15085-Requirments PDF

ECE Global Slide: 1 of 45
Your Global Partner in Engineering, Quality and Safety Compliance

Business in Europe Date: 2012 Edition
Design – Fabrication – Inspection – Certification
-EN 15085- Thomas Schmidt
ECE Global We are ISO 9001:2008 Certified

Your Global Partner in Engineering, Quality and Safety Compliance Design – Fabrication – Inspection – Certification
We deliver engineering verification services, new and in-service equipment assessments and inspections, compliance assessments
•Construction Surveillance •CWI, IWE, EWE •PQR / WPS Approvals

•As-built & In-Service Inspections •Visual Inspections (VT) •Welder Qualifications / Training
•Railcar Condition Inspection •UT, Phased Array UT, UTT •Welding Coordinator Service
•Monitor Repair Programs •Surface Flaw Detection (MT, PT) •Welding Management Systems
•Vendor Support Services •Positive Material ID Check (PMI) •Failure Assessments
Inspection & NDT Services Welding Services

Approvals ASNT, AWS, API, EN, ISO, … ASME, AWS, API, EN, ISO, …
•Approval & Certification Services •EN 15085 Welding of Rail Vehicle •AAR Assessments (e.g. Sect. J )
•AAR Rules (e.g. M-1003, ISO, ...) •ISO 3834 Quality System •Inspections (e.g. AAR Rule 88.B.2)
•European Rules (CE, EN, ISO, ...) •CE Marking •Truck / Brake Assessment
•Product Compliance Assessments •EN 473 NDE Testing •Rail Car Fabrication Consultation
•Pre-Certification/Consulting Services •Compliance Assessments •Quality System Implementation
Compliance For Europe For North America

ASME, AWS, EN, ISO, GOST, EU Directives, EN, ISO, … ASME, AWS, API, ISO, …
1256 Remington Rd. - Schaumburg, IL 60173 - USA American-European Working Group

+1 (847) 250-5240 (P) - +1 (847) 713-4860 (F) for Welding Rail Vehicles (AEWRV)
infoece@eceglobal.com - www.eceglobal.com rail@eceglobal.com
Helping with clientele success, nationally / globally, with cost-effective pricing, excellent service and a quick turnaround is our policy.
Common name Official name Accession Population Area (km²) Area (miles²) Capital
1 Austria Republic of Austria 1-Jan-95 8,340,924 83,871 32,383 Vienna
2 Belgium Kingdom of Belgium 25-Mar-57 10,666,866 30,528 11,787 Brussels
3 Bulgaria Republic of Bulgaria 1-Jan-07 7,640,238 110,910 42,823 Sofia
4 Cyprus Republic of Cyprus 1-May-04 778,700 9,251 3,572 Nicosia
5 Czech Republic Czech Republic 1-May-04 10,403,100 78,866 30,450 Prague
6 Denmark Kingdom of Denmark 1-Jan-73 5,511,451 43,094 16,639 Copenhagen
7 Estonia Republic of Estonia 1-May-04 1,340,935 45,226 17,462 Tallinn
8 Finland Republic of Finland 1-Jan-95 5,312,415 338,145 130,559 Helsinki
9 France French Republic 25-Mar-57 64,473,140 674,843 260,558 Paris
10 Germany Federal Republic of Germany 25-Mar-57 82,218,000 357,050 137,858 Berlin
11 Greece Hellenic Republic 1-Jan-81 11,125,179 131,990 50,962 Athens
12 Hungary Republic of Hungary 1-May-04 10,036,000 93,030 35,919 Budapest
13 Iceland Republic of Iceland --- 316,252 103,125 39,770 Reykjavík
14 Ireland Ireland 1-Jan-73 4,501,000 70,273 27,133 Dublin
15 Italy Italian Republic 25-Mar-57 59,619,290 301,318 116,340 Rome
16 Latvia Republic of Latvia 1-May-04 2,266,000 64,589 24,938 Riga
17 Lithuania Republic of Lithuania 1-May-04 3,357,873 65,303 25,214 Vilnius
18 Luxembourg Grand Duchy of Luxembourg 25-Mar-57 483,800 2,586 998 Luxembourg
19 Malta Republic of Malta 1-May-04 407,810 316 122 Valletta
20 Netherlands Kingdom of the Netherlands[t 6] 25-Mar-57 16,471,968 41,526 16,033 Amsterdam
21 Norway Reich Commissariat of Norway --- 4,954,000 385,252 148,746 Oslo
22 Poland Republic of Poland 1-May-04 38,115,641 312,683 120,728 Warsaw
23 Portugal Portuguese Republic 1-Jan-86 10,599,095 92,391 35,672 Lisbon
24 Romania Romania 1-Jan-07 21,498,616 238,391 92,043 Bucharest
25 Slovakia Slovak Republic 1-May-04 5,400,998 49,037 18,933 Bratislava
26 Slovenia Republic of Slovenia 1-May-04 2,025,866 20,273 7,827 Ljubljana
27 Spain Kingdom of Spain 1-Jan-86 46,661,950 506,030 195,379 Madrid
28 Sweden Kingdom of Sweden 1-Jan-95 9,253,675 449,964 173,732 Stockholm
29 Switzerland Swiss Confederation --- 7,785,600 41,285 15,940 Bern
30 United Kingdom United Kingdom of Great Britain 1-Jan-73 61,003,875 244,820 94,526 London
EU-27 European Union total 499,514,405 4,456,304 1,720,590 –
North America Canada, USA, Mexico 528,720,588 24,709,000 9,540,000 Washington
Difference 16,150,331 19,723,034 7,614,954
Official name Population Area (km²) Area (miles²)
European Union total

