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PD 6705-3 - 2009

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229 views28 pages

PD 6705-3 - 2009

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Pedro Baltazar
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© © All Rights Reserved
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PD 6705-3:2009

BSI Standards Publication

PUBLISHED DOCUMENT

Structural use of steel


and aluminium
Part 3: Recommendations for the execution
of aluminium structures to BS EN 1090-3

This publication is not to be regarded as a British Standard.


PD 6705-3:2009 PUBLISHED DOCUMENT

Publishing and copyright information


The BSI copyright notice displayed in this document indicates when the
document was last issued.

© BSI 2009

ISBN 978 0 580 65116 8

ICS 91.080.10

The following BSI reference relates to the work on this standard:


Committee reference B/525/9

Publication history
First published December 2009

Amendments issued since publication

Date Text affected


PUBLISHED DOCUMENT PD 6705-3:2009

Contents
Foreword ii
1 Scope 1
2 Normative references 1
3 Terms and definitions 2
4 Recommendations for the use of BS EN 1090-3 2
4.1 General 2
4.2 Service category 3
4.3 Execution classes 3
4.4 Specification and documentation 3
4.5 Constituent products 4
4.6 Preparation 5
4.7 Welding 5
4.8 Mechanical fastening and adhesive bonding 7
4.9 Corrosion protection 9
4.10 Inspection, testing and corrections 10
Bibliography 21
List of tables
Table 1 – Maximum diameter of pores 4
Table 2 – Bedding torque values for Step 1 of the part-turn method 8
Table 3 – Rotation values for Step 2 and Step 3 of the part-turn
method 9
Table 4 – Minimum extent of supplementary NDT of shop welds in all
alloys, except 7***, for EXC2 and quantified service category F20 14
Table 5 – Adjustments in proportions of NDT for conditions other than
those covered by Table 4 and Table 6 14
Table 6 – Minimum extent of supplementary NDT of shop welds in
all alloys, except 7***, for EXC2 and quantified service categories
F25 to F63 15
Table 7 – Weld acceptance criteria for visual inspection 16
Table 8 – Weld acceptance criteria for visual inspection for
quantified service categories F25 to F63 where limits different
from F20 in Table 7 18
Table 9 – Weld acceptance criteria for penetrant testing 19
Table 10 – Weld acceptance criteria for ultrasonic testing with limited
optional radiographic testing 20

Summary of pages
This document comprises a front cover, an inside front cover,
pages i to ii, pages 1 to 22, an inside back cover and a back cover.

© BSI 2009 • i
PD 6705-3:2009 PUBLISHED DOCUMENT

Foreword
Publishing information
This part of PD 6705 is published by BSI and came into effect on
31 December 2009. It was prepared by Subcommittee B/525/9,
Structural use of aluminium. A list of organizations represented on
this committee can be obtained on request to its secretary.

Relationship with other publications


This Published Document gives guidance on the use of BS EN 1090-3
for the execution of aluminium structures in the UK.

Information about this document


BS EN 1090-3 will replace BS 8118-2 after a period of coexistence. The
replacement of BS 8118-2 will represent a substantial change in design
practice in the UK. The purpose of this Published Document is to
ensure that aluminium structures will be executed with the same level
of assurance of reliability as that implicit in BS 8118-2.
The guidance given in this Published Document consists of
non-contradictory complementary information (NCCI) to enable the
user to apply BS EN 1090-3 in a safe and cost-effective manner, with
particular reference to the following:
a) selection of options where they are defined in BS EN 1090-3;
b) alternative information where permitted in BS EN 1090-3.

Presentational conventions
The provisions in this Published Document are presented in roman
(i.e. upright) type. Its recommendations are expressed in sentences in
which the principal auxiliary verb is “should”.
Commentary, explanation and general informative material is presented
in smaller italic type, and does not constitute a normative element.

Contractual and legal considerations


This publication does not purport to include all the necessary provisions
of a contract. Users are responsible for its correct application.
Compliance with a Published Document cannot confer immunity from
legal obligations.

ii • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

1 Scope
This part of PD 6705 gives guidance on the use of BS EN 1090-3 for the
execution of aluminium structures designed to BS EN 1999.
It is applicable to the same scope of application as in BS EN 1090-3,
unless otherwise stated.
The specification information included in this document is applicable
only when the design guidance in PD 6702-1 has been followed.

2 Normative references
The following referenced documents are indispensable for the
application of this document. For dated references, only the edition
cited applies. For undated references, the latest edition of the
referenced document (including any amendments) applies.
BS EN 1011-4:2000, Welding – Recommendations for welding of
metallic materials – Part 4: Arc welding of aluminium and aluminium
alloys
BS EN 1011-6, Welding – Recommendation for welding of metallic
materials – Part 6: Laser beam welding
BS EN 1011-7, Welding – Recommendation for welding of metallic
materials – Part 7: Electron beam welding
BS EN 1090-3:2008, Execution of steel structures and aluminium
structures – Part 3: Technical requirements for aluminium structures
BS EN 1289:1998, Non-destructive testing of welds – Penetrant testing
of welds – Acceptance levels
BS EN 1435:1997+A2:2004, Non-destructive testing of welds –
Radiographic testing of welded joints
BS EN 1714:1998+A2:2004, Non-destructive testing of welds –
Ultrasonic testing of welded joints
BS EN 1999, Eurocode 9: Design of aluminium structures
BS EN 1999-1-1:2007, Eurocode 9: Design of aluminium structures –
Part 1-1: General structural rules
BS EN 1999-1-3:2007, Eurocode 9: Design of aluminium structures –
Part 1-3: Structures susceptible to fatigue
BS EN 14399-3:2005, High-strength structural bolting assemblies for
preloading – Part 3: System HR Hexagon bolt and nut assemblies
BS EN ISO 6520-1:2007, Welding and allied processes – Classification of
geometric imperfections in metallic materials – Part 1: Fusion welding
BS EN ISO 7093-1:2000, Plain washers – Large series – Part 1: Product
grade A
BS EN ISO 10042:2005, Welding – Arc-welded joints in aluminium and
its alloys – Quality levels for imperfections
BS EN ISO 13919-2:2001+A1:2004, Welding – Electron and laser beam
welded joints – Guidance on quality levels for imperfections – Part 2:
Aluminium and its weldable alloys
BS EN ISO 15612, Specification and qualification of welding
procedures for metallic materials – Qualification by adoption of a
standard welding procedure

