Steel and aluminum structures have become more preferable today due to their high strength, lightness, flexibility, resistance of earthquake, high speed construction advantage and supporting of different designs and modern architectures.
The preference of steel and aluminum structures in many areas such as prefabricated buildings, bridges, footbridges, stadiums, hangars, skyscrapers, scaffolding and formwork systems create a need to develop inspection and control processes. We can see new regulations in many fields with the aim of minimizing the risks because of the importance of human life.
EN 1090 covers the construction and conformity assessment of steel and aluminum structures. The main purpose is to ensure that the durability and mechanical resistance of the buildings should be at a sufficient level and to provide that the structures can be used for a long time.
EN 1090 contents three parts as below;
EN 1090-1 : Requirements for conformity assessment of structural components
EN 1090-2 : Technical requirements for steel structures
EN 1090-3 : Techncial requirements for aluminium structures
One of the requirements of certification principles in EN 1090-1 is the requirement of CE marking for Welding Consumables.
Another requirement is the fulfillment of quality control and assurance requirements according to related execution class in EN 1090-2.
Execution classes of the building are determined according to structure type (static or dynamic), economic-social-environmental effects in case of damage and the quality of the used main material.
There are 4 different execution classes with increased requirements from 1 to 4 and each execution class forward the manufacturer to the relevant part of EN ISO 3834 for the necessary requirements.
At this point, the other important detail is that the requirement of WPS and WPQR depending on the execution class.
Manufacturers can start a suitable production for EN 1090 with an approved WPS which are prepared according to related execution class and quality conditions of EN 1090 and EN ISO 3834.
Welding Procedure Specification (WPS) and Welding Procedures Approval (WPQR) are required for the following execution classes.
EXC2 (EN ISO 3834-3)
EXC3 (EN ISO 3834-2)
EXC4 (EN ISO 3834-2)
Magmaweld has been created its own WPS packages for the manufacturers and had been presented with this package with some advantages like saving time, cost, quality and traceability. In addition, using Magmaweld MagNET system with adaptable Magmaweld WPS package can provide following all activities about the welding parameteres on-time.
Magmaweld WPS Packages
Destructive and non-destructive test methods are used to control the welded parts in manufacturing. Non-destructive testing methods can give us information about welding defects in the weld beads, but destructive testing methods must be applied to check the mechanical properties of the weld beads.
Destuctive tests are not possibble for each construction, part or equipment which are produced. Because of that, a test piece is prepared with the nearest details and design of the real production. Welding test is done and all details of the test connditionn and parameters are recorded. After all necessary tests are carried out on the test plate, this process is approved as the “welding procedure”. The main production can be started according to this approved welding procedure. This process is like a quality assurance for the productions.
The procedures are defined as WPS (Welding Procedure Specifications) and they are used to be sure that the welded productions fulfill all quality requirements according to the European or American standards.
WPS (Welding Procedure Specifications) can be prepared with different qualification methods that can be selected according to the production type and requirements. These methods had been listed below;
EN ISO 15614 Welding Procedure Test
EN ISO 15613 Pre-Production Welding Test
EN ISO 15612 Standard Welding Procedure
EN ISO 15611 Previous Welding Experience
EN ISO 15610 Tested Welding Materials
After selecting the qualification method, WPS will be prepared at the end of the following steps;
1. pWPS (Preliminary Welding Procedure Specifications): Preliminary Welding Procedure Specifications is the draft document that includes all information on the welding to be performed in the welding procedure test and that is prepared in line with past experiences.
2. WPQR (Welding Procedure Qualification Report): Welding Procedure Qualification Report (WPQR) is the document that contains results of the tests performed for qualification and whose compatibility is approved by the supervisory body.
3. WPS (Welding Procedure Specifications): WPS refers to production procedures that are arranged in line with scope ranges WPQR.
WPS preparations are time consuming and costly processes for manufacturers. Magmaweld has made Magmaweld WPS packages for the end users in cooperation with GSI-SLV TR by bringing together its own knowledge, welding consumables and welding machines.
Magmaweld WPS packages have been prepared with the following two standards that can be used for production according to EN 1090-2 EXC2 and EN ISO 3834-3 specifications.
1- EN ISO 15612 Standard Welding Procedure
2- EN ISO 15610 Tested Welding Materials
EN ISO 15612 Standard Welding Procedure
Magmaweld’s WPS package contains 138 WPSs that have been created for Magmaweld MG2 (G3Si1) 1.00mm and 1.20mm products.
-WPSs were prepared with 1.00mm and 1.20mm diameter wire for using from 2 mm to 30 mm thickness with C1 or M21 gas.
-These WPS's may be used in materials with lower quality than S355 and equal to S355
For the use of these WPSs;
-The manufacturer shall perform welding coordination in line with EN 14731 while doing welded manufacture in accordance with EN 1090-2 and satisfy the quality terms in line with the relevant part of EN ISO 3834.
The standard welding procedure is qualified for use in production with welding power sources and welding equipment having electrical and mechanical characteristics which are capable of achieving those used in preparing the test weld for WPQR.
- The procedures can be used by qualified welders or welding operators for mechanized welding according to EN1418.
EN ISO 15610 Tested Welding Materials:
This part contains 9 WPQRs that were prepared for our ESR 13, ESB 48, ESB 50, ESB 52, TG 2, MG 2, MG 3, FCW 11 and FCW 21 products. They may be used in materials with lower quality than S275 and equal to S275.
For these WPSs;
- It is only allowed in arc and gas welding methods.
- Usage is restricted to trade names of welding consumables which are include of the package.
-It is only covered from 3mm to 40mm thickness range.
-This standard is not applicable where requirements for hardness or impact properties, preheating, controlled heat input, interpass temperature and post-weld heat-treatment are specified for the welded joint.
The conditions to be satisfied in order for qualification to be valid:
- Properties of the base metal to be used
- Test document specified by the producer of welding consumables
- It should include copies of WPQR test reports.