512,570,257 4,985,966 1,925,046
North America 528,720,588 24,709,000 9,540,000
16,150,331 19,723,034 7,614,954
Canada (2011) 34,482,779 9,984,670 3,855,103

The goal of harmonization:
Harmonization within the European Union
* Freedom
* Trade: Unification and mutual requirements
* Common safety requirements; e.g.:
• Public health and safety
• Workers protection and safety
• Plant & facility safety
• Product safety
Certification for Europe
Many requirements apply when designing, fabricating and operating rail vehicles in Europe
CE Marking, etc certification of pressure equipment, electrical equipment, EMC,

fire protection, operating in tunnel, … and more
EN 15085 new building and repair work of rail vehicle and components
EN 12663 Structural requirements of railway vehicle bodies
etc. ….
Derailment Safety
Operational Safety, Side wind
Stress Safety (Active and Passive)
Control Systems, Safety Technology, Software
Brake System
Vehicle Profile / Clearance
Fire Safety, Environmental Protection
Workers Protection
Vehicle Accessories / Equipment
What does it take for a fabricator of
Welded Rail Vehicles and Components
to sell products in Europe?

EN 15085 and AWS D15.1
We will focus on EN 15085 – Welding of Rail Vehicles and Components
Part 1: General
Part 2: Quality requirements and certification of welding manufacturer
Part 3: Design requirements
Part 4: Production requirements
Part 5: Inspection, testing and documentation
And focus on AWS D15.1 – Railroad Welding Specification for Cars and
Locomotives
American-European Working Group for Welding Rail Vehicles

(AEWRV) rail@eceglobal.com
Did you know:
Over 300 companies in China are certified per EN 15085 by 2012 ending
Canada roughly 5 Companies

USA roughly 15 Companies
Mexico roughly 0 Companies are certified per EN 15085!
That Quality Assurance / Quality Control Programs combined with some

approvals is an investment with an incredible ROI?
Country company
CA Advance Manufacturing Technologies Inc. (DIN EN 15085-2)
CA Alloy Welding Centre Limited (DIN EN 15085-2)
CA China Steel Inc. (DIN EN 15085-2) open audit process
CA Phillips & Temro Industries LTD (DIN EN 15085-2)
CA Recreational & Industrial Products Corp. (DIN EN 15085-2)


The intent of the workgroup is:
To represent the interest of the North American Railroaders with focus on

exporting its products to EU countries and other global destinations (e.g. S.A.).
Our meeting outcome will provide insights, input and advice to Technical
Committee’s for the development of e.g. AWS D15.1 and EN 15085.
Even though these standards are addressing the same industry and same
companies, the overall scope and approach is different.
EN 15085 Scope
applies to manufacturers’ of welded rail vehicles and components

EN 15085
outlines certification and quality requirements

covers new building and repair work of rail vehicle and components.
covers steel and aluminum (principles apply to other materials equally)
ECE Global Slide: of 45
Europe changed ….. Product Liability;