© BSI 2009 • 1
PD 6705-3:2009 PUBLISHED DOCUMENT

BS EN ISO 15614-11, Specification and qualification of welding


procedures for metallic materials – Welding procedure test – Part 11:
Electron and laser beam welding
BS EN ISO 25239-3, Friction stir welding – Aluminium – Part 3:
Qualification of welding operators 1)
BS EN ISO 25239-4, Friction stir welding – Aluminium – Part 4:
Specification and qualification of welding procedures 1)
BS EN ISO 25239-5, Friction stir welding – Aluminium – Part 5: Quality
and inspection requirements 1)
PD 6702-1, Structural use of aluminium – Part 1: Recommendations for
the design of aluminium structures to BS EN 1999

3 Terms and definitions


For the purposes of this part of PD 6705, the terms and definitions
given in BS EN 1090-3 and PD 6702-1 apply.

4 Recommendations for the use of


BS EN 1090-3

4.1 General
The recommendations in this part of PD 6705 are based on the
National Annexes to BS EN 1999 and the design recommendations
in PD 6702-1, which provides non-contradictory complementary
information on the design rules in BS EN 1999.
Guidance is given in PD 6702-1 on the selection of execution class,
which is one of the means of providing different levels of reliability of
structural performance. This is achieved in BS EN 1090-3 by varying the
level of assurance that the quality standards assumed in deriving the
BS EN 1999 resistance data have been met in construction.
A major factor in the determination of the quality requirements is the
degree of cyclic loading which the structural components need to resist.
BS EN 1999-1-3 does not provide normative fatigue design data and
the informative fatigue data in BS EN 1999-1-3:2007, Annex J, have not
been accepted by the UK. Alternative fatigue rules are instead given in
PD 6702-1. These latter rules are consistent with a set of quality levels,
based on fitness for purpose, which are different from those given
in BS EN 1999-1-3:2007, Annex J, and BS EN 1090-3. Furthermore, the
quality levels assumed in PD 6702-1 are based on specific methods and
extents of inspection unlike those given in the European Standards.
The quality levels and extents of inspection in BS EN 1090-3 are
differentiated on the basis of two service categories depending on
whether the structure/component is classified as “predominantly
static” or “significant fatigue”. There is no further definition in
BS EN 1090-3 as to how these two conditions are to be differentiated
in a quantitative way.

1)
In preparation.

2 • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

In order to overcome these impediments to safe use, PD 6702-1 has


adapted the principle of the service category to provide a set of
fully quantified service categories which are used to define in this
document the extents of inspection and acceptance levels that are
compatible with the recommended design rules in PD 6702-1 (see 4.2).
For these reasons it is essential that the recommendations of this
document are followed for execution when the recommendations in
PD 6702-1 have been used for the design.
Additional information has been given in accordance with
BS EN 1090-3:2008, Table A.1 and Table A.2, except where it relates
to matters which might be dependent on a specific project.

4.2 Service category (see BS EN 1090-3:2008, 3.13)


These recommendations make use of the following quantified
service category designations in increasing order of performance
requirement: F12, F20, F25, F31, F40, F50, F63 (see 4.1).
If no quantified service category is specified for a structure, component
or part of a component, it should be assumed that F20 applies.
NOTE 1 The background to the quantified service category designations
can be found in PD 6702-1.
NOTE 2 The following subclauses of this document contain
recommendations which are differentiated on the basis of quantified
service category: 4.5.1, 4.5.2, 4.6.1, 4.6.3, 4.7.4, 4.8.1, 4.10.1.2, 4.10.2,
4.10.3, 4.10.4 and 4.10.5.

4.3 Execution classes (see BS EN 1090-3:2008, 3.8 and 4.1.2)


It should be noted that the execution class (EXC) provides a measure
of the degree of assurance that the work has or will be carried out to
the required quality. This is primarily differentiated by the extent of
documented records as well as procedure and product testing. It does
not define the quality requirement itself, which is dependent on the
service category (see 4.2).
NOTE The following subclauses of this document contain additional
recommendations relating to those requirements in BS EN 1090-3 which
are differentiated on the basis of execution class: 4.4.1, 4.4.2, 4.7.2, 4.7.3,
4.7.5, 4.7.6, 4.8.2 and 4.10.3.

4.4 Specification and documentation

4.4.1 Quality documentation (see BS EN 1090-3:2008, 4.2.1


and Annex B)
It is recommended that BS EN 1090-3:2008, 4.2.1, items a) to f) are
documented for EXC2, regardless of whether this documentation has
been specified.

4.4.2 Quality plan (see BS EN 1090-3:2008, 4.2.2 and Annex B)


It is recommended that a quality plan appropriate to the work and
based on BS EN 1090-3:2008, Annex B, is prepared wherever EXC2,
EXC3 or EXC4 is specified.

© BSI 2009 • 3
PD 6705-3:2009 PUBLISHED DOCUMENT

4.5 Constituent products

4.5.1 Wrought products (see BS EN 1090-3:2008, 5.3 and Table 1)


Where hollow extrusions formed by a porthole or bridge die are
used to carry tension transverse to the direction of extrusion, special
precautions should be taken during the extrusion process to verify
that the die seam welds are structurally sound. These precautions are
as follows.
a) The start, finish and intermediate billet-to-billet joint positions in
each extruded length should be identified.
b) Sample sections from the extrusion should be cut out from the
locations identified in item a). Where more than one cell exists in
the cross-section, two adjacent sections should be cut out.
c) Alternate cells in the first cross-section should be subjected to
expansion by forcing a tapered mandrel or “drift” into the cell
until tearing occurs. This process should be repeated on the
adjacent cells in the second section.
d) The tear fracture faces should be examined for evidence of poor
bonding and low ductility of the extrusion weld.
e) If evidence of poor bonding is found, further sections should be
taken from the extrusion and retested as in items c) and d) until
sound lengths of extrusion are revealed.
f) Where it is practicable to conduct transverse tensile tests from
samples taken from seam weld locations, the mechanical properties
should be shown to conform to the relevant product standard.
g) In critical cases where a high transverse tensile utilization grade
is required or where the quantified service category exceeds F20
in the transverse direction, it is recommended that the billet is
subjected to non-destructive testing (NDT) to prove that it is free
from internal flaws.

