, stud we
elding accorrding to EN
N ISO 145555), the operrating perso
onnel
must be trained on the used welding machine
m
an
nd have a valid operator certifiicate
according to EN 1418
8/ EN ISO 1
14732.

4.2.4

Welding instructio
ons (WPS))

4.2.5

Ve
erified welding instructtions are req
quired from
m the Supplieer for the manufacturin
m
ng of
structural steelwork.
Th
he general rules for requiremen
nts and qu
ualificationss of weldin
ng methodss for
metalic mate
erials are re
egulated in
n EN ISO 15607. Thee technical content off the
we
elding instru
uctions is sp
pecified in EN
E ISO 156
609 and EN
N ISO 14555
5.
Fo
or materials
s S235, S27
75 and S35
55 according to EN 100025, which
h are processsed
wiith manual or
o partially mechanicall welding methods, thee WPS is ve
erified accorrding
to
o EN ISO 15
5610, 15611
1, 15612 an
nd 15613 an
nd 15614-1..
Fo
or fully mec
chanical an
nd automatted welding methods, the WPS is verified by a
re
ecognised body accord ing to EN IS
SO 15613.
Th
he WPS for
f
stud w elding is verified
v
via
a a weldinng procedure qualifica
ation
acccording to EN ISO 145
555.

Operatin
ng equipm
ment
The weld
ding workshop for th
he manufa
acturing mu
ust have tthe equipm
ment for seam
s
preparatio
on, welding, testing and
d transport. This equipment must be suitable for meeting
g the
welding re
equirements
s for the diffferent welding tasks.

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The main equipment is describe

ed in EN ISO
O 3834-2 an
nd -3.

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Weldin
ng work
k

5.1

Design

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Design an
nd dimensio
oning of the welding seams accord
ding to EN 11993.
Welding seam
s
symbo
ols accordin
ng to EN 22
2553.
For fillet welds
w
the fo
ollowing app
plies:

Th
he tracing dimension
d
''a' should not
n exceed 0.7 of the tthickness of
o the thinne
er of
the parts bein
ng joined.
To
o avoid inc
complete fu sion and cracks,
c
the following vvalues are required
r
ass the
minimum thic
ckness of ssingle-layer welded fillet welds ass a function
n of the gre
eater
we
elded material thicknesss tmax:
amin = 4 mm

for tmax = 13 to 17 mm

amin = 5 mm

for tmax = 18 to 25 mm

amin = 6 mm

for tmax 26 mm

orkpiece mu
ust be pre-hheated.
If these values cannot be met, the wo
p
to co
orrosion, we
elding seam
ms must be
e executed without intterruption or
o a
In areas prone
cutout weld shall be used.
u
Interrrupted fillet welds may only be exeecuted with
h the agreem
ment
of HZI.
s
of qu
uality class B accordin
ng to EN IS
SO 5817 shhall be clearrly labelled with
Welding seams
the weldin
ng seam sy
ymbol and the additio
onal letter "B"
" on the workshop and installa
ation
drawings. For all othe
er welding sseams, quality class C
C applies.

5.2

Welding
g seam preparati
p
ion
Welding seam
s
preparration accorrding to EN ISO 9692.

5.3

Pre-hea
ating
Pre-heatin
ng must be carried out according to
t EN ISO 13916
1
and E
EN 1011-2.

5.4

Welding
g

5.4.1

Welding processe
es
This TII in
ncludes we
elds which are executted by one
e of the fol lowing welding processes
according to EN ISO 4063.
Table 2: Welding
W
proc
cesses
Item

Weldin
ng process

141

Tungte
en inert gas

111

Manua
al arc welding
g

114

Arc we
elding with flu
ux-cored elec
ctrode, witho
out inert gas

12

Subme
erged arc we
elding

131

Metal inert gas wel ding (MIG)

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Table 2: Welding
W
proc
cesses
Item

Weldin
ng process

135

Metal active
a
gas we
elding (MAG
G)

136

Metal active
a
gas we
elding with flux-cored wirre

137

Metal inert gas wel ding with flux

x-cored wire

78

Stud welding
w

Other weld
ding methods than tho
ose stated above
a
must be approveed by HZI.