Declaration
From a Country by Country Approval Scheme of Conformity,
to the New European Approach! EU Representation
……
Non regulated /
voluntary / Business Excellence &
market oriented European Competitiveness
initiatives
Quality Policy – System/Personnel
Global Approach
New Approach
regulated /
mandatory / Old Approach
initiatives ‘80 ‘83 ‘85 ‘89 ‘90 ‘94 ‘95 ‘96 ‘00 ‘01 ‘02
EN 15085-2: Definition of certification levels
Annex A (informative)
Possible allocation of parts and subassemblies of rail vehicles to the certification levels
Certification Parts classification
level
Level CL 1 New build, conversion and repair of rail vehicles and their components Examples for components: • bogies (headstocks, solebars, cross bearers,
bogie frames) • under-frames (extensions, solebars, cross bearers, assembly) • vehicle body (front walls, side walls, roof) • draw and buffing gear •
supporting frames for external equipment parts (e. g. tanks, electrical, air-conditioning and compressed air containers) • wheel set mountings, axle
boxes, spring supports, shock absorbers, vibration dampers • brake equipment (magnetic track brake, brake rods, brake triangles, brake cylinders,
brake cross beams) • supporting frames for heavy duty vehicles including road/rail vehicles • welded components for drag transmission from bogie
to vehicle (bolster) • fuel tanks of vehicles • finishing welding of castings within components indicated above • pressure gas tanks, tanks and tank
containers of rail vehicles with test pressure a • containers for dangerous materials a.
Level CL 1 New build, conversion and repair of rail vehicles and their components, depending on the weld performance class (CL 1 only for CP A, CP B or CP C1),
or e.g.: • entrance doors, end doors • self-supporting equipment boxes and underfloor containers (fresh water and waste-water containers) • external
Level CL 2 machine equipment parts (transformer, engine, transmission suspension) • roof construction (pantograph, paneling) • machine room equipment
(transformer casing, transformer suspension, engine suspension, transmission suspension, attachment for traction motor, instrument racks) •
power transmission parts (traction coupling, cardan shafts) • traverses (i.e. car wagon) • turning and tipping equipment ⎯ obstacle deflectors •
stanchions and lashing rings • compressed-air reservoirs for rail vehicles a ⎯ pressurized pipes.
Level CL 2 New build, conversion and repair of non-pressurized containers without special test pressure, e.g.: • payload container for non-dangerous materials
• other transport containers. New build, conversion and repair of structural parts for rail vehicles, e.g.: • internal parts of passenger coaches
(partitions, walls, doors, paneling) • supporting frame for internal parts (electrical, air-conditioning and compressed air installations) • driving cab
equipment • lavatory parts and water containers with installations • sliding doors in vehicles including runways • fastenings for brake pipes • non-
self-supporting equipment boxes underneath the base frame (without supporting frame) • gearboxes and consoles for hand brake operation •
steps, hand rails (including handrails in entry areas) and railings external to the vehicle.
Level CL 3 New build, conversion and repair production of simple attached parts for rail vehicles, e.g: • cranks and levers for various operations ⎯ striking plates
• equipment boxes and switch cabinets in rail vehicles (including gearboxes and consoles for hand brake operation, without supporting frame) •
holders for index plates ⎯ wheel scotches • covers for freight wagons (heat protection on tank wagons) • steps, handrails, railings on rail vehicles.
New build, conversion and repair of parts or trade supply parts for rail vehicles, for instance: ⎯ seating frames ⎯ window frames ⎯ ventilation grilles.
Level CL 4 This certification level is valid for manufacturers that do not carry out their own welding fabrication if welded components and parts are: ⎯ designed
⎯ bought and assembled.
a The requirements of this standard will be superseded by specific product standards, e.g. EN 286, air reservoirs.
CL 1: New build, conversion and CL 1 / 2: New build, conversion CL 2: New build, conversion and
repair of rail vehicles and their and repair of rail vehicles and repair of non-pressurized
components Examples for their components, depending containers without special test
components: on the weld performance class pressure, e.g.:
(CL 1 only for CP A, CP B or CP
C1), e.g.:
• bogies (headstocks, solebars, • entrance doors, end doors • payload container for non-
cross bearers, bogie frames) • self-supporting equipment dangerous materials
• underframes (extensions, boxes and underfloor • other transport containers.
solebars, cross bearers, containers (fresh water and New build, conversion and
assembly) waste-water containers) repair of structural parts for
rail vehicles, e.g.:
• vehicle body (front walls, side • external machine equipment • internal parts of passenger
walls, roof) parts (transformer, engine, coaches (partitions, walls,
• draw and buffing gear transmission suspension) doors, paneling)
• supporting frames for • roof construction • supporting frame for internal
external equipment parts (e. (pantograph, paneling) parts (electrical, air-
g. tanks, electrical, air- • machine room equipment conditioning and compressed
conditioning and compressed (transformer casing, air installations)
air containers) transformer suspension, • driving cab equipment
engine suspension, • lavatory parts and water
• wheel-set mountings, axle
transmission suspension, containers with installations
boxes, spring supports, shock
absorbers, vibration dampers attachment for traction
motor, instrument racks)
EN 15085 Essential
provides an essential link
between performance requirements during design (e.g. static / dynamic safety)
and achieving appropriate weld quality during production or repair
and inspection requirements during production and in-service maintenance
The same applies to CE Marking
Knowing engineering / fabrication / inspection /