4.5.2 Castings (see BS EN 1090-3:2008, 5.3 and Table 3)


It is recommended that the guidance given in BS EN 1999-1-1:2007,
C.3.4.2, is followed with the exception that the maximum diameter
of pores given in BS EN 1999-1-1:2007, C.3.4.2(2), item b) should not
be used. The maximum diameter of pores should instead conform to
Table 1.

Table 1 Maximum diameter of pores

Quantified service category Maximum pore size


mm
F12 4,0
F20 3,0
F25 2,2
F31 1,5
F40 0,9
F50 0,5
F63 0,3

4 • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

If castings require subsequent machining, the machined surfaces


should be subject to further surface inspection prior to incorporation
into the structure.

4.5.3 Welding consumables (see BS EN 1090-3:2008, 5.5)


The combination of parent material and consumable should conform
to BS EN 1011-4:2000, Table B.2, unless otherwise specified. Where
there is a choice of consumable type in this table, the criteria for
selection should be agreed with the project specifier.
In all cases, the consumable should be of the same type used to
qualify the weld procedures used for the project.

4.6 Preparation

4.6.1 Identification (see BS EN 1090-3:2008, 6.2)


Hard stamps should not be used in the following circumstances:
a) on 7000 alloy material;
b) where quantified service categories above F20 are required;
c) on thin material where denting might occur;
d) where otherwise forbidden by the specifier.
The same restrictions apply to soft or low stress stamps except that
they should not be used where quantified service categories above F31
are required.

4.6.2 Holing for fasteners (see BS EN 1090-3:2008, 6.6)


Where holes are drilled in parts assembled and tightly clamped
together, burrs on faying surfaces only need to be removed if the
parts are subsequently separated prior to final assembly.

4.6.3 Assemblies (see BS EN 1090-3:2008, 6.9)


Complete or staged assemblies of structures should be used in the
following circumstances:
a) where close dimensional tolerances are necessary in the final
structure for functional reasons;
b) where the fit-up of butting pre-loaded bolted joints is critical to
the ductility or fatigue performance of the joint. In the latter case,
quantified service categories above F20 should be considered.

4.7 Welding

4.7.1 Welding processes (see BS EN 1090-3:2008, 7.3)


Welding may be carried out by the following processes subject to the
recommendations in 4.7.2, 4.7.3, 4.7.4, 4.7.5, 4.10.3.2, 4.10.4.2, 4.10.5.2
and 4.10.5.3:
a) laser beam welding;
b) electron beam welding;
c) friction stir welding.

© BSI 2009 • 5
PD 6705-3:2009 PUBLISHED DOCUMENT

4.7.2 Qualification of welding procedures


(see BS EN 1090-3:2008, 7.4.1 and 7.5.1)

4.7.2.1 Arc welding


Qualification by means of BS EN ISO 15612 for EXC2 should only be
allowed for 3*** and 5*** wrought alloys.

4.7.2.2 Laser and electron beam welding


Qualification of procedures should be in accordance with
BS EN ISO 15614-11.
Procedure examination and testing should be in accordance with
BS EN ISO 13919-2:2001+A1, acceptance level B.

4.7.2.3 Friction stir welding


Qualification of procedures should be in accordance with
BS EN ISO 25239-4 2).
Eddy current and ultrasonic testing should be performed on butt weld
test pieces prior to sectioning. Indications should be examined by
macro-section. Cracks, lack of bond, lack of penetration and cavities
should be cause for rejection. Any evidence of inadequate bond might
require further investigation by transverse root and face bend testing.
NOTE Ultrasonic testing might require the use of specialist methods,
such as phased array.

4.7.3 Qualification of welding operators


(see BS EN 1090-3:2008, 7.4.3 and 7.5.1)

4.7.3.1 Laser beam and electron welding


The guidance given in BS EN 1011-6 for laser beam welding personnel
and BS EN 1011-7 for electron beam welding personnel should be
followed.

4.7.3.2 Friction stir welding


Friction stir welding operators should be qualified in accordance with
BS EN 25239-3 2).

4.7.4 Welding co-ordination personnel


(see BS EN 1090-3:2008 7.4.4, 7.5.1 and Table 7)
For EXC2 and parent metal other than 3*** and 5*** alloys, specific
technical knowledge should be sought for all thicknesses.

4.7.5 Preparation and execution of welding


(see BS EN 1090-3:2008, 7.5.1)

4.7.5.1 Laser beam welding


Laser beam welding should be carried out in accordance with
BS EN 1011-6.

2)
In preparation; due to be published in 2010.

6 • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

4.7.5.2 Electron beam welding


Electron beam welding should be carried out in accordance with
BS EN 1011-7.

4.7.5.3 Friction stir welding


Friction stir welding should be carried out in accordance with
BS EN 25239-5 3), with the exception that the scope of inspection and
testing and the acceptance standards for production welds should
be agreed between the contracting parties prior to fabrication
(see 4.10.3, 4.10.4 and 4.10.5).

4.7.6 Temporary attachments (see BS EN 1090-3:2008, 7.5.5)


Welded temporary attachments should only be permitted when the
designer is satisfied that the effects on strength have been allowed for.
It is recommended that welded temporary attachments are not
permitted in the following conditions:
a) where the attachments are not removed and the quantified
service category exceeds F20;
b) when the attachments are removed, ground flush, subjected to
surface NDT and the quantified service category exceeds F31.

4.7.7 Tack welds (see BS EN 1090-3:2008, 7.5.6)


The requirements specified for EXC3 and EXC4 regarding their inclusion
in the welding procedure specification should also be applied to EXC2.

4.7.8 Run-on/run-off pieces (see BS EN 1090-3:2008, 7.5.8)


Run-on/run-off pieces should be used for EXC2.

4.8 Mechanical fastening and adhesive bonding

4.8.1 Nut locking devices (see BS EN 1090-3:2008, 8.2.5 and 8.3.1)


Nut locking devices in non-pre-loaded assemblies should be used:
a) in lap joints where load reversal is expected in service;
b) in joints where a quantified service category exceeding F20 is used.

