AS/NZS 1163:2009 Australian/New Zealand Standard™ Cold-formed structural steel hollow sections jon or use on network prohibited (10005427 ‘Orginatad as AS A17?— 1968. Frevous edian AS 1165—1991 ‘Jonty revised and cesignated as ASINZS 1163:2008, copyaicnT 1 Standards Australa/Stangards New Zealand All rights are reserved. No part af this work may be reproduced or copies in any form er by any means, electronic ot mechanical, nclusing photocopying, without the writen Permission ofthe pubisher Jointly published by Standaras Australia, GPO Box 476, Sydney, NSWY 2007 and Standards New Zealand, Private Bag 2439, Welingion 6140, LUcensed to Me Kevin Macartney on 4 March 2010.1 user personal user lence only Storage. ISBN 0 7337 9907 &Lisensed to MK. Kevin Macartney on March 2010.1 usar personal user lcenoe ony. Storage, disbution or us on network prohibited (10005427), ASINZS 11632009 PREFACE This Standard was prepared by the Standards Australia/Standards New Zealand Committee BD-023 on Structural Steel, to supersede AS 11631991, Structural steel hollow sections. This edition incorporates the following major changes to the previous edition: (a) The adoption by Standards New Zealand to make it a joint Australian/New Zealand Standard (Le. AS/NZS 1163). (©) Guidance Note on chemical composition classes, which considers suitabi fabrication hot-dip galvanizing, ty for after- (©) The provision for non-destructive testing of the hollow section longitudinal weld seam, (@) Qualification for impact test requirements for hollow sections with nominal thickness less than 6 mm. (©) Increased groupings for elongstion results for hollow sections based on the diameter or face slenderess. (© A minimum weld seam or parent metal thickness after external scarfing or removal of, surface defects, or both, (g) The requirement for individual length marking in order to comply with this Standard. This requirement does not apply to New Zealand. + information in the (hy) Furth informative’ appendix on ‘Purchasing Guidelines” (i) The mandatory requirement for test reports and test certificates to be performed by third-party accredited laboratories. (i) The introduction of mandatory minimum information required on test certificates. (k) The inclusion of Appendix B on ‘Product Conformity’ as a mandatory provision for conformance with this Standard (1) The introduction of new ‘informative’ Appendix C on ‘Basis of Assessment of Compliance of Mechanical Properties by Statistical Sampling’ (im) Where applicable, the alignment of technical requirements, dimension symbols and section tolerances with ISO 10799, Structural steels—Cold-formed, welded, structural hollow sections—Technical delivery requirements, ISO 4019, Structural steels—Cold-formed, welded, structural hollow sections, dimensional and section properties, and EN 10219. Cold formed welded structural hollow sections of non-alloy and fine grain steels (n) Where possible, the alignment of contents with AS 3597, Structural and pressure vessel steel—Quenched and tempered plate, ASINZS 3678, Structural stee!—Hot- rolled plates, floorplates and slabs, AS/NZS 3679.1, Structural steel—Hot-rolled bars and sections and ASINZS 3679.2, Structural steel—Welded I sections To permit the steel industries time to adjust to the new Standard, the 1991 version of AS 1163 will remain available superseded and will be withdrawn 12 months from the date of publication of this Standard A statement expressed in mandatory terms in a Note to a table is deemed to be a requirement of this Standard, ‘The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an “informative” appendis is only for information and guidance110006427, Lens! to MK. Kevin Macartney an 4 March 2010.1 user persona user licence ony. Storage, distribution or use on network prohibes 3 ASINZS 1168:2009 CONTENTS: SCOPE. senna nnesnnnneee a NORMATIVE REFERENCES 7 4 DEFINITIONS... NOTATION DESIGNATION....... MANUFACTURING PROCESS—STEEL FEED. CHEMICAL COMPOSITION ene MANUFACTURING TOLERANCES. 9 FREEDOM FROM DEFECTS... oan eet 4 ‘TESTING nares Sette: MECHANICAL PROPERTIES REMOVAL OF SURFACE DEFECTS... . IDENTIFICATION, CERTIFICATION AND INDEPENDENT TESTS. 