and certification principles is “key”
for fabrication supervisory
How can the cost for doing business with Europe be estimated?
 Internal sales experience?
 Calls to service providers?
 Negotiation of customer requirements to what is standard practice?
 Other ….
Would you believe me, if I would state that:

 defining cost saving questions for a customer is tough!
 negotiating standard practice processes costs more time and money
than complying with EU requirements!
 calling service providers may end up with a surprise!
 Other ….
Let me try to plant a suggestion …..

A pound of Canadian feathers

cradles as much as
A pound of European feathers
Stress categories and Safety categories
Weld performance class “CP A” through “CP D” set the rules for
 Quality System Requirements
 Personnel Qualification Requirements
 Process Approval Requirements
 Cost for Certification!
Assessing and defining Weld Performance Requirements is a fundamental need,

regardless if the products operates in Europe or Canada or North America or
……
Stress category Safety categories
High Medium Low
High CP A a CP B c CP C2
Medium CP B b CP C2 CP C3
Low CP C1 d CP C3 CP D
Back to the roots! – definitions “breakdown” …..
certification level “CL” weld performance class “CP”

weld inspection class “CT”
some default “CL” – EN 15085-2, Annex A
stress category safety category
The safety categories are differentiated as follows:

stress factor
high Failure of the welded joint leads to consequential events with
EN 15085-3 Table 1 personal injuries and breakdown of the overall function.
medium Failure of the welded joint leads to an impairment of the overall

function or can lead to consequential events with personal injuries.
low Failure of the welded joint does not lead to any direct impairment of
the overall function. Consequential events with personal injuries
are unlikely.
Rely on what you know …….
Adopt what is global practice …….
Build bridges, do not reinvent the wheel ……

EN 15085-3: Design Requirements
Stress Safety Weld Quality levels Inspection Volumetric Surface tests Visual
category category performanc for class tests MT or PT examination
e class imperfections RT or UT VT
EN ISO 5817
EN ISO 10042
see Table 5 or
High High CP A CT 1 100% 100% 100%
Table 6
High Medium CP B B CT 2 10% 10% 100%
Medium High CP B B CT 2 10% 10% 100%
Low High CP C1 C CT 2 10% 10% 100%
High Low CP C2 C CT 3 Not required Not required 100%
Medium Medium CP C2 C CT 3 Not required Not required 100%
Medium Low CP C3 C CT 4 Not required Not required 100%
Low Medium CP C3 C CT 4 Not required Not required 100%
Low Low CP D D CT4 Not required Not required 100%

Business
Imperfections in Europe EN 15085-3 (Table 5) Date: 2012 Edition
according to
-EN 15085-
Weld performance classes
Weld performance classes Thomas Schmidt
EN ISO 5817 (Steel)
EN 15085-3: Design Requirements CP A CP B CP C1 / CP C2 / CP C3 CP D
1.1 to 1.6, 1.13, 1.15,
1.18, 1.19, 1.22, 2.1, B B C D
2.7, 2.8, 2.11 to 2.13,
1,7, 1.8, 1.9, 1.11,
1.14, 1.17, 1.23, 2.2,
Not permitted B C D
2.3 to 2.6, 2.9, 2.10,
3.1
1.10, 1.16, 1.20,
Not applicable B C D
1.21, 3.2
1.12 a, 4.1, 4.2 These imperfections are not assessed
a For CPA, see also 7.3.15.
How should the inspection class be introduced to fabrication?

