Services

EN1090 Services

CE/UKCA Marking of Structural Steelwork

On 1st July 2014, it became a legal requirement under the Construction Products Regulations (CPR) to CE Mark fabricated steelwork sold in the UK.

CE Marking has been replaced by UKCA (UK Conformity Assessed) Marking. UKCA Marking has the same requirements as CE/UKCA Marking, but it is not recognised as compliant in Europe. At the time of writing, both UKCA and CE marking are accepted in the UK for fabricated steelwork sold in the UK.

Icespec’s experienced engineers have extensive experience in the preparation of companies for CE/UKCA Marking accreditation and ISO 3834 compliance (note that ISO 3834 accreditation is now a mandatory requirement under NSSS 7 and the Specification for Highways Works, Series 1800). Icespec can also provide Responsible Welding Coordination (RWC) personnel as part of an overall package.

For Designers, Main Contractors and Specifiers:

CE/UKCA Marking is not a quality mark and does not, by itself, confirm compliance with a project specification. Icespec Engineers can support the project team in verifying that supplied products meet both CE/UKCA Marking legislation and specification requirements.

Icespec also provides CPD events to keep Specifiers, Employers and Engineers informed of CE/UKCA Marking legislation requirements.

For Fabricators:

Icespec offer the most comprehensive service available that guides the fabricator through every aspect of the CE/UKCA Marking requirements from an initial review right through to CE/UKCA marking assessment by the Conformity Assessment / Notified Body.

This includes:

I. Initial visit to review existing processes and systems

II. Preparation of a gap analysis report

III. Guidance on additional procedures and requirements, including Factory Production Control (FPC) and Welding Quality Management System (WQMS)

IV. Assistance with preparing procedures, FPC and WQMS documentation

V. Monitoring visits to support implementation of procedures, FPC and WQMS

VI. Training personnel in procedures, FPC, WQMS and visual welding inspection

VII. Provision of welding certification documentation, including WPQRs, WPSs and WQTCs

VIII. Acting as RWC for all Execution Classes

IX. Attendance during assessment by the Notified Body

Icespec will provide a tailored quotation, recognising that each fabricator’s requirements are different. We charge only for the work carried out, with no obligation to commit to a fixed package.

Welding Consultancy Services

Welding engineering covers a broad range of disciplines, including weld design, materials processing and metallurgy, fabrication, quality control and repair. Icespec’s welding consultants help you understand and resolve challenges across disciplines including:

          I.               Weld design

        II.               Welding metallurgy and weldability

      III.               Fabrication and installation

     IV.               Automation and Integration

       V.               Distortion control

     VI.               Quality control

   VII.               Repair

VIII.               Codes and standards interpretation

Our experience spans pressure vessels, boilers, heavy structural steelwork, pipeline fabrication and installation, and new build and repair work for power generation, including nuclear. We also bring extensive expertise in resolving welding issues across a wide range of processes and materials.

Icespec’s welding engineers have supported fabrication and welding engineering activities across a wide range of sectors, including oil and gas, power, aerospace, construction engineering and automotive, with expertise in areas such as welding techniques and welder qualification.

Icespec’s welding engineers hold relevant professional qualifications, including European Welding Engineer certifications and MSc qualifications in Welding Engineering. This technical competence enables them to provide practical guidance on industry best practice for resolving fabrication, weldability and welding engineering issues.

Our independent expertise helps customers save time and reduce costs, particularly where in-house welding capability is limited or complex fabrication and welding challenges need to be resolved.

WPQR & WQTC Services

Introduction

Welding certification issued by Icespec is recognised Internationally by insurance and regulatory bodies, giving customers trusted proof of technical compliance for their projects. Our weld reports and documentation cover all customer requirements and provide a clear, detailed record of what we have inspected, analysed, tested and concluded.

Welding Procedure Certification

Icespec’s Independent Certification service provides a complete turnkey package for reviewing and producing Welding Procedure Qualification Records and Procedure Qualification Records (WPQRs/PQRs).

