11.6 - Stud welding: Testing
The testing and recording of welded shear stud tests should be undertaken in accordance with BS EN ISO 14555:2014 and BCSA Code of Practice for Metal Decking and Stud Welding.
Pre-start test
At the start of every welding shift a Welding Procedure Qualification Record Test (WPQR) must be undertaken. The settings used during this test should fall within the parameters set out in the SMD Welding Procedures Specification (WPS).
Refer to SMD WPS Technical Guidance sheet 551 for more information.
Refer to SMD WPS Technical Guidance sheet 552 for more information.
The WPQR test involves welding 10 no. test studs. These studs shall be bent to an angle of 30 degrees from their original axis by placing a bending bar over the stud and manually bending the stud in the direction of the span of the beam towards the nearest column. Should failure occur, the equipment should be reset and settings adjusted, replacement studs welded and tests repeated to ensure acceptable quality. A record of the WPQR location and settings should be marked on a QA record drawing in line with the requirements of BS EN 14555:2014.
Note: The settings for the WPQR will differ for each site due to numerous factors including; atmospheric conditions, weather, parent steel grade, cable distance, ambient temperature etc.
Surveillance testing
As welding progresses, the ferrules shall be broken away from the base of the stud to enable visual inspection. The broken ferrules are typically left on the deck to be absorbed into the concrete and treated as inert aggregate. All shear studs shall then be ring tested by tapping the head of the shear stud with a hammer, studs that do not give a resonating ring sound should be bend tested.
Bend testing must be carried out as described in the Pre-Start (WPQR), but to an inclination of 15 degrees (1 in 4). The bend test shall be carried out to the greater of 5% or at least 2 no. studs per beam. Should a shear stud fail in any location, three studs on either side should also be tested.
Any failing studs will need to be replaced. Tested and failed studs shall be noted and marked up on a QA record drawing.
When testing shear studs reference should be made to the manufacturer’s instructions, BS EN 1994-1-1, BS5950: Part 3: Section 3.1, BCSA Code of Practice for Metal Decking and Stud Welding, National Structural Steelwork Specification and BS EN ISO 14555:2014.
Refer Nelson Stud Welding – Application Information: Removal of Broken Ferrules - WTD (31/01/2006). Stud welding at low temperatures – D.J. Laurie Kennedy
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