19 ROUNDING OF NUMBERS... psttnetnnne sen MANIPULATION 2 NOMINAL DIMENSIONS, SECTION PROPERTIES AND MASS ncccccsnne 2] SAMPLING AND TESTING TO DEMONSTRATE PRODUCT CONFORMITY...21 APPENDICES A B c D PURCHASING GUIDELINES... edt seers 32 PRODUCT CONFORMITY, nnn 4 BASIS FOR ASSESSMENT OF COMPLIANCE OF MECHANICAL PROPERTIES BY STATISTICAL SAMPLING .....0 DIMENSIONS AND PROPERTIES OF CROSS-SECTION. BIBLIOGRAPHY 4ioansed to Mr. Kevin Macartney on 4 March 2010. 1 user personal usr licence only. Storage, ditrution ar use on network pried (10095427) AS/NZS 1163:2009 4 STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Cold-formed structural steel hollow sections 1 SCOPE This Standard specifies the requirements for cold-formed, electric resistance-welded, carbon stec! hollow sections used for structural purposes. It considers three strength grades, with or without impact properties, that are suitable for welding. It is applicable to structural hollow sections formed cold without subsequent heat treatment, The Standard does not caver submerged arc-welded, helically welded or U'ed and O'ed steel hollow sections. NOTE: For guidelines on information to be supplied at the time of enquiry or order, see Appendix A, Means for demonstrating conformance with this Standard are given in Appendix B. 2 NORMATIVE REFERENCES TThe following are the normative documents referenced in this Standard: NOTE: Documents referenced for informative purposes are listed in the Bibliography AS 1391 Metallic materials—Tensile testing at ambient temperature 1544 Methods for impact tests on metals 1544.2 Part 2: Charpy V-notch 173: Methods for the determination of grain size in metals 2706 Numerical values—Rounding end interpretation of limiting values 4750 Eleotrogalvanized (zinc) coatings on ferrous hollow and open section ASINZS 1050 Methods for the analysis of iron and steel 1050.1 Part 1: Sampling iron and steel for chemical analy 1954 Structural steel welding 1554.1 Part 1: Welding of steel structures 4680 Hot-dip galvanized (zine) coatings on fabricated ferrous articles 4792 Hot-dip galvanized (inc) coatings on ferrous hollow sections, applied by a continuous or a specialized process 4855 Welding consumables—Covered electrodes for manual metal arc welding of non-alloy and fine grain steels—Classification 1s 643 Steels—Micrographie determination of the apparent grain size 2566 Steel—Conversion of elongation values 2566-1 Part |: Carbon and low alloy steels 7966 Acceptance control charts coPvRIGHTLenses to Mr. Kevin Macartney on 4 Match 2070.1 user personal wser cence ony. Storage, distibution or use on network prohibited (10005427), ASINZS 1163:2008 Iso 9304 Seamless and welded (except sub-merged arc-welded) steel tubes for pressure purposes—Eddy current testing for the detection of imperfections 9402 Seamless and welded (except sub-merged are-welded) steel tubes for pressure purposes—Full peripheral magnetic transducer/flux leakage testing of ferromagnetic steel tubes for the detection of longitudinal imperfections 9764 Electric resistance and induction welded steel tubes for pressure purposes— Ultrasonic testing of the weld seam for the detection of longitudinal imperfections 14284 Steel and iron—Sampling and preparation of samples for the determination of chemical composition 3. DEFINITIONS For the purpose of this Standard, the definitions below apply. 3. Batch Hollow sections of the same size, nominal thickness and grade manufactured from the same cast and tube forming process (tube mill) 3.2 Cast analysis Chemical analysis determined from a test sample taken during steel casting, 3.3, Cold-formed hollow section Hollow section formed and shaped at ambient temperature from a single strip of steel, both edges of which ate continuously welded by the contact tip or induction coil electric resistance process. 3.4 Longitudinal direction Direction parallel to the longitudinal weld seam, 3.5 Longitudinal weld seam Continuous weld joining both edges of the single strip of steel used to form a hollow section 3.6 Product analysis shed material Chemical analysis determined from a test sample of the 3.7. Structural hollow sections ‘Tube intended to be used for structural purposes. 