Our qualified, experienced engineers attend your site to witness welding activities and support a smooth process from start to finish. Because our engineers have practical welding experience, they understand the process first-hand and can efficiently gather the data needed to produce the relevant certification.

Icespec have partnerships with ISO/IEC 17025 laboratories worldwide ensuring efficiency of results at competitive rates.

Our experience and expertise minimise customer involvement and disruption to operations. Icespec understands the increasing cost pressures faced by manufacturers, so we always aim to secure the broadest possible approval range for each welding procedure qualification.

Welder Performance Qualification

Our Surveillance Department independently witnesses and verifies welders as they produce test pieces in line with detailed written instructions, typically a Preliminary Welding Procedure Specification (pWPS) or Welding Procedure Specification (WPS). We then coordinate testing through our independent UKAS-accredited laboratory partners to support qualification or coding to nationally, European or internationally recognised standards.

Our experienced Engineering Department witnesses and verifies welders as they produce test pieces in accordance with detailed written instructions, typically a Preliminary Welding Procedure Specification (pWPS). We then coordinate laboratory testing to support welder coding or qualification to nationally, European or internationally recognised standards. We also provide programmes for managing ongoing welder qualification and requalification, including the organisation of evidence required to support certificate prolongation. 

Welding Procedure And Welder Qualification Testing

Icespec works with a range of Conformity and Notified Bodies accredited by national authorities, including UKAS, DAkkS and SWEDAC. This enables us to witness Welding Procedure and Welder Qualification tests for work carried out under the Pressure Equipment (Safety) Regulations 2016 and the Pressure Equipment Directive 2014/68/EU.

Our independent third-party engineering services are available across the UK, Europe and internationally. All work is completed in line with nationally, European and internationally recognised standards, including:

I.                         ISO 15614 — welding procedure qualification

II.                       BS EN ISO 9606 — welder qualification

III.                    ASME IX — welding procedure and welder performance qualification

IV.                    BS 4872 — welder competence and qualification

Process of Preparing a Welding Procedure Specification

Preparing a Welding Procedure Specification involves several key variables, including:

I.                         Welding process

II.                       Base material group and thickness

III.                    Pipe diameter

IV.                    Welding position

V.                      Type of mechanisation

VI.                    Product type and weld type

VII.                 Filler material classification

VIII.               Current type and polarity

IX.                    Heat input

X.                       Post-weld heat treatment

Icespec manages the full process on your behalf, reducing client input and simplifying qualification. Once complete, we provide an all-inclusive Welding Procedure Qualification Record to support approval of your WPS.

Please contact us to discuss your requirements and find out how our services can support your project.

Training Services - EN 1090 & ISO 3834 Appreciation Course

Overview

A manufacturer with an EN ISO 3834 certification stands out against the rest, as it shows they've been independently assessed for welding. One of the key elements is that it requires the manufacturer to demonstrate the competence of their welding coordinators. However, the properties of welded products cannot be confirmed by testing alone.

ISO 3834: 2021 as a standard, defines the necessary controls and procedures for welding and its associated activities. It is then recognized that the quality of the welds in the final product will meet the specifications; for example EN 1090. A reference to the particular part of EN ISO 3834 should be sufficient as manufacture; capabilities to control welding activities both in workshop and on sites. In some cases, compliance with EN ISO 3834: Part 2, 3 or 4 is mandatory.

EN ISO 3834: 2021 has a strong relation to the EN 1090-2, this standard divides construction products into four Execution Classes. Depending on the Execution Class the particular part of the EN ISO 3834 is applicable / required. During this one-day workshop you will learn how to "translate" the standards EN ISO 3834 and EN 1090:2: 2024 into your own organization. The aspects personnel, tools & machines, inspection, welding coordination, etc. are dealt with in a practical way in order so you can implement this into your management system.

The course is aimed at Managers, Supervisors, Team Leaders, Foremen, Design Engineers, Project Engineers, Quality Assurance personnel, Welding Inspectors & Senior Welders who have a basic understanding of welding principles and work in the structural fabrication industry with tasks and responsibilities in accordance with EN 1090-1 & EN ISO 3834.