4.8.2 Nut designation markings (see BS EN 1090-3:2008, 8.2.5)


For EXC2, nuts above grade 4 should be assembled with their grade
designations visible. However, this might not be necessary if only one
grade of nut is being used in the project for each size of bolt and
the nuts are assembled randomly (with a 50% probability that the
designation is showing).

4.8.3 Oversized washers (see BS EN 1090-3:2008, 8.2.6)


Oversized washers should be used where oversized or slotted holes
are specified.

3)
In preparation; due to be published in 2010.

© BSI 2009 • 7
PD 6705-3:2009 PUBLISHED DOCUMENT

Oversized washers to BS EN ISO 7093-1:2000, hardness class 300,


are recommended where pre-loaded bolts are used in joints where
the minimum specified proof strength of the parent metal is less
than 150 MPa.
NOTE BS EN 1999-1-1:2007, 8.5.9.1(1) specifies that the minimum
specified proof strength of the parent metal is to be greater than 200 MPa
for joints designed as slip-resistant joints with pre-loaded bolts.

4.8.4 Tightening of pre-loaded connections


(see BS EN 1090-3:2008, 8.3.2)
The part-turn method may be used for tightening pre-loaded Grade 8.8
bolts to BS EN 14399-3:2005 (HR type). Nuts to BS EN 14399-3:2005,
Property Class 10, are recommended in the case of coated bolts, to
reduce any risk of thread stripping. Ko bolt assemblies may be used,
which do not need certified load/torque characteristics.
NOTE The part-turn method has been used as a standard method of
tightening Grade 8.8 bolts in slip resistance joints in the UK and provides
preloading forces in accordance with those given in BS EN 1090-3:2008,
Table 8. Advantages of this method over the torque method are:
a) the lack of dependence on torque/load characteristics;
b) reduced risk of overstretching of the bolt;
c) achievement of higher margins in practice above the preloading
forces in BS EN 1090-3:2008, Table 8.
Step 1 of the tightening procedure for the part-turn method involves
tightening all nuts in the joint to a bedding torque. This might require
more than one torquing cycle. The bedding torque values should be in
accordance with Table 2.

Table 2 Bedding torque values for Step 1 of the part-turn method

Bolt diameter (d) Bedding torque


mm Nm
16 80
20 160
22 210
24 270
27 340
30 460

Step 2 of the tightening procedure involves indelibly marking all the


nuts and the ends of the bolt threads at the same polar location,
followed by applying rotations to the nuts relative to the bolts in
accordance with Table 3.
Step 3 of the tightening procedure involves applying a further nut
rotation, not less than 72 hours after Step 2, in accordance with Table 3.

8 • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

Table 3 Rotation values for Step 2 and Step 3 of the part-turn method

Total grip thickness (tg) A) Rotation


Step 2 Step 3
mm ° °
tg G 5d 180 (½ turn) 45 (1⁄8 turn)
5d < tg G 10d 270 (¾ turn) 45 (1⁄8 turn)
A)
Includes packing and washers; d = bolt diameter.

4.8.5 Adhesive bonded joints (see BS EN 1090-3:2008, 8.6)


The correct performance of adhesive bonded joints is only obtained
if the recommendations of the adhesive manufacturer are followed
rigorously.
Therefore, a work procedure should be prepared, based on the
manufacturer’s instructions, and should include the following:
a) the full designation of the adhesive products;
b) the surface preparation of the parts;
c) the method of jigging and clamping the parts;
d) the method of preparing/mixing the adhesive products;
e) the tolerance limits on fit up;
f) the method of applying the adhesive to the parts;
g) restrictions on environment (e.g. temperature, humidity);
h) restrictions on time for the following operations;
• maximum shelf-life (storage before use);
• minimum mixing time;
• maximum time between mixing and joint closure;
• minimum clamping time;
• minimum curing time prior to application of load;
i) inspection stages (see 4.10.7).
Where specific prior test data do not exist, a procedure test piece
should be prepared and subjected to load test to qualify the procedure.
A similar test may be carried out to quantify the operative carrying out
the work.

4.9 Corrosion protection


(see BS EN 1090-3:2008, Clause 10 and Annex F)
BS EN 1999-1-1:2007, Annex D, gives background information on the
need for corrosion protection.

© BSI 2009 • 9
PD 6705-3:2009 PUBLISHED DOCUMENT

4.10 Inspection, testing and corrections

4.10.1 Constituent products (see BS EN 1090-3:2008, 12.2.1)

4.10.1.1 Prior to fabrication


BS EN 1090-3:2008, 12.2.1, states that there are no requirements for
specific testing of constituent products unless specified. The specification
of testing should be deemed to include any testing requirements in the
product standards specified by BS EN 1090-3. For example, in the case
of EXC2, EXC3 or EXC 4, BS EN 1090-3:2008, 5.2, requires an inspection
certificate 3.1, which relates to specific testing.

4.10.1.2 After fabrication


Accessible surfaces of parent metal should be inspected by the
penetrant method when the following conditions apply:
a) machined or ground surfaces which require a quantified service
category of F50 or above;
b) hollow extrusions where a quantified service category of F25
or above is required in the direction transverse to the extrusion
direction.

4.10.2 Methods of inspection (see BS EN 1090-3:2008, 12.4.2.1)


BS EN 1714:1998+A2, ultrasonic test class B, is deemed to be adequate
for quantified service categories up to F31. For F40 and above,
BS EN 1714:1998+A2, ultrasonic test class C, should be applied.

4.10.3 Extent of weld non-destructive inspection


(see BS EN 1090-3:2008, 12.4.3.1, 12.4.3.2 and Annex L)

4.10.3.1 Arc welds


BS EN 1090-3:2008, Annex L, which is informative, should not be used
for the scope of weld inspection, as it is based on informative design
criteria in BS EN 1999 which have not been adopted by PD 6702-1.
To ensure compatibility with the design recommendations of
PD 6702-1, the extent of NDT should be as given in Table 4 which
gives the minimum recommended proportions of welded joints which
should be subjected to supplementary NDT for the most common
conditions. The percentages in this table should apply to the number
of joints tested up to weld lengths of one metre in any joint. For joints
with weld lengths exceeding one metre, the percentage should apply
to the proportion of weld in every joint.
Where other conditions apply, the proportion tested may be increased
(or decreased) by one or more levels in accordance with Table 5. This
should be done by applying the next highest (or lowest) proportion
using the following sequence of seven increasing levels of proportion:
0%, 2%, 5%, 10%, 20%, 50%, 100%.
For example, if the recommendation in the table is 20%, an increase
of one level changes the recommendation to 50% and a decrease of
one level to 10%.