Imperfections EN 15085-3 (Table 5)
Inspection shall be very well according to Weld performance classes
Welder / Operator
trained and familiar with Weld performance
classes CP C1 / CP C2 / must perform on
CP A CP B CP D
inspection / validation EN ISO 5817 (Steel) CP C3 highest acceptance
1.1 to 1.6, 1.13, 1.15,
requirements! 1.18, 1.19, 1.22, 2.1, B B C D
level.
2.7, 2.8, 2.11 to 2.13,
cost control: fabrication, inspection, repair, estimation, parts
Engineering must be very familiar Engineering must produce sound and

with the codes and requirements! informative drawings!
let’s summarize!
• determined by weld performance class “CP”

“CL”
• stress category – approved calculations & drawings

“CP” • safety category – risk assessment / engineering
• engineering • welding coordinator • inspection

• sales / purchasing
• PQR / welder / welding operator

Fabrication • inspector
• “CL” mandates inspection scope

“CT” • “technology” can demand deviation from rules
AWS D15.1: Brief Background on AWS Welding of Railroad Components
Purpose of Standard - A single comprehensive document of welding data,

applicable throughout the railroad industry
- Contribution to improvements in welding quality and
performance
Committee Members Experts from all segments of the industry

- Users
- Suppliers
- General Public
- Representatives of the Association of American Railroads (AAR)
General Scope Information
This document includes data from

- AWS D1.1/D1.1M, Structural Welding Code—Steel
- AWS D1.2/D1.2M, Structural Welding Code— Aluminum
- AWS D1.3/D1.3M, Structural Welding Code—Sheet Steel
- AWS D1.6/D1.6M, Structural Welding Code—Stainless Steel
Material Thickness ≥ 1/8 in [3 mm]

• Clauses 1 through 17: General requirements for welded construction for metal
components 1/8 in [3 mm] or greater, in thickness
Material Thickness Less ≤ 1/8 in [3 mm]

• Clauses 18 through 23: Welding of base metals less than 1/8 in [3 mm] in thickness 11
gauge (0.1196 in [3.04 mm]) material may be considered 1/8 in [3 mm] plate or sheet
steel
AWS D15.1: - Pragmatic
- Based on experience
Not included: - Focused on essential tasks and disciplines related to welding

Product
Classification - Details requirements for welding process qualifications
and Quality
System - Addresses welding personnel qualification
Requirements
… - Partially addresses inspection personnel qualification
No reference to
i.e. M-1003 - Defines acceptance criteria for weld quality
- Highlights requirements certain product


Inspection / Welding
AWS D15.1 - Content: Acceptance Requirements
AWS D15.1
Welding
Technique and
Personnel
Does not include Workmanship
Qualification
information / requirements
concerning
Procedure Prequalified
Qualification WPS
PRODUCT CERTIFICATION
QUALITY SYSTEMS General
Qualification
Requirements
Only a limited comparison between AWS D15.1 and EN 15085 is currently possible!
However, similarities in PHILOSOPHIES can be recognized!

Product Liability;
Quality Assurance / Control System Declaration
of Conformity,
Certification – Tool to Compliance EU Representation
……
Non regulated /
voluntary / Business Excellence &
market oriented European Competitiveness
initiatives
Quality Policy – System/Personnel
Global Approach
New Approach
regulated /
mandatory / Old Approach
initiatives ‘80 ‘83 ‘85 ‘89 ‘90 ‘94 ‘95 ‘96 ‘00 ‘01 ‘02
EN 15085-2: Quality requirements and certification of welding manufacturer

Definition of requirements for welding manufacturer
Certification levels
Level CL 1 Level CL 2 Level CL 3 Level CL 4
Manufacturer Certification Required Required Not required Required
Weld performance class CP A to CP D (CP C1) a , CP C2 to CP D CP D CP A to CP D
Quality requirements b EN ISO 3834-2 EN ISO 3834-3 EN ISO 3834-4 EN ISO 3834-3
For:
Welding coordinator Level A Level B or C No requirement level 1 welding work: Level A
level 2 welding work: Level B or C
Deputy: Level A c Further
Deputy of the welding coordinator Deputy: Level C No requirement No requirement
deputies: Level B or C d
Depending on the welding process and material group, qualified welders or welding operators
Welders and operators are required according to EN 287-1 (for steels), EN ISO 9606-2 (for aluminum) or EN 1418 (for Not relevant
welding operators).
- Testing personnel for welding quality tests
- Testing supervisors for welding quality tests: responsible welding coordinator (not for CL 3)
Testing personnel Not relevant
- Non-destructive testing personnel: level 1 according to EN 473
- Testing evaluator for non-destructive testing: level 2 according to EN 473.
Welding instruction WPS according to the relevant parts of EN ISO 15609 or EN ISO 14555 or EN ISO 15620 Not relevant
WPS qualified by WPQR the relevant parts of EN ISO 15610,

