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Contents:TOP 1. Scope
2. Standards
3. Basic principles
3.1 Prerequisites
3.2 Imperfections
3.3 Quality requirements
3.4 Quality grades and quality levels
3.5 Types of stress
3.6 Strength calculation
3.7 Penetration welding
4. Pysical properties
5. Workmanship standards
5.1 Necessary welder evaluations
5.2 Necessary joint preparation
5.3 Incomplete penetration
5.4 Single or double sided welding
5.5 Relative implementation costs
6. Evaluations and tests
6.1 Evaluation
6.2 Scope of testing and quality level
6.3 Test method
6.4 Special testing provisions
7. Selecting quality grade
7.1 Quality level based on general requirements
7.2 Quality level based on general influencing factors
8. Selection of welding process and joint shape
9. Drawing data
9.1 Drawing of a weld joint with quality level 3
9.2 Joint drawing upon modified testing scope
9.3 Joint drawing of prescribed welding process
10. Illustration and term definition
10.1 Cracks, cavities, solid inclusions and incomplete fusion
10.2 Incomplete penetration
10.3 Face or root gap b

1. Scope This standard shall serve as a guideline for selection of quality grades of fusion welded joints in
steel for elevator constructions as well as clarification of basic principles and how quality grades
relate to quality requirements and evaluation of weld joints.

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2. Standards 1. EN 287-1, "Approval testing of welders - Fusion welding - Part 1: Steels"

2. EN ISO 6520-1, "Welding and allied processes - Classification of geometric imperfections
in metallic materials - Part 1: Fusion welding"
3. ISO 5817, "Fusion welded joints in steel, nickel, titanium and their alloys
(beam welding excluded) - Quality levels for imperfections"
4. Work sheet DVS 0705, "Recommendations regarding Quality Level Selection in accordance
with EN 25817 and ISO 5817, Butt Welds and Fillet Welds in Steel"
5. DIN 15018 Part 1, "Cranes, Steel structures, Verification and analyses"

This document has to be archived according to ON 0-10310 A4pt/Valid from1. April 06

Modification Ae 0 Ae 1 Ae 2 Ae 3 Ae 4 Ae 5 Ae 6 Prepared 10-08-27 halterma

KA No. 941132 Reviewed 10-08-27 hosslegr
KA Date 10-08-27 Norms chkd 10-08-27 minged
Released 10-08-27 halterma
Remark
Welding, Quality Grades Replaces / Mod.
Basis Drawing No Pg. Format
Guidlines for Selection xxxxx
xxxxx 10 A4
Classification Lead Office Page Lang.
INVENTIO AG CH-6052 Hergiswil NOK NOK N49900116 1 EN
Copyright © 2006 INVENTIO AG All rights reserved .INVENTIO AG, Seestrasse 55, CH-6052 Hergiswil, owns and retains all copyrights and other intellectual property rights in this document. It shall
only be used by SCHINDLER personnel or authorized SCHINDLER agents for purposes which are in the interest of SCHINDLER. Any reproduction, translation, copying or storing in data processing units
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3. Basic 3.1 Prerequisites

principles
The presumption is made that quality, weld-able, unalloyed structural steel is used for all welded
elevator constructions, that customary surface treatments, such as protective coating,
galvanization, etc., are first used after the weld has been laid, and that environmental impact
through appropriate constructive or other measures shall normally have no effect on the physical
properties of the weld joints.

3.2 Imperfections

When fusion welded joints are created, six classes of imperfections are possible (2):
Nr. Group
1 Cracks
2 Cavities
3 Solid inclusions
4 Lack of fusion and penetration
5 Imperfect shape and dimension
6 Miscellaneous imperfections

These deviations from the ideal joint can result in loss of strength and, as relates to quality
requirements, additional costs for production and quality control Table 3

3.3 Quality requirements

Requirements for necessary properties (e.g. physical properties, thickness, corrosion resistance)
and workmanship (e.g. limits for imperfections, additional machining) of weld joints must be
specified in order to produce satisfactory welded joints.

The requirements must be defined and compliance must be verifiable. The verification can be
rendered on welded joints in components or on samples that are subject to similar conditions
(Standard N 944624 E, Section 1).