Delivery

The course is delivered by European Welding Engineer’s who have extensive experience in qualifying across various industries, in a vast array of materials and processes.

Content:

The course content is for anyone who is wanting to gain an understanding of the following:

        I.          What is EN 1090 and does it apply to me?

      II.          What is EN ISO 3834 and does it apply to me?

     III.          How to comply with EN 1090 – Implementing a ‘Factory Production Control’ system

    IV.          How to comply with EN ISO 3834 – Implementing a ‘Welding Quality Management’ system

      V.          Requirements for Welding coordinators

    VI.          What to expect during an audit

Training Services - Carbon Steels Weldability

Overview

The welding of different types of carbon steels requires a number of considerations to be assessed in order that the finished weld satisfies its intended purpose. This course looks at various topics related to the welding of a range of steels and provides course members with a basic understanding of the controls required.

This course is aimed at but not limited to; Non-welding personnel including Engineers who are required to appreciate weldability problems and solutions. Also suitable for welding inspectors, welding engineers and welding supervisors who are required to understand the technical considerations of different carbon steels types and their weldability

Delivery

The course is delivered by European Welding Engineer’s who have extensive experience in qualifying across various industries, in a vast array of materials and processes.

Content:

The course content is for anyone who is wanting to gain an understanding of the following:

        I.          Review of different steel types

      II.          manufacture of steels

     III.          Achievement of mechanical and metallurgical properties

    IV.          Structure of the welded joint

      V.          Heat affected zone metallurgy

    VI.          Weld metal metallurgy

   VII.          Welding process selection

 VIII.          Welding consumable selection

    IX.          Heat input control

      X.          Combined thickness, Carbon equivalents & the need for pre-heat

    XI.          Welding techniques

   XII.          Cracking in steels – causes and avoidance

Training Services - Development of ISO 15609-1 Welding Procedure Specifications Course

Overview

What are Welding Procedure Specifications (WPS) - Weld Procedure Specifications are ‘shop floor’ documents which detail the essential welding variables required to manufacture a welded joint to the required level & provide all the necessary information to ‘make’ a weld to the specified quality levels. This course is aimed at delivering knowledge to the candidate which enables them to:

        I.          Formulate their own welding documentation (WPS) to ensure compliance to various construction codes such as but not limited to: EN 1090 for Structural Steelwork, EN 13480 for Pressurised Pipework and EN 13445 for Pressure Vessels.

       II.          Review their own companies / businesses welding documents to ensure they are compliant with EN ISO 15608, EN ISO 15609, EN ISO 15613 & EN ISO 15614 range of standards.

     III.          Carry out welding compliance reviews on Sub-Contractor welding related documentation.

     IV.          Gain a working knowledge of the EN ISO welding compliance codes: EN ISO 15608, EN ISO 15609, EN ISO 15613 & EN ISO 15614 through interactive lectures and small activities.

The One-day course consists of two parts:

        I.          The first part of the day is split up into four individual lectures which deliver the knowledge of the EN ISO standards specified above and how to apply them in practical work situations. Icespec will provide the relevant standards, materials and templates.

       II.          A demonstration of WPS formulation will be delivered by Icespec Personnel, detailing where the information is derived from and how to practically apply it.

     III.          The second part of the day is split up into mini-interactive exercises where the candidate will be writing and formulating their own WPS’s from materials & templates provided supported by Icespec Personnel.

Candidates will be given an example WPS bank at the end of the course along with various other templates and materials to help them in their day to day roles.

Delivery:

The course is delivered by European Welding Engineer’s who have extensive experience in qualifying across various industries, in a vast array of materials and processes.

Content:

The course content is for anyone who is wanting to gain an understanding of the following:

      I.     Welding Compliance – Why is it Required? How do I know if I need Welding Procedures?

       II.          Standards overview and details – What are the details of the standards; what are the ranges of approval? How do they link together?

     III.          Materials and Welding Processes, what is required and what are the limitations?

     IV.          Material and sample testing, what’s required? How do they test the Materials? 

      V.          What does a completed Welding Procedure Qualification Record and a Welding Procedure Specification look like and what does it need to contain.