EN ISO 15611, EN ISO 15612, EN ISO 15613, EN ISO 15614 e
WPS qualified by WPQR only if
Welding instruction or EN ISO 14555 or EN ISO 15620 (for details see EN 15085-4) Not relevant
specified in the contract
For CP D, only if specified in the contract.
a CL 1 when CT 1
b The requirements of the relevant part of EN ISO 3834 shall be met, but no certification according to EN ISO 3834 is required.
c Level A deputy is not required for small welding manufacturers with a single welding shop.
d For welding manufacturers with several welding shops an additional deputy, Level C, is required for each welding shop.
e For railway applications, only EN ISO 15614-1, EN ISO 15614-2, prEN ISO 15614-3, EN ISO 15614-4, EN ISO 15614-7, EN ISO 15614-11, EN ISO 15614-12 and
EN ISO 15614-13 are relevant.
EN 15085-2: Quality Assurance / Control ISO 3834 – Similar to ISO 9000

– BUT SPECIFIC for Welding Shops
Recourse Continuous Customer

Audits
Management Improvement Satisfaction
Customer Requirements
Communication
Customer
Engineering / Product
Sales & Projects Customer
Product Realization /
Service
Development Fabrication
Communication
Development
Procurement
Management
Product/Process
Maintenance
Control of Non-
Equipment
Conforming
Material
Test
Communication
Control od Documents & Records
Welding Coordination – A Key Function within the System
Level CL 1 Level CL 2 Level CL 3
Manufacturer Certification Required Required Not required
Weld performance class CP A to CP D (CP C1) a) , CP C2 to CP D CP D
Quality requirements b) EN ISO 3834-2 EN ISO 3834-3 EN ISO 3834-4
Welding coordinator Level A Level B or C No requirement
Deputy: Level A c)
Deputy of the welding
additional deputies: Deputy: Level C No requirement
coordinator
Level B or C d)
a) CL 1 when CT 1
b) The requirements of the relevant part of EN ISO 3834 shall be met, but no certification according to EN
ISO 3834 is required.
c) Level A deputy is not required for small welding manufacturers with a single welding shop.
d) For welding manufacturers with several welding shops an additional deputy, Level C, is required for each
welding shop.
95
Welding Coordination – A Key Function within the System
welding coordinators are an essential link
- design requirements purchasing engineering

(e.g. static / dynamic safety)
- weld quality
(production or repair)
- inspection requirements
(production / maintenance) sales
welding quality
coordinator
welding fabrication
certification level “CL” based on a weld! Later: “CL” definition acc to EN 15085-2
The European Standard Focus on Material

Suitability for
design requirements Welding/Fab.
infrastructure conditions
This is not
e.g. low temperature new ……
-Design Design
-Production
This is
weld performance
now part of an approval/certification
-In-Service
Requirements
material suitability
process …. Weldability
Of
The pragmatic
Attention SALES ! approach is going to be replaced
Components
Attention PURCHASING !
with a new approach
“inspectability”
- new construction Inspection
- in-service Testing
- maintenance Validation
Sectioned close to center stiffener
A216 WCC A588

ASTM A588 Chemical Composition

The Element Max (%)
Grade
C Mn P S Si Cu Ni Cr Mo V N Nb
A 0.19 0.80-1.25 0.04 0.05 0.30-0.65 0.25-0.40 0.40 0.40-0.65 … 0.02-0.10 0.01 ..
Carbon Equivalent: CEV [max]: 0.60

CET [max]: 0.38
CET = C +((Mn+Mo)/10)+((Cr+Cu)/20)+Ni/40
(CET: acc. Uwer and Hoehne)
ASTM A216 Chemical Composition

The Element Max (%)
Grade
C [max] Mn [max] P [max] S [max] Si [max] Cu [max] Ni [max] Cr [max] Mo [max] V [max] Rest
WCC 0.25 1.20 0.04 0.045 0.60 0.30 0.50 0.50 0.20 0.03 1.00 ..
Carbon Equivalent: CEV [max]: 0.55

