AS/NZS 1554.2:2003
(Incorporating Amendment No. 1)
Australian/New Zealand Standard™
Structural steel welding
Part 2: Stud welding (steel studs
to steel)
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AS/NZS 1554.2:2003
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee WD-003, Welding of Structures. It was approved on behalf of the
Council of Standards Australia on 3 June 2003 and on behalf of the Council of
Standards New Zealand on 4 June 2003. It was published on 5 August 2003.
The following are represented on Committee WD-003:
Australian Chamber of Commerce and Industry
Australian Industry Group
AUSTROADS
Bureau of Steel Manufacturers of Australia
Electricity Supply Association of Australia
Institution of Engineers Australia
New Zealand Heavy Engineering Research Association
New Zealand Non-destructive Testing Association
New Zealand Welding School
Steel Reinforcement Institute of Australia
University of Sydney
Welding Technology Institute of Australia
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This Standard was issued in draft form for comment as DR 02616.
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AS/NZS 1554.2:2003
(Incorporating Amendment No. 1)
Australian/New Zealand Standard™
Structural steel welding
Part 2: Stud welding (steel studs
to steel)
Originated as AS CA 8.2—1972.
Previous edition AS 1554.2—1993.
Jointly revised and designated AS/NZS 1554.2:2003.
Reissued incorporating Amendment No. 1 (December 2003).
COPYRIGHT
© Standards Australia/Standards New Zealand
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Jointly published by Standards Australia International Ltd, GPO Box 5420, Sydney, NSW 2001
and Standards New Zealand, Private Bag 2439, Wellington 6020
ISBN 0 7337 5382 5
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AS/NZS 1554.2:2003 2
PREFACE
This Standard was prepared by the Standards Australia Committee WD-003, Welding of
Structures, to supersede AS 1554.2—1993.
This Standard incorporates Amendment No. 1 (December 2003). The changes required by
the Amendment are indicated in the text by a marginal bar and amendment number against
the clause, note, table, figure or part thereof affected.
The objective of this Standard is to provide requirements for the stud welding of steel studs
to steel elements.
This edition includes requirements for the welding of coated steels, including
(a) reference to AS 3597, AS/NZS 4360 and IEC 60974-1(see Appendix B); and
(b) amending Item 3.1(b) and the second paragraph of Clause 5.5.
Following publication of this edition, the Committee also intends to commence a full
revision of the Standard.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements to this Standard.
The term ‘normative’ has been used in this Standard to define the application of the
appendix to which it applies. A ‘normative’ appendix is an integral part of a Standard.
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3 AS/NZS 1554.2:2003
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE......................................................................................................................... 4
1.2 INNOVATION ............................................................................................................ 4
1.3 REFERENCED DOCUMENTS................................................................................... 4
1.4 DEFINITIONS............................................................................................................. 4
1.5 BASIC WELDING REQUIREMENTS ....................................................................... 5
1.6 SAFETY PRECAUTIONS .......................................................................................... 6
SECTION 2 MATERIALS OF CONSTRUCTION
2.1 GENERAL REQUIREMENTS FOR STUDS.............................................................. 7
2.2 STUD MATERIAL...................................................................................................... 8
2.3 PARENT MATERIAL............................................................................................... 10
SECTION 3 STUD APPLICATION QUALIFICATION
3.1 GENERAL................................................................................................................. 11
3.2 PREPARATION OF TEST SPECIMENS ................................................................. 11
3.3 TESTING................................................................................................................... 11
3.4 TEST DATA.............................................................................................................. 13
SECTION 4 PROCEDURAL CONTROL
4.1 PREPRODUCTION TESTING ................................................................................. 14
4.2 PRODUCTION WELDING....................................................................................... 15
4.3 STUD-WELDING OPERATORS QUALIFICATION .............................................. 15
SECTION 5 PRODUCTION TECHNIQUE AND WORKMANSHIP
5.1 PREPARATION BEFORE WELDING ..................................................................... 16
5.2 WELDING................................................................................................................. 16
5.3 STUD SPACING ....................................................................................................... 18
5.4 FINISHED WELDS................................................................................................... 18
5.5 STUD WELDING THROUGH SHEET METAL ...................................................... 18
5.6 WORKMANSHIP ..................................................................................................... 18
SECTION 6 TESTING OF FINISHED WELDS
6.1 NON-THREADED STUDS SHEAR CONNECTORS AND HEADED
CONCRETE ANCHORS........................................................................................... 20
6.2 THREADED STUDS................................................................................................. 20
6.3 USE OF TESTED STUDS......................................................................................... 21
6.4 ADDITIONAL TESTING FOR STUDS WELDED TO BEAMS WITH
ADVERSE SURFACE CONDITIONS...................................................................... 21
6.5 UNSATISFACTORY WELDS.................................................................................. 21
APPENDICES
A MATTERS FOR RESOLUTION............................................................................... 22
B LIST OF REFERENCED DOCUMENTS.................................................................. 23
C MANUFACTURER’S STUD BASE QUALIFICATION REQUIREMENTS ........... 25
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STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND
Australian/New Zealand Standard
Structural steel welding
Part 2: Stud welding (steel studs
to steel)
S E C T I O N 1 S C O P E A N D G E N E R A L
1.1 SCOPE
This Standard prescribes requirements for the stud welding of steel studs to steel elements,
such steel studs being used for the attachment of members and connection devices to
concrete (as concrete anchors and as shear connectors in composite steel/concrete
construction), and for the fastening of other members and appurtenances. It also applies to
the stud welding of steel studs through light-gauge steel sheet either coated or not coated,
and includes requirements for the stud material, the parent material, the qualification of
stud bases, stud welding procedure and operators, and the workmanship and testing of the
finished welds.