3.8 Testing Mechanical and chemical analysis tests as required by this Standard, 3.9 Test piece Piece prepared for testing, made from a test specimen by a mechanical operation. 3.10 Test sample Portion of material or product or a group of items selected from a batch or group by sampling. 3.11 Test specimen Portion or a single item taken from the test sample for the purpose of applying a particular test copyRicrLicensed to Mr. Kevin Macartney on 4 March 2010.1 user personal user licence only. Storage, distribution or use on network prohited (19095427), ASINZS 1163:2009 6 3.12. Transverse direction Dircetion at right angles to the longitudinal weld seam. 3.13 Unit Length of hollow section. 4 NOTATION ‘The symbols used in this Standard are listed in Table 1 5 DESIGNATION All grades shall be designated in the format shown in the following example: ASINZS 1163-C350L0 where AS/NZS 1163 = number of this Standard c = cold-formed sections 350 = minimum yield strength in MPa (see Table 6) L = guaranteed impact properties of the material (when applicable) o = low temperature impect test at 0°C (when applicable) 6 MANUFACTURING PROCESS—STEEL FEED. ‘The steel shall be made by the basic oxygen process or an electric process at the steel manufacturer's option. The steelmaking process shall be shown on test certificates. Additional refining by vacuum are remelt, electroslag refining or secondary steelmaking practices such as vacuum degassing or calcium injection, or both, is permitted The steel shall be fine-grained and be made from fully killed, continuously cast steels. The coil shall be produced on a hot strip mill coPyRIGHTLicensed to ir Kevin Macartney 094 March 2010.1 user personal user cance any. Storage, distribution or ws on network prohibited (10095427), 7 ASINZS 1163: TABLE 1 NOTATION Symbot | _unit Description A ram _| eross-seetional area ay ‘rin?_| gross area ofthe crosncection 5 rm | nominal length of sige of a square hollow section; nominal length of the shorter side of a rectangular hollow section € ini | torsion modulus ener rom _| length of external comer profile of square or estanguler hollow section @ rom | nonvinal length of the longer sie of a rectangular hollow section & ‘am __ | nominal ouside diameter oF circular hollow seston Goon dogg | AM | maximo and mini outside exerol diameter ofa eeeular hollow section, measured inthe same plane 5 ‘am__| deviation fom saiehiness i rim’ second moment of area z runé__|tersion constant (polar moment of neni for circular hollow setions only) L rim | enath ly sum gauge length m ‘gin_| mass per unit length @ %4 | ousofroundness ei som [radios of gyration he nim | extemal comer radios ofa square or rectangular hollow section S ron _| plant sation modulus 5% san? _| original cossseutional aca A ‘nen_| nominal hikes 5 vam | total ovis % tum [ fist measured ot one end of seston u smm_| eoncavity of aside of «square or rectangular hollow section me mmm_| convexity of side ofa square or rectangular hollow section z ram? _| elastic section metus @ degrees [angle between adjacen sides ofa aque or reclangelar hollow ston 7 CHEMICAL COMPOSITION 7.1 General ‘The method of sampling for chemical analysis shall be in accordance with ISO 14284 Chemical composition shall be determined in accordance with AS/NZS 1050.1 7.2 Cast analysis A chemical analysis of the steel from each cast shall be made to determine the proportions of the specified clements, ‘The reported cast analysis of the steel from which a hollow section is manufactured shall conform to the limits given in Table 2 for the appropriate grade. COPYRIGHTASINZS 1163:2009 ® 1.3, Product analysis ‘The chemical analysis of the finished product is not a requirement of this Standard. When the stecl is subject to @ product analysis, the analysis shall conform to the limits given in Table 2 for the appropriate grade. TABLE 2 CHEMICAL COMPOSITION ‘Chemical composition (east or product analysis) (see Note 2) Yo max. Grades al Micro [CE wee | c | si fovm |e | s | ce | mo] ace | ti | alloying | (see Note 1) Note 3) ctements_[ Note 4) case, 2 3 | 50 | 00s | 0. 