1. New Zealand Steel Fabricator Certification Scheme ″ISO 3834 PLUS″
July 2014
International Institute of Welding
Quality Management in Welding and Allied Processes SC-QUAL
Commission XIV Education and training
New Zealand Steel Fabricator Certification Scheme ″ISO 3834 PLUS″
Michail Karpenko
Manager
Alistair Fussell
Manager SCNZ

2. The scope of this presentation
Introduction
New Zealand welding standards overview
Challenges and Opportunities
The Certification Scheme ISO 3834 “PLUS”
Establishing regulatory framework
Summary

4. Seismic welding in NZ – some examples
Wellington’s McKenzie Building
Kilmore Street Medical Centre
Wellington Airport
WMIT Campus
Forsyth Barr Stadium
Removable EBF link solutions

5. Framework of design and fabrication standards for structural steel work
Design of steel structures to:
NZS Steel Structures Standard
(NZS will be replaced by NZS 3404 Part 1 to part 7 soon)
Fabrication of steel structures to:
NZS Steel Structures – Part 1: Materials, fabrication, and Construction
AS/NZS 1554 Structural steel welding Part 1 to 7

6. New Zealand welding QA requirements
The requirements of AS/NZS cover most of the items of ISO
ISO 3834 is a recommended QA system in AS/NZS and NZS
ISO 3834 has been adopted as AS/NZS ISO 3834
The importance levels of AS/NZS 1170 echoes the consequence Classes of EN 1990.
However, most of the QA-related items are informative and therefore are not followed.

7. Challenges Materials traceability Compliance issues
Health and safety aspects in seismic environment
Imported sub-quality steelwork
Low-cost competition
Repair cost and legal issues
Quality management recommendations are non-mandatory (there is no “NZS 1090”)

8. Opportunities Creating the same rules for everyone.
Improve confidence in steel as a ultimate solution for structural applications.
Improve safety and reliability of structural steelwork in NZ seismic environment.
Protect the market from sub-quality products.
Better differentiation from the competitors without the certification
Possible advantages in insurance premiums

9. The Approach
Establish a Working Group consisting of fabricators (business owners).
Identify items critical for reliability of structural steelwork.
Identify and implement a suitable QA system that addresses these items.
Work with designers, specifies, regulatory authorities, and standard committees.

10. Scheme goal
To ensure fabricators have the appropriate personnel and procedures in place to consistently produce work of the required quality.

11. Governance structure and roles
-Marketing
-Standard setting
- Regulatory aspects
Certification Company
-Administer scheme
-Undertake company audits
- HERA ANBCC
HERA
-Training
-Standard setting
- Contract auditing resource
Governance board
-Standard setting
- Discipline

12. Construction category
Examples
CC1
Farm buildings
Towers in rural settings
Masts
Fences
CC2
Low rise industrial buildings
Low/ medium rise office, residential, retail buildings gravity systems and category 3,4 seismic load resisting systems in such buildings
Car parking structures
CC3
Stadia
Public buildings with large crowds
Post emergency buildings
Medical facility
Transit buildings (major train stations, airport terminals)
Large schools, adult education facilities
Emergency services (fire, police stations)
High rise office/apartments
Category 1,2 seismic load resting systems for low and medium rise buildings
Road bridges, rail bridges (non-fracture critical components)
CC4
Rail bridge (fracture critical component)

13. Technical requirements for SFC
NZS
Fabrication (FPC covering key workshop activities )
& erection
Materials
AS/NZS 1163
-AS/NZS
-AS/NZ
-AS/NZS3678
Bolts
AS1252
Coatings
AS2312
Welding
AS/NZS
Weld Quality
AS/NZS ISO 3834
(CC3,4 only)

14. Architecture of the SFC
Description
Normative requirements for Construction Category
CC1
CC2
CC3
CC4
1. Fabrication documentation
Quality documentation
No specific requirement (NSR)
Required
Quality plan
NSR
As built shop drawings
Retention period quality documentation
five years minimum
2. Sub-contracting
Sub-contractor
NOTE 9
3. Materials
Use of model specification for bolt and material purchase
Inspection documents (mill and manufacturer certs)
As required by NZS and product standards
As required by NZS and product standards
Traceability (Note 2)
Partial traceability required
Full traceability required
Marking