This Standard does not apply to the welding of studs to pressure vessels.
A list of matters for resolution between the principal and fabricator is given in Appendix A.
1.2 INNOVATION
Any novel materials, welding processes or consumables, or methods of construction that do
not comply with a specific requirement of this Standard, or are not mentioned in it, but
which give equivalent results to those specified, are not necessarily prohibited. The
Standards Australia Committee on Welding of Structures can act in an advisory capacity
concerning equivalent suitability, but specific approval remains the prerogative of the
inspecting authority.
1.3 REFERENCED DOCUMENTS
A list of documents referred to in this Standard is given in Appendix B.
1.4 DEFINITIONS
For the purpose of this Standard, the definitions given in AS 2812 and those below apply.
1.4.1 Fabricator
The person or organization responsible for the welding of the structure during fabrication or
erection.
1.4.2 Inspecting authority
The building authority having statutory powers to control the design and erection of
buildings or structures.
NOTE: Where the structure is not subject to statutory jurisdiction, the principal is deemed to be
the inspecting authority.
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1.4.3 Inspector
A person employed by or acceptable to the inspecting authority or principal for the purpose
of inspecting welding in accordance with this Standard.
1.4.43 May
Indicates the existence of an option.
1.4.5 Principal
The purchaser or owner of the structure being fabricated or erected or his/her nominated
representative.
1.4.6 Ring test
Tapping a stud with 3 kg (approximately) hammer in the direction of the beam—if the stud
gives a ‘ring’ sound, it passes the test; if it gives a ‘dead’ sound it fails the test.
1.4.7 Shall
Indicates a requirement.
1.4.8 Shear connector
A stud to transmit shear between a steel member and a concrete element in a composite
construction.
1.4.9 Should
Indicates a recommendation.
1.4.10 Stud
A short length of rod or bar, which may take a variety of shapes to suit the individual
application.
1.4.11 Stud base
The stud tip at the welding end, including flux and ferrule and 3 mm of the body of the stud
adjacent to the tip.
1.4.12 Stud welding operator
The person who performs the stud welding operation.
1.4.13 Wet weather capable
A stud-welding machine designed to safely weld in damp or wet conditions (Category C
environment, see AS 1674.2), incorporating a cycle that preheats the site to which a stud
will be welded for sufficient time to dry the affected area prior to the welding of the stud.
1.5 BASIC WELDING REQUIREMENTS
The basis of this Standard is that stud welds shall—
(a) only use studs or shear connectors with qualified stud bases;
(b) be made in accordance with a qualified stud-welding procedure;
(c) be made by a welder suitably qualified to carry out such a procedure; and
(d) comply with all the appropriate requirements of this Standard.
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1.6 SAFETY PRECAUTIONS
1.6.1 Welding safety
Welding shall be carried out in accordance with the following Standards:
AS 1470, AS 1674.1, AS 1674.2, AS/NZS 1336, AS/NZS 1337, AS/NZS 1338.1,
AS/NZS 2865.
1.6.2 Welding equipment
Welding plant and equipment shall comply with all relevant sections of appropriate
regulations, and the following Standards:
AS 1966.1, AS 1996.2, AS 2799, AS/NZS 1995, IEC 60974-1.
1.6.3 Other hazards
The fabricator shall identify and manage other risks and hazards of welding not controlled
by Clauses 1.6.1 and 1.6.2. In particular, due consideration shall be given to the control and
dispersal of emitted fume, especially when welding through paints, primers and other
surface coatings.
NOTES:
1 Guidance on the management of risk is given in AS/NZS 4360.
2 For further guidance on safety precautions, refer to WTIA Technical Notes 7 and 22.
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S E C T I O N 2 M A T E R I A L S O F C O N S T R U C T I O N
2.1 GENERAL REQUIREMENTS FOR STUDS
2.1.1 Stud design
Studs shall be of a design suitable for arc welding to steel members with automatically
timed stud welding equipment. The type, size or diameter, and length of stud shall be as
specified by the drawings, specifications, or special provisions, as approved by the
principal. The dimensions and tolerances of standard-type headed shear connectors are
given in Figure 2.1.