1 | 040 06 a 25 smo | ©2 | 0s | 050 [ous } oo} o1s Jor | a1 0.08 | eens) | 92 eae 20 | oss | 160 fous] 909] 030 foi} 010 ots | of ee | 028 140 foos| oor] 030 for} om cere | 08 6450, |) 020 | oas | 1.30 | 00s | 003 | 050 oto | os pts Toa 55010 se0 Note 6) NOTES. 1 The use of sulphide modiicsion manufacturing techniques for these grades is exited 2 The following elements may be presen tothe Lit stated (0) Copper 925%. () Nickel 02 3. Limits specifies ae for soluble or ttl alominivm, 4 Carbon equivalent (CE) is ealeulatedffom the following eqution Mn, CreMosV | Nise Pees ces Applies o niobium and vandium only, However, niobium greater dan 0.019% sno ented cE=C# 6 Applies wo niobium, vanadium and ianium enly, However, vanadiom greater than 6.10% snot peniied 7.4 Suitability for zine coating Zine coating requirements shall be agreed between the manufacturer and the purchaser. Hot-dip galvanized coating requirements shall be as specified in AS/NZS 4680, AS 4750 or ASINZS 4792, as appropriate NOTE: The suitability for hot-dipped zine coating should be agreed detwoen the manufacturer and the purchaser (see Paragraph A2 of Appendix A). As a guide only, the following steel chemistry percentage limits are noted by the industey associated with hot-dip galvanizing (ie. Galvanizers. Association of Australia (GAA), Galvanizers Association of New Zealand (GANZ) (@) Suitable: Si < 0.060; Si + 2.5 < 0.090. (©) Suitable: 0.14 < Sis 0.24 (©) Caution: 0.080 < Sis 0.14 (4) For Si>0.24, itis recommended thatthe purchaser and supplier agree on the adequacy of the product for hot-dip galvanizing Further information may be obtained from hot-dip galvanizers, hollow section and steel manufactures. § 3 5 z z t ‘ 2 : i 3 : g : 3 8 3 3 i i i E 2 i Unless further advice is provided, it is recommended that a sample be hotedip galvanized to determine the actual performance for any given process, bath and tube characteristies. COPYRIGHTlcense to Nt. Kevin Macartney on 4 March 2010.1 user personal user licence ony. Storage, distribution or use en network profited 10096427), ’ ASINZS 1163:2009 § MANUFACTURING TOLERANCES 8.1 General Tolerances and limits on the dimensions and mass of cold-formed hollow sections shall conform with the values given in— (a) Table 3, for shape and mass; (b) Table 4, for external corner profiles: and (©) Table 5, for tength. Where relevant, Tables 3, 4 and 5 shall be read in conjunction with Clause 8.2, The internal corners of square and rectangular hollow sections shall be rounded NOTE: The internal comer profile is not specified TABLE 3 TOLERANCES FOR SHAPE AND MASS Characteristic Circular hollow sections | Square and rectangular hollow sections rem) 5166, with minimum of 20.5 mm 10%. 10% with & max of #2 mm or hollow sections having a | diameter to thickness ratio not exezeding 100 (see Note 1) Concavitylconvenity | = ‘Ma, 0.8% or 0.5 mam, (see Nave 2) whichever is greater Squareness ofsidee | 7 90°41 External corner profile | a See Table 4 Dost = 2H$ moni Tenge raightness (0.20% of total length 0.15% of total length (oe Note 3) Mase (m) per unit length | Not less than 0.96 times the specified mase (Note 4) on individual lengths NOTES: 1 Where the diameter to thickness ratio exceeds 100, the tolerance on out-f-rounedness becomes the subject of agreement Between the manufacturer and purchaser The tolerance on convenity and concavity is independent of the tolerance on extemal dimensions. ‘The siaighiness tolerance applies co straightness in any one plane. In Tiew of any oiber requirement, the specified mass is eunsidered 10 be the nominal mass as noted in Clasze 16. TABLE 4 EXTERNAL CORNER PROFILE Perimeter External corner profile (cacy .or 1) (800 Note) Equivalent 49 50 % 50 oF less 1st 308 Equival tr than $0.» 50 Lato 3.04 NOTE: The sides need not be tangential to the corner ares, copyRichtLicensed io Mr. Kevin Macartney on 4 March 2010, 1 user personal user leenoe ony. Storage, distrbton or use on network prohibited (10005427), TABLE 5 TOLERANCES ON LENGTH (see Note) ‘Type of length Range Tolerance Random Iengtn | 4000 10 16000 with «range | 10% of sections supplied may be below (2000 per order item | the minimum for he ordered range but tot es than 75% ofthe minim Mil (or “100 mn unspecified’) length aul a mm <6000 a. sasnm Precision fngth aso siogoa | 45 m+ 1 mann 10 000 Is NOTE: The purchaser shal indicate in the enquiry and order the type of length required and the length or length range, 2s appropriate. Altematively, length tolerances shal! be specified at the time of onder. 