10 • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

If adjustments are made according to more than one condition in


Table 5, the net number of levels should be used, after adding and/or
subtracting the number of levels specified for each condition. For
example, if the proportion in Table 4 is 100% and the adjustments
according to Table 5 are −1, −1 and +1 level respectively, the net
adjustment would be −1 level, which would result in a proportion
of 50%.
For F25 and above, the minimum recommended proportions of
welded joints which should be subjected to supplementary NDT for
the most common conditions are given in Table 6.
The following points should be noted in relation to BS EN 1090-3:2008,
12.4.3.1 and 12.4.3.2.
a) SC1 and SC2 are only used in these clauses in relation to
Tables L.2 and L.3 in Annex L, which are not to be used [see
BS EN 1090-3:2008, 12.4.3.2(a)]. For this reason, these service
categories do not require inclusion in the specification with
respect to extent of inspection (see BS EN 1090-3:2008, 12.4.3.1).
b) The range of quantified service categories (F12 to F63)
encompasses the range of design performance conditions in
BS EN 1999 and hence is equivalent to the range nominally
covered by SC1 and SC2. For compatibility with PD 6702-1, the
quantified service category should therefore be included in the
specification for the extent of inspection (see BS EN 1090-3:2008,
12.4.3.1). It should be noted that the “utilization grade” is only a
factor in the determination of F12 (see PD 6702-1:2009, Table 2).
c) BS EN 1090-3:2008, Table 9, represents a minimum scope of
application of the test methods, which is increased in some
situations in Table 4, Table 5 and Table 6 of this document.
d) The use of BS EN 1090-3:2008, Annex J, for the designation
of requirements for each weld is not recommended. The
requirements for each weld do not need to be explicitly stated
if F20 and EXC2 apply, which is the most common situation (see
BS EN 1090-3:2008, 4.1.2, and PD 6702-1:2009, 4.1.5.1). Otherwise
the quantified service category and execution class only need to
be specified for each joint, component or part of the structure
when fully defining the methods and extent of inspection (and
acceptance criteria; see 4.10.5).

4.10.3.2 Laser beam, electron beam and friction stir welds


The extent of NDT should be similar in principle to that given in
Table 4, Table 5 and Table 6. However, it is recommended that this
is reviewed on a project basis and agreed between the contracting
parties prior to fabrication (see also 4.10.4.2).

4.10.4 Destructive testing (see BS EN 1090-3:2008, 12.4.3.3)

4.10.4.1 Arc welding


For quantified service categories above F31, it is recommended that
run-on/run-off plates on longitudinal welds are tested on a 5% basis
and a macro-section taken to verify the internal quality. This should
include a tack weld if these are used in the work.

© BSI 2009 • 11
PD 6705-3:2009 PUBLISHED DOCUMENT

4.10.4.2 Laser beam, electron beam and friction stir welding


The general principles for longitudinal welds in 4.10.4.1 should apply
to these processes.
In the case of friction stir welding, more emphasis should be placed
on bend testing of production run-on/run-off plates, with a reduced
emphasis on ultrasonic testing, to provide assurance that bond integrity
is being maintained. This principle should be applied to transverse butt
welds for quantified service categories of F20 and above.

4.10.5 Acceptance criteria for welds


(see BS EN 1090-3:2008, 12.4.4, Annex L and Annex M)

4.10.5.1 Arc welding


BS EN 1090-3:2008, Annex L and Annex M, should not be used for
weld acceptance criteria as they are based on informative design
criteria in BS EN 1999 which have not been adopted by PD 6702-1.
To ensure comparability with the design recommendations of
PD 6702-1, the weld acceptance criteria should be applied in
accordance with the following tables in this document, according to
the method of inspection used:
a) visual inspection: Table 7 and Table 8;
b) penetrant testing: Table 9;
c) ultrasonic and optional radiographic testing: Table 10.
The following points should be noted in relation to
BS EN 1090-3:2008, 12.4.4:
1) SC1 and SC2 are only used in these clauses in relation to Tables L.4
and L.5 in Annex L, which are not to be used (see BS EN 1090-3:2008,
12.4.4.1 and 12.4.4.2). For this reason, these service categories
do not require inclusion in the specification with respect to weld
acceptance criteria (see BS EN 1090-3:2008, 12.4.3.1).
2) The acceptance criteria in Table 7, Table 8, Table 9 and Table 10
are consistent with the principles used in BS 1090-3:2008, 12.4.4,
including the referenced annexes and standards, as follows:
i) reference is made to BS EN ISO 10042 imperfections;
ii) some BS EN ISO 10042 imperfections have been omitted;
iii) some BS EN ISO 10042 imperfection limits have been altered;
iv) additional imperfections have been added.
3) The acceptance criteria in Table 7, Table 8, Table 9 and Table 10
represent the physical limits which are acceptable for performance
purposes. No allowance has been made for measurement error.
In cases of doubt, particularly in the assessment of a buried
imperfection, the imperfection should be rejected and its true
dimension verified by excavation for the purposes of calibration of
the NDT measurement technique.

4.10.5.2 Laser and electron beam welding


The imperfection types to which these processes are susceptible are
not dissimilar to those to which arc welding processes are prone. The
size, shape and risk of occurrence might be different, according to the
procedure, joint geometry and materials being welded.

12 • © BSI 2009
PUBLISHED DOCUMENT PD 6705-3:2009

For the purposes of specifying acceptance criteria, based on fitness


for purpose principles, the dimensional limits in Table 7, Table 8,
Table 9 and Table 10 may be used as a guide in terms of the required
quantified service category.
It is recommended that the acceptance criteria are reviewed on a
project basis and agreed between the contracting parties prior to
fabrication.