CET [max]: 0.44
CET = C +((Mn+Mo)/10)+((Cr+Cu)/20)+Ni/40
(CET: acc. Uwer and Hoehne)
Tp = 697 X CET + 160 X tanh (d/35) + 62 X HD 0 35 +(53 X CET- 32) X Q - 328 (°C) i ii iii
Weldment: ASTM A588-A Plate with ASTM A216-WCC Casting

Material: ASTM A588-A
WPS BT002-1 (with Backing)
HD: 1/Q: Root HD: 1/Q: Intermediate HD: 5/Q: Root HD: 5/Q: Intermediate
Tp 58.22863 Tp 56.09383 Tp 105.1295 Tp 102.9947
Factor 1 697 Factor 1 697 Factor 1 697 Factor 1 697
CET 0.38 CET 0.38 CET 0.38 CET 0.38
d 14 d 14 d 14 d 14
35 35 35 35
tanh(d/35) 0.379949 tanh(d/35) 0.379949 tanh(d/35) 0.379949 tanh(d/35) 0.379949
HD 1 HD 1 HD 5 HD 5
HD 0.35 1 HD 0.35 1 HD 0.35 1.756465 HD 0.35 1.756465
CET 0.38 CET 0.38 CET 0.38 CET 0.38
Q 0.12 Q 0.30 Q 0.12 Q 0.30
AWS D15.1 ofdoes

1. i Determination not
the lowest require
preheat pre-heating
temperature for cold cracking I per default.
sate welding of steels. Authors Uwer D, Hoehne H, IIW. Do c IX-
1631 - 91.
If2.the weld ofismethods
ii Comparison in a high stressed
for determining area, pre-heating
weld procedures for the avoidance of requirements shouldAuthors
hydrogen cracking in fabrication. be reviewed!
Hart
P.H.M, Pargetter R.J, Wright M.D, IIW. Doc IX- 1602-90
3. iii Industry standards
Welding Coordination
AWS D15.1, Clause 4.7:
• Fabricator Engineer is responsible for interpretations related to approval needs

• If so agreed, same responsibility applies to Owner’s Engineer
• When both engineers are assigned, the references assigned to only one entity
shall apply to both entities
Note: Engineers are often degreed mechanical or civil engineers
EN 15085-2, Annex B: Competence of Welding Coordinator
• Welding coordinator a comparable educational program as outlined in EN

15085-2, Sect 512 and EN ISO 14731 is not available in AWS D15.1
• AWS D15.1 requires the company to employ suitably educated employees
EN 15085-2 and AWS D15.1

inspection
sales
customer
purchasing
national safety authority

engineering
fabrication
Summary
1) Manufacturer’s of welded products will have to be certified according to the

Certification Level (CL) and Weld Performance Class (CP)
2) Front End Loading standard knowledge and engineering / fabrication
requirements safes time, cost and increases confidence
3) Quality System approval per EN 15085-2 with compliance to ISO 3834 is a
FUNDAMENTAL MILESTONE
4) Personnel with suitable qualifications are essential
a. Welding Coordinator – Technology and Standards
b. NDE Personnel Qualification per EN 473/ISO 9712 depends on CP Class
5) Approved welding procedure per EN / ISO
6) Welder / Welding Operator approval per EN / ISO
7) Contractual agreements shall include technology requirements
Summary --- Estimated Time Frames for Companies with QA Systems
Assess the Weldment for X days, depending on

Classification complexity
Quality System an
1 to 2 days, Gap Audit
Fabrication Performance
Welding Procedure and X days, plus Time for

Welder Approvals Testing Lab
Personnel Training for

X days, including Test
Welding Coordination
Personnel Training for X days, depending on

Inspection / NDE current status
Implementation Support and Duration, as well as

Certification Audit and Cost need to be added!
What does it take to become AAR Section J, M-1003

Certified?

Maybe in the near future, the score card looks like this?
Over 300 companies in China that are certified per EN 15085 by 2012 ending
Canada roughly 55+ Companies

USA roughly 55+ Companies
Mexico roughly 55+ Companies are certified per EN 15085!
That Quality Assurance / Quality Control Programs combined with some

approvals is an investment with an incredible ROI?
Please stay on track!