8.2 Measurement of size and shape 821 General All external dimensions shall be measured at a distance from the end of the hollow section of not less than d, for circular seetions, b for square sections and d for rectangular sections, with a minimum of 100 mm. 8.2.2 External dimensions For circular hollow sections, the diameter (d,) shall be measured. ‘The limiting cross-sectional positions for measuring b and d of square and rectangular hollow sections are shown in Figure | NOTE:A caliper gauge, circumference tape or other suitable device may be used at the diseretion of the manufacturer. copyRiGHtLUcansed to My Kevin Macartney on 4 March 2010, 1 user personal user cence only. Storage, dsirbution or use on aehwork prohibited (10095427). i ASINZS 1163:2009 Measurement of “b, a in hers Measurement of “t’ in here a NOTE: The 5 mm cimension isa maximum when measuring oF dd a minimom when measuring DIMENSIONS IN MILLIMETRES: FIGURE 1 LIMITING CROSS-SECTIONAL POSITIONS FOR MEASURING DIMENSIONS b, dAND {FOR SQUARE OR RECTANGULAR HOLLOW SECTIONS. 8.2.3. Thickness The thickness (#) shall be measured at a position of not less than 2¢ or 25 mm, whichever is, lesser, from the weld seam, ‘The limiting cross-sectional positions for measuring the thickness of square and rectangular hollow sections are shown in Figure 1 NOTE: Thickness is normally measured within @ distance of half the outside diameter or half the longer side length from the end of the section 8.2.4 Outof-roundness ‘The out-of-roundness (0) of a circular hollow section shall be calculated as a percentage, from the following equation: Sonn ~ Hoan. 199) agers 2 B24 8.2.5 Concavity and convexity The concavity (x1) or the convenity (x2) of the sides of a square or rectangular hollow section shall be measured as shown in Figure 2 ‘The percentage concavity or convexity shall be calculated as follows: 7.100% 6 2 100% 3 AL. 100% ad x 72 100% a copyRisHTLUcensed to Mr. Kvn Macarney on 4 March 2010, 1 user personal user icenee ony. Storage, distrbuton er use on network pobiited (10095427), ASINZS 1163:2009 2 where # and d are the lengths of the sides containing the concavity (x,) or the convexity (a). fa | i FIGURE 2 MEASUREMENT OF CONCAVITY/CONVEXITY OF SQUARE OR RECTANGULAR HOLLOW SECTIONS 8.2.6 Squareness of sides The deviation from squaroness of the sides of a square or rectangular hollow section is defined as the difference between 90° and as shown in Figure 3. Deviation from squareness = 20° ~ FIGURE 3 SQUARENESS OF SIDES OF SQUARE ‘OR RECTANGULAR HOLLOW SECTIONS 8.2.7 External corner profile The external corner profile of a square or rectangular hollow section shall be measured at the discretion of the manufacturer, as follows: (a) Measure the external corner radius (r,). Use a radius gauge or other suitable device (b) Measure the length of the external corner profile (c, and c) (see Figure 4). copyRicHtLUoensed to Mr. Kove Macartney on 4 March 2010.1 user personal usar licence ony. Storage, cistibuton or use an network prohibited (19005427), 3 ASINZS 1163:2009 NOTE: c, and, ean he messured asthe distance beween the inrerseetion of the Mt side and the comer ac ad the interseetion ofthe line projections of the Mat sides tothe comer FIGURE 4 EXTERNAL CORNER PROFILE OF SQUARE OR RECTANGULAR HOLLOW SECTIONS 8.2.8 Twist ‘The total twist (v) in a square oF rectangular hollow section shall be determined, at the discretion of the mamafaeturer, as follows (@) Place the hollow section on a horizontal surface with one side at one end pressed flat against the surface. At the opposite end of the hollow section, determine the difference of in the height of the two lower comers from a horizontal surface (see Figure 5). (b) Measure v with a spirit fevel and micrometer (serew) gauge