3.4 Quality grades and quality levels

As a means of classifying joints, specific quality grades have been defined for elevator construction
and quality levels with limits for imperfections for the evaluation of joint workmanship have been
established in accordance with E DIN EN ISO 5817 (Table 1 and Standard N 944624 E, Section
2).

Table 1: Quality Grades and Quality Levels with Limits for Imperfections

Schindler's quality grades Q4 Q3 Q2

Quality levels as per prEN ISO 5817 D C B
Limits for imperfections Moderate Intermediate Stringent

TOPTOP

4. Physical The appropriateness of the welded joint for static and dynamic stress depends on the function, joint
properties type, joint shape and workmanship as well as strength verification (Standard N 944655 E).
Examples of static and dynamic strength (in accordance with IIW recommendations) for quality
grades Q4, Q3, and Q2 in a butt weld with transverse load are found in Table 2:. In these
benchmarks, the effects of undercuts and imperfections are taken into account.
Table 2: Physical properties in an example of a butt weld with transverse load

Quality grade Q4 Q3 Q2
Quality level D C B

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Static strength approx. approx.

approx.100%1)
(Use of the tolerable stress) 50%2) 75%1)
Dynamic strength
401)/713) 631)/803) 711)/1003)
(vibration resistance)
1) Without special provisions
2) With special provision: Undercut not permitted in quality grade Q4
3) With special provisions: Various restrictions in accordance with limits.

5. The creation of fusion welded joints in accordance with quality requirements

Workmanship (Standard N 944624 E, Section 1) necessitates the establishment of standards.
standards For quality grades Q4, Q3 and Q2, Table 3 contains information on workmanship standards,
dimensional limits, procedures and benchmarks:
5.1 Necessary welder evaluations in accordance with EN 287 for quality grades Q3 and Q2.
5.2 Necessary joint preparation through cleaning and, if necessary, grinding
(Standard N 944631 E).
5.3 Incomplete penetration is permitted for quality grade Q4 to a limited extent; not permitted in
quality grades Q3 and Q2 (Standard N 944624 E, Section 2).
5.4 Single or double sided welding, necessary measures for the attainment of complete
penetration welding by back-gouging the root section and special measures for root welding when
only one side is accessible (Standard 944 631).

Table 3: Workmanship Standards

Quality grade Q4 Q3 Q2
Setup check and
Check as per EN Check as per EN
Welder evaluations practical know-
287 287
how for Q4
Joint preparation Cleaned bare, no Cleaned bare, Cleaned, no scale,
(Standard N 944631 E) scale. grind the fault rough grinding on
area the section
Incomplete penetration Permitted to a
Not permitted Not permitted
(Standard N 944624 E, Section 2) certain extent
Double sided welding Recommended Recommended Recommended
Necessary under
Back-gouge root section Not necessary Recommended
certain conditions1)
Special measures for root welding
when only one side is accessible Not necessary Recommended Necessary
(Standard N 944631 E)
Relative implementation costs
including scope of testing 100% 130% 160%
(benchmarks)
1)
Not necessary for established technology and special measures for the attainment of complete
penetration welding.

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6. Evaluations Proof of a quality grade is dependent on quality requirements, test feasibility, scope of testing and
and tests the necessary test method. Quality grade determines the scope of testing to be used and the test
method.
For quality grades Q4, Q3, and Q2, the corresponding procedure for the evaluation and testing of
joint workmanship is described in Table 4, Table 5, Table 6: und Table 7.
6.1 Evaluation of imperfections through interpretation of limits and diagrams
(Standard N 944624 E, Section 2)

6.2 Scope of testing and quality grade; Normally PU4 for quality grade Q4, PU3 for Q3 and
PU2 for Q2.

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6.3 Test method: Visual inspection; Radiography test (RT), Ultrasonic test (UT), miscellaneous
tests such as surface crack test and dimensional inspections of fillet welds.

6.4 Special testing provisions if the testing scope deviates from that of a normally classified
quality level and if special requirements are necessary (control plan). Test records of all
completed tests for quality grades Q3 and Q2 must be maintained as a control document.