4.10.5.3 Friction stir welding


This process does not involve fusion of the materials and is therefore not
prone to some of the imperfections found in arc welding (e.g. cracks,
porosity and lack of fusion).
The process is still prone to profile and geometrical discontinuities
including lack of penetration. While lack of fusion does not occur,
inadequate bonding might occur, which has similar characteristics in
terms of its potential as a cause of loss of section and as a crack initiator.
However, it is more difficult to detect ultrasonically (see 4.10.4.2).
For the purpose of specifying and agreeing acceptance criteria, the
recommendations in 4.10.5.2 apply in principle. The limits for lack of
fusion may be deemed to be suitable for assessment of inadequate
bonding.
NOTE For further information on imperfections and their terminology
in friction stir welds, see BS 499-1, BS EN 25239-1 and BS EN 25239-5. The
dimensional limits specified in BS EN 25239-5 might not be appropriate
for acceptance of production welds, depending on the required service
category.

4.10.6 Inspection of bolting (see BS EN 1090-3:2008, 12.5)


In pre-loaded connections, the bolt/nut assembly should be rejected if
the rotation is double marked (see BS EN 1090-3:2008, 12.6).

4.10.7 Adhesive bonding (see BS EN 1090-3:2008, 12.6)


Inspection stages should include:
a) verification of the adhesive products and their expiry dates;
b) verification of the condition of the parts prior to the application
of the adhesive;
c) verification of the fit up of the joint and the extent of coverage
around the joint by visual inspection.
Consideration should also be given to the use of coupon samples
during production which would be load tested at specified intervals to
provide assurance of quality.

4.10.8 Parent material


Penetrant dye testing in accordance with 4.10.1.2 should show the
surfaces to be free of indications.

© BSI 2009 • 13
PD 6705-3:2009 PUBLISHED DOCUMENT

Table 4 Minimum extent of supplementary NDT of shop welds in all alloys, except 7***, for EXC2 and
quantified service category F20

Weld type Orientation A) Thickness (t) or Proportion of joints tested


throat (a) B) %
mm Penetrant testing (PT) Ultrasonic testing (UT) C)
Butt Transverse t<8 100 Not applicable
8 G t G 20 20 50 D)
t > 20 50 100
Longitudinal t<8 50 Not applicable
8 G t G 20 5 0
t > 20 10 10
Fillet Transverse t G 20 5 No requirement
t > 20, a G 10 10 No requirement
t > 20, 10 < a G 15 20 0
t > 20, a > 15 20 10
E)
Longitudinal As per transverse fillet but reduced by 2 levels
A)
Transverse applies to all welds orientated within 60° of the longitudinal axis of members, except for connection
zones where all orientations are deemed to be transverse. Connection zones are all locations within 200 mm of a
main structural connection, loading point or support position.
B)
t = the maximum parent metal thickness in the joint.
a = fillet weld throat dimension (including any specified penetration).
C)
Evaluation level DAC –14 dB.
D)
100% for single sided butt where no access to root side.
E)
See 4.10.3.1

Table 5 Adjustments in proportions of NDT for conditions other than those covered by Table 4 and Table 6

Condition Change in level A)


Site welded joints +1
B)
Automatic and robotic welded joints −1
B)
Standard proprietary products manufactured on a mass production basis −1
EXC3 +1
7*** alloys +1
Quantified service category F12 (relative to F20) −1
After a non-conformance with acceptance criteria in Table 9 or Table 10, applicable +2 (min.)
to all joints of similar type tested in the same production batch; to be maintained
until the cause has been identified and rectified and defects eliminated
A)
See 4.10.3.1.
B)
Not applicable to transverse butt welds of F31 and above.

14 • © BSI 2009
Table 6 Minimum extent of supplementary NDT of shop welds in all alloys, except 7***, for EXC2 and quantified service categories F25 to F63

Weld Orientation A) Thickness (t) or Proportion of joints tested


type throat (a) B)
%
mm Penetrant testing (PT) Ultrasonic testing (UT) C) Radiographic
testing (RT) D)
F25 F31 F40 to F25 F31 F40 to F63 F31 F40 F50,
F63 F63
Butt Transverse t<8 100 100 100 Not applicable Not applicable Not applicable 20 100 —
PUBLISHED DOCUMENT

8 G t G 20 50 100 100 100 100 100 0 20 100


t > 20 100 100 100 100 100 100 0 50 100
Longitudinal t<8 100 100 100 Not applicable Not applicable Not applicable 10 50 100
8 G t G 20 20 50 100 10 20 100 0 10 100
t > 20 20 50 100 10 20 100 0 10 100
Fillet Transverse t G 20 20 100 100 No requirement No requirement No requirement No requirement
t > 20, a G 10 50 100 100 10 20 20
t > 20, 10 < a G 15 100 100 100 20 50 50
t > 20, a > 15 100 100 100 50 100 100
Longitudinal As per longitudinal butt weld
A) B)
and as per Table 4, footnotes A and B.
C)
Testing conditions to BS EN 1714 should be as follows:
• quantified service categories F25 and F31: Testing level B, Evaluation level DAC −14dB;
• quantified service category F40: Testing level C, Evaluation level DAC −17dB;
• quantified service categories F50 and F63: Testing level C, Evaluation level DAC −20dB;
• transverse indication scans required for longitudinal welds.
D)
Applies to in-line butt welds only. BS EN 1435:1997+A2, Class B, should be used.

© BSI 2009 •
PD 6705-3:2009

15
Table 7 Weld acceptance criteria for visual inspection
All dimensions in mm

Main Imperfection type A) Dimensional Joint type Weld Acceptance limits B), C) to quantified Remedial action in event of
criterion parameter B) type service category non-conformance E)
[ ] applies to longitudinal welds only D)