Thank you for you attention!
ECE Global We are ISO 9001:2008 Certified

Your Global Partner in Engineering, Quality and Safety Compliance Design – Fabrication – Inspection – Certification
We deliver engineering verification services, new and in-service equipment assessments and inspections, compliance assessments
•Construction Surveillance •CWI, IWE, EWE •PQR / WPS Approvals

•As-built & In-Service Inspections •Visual Inspections (VT) •Welder Qualifications / Training
•Railcar Condition Inspection •UT, Phased Array UT, UTT •Welding Coordinator Service
•Monitor Repair Programs •Surface Flaw Detection (MT, PT) •Welding Management Systems
•Vendor Support Services •Positive Material ID Check (PMI) •Failure Assessments
Inspection & NDT Services Welding Services

Approvals ASNT, AWS, API, EN, ISO, … ASME, AWS, API, EN, ISO, …
•Approval & Certification Services •EN 15085 Welding of Rail Vehicle •AAR Assessments (e.g. Sect. J )
•AAR Rules (e.g. M-1003, ISO, ...) •ISO 3834 Quality System •Inspections (e.g. AAR Rule 88.B.2)
•European Rules (CE, EN, ISO, ...) •CE Marking •Truck / Brake Assessment
•Product Compliance Assessments •EN 473 NDE Testing •Rail Car Fabrication Consultation
•Pre-Certification/Consulting Services •Compliance Assessments •Quality System Implementation
Compliance For Europe For North America

ASME, AWS, EN, ISO, GOST, EU Directives, EN, ISO, … ASME, AWS, API, ISO, …
1256 Remington Rd. - Schaumburg, IL 60173 - USA American-European Working Group

+1 (847) 250-5240 (P) - +1 (847) 713-4860 (F) for Welding Rail Vehicles (AEWRV)
infoece@eceglobal.com - www.eceglobal.com rail@eceglobal.com
Helping with clientele success, nationally / globally, with cost-effective pricing, excellent service and a quick turnaround is our policy.

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ECE Global Slide: 1 of 45

Your Global Partner in Engineering, Quality and Safety Compliance

ECE Global We are ISO 9001:2008 Certified

•Construction Surveillance •CWI, IWE, EWE •PQR / WPS Approvals

Inspection & NDT Services Welding Services

Compliance For Europe For North America

1256 Remington Rd. - Schaumburg, IL 60173 - USA American-European Working Group

Official name Population Area (km²) Area (miles²)

European Union total

North America 528,720,588 24,709,000 9,540,000

16,150,331 19,723,034 7,614,954

Canada (2011) 34,482,779 9,984,670 3,855,103

The goal of harmonization:

Harmonization within the European Union

* Trade: Unification and mutual requirements

* Common safety requirements; e.g.:

• Public health and safety

• Workers protection and safety

• Plant & facility safety

Certification for Europe

CE Marking, etc certification of pressure equipment, electrical equipment, EMC,

What does it take for a fabricator of

Welded Rail Vehicles and Components

to sell products in Europe?

EN 15085 and AWS D15.1

We will focus on EN 15085 – Welding of Rail Vehicles and Components

Part 2: Quality requirements and certification of welding manufacturer

Part 3: Design requirements

Part 4: Production requirements

Part 5: Inspection, testing and documentation

American-European Working Group for Welding Rail Vehicles

Did you know:

Canada roughly 5 Companies

That Quality Assurance / Quality Control Programs combined with some

CA Advance Manufacturing Technologies Inc. (DIN EN 15085-2)

CA Alloy Welding Centre Limited (DIN EN 15085-2)

CA China Steel Inc. (DIN EN 15085-2) open audit process

CA Phillips & Temro Industries LTD (DIN EN 15085-2)

CA Recreational & Industrial Products Corp. (DIN EN 15085-2)

American-European Working Group for Welding Rail Vehicles

The intent of the workgroup is:

To represent the interest of the North American Railroaders with focus on

applies to manufacturers’ of welded rail vehicles and components

outlines certification and quality requirements

Europe changed ….. Product Liability;

EN 15085-2: Definition of certification levels

provides an essential link

between performance requirements during design (e.g. static / dynamic safety)

and achieving appropriate weld quality during production or repair

and inspection requirements during production and in-service maintenance

The same applies to CE Marking

Knowing engineering / fabrication / inspection /

Would you believe me, if I would state that:

Let me try to plant a suggestion …..

A pound of Canadian feathers

Stress categories and Safety categories

Assessing and defining Weld Performance Requirements is a fundamental need,

Back to the roots! – definitions “breakdown” …..

certification level “CL” weld performance class “CP”

stress category safety category

The safety categories are differentiated as follows:

medium Failure of the welded joint leads to an impairment of the overall

Rely on what you know …….