15. Example: Partial and full traceability

16. Architecture of the SFC (continued)
Description
Normative requirements for Construction Category
CC1
CC2
CC3
CC4
4. Structural steel products
Cutting
NZS :2009, Section 3.2.2
NZS :2009, Section
Transition of thickness and width for seismic members
NSR
NZS :2009, Section
Holing
NZS :2009 section 3.25
NZS :2009 section 3.25
Straightening, curving and cambering
NZS :2009 section 3.2.1
NZS :2009 section
Competency of fabrication supervisor
NZQA Level 4 or similar (NOTE 8)
5. Welding (NOTE 5)
Welding quality requirements
AS/NZS
AS/NZS (Note 1)
AS/NZS ISO (Note 3)
Qualification of welding procedures
AS/NZS 1554 part 1 or 5
Weld categories GP SP
SP, FP
Welder qualifications
AS/NZS Section
AS/NZS Section
AS/NZS 2980, ISO
Qualification of welding coordination (supervisory) personnel
AS/NZS , Section
AS/NZS , Section Item (a) to (e)
ISO 14731
(Specific technical knowledge)
(Comprehensive technical knowledge)

17. Architecture of the SFC (continued)
Description
Normative requirements for Construction Category
CC1
CC2
CC3
CC4
Identification and traceability of welders (NOTE 6)
NSR
Required
Identification and traceability of welding procedures (NOTE 7)
Modification of existing structures
NZS :2009, Section 7
Welding consumables for earthquake resisting structures
NZS :2009, Section
Weld access holes
NZS :2009, Section
Welding of continuity stiffeners in earthquake resisting members
NZS :2009, Section
(if required)
NZS :2009, Section
Fracture control for railway bridges (FCP)
NZS :2009, Appendix A
Architecturally exposed structural steel
NZS :2009, Section 6
6. Welding Inspection
Review of NDT and visual examination requirements (Note 4)
Review of extent of non- destructive examination after non- compliance

18. Architecture of the SFC (continued)
Description
Normative requirements for Construction Category
CC1
CC2
CC3
CC4
Review of extent of non- destructive examination after non- compliance
NSR
Required
Qualification of the welding Inspection personnel
AS/NZS , Section 7
AS/NZS , Section 7
Inspection Plan
AS/NZS ISO
Inspection before, during and after welding
AS/NZS
7. Tolerances
Review of tolerances
Checklist(s) for tolerances

20. Essential steps to achieve SFC certification
Define certification level Construction Category (CC) required
Establish system to ISO (CC 3 & 4) or AS/NZS 1554 (CC 2) as applicable
Address the “plus” items of the Scheme
On-site assessment
Interview with Welding Coordination team
Report and resulting actions
SFC Certification including IIW MCS ISO 3834 (for CC 3 & 4) (valid for 5 years)
Annual surveillance (via audit)

21. Getting IIW Authorisation April 2014
IIW Authorised National Body for Companies Certification in NZ
HERA ANBCC

22. Establishing regulatory framework
Initially market driven
Code of practice developed
“AS/NZS 109X” standard under development
MBIE guidance document under considerations

24. How the Scheme will work?
Designer specifies applicable Construction Category(s) (CC) for the steel structure.
Fabricators get certified either for “ISO 3834 PLUS” (CC3&4) or “AS/NZS 1554 PLUS” (CC2).
The certification is valid for 5 years with the annual surveillance audit.
The Scheme will start as a voluntary one eventually becoming a part of regulatory requirements.
The Scheme will be introduced in September 2014.

25. SFC Interactions Designers Fabricators Public Regulators Standards
Owners

27. Summary “ISO 3834 PLUS”
SCNZ and HERA introduces Steel Fabricator Certification (SFC).
The goal of the Scheme is to ensure safety and reliability of structural steelwork in NZ seismic environment.
The Scheme is largely based on the requirements of ISO 3834 with “PLUS” items added to reflect the local specific.
ISO 3834 Part 4 is not applicable. It was replaced by auditable compliance with AS/NZS
ISO 3834 Part 3 was replaced by Part 2 due to “PLUS” requirements.

28. THE END