16 • © BSI 2009
PD 6705-3:2009

Description BS EN ISO Symbol BS EN ISO F20 F25 to F63


6520-1:2007 10042:2005 (For F12, see footnote F)
ref no. ref no.
Overall Weld location — Dr — All Fillet Dr ±10 [±10] As per F20 Refer to welding co-ordinator
joint error for remedial action
geometry
Incorrect weld — Dr — All All NP [NP] As per F20 Refer to welding co-ordinator
type for remedial action
Inadequate — Dr — All All Dr −0 [−5] As per F20 Add extra weld length
weld length
Linear 5071, 5072 h 3.1 In-line Butt h G 0,2t [0,3t] See Table 8 Remove existing weld, realign
misalignment butt joint, remake preparations and
hG4 [5]
check with PT, reweld to AWPS,
507 h — Cruciform All h G 0,4t [0,4t] See Table 8 check with UT
hG6 [6]
Angular 508 b — In-line Butt b G 2° [3°] See Table 8 Correct using approved
misalignment butt procedure. Check with PT
Root gap G) 617 h 3.2 Lap, tee, Fillet hG2 [3] See Table 8 Refer to welding co-ordinator
cruciform for remedial action
Surface Crack 100 to 106 — 1.1, 1.2 All All NP [NP] As per F20 Remove imperfections by
notches grinding to approved excavation
Lack of fusion 401, 506 — 1.8 All All NP [NP] As per F20 shape, check with PT, reweld
Lack of 402 h 1.9 All Single NP [h G 0.1t] As per [NP] to AWPS, refer to welding
penetration sided F20 co-ordinator for establishment
[h G 1] of cause
(unspecified) butt
Large cavities 2015, 2016, — — All Butt NP [NP] As per F20
202, 510
Undercut, 501, 509, 511, h 1.10, 1.16, All All h G 0,5 [1] See Table 8 Remove by grinding, repair to
under fill etc. 515, 517 1.18 AWPS
Pore 2017 d 1.6 All All dG2 [2] See Table 8 Remove to depth of 3 mm,
repair to AWPS
Toe angle 5051 a — All All a H 90° [90°] See Table 8 Correct with high speed rotary
burr or reweld to AWPS
Damage 601, 603 to 606 — — All All NP [NP] As per F20 Grind out to smooth profile,
repair by AWPS if h > 1
PUBLISHED DOCUMENT
Table 7 Weld acceptance criteria for visual inspection (continued)
All dimensions in mm

Main Imperfection type A) Dimensional Joint type Weld Acceptance limits B), C) to quantified Remedial action in event of
criterion parameter B) type service category non-conformance E)
[ ] applies to longitudinal welds only D)
Description BS EN ISO Symbol BS EN ISO F20 F25 to F63
6520-1:2007 10042:2005 (For F12, see footnote F)
ref no. ref no.
Loss of Insufficient 5213 h 1.13 Tee, lap, Fillet NP G) [h G 0.1a] G) As per F20 Increase size using same AWPS
PUBLISHED DOCUMENT

cross- weld throat, a H) cruciform G)


[h G 1]
section
G)
Insufficient leg — h — Tee, lap, Fillet NP [h G 0.1z] G) As per F20
length, z H) cruciform G)
[h G 2]
Multiple con- 201, 202, 501, h, l, d, lp 4.1 All All See [See As per F20 Increase cross sectional
forming surface 209, 511, 515, footnote J footnote J] area using methods above,
imperfections 5213 depending on imperfection type
Surface Spatter 602 — — All All Not permitted if See Table 8 Remove by grinding or blast
condition surface to receive cleaning
protective treatment
A)
The three digit BS EN ISO 6520-1 designation is deemed to include all four digit sub-categories.
B)
Symbols are as defined by BS EN ISO 10042:2005 or BS EN ISO 6520-1:2007.
Dr = the dimension (or weld type) specified on the drawings. NP = not permitted.
C)
Where more than one limit is given for an imperfection for a given quantified service category and weld orientation, all limits should apply.
D)
Longitudinal welds are those not deemed to be “transverse”; see Table 4, footnote A.
E)
AWPS = approved welding procedure specification for repair.
F)
For joints in any orientation to F12, the imperfection limits given for longitudinal welds [ ] for F20 are applicable.
G)
Where a root gap h has been observed in a tee, cruciform or corner joint, the nominal required fillet weld dimensions, as measured with a weld gauge, should be increased as follows,
unless compensating penetration beyond the root has been proven: minimum required throat size a + 0.7h; minimum required leg length z + h (on affected leg only). See also footnote H.
H)
Both a and z measurements should be checked, irrespective of which has been specified on the drawings. They are related as follows:

Angle between fusion faces 120° 110° 100° 90° 80° 70° 60°
z/a 2,0 1,74 1,56 1,41 1,31 1,22 1,15

See also footnote G.


J)
All permitted imperfections resulting in loss of cross-section should be summed and assessed as follows:
Shl + S0,5dt G 4,5t or [G 9t]. For fillet welds, “a” should be substituted for “t”. Shl should include subsurface imperfections assuming h = 3; see Table 10, footnote K.
Measurement length lp = 100 mm.

© BSI 2009 •
PD 6705-3:2009

17
Table 8 Weld acceptance criteria for visual inspection for quantified service categories F25 to F63 where limits different from F20 in Table 7
All dimensions in mm

Imperfection type A) Acceptance limits according to quantified service category B), C) [ ] applies to longitudinal welds only D) Remedial action
in event of
F25 F31 F40 F50 F63 non-conformance

18 • © BSI 2009
Linear In-line h G 0,15t [0,2t] h G 0,1t [0,2t] h G 0,05t [0,2t] h G 0,05t [0.2 t] h G 0,05t [0,05t] As per Table 7
PD 6705-3:2009

misalignment butt
hG4 [5] hG3 [4] hG3 [4] hG3 [4] hG1 [1]
Cruci- h G 0,3t [0,4t] h G 0,2t [0,4t] h G 0,1t [0,3t] h G 0,1t [0,2t] Not [Not
form applicable applicable]
hG5 [6] hG4 [6] hG3 [5] hG3 [3] Not [Not
applicable applicable]
Angular misalignment b G 2° [3°] b G 1,5° [2°] b G 1° [2°] b G 0,5° [2°] b G 0,5° [1°] As per Table 7
G)
Root gap hG2 [2] hG2 [2] hG1 [1] h G 0,5 [0,5] Not [Not As per Table 7
applicable applicable]
Undercut, underfill h G 0.3 [h G 1] NP [h G 1] NP [h G 0,5] NP [h G 0,5] NP [NP] As per Table 7
Porosity d G 1,5 [1,5] dG1 [1] NP [NP] NP [NP] NP [NP] As per Table 7
Toe angle a H 110° [90°] a H 150° [90°] a H 165° [110°] a H 175° [110°] a H 175° [175°] As per Table 7
Spatter Not permitted NP [NP] NP [NP] NP [NP] NP [NP] See footnote E
if surface to
receive protective
treatment
*Variation in root or cap Dh G 3 H) [Dh G 3] Dh G 2 H) [Dh G 2] Dh G 1 H) [Dh G 1] Dh G 0,5 H) [Dh G 0,5] NP [NP] See footnote F
longitudinal profile B)
A)
Imperfection types as designated in Table 7.
B)
Symbols are as defined by BS EN ISO 10045:2005 or BS EN ISO 6520-1:2007.
NP = not permitted. Dh = the maximum variation in cap or root profile measured along weld axis over any length of 3 mm.
C)
Where more than one limit is given for an imperfection for a given quantified service category and weld orientation, all limits should apply.
D)
Longitudinal welds are those not deemed to be “transverse”; see Table 4, footnote A.
E)
For F40 and above, remove with high speed rotary burr.
F)
Correct by tapering slope to shallower angle or repair to AWPS (approved welding procedure specification for repair).
G)
Correct fillet weld sizes as per Table 7, footnote G.
H)
Transverse welds outside connection zones are exempt from this restriction (see Table 4, footnote A).
PUBLISHED DOCUMENT
Table 9 Weld acceptance criteria for penetrant testing