Table 4: Evaluation of Joint Workmanship

Quality grade Q4 Q3 Q2
Acceptable
Localized small, short imperfections. Size subject to limits.
imperfections 1)
Surface crack, Surface crack,
copper inclusion, crater crack,
Surface crack, crater crack,
incomplete fusion, surface pore,
surface pore, crater pipe,
Unacceptable long incomplete fusion,
incomplete fusion,
imperfections 1) imperfections, e.g. incomplete
incomplete penetration,
related to penetration, burn
burn through, stray arc, etc.
incomplete through, stray arc,
penetration. poor restart, etc.
1) Interpretation of limits and diagrams in accordance with Standard N 944624 E, Part 2.

Table 5: Scope of Testing

Quality grade Q4 Q3 Q2
Scope of testing PU4 PU3 PU2

The tests can be defined as follows:

If unacceptable faults are detected during random sampling, the scope of testing is expanded as
follows:

Random sampling in % 5 10 15 25
1st Extension in % 10 30 20 50
2nd Extension in % 20 40 60 100

3rd Extension in % 100 100 100

In the event of unacceptable faults, the 1st, 2nd or 3rd extension is put into effect until the last
extension test results in no unacceptable faults.

Table 6: Test Methods

Quality grade Q4 Q3 Q2
Visual inspection 100% 100% 100%
Radiography test (RT)
Random sampling 10% RT or 25% UT
Throat thickness up to 16 mm
using RT or UT
Ultrasonic test Normally no RT or
based on 10% RT or 50 % UT or
(UT) UT test.
specification from specifically targeted
Throat thickness greater than welding supervisor RT
16 mm

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100% surface
inspection, liquid
penetration test,
Targeted surface magnetic crack
inspection, liquid inspection, e.g. for:
penetration test, a) Extremely high
Normally no
Surface inspection magnetic crack dynamic loads
surface inspection
inspection for
b) Wear-resistant
dynamic loads, e.g.
manganese steels
weld intersections
c) Other welded
joints vulnerable
to cracks

Dimensional inspections of fillet

10% 25% 50%
welds:

- If the test is difficult to interpret, the fault zone must be repaired and rechecked.
- Surface crack test is stipulated by engineering on the drawing.
Table 7: Special Test Provisions

Quality grade Q4 Q3 Q2
Scope of testing and As a basic principle, a quality grade is directly assigned a testing scope.
quality grade If necessary, a quality grade can be assigned a different scope of
testing. This must be stipulated on the drawing.
Special requirements If the tests in their designated or an expanded scope are to be stipulated
(Control plan) or monitored by the customer or public authorities, such must be marked
on the drawing. If necessary, a special control plan (welding sequence
plan) must be drawn up.
Test record An inspection record of all completed tests must
be compiled.

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7. Selecting Quality grades shall be stipulated by engineering, with the support of the welding supervisor if
quality grade necessary, in sequential order before the start of production. They shall also be recorded in the
documentation required for manufacturing and inspection.

a: Quality grade based on general requirements

b: Quality grade based on general influencing factors

7.1 Quality grade based on general requirements

7.1.1 In corporate constructions weld joints can be laid out and formed in such a way that they fall
into the category of quality grade Q4 or, if necessary Q3, and Q2 can be replaced by Q3.

7.1.2 Only as an exception on commission constructions can the use of quality grade 2 not
be dispensed with if it is due to country or customer-specific requirements (see above).

7.1.3 Fillet welds may not be rated higher than Q3 (unless there are special provisions) if the inner
inspection data indicates testing difficulty.

7.2 Quality grade based on general influencing factors

Taking general requirements into consideration, quality grade is to be selected based on the
following general influencing factors:

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- Type of stress
(static, dynamic)

- Material properties
(e.g. tendency for cold crack formation, brittle fracture, wear, lamellar tearing)

- Constructive conditions
(geometric influences, joint shapes)

- Stress
(stress concentration, undercut effect)

- Test feasibility
(accessibility, disruptive or non-disruptive test)

- Environmental impact
(corrosive or erosive)

- Machining
(metal-cutting, non-cutting, additional machining)

- Surface treatment
(protective coating, galvanizing)

- Costs
(manufacture, evaluation, testing, correction).