     VI.          Formulation of a TIG / MAG & MMA WPS’s

    VII.          Formulation of a TIG/MMA (Dual Process) WPS

Training Services - Welding Coordination Course

Overview

Icespec deliver a course to comply with the requirements of The Construction Products Regulations (CPR - 89/106-EEC) and BS EN 1090-1:2009 +A1:2011.

The two day course covers the tasks and responsibilities of a RWC, up to and including Execution Class 2. Following the two day course there will be a one revision session followed by a multi choice examination.

Each candidate will receive a “Certificate of Competence” (up to and including Execution Class 2 of BS EN 1090-1) following the two day course and a successful site assessment by Icespec.

The course is aimed at Managers, Supervisors, Team Leaders, Foremen, Design Engineers, Project Engineers, Quality Assurance personnel, Welding Inspectors & Senior Welders who have a basic understanding of welding principles as outlined above and work in the structural fabrication industry with tasks and responsibilities structures up to & including Execution Class 2 of BS EN 1090-1.

Delivery:

The course is delivered by European Welding Engineer’s who have extensive experience in qualifying across various industries, in a vast array of materials and processes.

Content:

The course content is for anyone who is wanting to gain an understanding of the following:

        I.          Health and Safety – Specific to fabrication & welding activities

      II.          Basic metallurgy & material weldability

     III.          Welding & related processes

    IV.          Design of steel structures and appreciation of welded joints and symbols

     V.          Qualification of welding procedures

    VI.          Qualification of welders and welding operatives

   VII.          Inspection of defects and imperfections in welds

  VIII.         NDT techniques and processes

    IX.          How to comply with BSEN 1090 and BSEN ISO 3834.

X. The role of the Welding Coordinator

Training Services - Stainless Steel Weldability

Overview

The welding of different types of the various stainless steels requires a number of considerations to be assessed in order that the finished weld satisfies its intended purpose. This course looks at various topics related to the welding of a range of  stainless steels and provides course members with a firm understanding of the controls required.

This course is aimed at but not limited to; Non-welding personnel including Engineers who are required to appreciate weldability problems and solutions. Also suitable for welding inspectors, welding engineers and welding supervisors who are required to understand the technical considerations of different stainless steels types and their weldability

Delivery:

The course is delivered by European Welding Engineer’s who have extensive experience in qualifying across various industries, in a vast array of materials and processes.

Content:

The course content is for anyone who is wanting to gain an understanding of the following:

        I.          Review of stainless steel types; martensitic, ferritic, austenitic, PH, Duplex stainless steels

      II.          Achievement of mechanical and metallurgical properties

     III.          Structure of the welded joint

    IV.          heat affected zone metallurgy

      V.          Weld metal metallurgy

    VI.          Welding process selection

   VII.          Welding consumable selection

 VIII.          Heat input control

    IX.          Cr-Ni equivalents

      X.          Schaeffler and Delong diagrams

    XI.          Welding techniques

   XII.          Cracking and corrosion in stainless steels – causes and avoidance

Training Services - Visual Inspecion

Overview

This welding inspection course will teach you visual inspection procedures, relevant codes of practice and terms and definitions. You will also learn about welding processes and defects, weld measurements, practical inspection and reporting, and the typical welding inspection documentation and requirements

The Icespec Visual Welding Inspector course is designed for welders, operators, line inspectors, and foremen who carry out the visual examination of welded joints. It is also suitable for welding quality control staff and anyone who needs basic training in welding inspection alongside a qualification.

Delivery:

The course is delivered by European Welding Engineer’s who have extensive experience in qualifying across various industries, in a vast array of materials and processes.

Content:

The course content is for anyone who is wanting to gain an understanding of the following:

        I.          Codes and Standards

      II.          Terminology of welded joints

     III.          Inspection of materials

    IV.          Welding processes

      V.          Welding consumables – identification

    VI.          Visual examination and dimensional checking before and after welding

   VII.          Identification of pre-heat

 VIII.          Health and safety requirements and practices

    IX.          Visual examination of repaired welds

      X.          Non Destructive Testing processes

    XI.          Interpretation of WPS’s