5.4.2

Welding additives
Welding additives
a
mu
ust be name
ed according to the corrrespondingg European standard.
All weldin
ng additives
s must be stored and
d handled carefully annd in agree
ement with
h the
correspon
nding stand
dards and the manuffacturers re
ecommendaations. Dam
maged wellding
additives must
m
not be
e used anym
more.

5.4.3

Hot-dip galvanised
g
d compon
nents
If components are ho
ot-dip galvan
nised, the fo
ollowing items must bee observed:

5.4.4

Interrupted fillet welds a re not allow

wed.
Th
he welding seams mu
ust be clea
anly execute
ed and muust not have
e any pore
es or
un
ndercuts. For example
e, it must be
e made surre that no w
welding cinders are lefft on
the welding seam.
s
Se
eparating agent sprayss may not be
b used.
Th
he chemica
al composiition of the
e chosen welding addditives mu
ust be cho
osen
acccording to the compo
osition of the
e used bas
sic material.. Critical Si contents in
n the
we
elding addittives will ha
ave a negattive influenc
ce on the re
result of hott-dip galvan
nised
su
urfaces.
Byy using a welding
w
seq uence plan
n, the internal welding stresses sh
hould be evvenly
distributed over
o
the ccross secttion, thus avoiding distortion during ho
ot-dip
ga
alvanising, or at leastt limiting this to an ac
cceptable m
minimum. The toleran
nces
sp
pecified und
der section 3
3.4 apply.

Weather protection
The areass to be weld
ded are to b
be protected
d from adve
erse effectss of weatherr, such as wind,
w
moisture and
a cold. Appropriate
A
e measures are to be taken, andd if necessa
ary, the wellding
parts are to
t be pre-he
eated.

5.5

Adjustm
ment worrk
By taking
g appropria
ate measurres, e.g. pre-bending
p
, defined welding se
equences, etc.,
adjustmen
nt work can be reduced
d to a minim
mum.

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Weldin
ng seam
m testing
g

6.1.1

General

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The testin
ng must be carried out by qualified
d personnel under the responsibillity of a certtified
stage-3 exxpert accord
ding to EN ISO 9712.

6.1.2

Visual in
nspection of welding
g seams
All welding
g seams mu
ust undergo
o a visual in
nspection along their enntire length.
Welding seams
s
are visually
v
insp
pected acco
ording to EN
N ISO 176377.

6.1.3

Non-destructive te
esting (ND
DT)
To guaran
ntee the qua
ality of runn
ning produc
ction, the ch
heck must bbe carried out
o accordin
ng to
EN 1090, Table 24.
wing NDT methods
m
mu
ust be carriied out in agreement
a
w
with the ge
eneral principles
The follow
given in EN
E ISO 17635 and w
with the requirements of
o the stanndard which
h applies to
o the
respective
e method:

6.1.4

Pe
enetration test (PT) acccording to EN
E ISO 345
52 and EN 5571-1
Magnetic parrticle testing
g (MT) acco
ording to EN
N ISO 176388 and EN IS
SO 9934
Ulltrasound te
esting (UT) according to
t EN ISO 23279,
2
EN I SO 17640 and EN 583
3
Ra
adiographic
c testing (RT
T) according to EN444
4 and EN 14435
on of the NDT meth
Th
he fields of
o applicatio
hods are ddefined in the appliccable
standards.

Non-destructive te
esting of h
highly stre
essed welding seam
ms
All highly stressed welding
w
sea
ams of qua
ality class B must be ultrasonic or radiogra
aphic
tested with
hout excepttion.
Since fillett welds of quality
q
classs B cannot be tested with
w RT/UT, they may only
o
be mad
de in
agreemen
nt with HZI.

6.1.5

Optionall joints in steel struc

ctural eng
gineering
Unplanned
d optional joints on sh
heet metal and
a profiles require pri or approval by HZI. If they
RT, test cla
are approved, they must
m
underg
go a non-de
estructive te
est (UT or R
ass B accorrding
to EN ISO
O 17635), which must b
be documen
nted. The op
ptional jointts must be cleanly
c
polisshed
(seam pro
otrusions will not be acccepted).

6.1.6

Correctin
ng of defe
ective weld
d joints

If welding seams do nott meet the assessmen

nt criteria, thhey must be
e professionally
co
orrected and
d checked a
again

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