Imperfection type Acceptance Indication Acceptance limits according to quantified service category A) Remedial actions in event of
standard pattern B) non-conformance C)
[ ] applies to longitudinal welds with longitudinal linear indications only
F20 F25 F31 to F63
(For F12, see footnote D)
Surface notches BS EN 1289:1998 Isolated Level 2 [Level 3] Level 1 [Level 2] NP [NP] Remove by high speed burr
identified in Table 7 machining with machining marks
and Table 8 Grouped E) NP [NP] NP [NP] NP [NP] in longitudinal direction. Repair
to AWPS if non-conformance
PUBLISHED DOCUMENT

with Table 7 and Table 8 depth


requirements (h).
A)
NP = not permitted.
B)
Longitudinal welds are those not deemed to be “transverse”; see Table 4, footnote A.
C)
AWPS = approved welding procedure specification for repair.
D)
For joints in any orientation to F12, the imperfection limits given for longitudinal welds [ ] for F20 are applicable.
E)
“Grouped” should be deemed to apply to any indications separated by less than 2.5 mm.

© BSI 2009 •
PD 6705-3:2009

19
Table 10 Weld acceptance criteria for ultrasonic testing with limited optional radiographic testing
All dimensions in mm

Imperfection type A) Dimensional Location Acceptance limits according to quantified service category B), C) Remedial action
parameter B) in cross- in event of non-
[ ] applies to longitudinal welds only D)
section or conformance E)
Description BS EN ISO Symbol BS EN ISO throat F20 F25 F31 F40 F50, F63

20 • © BSI 2009
PD 6705-3:2009

6520-1:2007, 10042:2005 (For F12, see


ref no. ref no. footnote F)
Cracks 100 to 106 — 2.1, 2.2 Full depth NP H) [NP] H) NP H) [NP] H) NP H) [NP] H) NP J) [NP] J) NP K) [NP] K) Refer to welding
co-ordinator
Pores G), 2011, 2014, h, l 2.3, 2.6, 2.7 Within hG3 [3] hG3 [3] NP H) [h G 3] NP J) [NP] J) NP K) [NP] K)
to determine
inclusions G), 2015, 2016, to 2.12 6 mm
l G 10 [20] lG5 [10] NP H) [l G 5] NP J) [NP] J) NP K) [NP] K) cause. Remove
cavities G), 202, 203 of any
by grinding
lack of 301 to 304, surface
to approved
fusion, 401, 402
Deeper hG3 [3] hG3 [3] hG3 [3] NP H) [h G 3] NP J) [NP] J) excavation
lack of
than shape. Check
penetration l G 1,5t [3t] l G 10 [1,5t] lG5 [20] NP H) [l G 5] NP J) [NP] J)
6 mm with PT. Reweld
from any to AWPS.
surface
h, l, lp, 4.1 Full depth Sl G 1,5t L) [3t] L) Sl G 1,5t L) [3t] L) Sl G 1,5t L) [3t] L) NP [Sl G 1,5t] L) NP [NP]
H, L
lp = 100 [100] lp = 100 [100] lp = 100 [100] NP [lp = 100] NP [NP]
HH6 [6] HH6 [6] HH6 [6] NP [H H 6] NP [NP]
L H 10 [10] L H 10 [10] L H 10 [10] NP [L H 10] NP [NP]
M)
Uniformly 2012, 2013 — 2.4, 2.5 Full depth Not permitted if obstructs detection or evaluation of imperfections above NP [NP] M)
distributed
or clustered
porosity
A)
The three digit BS EN ISO 6520-1 designation is deemed to include all four digit sub-categories.
B)
Symbols are as defined by BS EN ISO 10042:2005.
NP = not permitted. H = the clear gap between adjacent imperfections measured in through thickness direction. L = the gap between ends of adjacent imperfections measured along weld axis.
C)
Where more than one limit is given for an imperfection for a given quantified service category and weld orientation, all limits should apply.
If surface breaking imperfections are detected by UT, the criteria given in Table 7, Table 8 and Table 9 apply.
D)
Longitudinal welds are those not deemed to be “transverse”; see Table 4, footnote A.
E)
AWPS = approved welding procedure specification for repair.
F)
For joints in any orientation to F12, the imperfection limits given for longitudinal welds [ ] for F20 are applicable.
G)
Radiographic testing may be used to assist in interpretation of these imperfections.
H)
Rejection level DAC −14dB.
J)
Rejection level DAC −17dB.
K)
Rejection level DAC −20dB.
L)
If permitted surface imperfections resulting in loss of cross-section also exist, the criteria in Table 7, footnote J also apply.
M)
Also, not permitted when checked by radiographic testing.
PUBLISHED DOCUMENT
PUBLISHED DOCUMENT PD 6705-3:2009

Bibliography
For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including
any amendments) applies.
BS EN ISO 10042, Welding – Arc-welded joints in aluminium and its
alloys – Quality levels for imperfections
BS EN ISO 25239-1, Friction stir welding – Aluminium – Part 1:
Vocabulary 4)

4)
In preparation.

© BSI 2009 • 21
PD 6705-3:2009 PUBLISHED DOCUMENT

22 • © BSI 2009 This page deliberately left blank


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