Shank diameter
(C)
Length (L)
tolerance
Head diameter
(H)
Minimum head
height (T)
12.7 +0.00
−0.25
±1.6 25.4 ±0.4 7.1
15.9 +0.00
−0.25
±1.6 31.7 ±0.4 7.1
19.0 +0.00
−0.38
±1.6 31.7 ±0.4 9.5
22.2 +0.00
−0.38
±1.6 34.9 ±0.4 9.5
NOTE: L = manufactured length before welding.
DIMENSIONS IN MILLIMETRES
FIGURE 2.1 DIMENSIONS AND TOLERANCES FOR
STANDARD-TYPE HEADED SHEAR CONNECTORS
2.1.2 Ferrule
A ferrule of heat-resistant ceramic or other suitable material shall be furnished with each
stud.
The type of ferrule used shall be appropriate to the application.
NOTE: Ferrules for clean beam welding are different to ferrules for through deck welding and the
two must not be interchanged. Ac
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2.1.3 Flux
A suitable deoxidizing and arc stabilizing flux for welding shall be furnished with each stud
of 8.00 mm diameter or larger. Studs less than 8.00 mm in diameter may be supplied with
or without flux.
2.1.4 Stud bases
Only studs with qualified stud bases shall be used. A stud base, to be qualified, shall
comply with the test requirements prescribed in Appendix C. The ferrule used in production
shall be the same as used in stud base qualification tests or as recommended by the stud
manufacturer. Qualification of stud bases in accordance with Appendix C shall be the
responsibility of the stud manufacturer.
2.1.5 Manufacture
Stud manufacture shall be by heading, rolling or machining techniques. Finished studs shall
be of uniform quality and condition, free of injurious laps, fins, seams, cracks, twists, bends
or other injurious discontinuities or defects.
Radial cracks or bursts in the head of a stud shall not be the cause for rejection, provided
that the cracks or bursts do not extend more than half the distance from the head periphery
to the shank as determined by visual examination.
When requested by the principal or the inspecting authority, the fabricator shall provide the
following information:
(a) A description of the stud and ferrule.
(b) Certification from the stud manufacturer that the stud base is qualified as specified in
Clause 2.1.4. Such certification shall include copies of certified results of laboratory
tests required, as specified in Appendix C.
2.2 STUD MATERIAL
2.2.1 Manufacture
Studs shall be made from cold-drawn stock complying with the requirements of AS 1443,
Grades 1010 through 1020, either semi-killed or fully killed steel.
2.2.2 Mechanical properties
2.2.2.1 General
Mechanical properties of studs shall be determined by tensile testing either the steel after
cold finishing or the full diameter finished studs, in accordance with AS 1391.
2.2.2.2 Testing
Tests shall be made on tensile test specimens obtained in accordance with AS 1391, or on
finished studs welded to test plates of AS 3678 Grade 250 steel, using a test fixture similar
to that shown in Figure 2.2, or a tensile machine that grips the ends of the studs in the jaws
of the machine. Plates of adequate size may be fillet welded to the unwelded end for studs
without heads. The rate of straining when approaching the yield point shall lie within the
highest range of strain rate given in AS 1391.
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FIGURE 2.2 TYPICAL TENSILE TEST FIXTURE
2.2.2.3 Requirements
Unless otherwise specified by the principal or the inspecting authority in accordance with
Appendix A, the mechanical properties of the studs shall comply with Table 2.1.
TABLE 2.1
MECHANICAL PROPERTIES OF STUDS
Property
Shear connectors
(Note 1)
Other than shear
connectors (Note 2)
Minimum tensile strength 410 MPa 380 MPa
Minimum yield strength (0.2% proof
stress)
345 MPa Not applicable
Minimum elongation on 5.65 √S
o
(where S
o
= the original cross-sectional
area within the gauge length) (Note 3)
12% 10%
Minimum reduction in area 50% 50%
NOTES:
1 Studs that are headed, bent or of other configuration in 12.7 mm, 15.9 mm, 19 mm,
and 22.2 mm diameter are used as an essential component in composite beam design
and construction.
2 General purpose studs of any type and size used for purposes other than shear
transfer in composite beam design and construction.
3 If the elongation is measured on a 50 mm gauge length, it shall comply with the
following values:
Stud
diameter
Minimum elongation, %
mm
Shear
connectors
Other than shear
connectors
12.7
15.9
19.0
22.2
13
14
16
17
11
12
13
14
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2.2.2.4 Validity of tests
The test result shall be regarded as valid, irrespective of the position of fracture, provided
that the specified minimum elongation has been obtained. If the specified minimum
elongation has not been obtained, the results of the test shall, unless otherwise agreed by
the principal or the inspecting authority, be discounted if the distance between the fracture
and the near gauge mark is less than one-third of the gauge length or if fracture occurs
outside the gauge leng