Quality grade Q4:

For welded joints that are subjected to intermediate static and slight dynamic stress, that must fulfill
minor requirements and whose failure would only affect the main functions of the construction as a
whole to a minor degree. Availability is only slightly impaired and can be restored with minimal
effort. No bodily injury is expected.

Quality grade Q3:

For welded joints that are subjected to intermediate static and intermediate dynamic stress
(pulsating stress) or must satisfy other moderate requirements and whose failure would
significantly affect the main functions of the construction as a whole. Availability is impaired but can
be restored with average effort. Bodily injury is not expected, but cannot be ruled out.

Quality grade Q2:

For welded joints that are subjected to great static and dynamic stress (fluctuating stress), that
must fulfill substantial requirements under hard terms and whose failure would result in total
breakdown of the main functions of the construction as a whole. Availability can only be restored
with great effort. Bodily injury is possible.

Quality grade Q1 has been eliminated under the terms of EN 25817 and EN ISO 5817. Thus,
no further reference shall be made to it in this standard.

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8. Selection After selection of quality grade, the welding process and corresponding joint shape
of welding (Standard N 944631 E) must be selected and identified with consideration given to quality
process and requirements.
joint shape Normally the welding process need not be indicated on the drawing, as it is stipulated by
production planning or the welding supervisor. The prescribed welding process is to be designated
as in 1.

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9. Drawing The drawings and illustrations of joints are defined in the section Welding Drawings. See the
data following examples.

9.1 Drawing of a weld joint with quality grade Q3:

Signifying:

9.2 Joint drawing upon modified testing scope:

Signifying

as per Table 5

9.3 Joint drawing of prescribed welding process:

Signifying

If the same quality level applies to all joints in a drawing, specification need only be made once on
an easily visible spot on the drawing. Quality grades deviating from this can be indicated in
parenthesis Q3(Q4).

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10. The described terms and the effects of welding faults and workmanship on strength are illustrated
Illustration and explained on the following welded joints with butt and fillet welds.
and term
10.1 Cracks, cavities, solid inclusions and incomplete fusion
definition
Imperfections such as cracks, cavities, solid inclusions and incomplete fusion are diagrammed in
Illustration 1.
Cracks Cavities

Solid inclusions Incomplete penetration

Illustration 1: Imperfections

If no test results are available, it is to be presumed that strength has been equally impaired through
similar size cavities, solid inclusions and incomplete fusion. The effect of cracks is greater. For
quality grades Q4, Q3 and Q2, cracks are not considered permissible imperfections
(Standard N 944624 E, Section 2).

10.2 Incomplete penetration, root face thickness, imperfect shape and dimension Internal
and external incomplete penetration, root face thickness, construction-dependent non-penetration
as well as imperfect shape and dimension due to tensile and bending stress are depicted in
Illustrations 2 through 7.
Tensile stress F Tensile stress F

Illustration 2: Incomplete penetration Illustration 3: Incomplete root penetration

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Tensile stress F and bending stress

Tensile stress F
M=F·e

Illustration 4: Non-penetration, Illustration 5: Non-penetration,

root face thickness c root face thickness c

Tensile stress F Tensile stress F and bending stress M = F · e

Illustration 7: Incomplete penetration,

Illustration 6: Incomplete penetration, poor fit
Insufficient throat thickness
During strength calculation, the general existing additional bending stress and the actual weld
throat thickness must be taken into account.

10.3 Face or root gap b

The distance between the weld faces before welding are designated as face or root gap b
(Standard N 944631 E).
This root gap b is not to be confused with incomplete penetration after welding.
The aim of selecting a specific face or root gap b is:
- Better accessibility with the electrode and thereby better likelihood of satisfactory
penetration welding (one/both sides or back-gouged/not back-gouged).

- Reduction of shrinkage stress (transverse shrinkage).

- Paying attention to shrinkage before welding by bearing in mind the degree of shrinkage
so as to obtain the stipulated finished size after welding.

As a rule, all joints to be penetration welded are to be prepared with root gap b (in stages by
TOP adding removable spacers, applying beads of adhesive, additional grinding, etc.)
In sound welds, root gap b is fully welded. See Illustration 8.

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Illustration 8: Face or root gap b

The size of root gap b depends on the joint shape (Standard N 944631 E).
Butt welds created without root gap b can best be classified under quality grade Q4.

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