or other suitable device The reference length of the spirit level shall be the distance between the intersection of the flat sides and the external corner profile (see Figure 6). v is the difference between the valtes vy (see Figure 6) measured at each end of the section. FIGURE 5 TOTAL TWIST OF SQUARE OR RECTANGULAR HOLLOW SECTIONS. copyRicHTUoensed to Mr, Kevin Macartney on 4 Mach 2010, 1 user personal user cence only. Storage, dishbution or use on network prohibited (10095427). ASINZS 1163:2009 4 oN Leena: 4 Spirit teve! 2 Micrometer gauge 3. d for rectangular sections, & for square sections FIGURE 6 MEASUREMENT OF TWIST 8.2.9 Straighiness ‘The deviation from straightness (e) of the total length of a hollow section shall be measured at the point of maximum departure of the section from a straight line connecting its two ends, as shown in Figure 7. The percentage deviation from straightness shall be calculated as follows: £ x 100% L FIGURE 7 MEASUREMENT OF DEVIATION FROM STRAIGHTNESS 9. FREEDOM FROM DEFECTS 9.1 General ‘The seetion shall be free from lamination, surface flaws and other defects detrimental to its use for structural purposes. 9.2. Weld seam 9.2.1 Position For rectangular and square hollow sections, the weld seam shall not be placed within a distance of three times the wall thickness from the apex of the corner radius. NOTES: 1 The apex of the corner radius is defined as the intersection point of the lines emanating from ‘ovo external adjoining faces of the hollow section. 2 Some end-use applications may require the weld seam to be placed close to the corner radius. This should be noted at the time of enquiry or order (see Appendix A) with the finished hollow sections not exhibiting any cracking or brittle behaviour. For the adequate performance of the comer radius and weld seam, such hollow sections are not considered 10 be in the scope of this Standard, copyaishnce onty. Storage, dstibuton of use on nehwork prohibited (10095427). Lonsed to Mr. Kevin Macartney on 4 March 2010. 1 user personal user 9.2.2 Defects At the manufacturer's discretion, the weld seam of welded structural hollow sections may be subjected to non-destructive examination (NDE). The NDE may be carried out either on the circular shape prior to final forming or on the hollow sections after final forming. Where NDE is employed, the weld seam shall be tested in accordance with one of the following: (a) ISO 9304 to acceptance Level L4, except that the rotating tube/pancake coil technique shall not be permitted. (b) ISO 9402 or ISO 9764, with the exception that the acceptance level shall be based on, at minimum, the use of N 15 internalfexternal notches and for the application of 1SO 9402, a notch of no greater than twice the depth of the reference notch, with a maximum of 1.0 mm, shall apply. 10 TESTING 10.1 Selection of test samples Test pieces for tensile tests, impact tests and cold-flattening tests shall be taken from a single test saraple. ‘Test pieves shall be in the same condition as the sections that they represent. 10.2. Position and orientation of test pieces 10.2.1 Tensile test and impact test The test piece shall be cut such that the major axis is in the longitudinal direction and shall be selected from any position along the length of the test specimen such that the requirements of Clause 10.5.2 or 10.5.3 are complied with, 10.2.2 Cold flattening test ‘The test piece shall be cut in the transverse direction and shall be cut from one end of a test, specimen that contains a longitudinal weld seam. 10.3. Number of mechanical tests One of the methods specified in Appendix B shall be used. 10.4. Retests ‘The test piece shall be cut from a test sample from the same batch. Retests procedure shall be as described in Appendix B. 10.5. Preparation of test pieces for mechanical testing 105.1, General It shall be permissible to discard a test piece that shows defective machining or develops flaws during preparation and to submit another test piece. 10.5.2 Tensile rest pieces 10.5.2.1 Form of test piece The tensile piece shall be in the form given in either Item (a) or (b) as follows: (@) A test piece with dimensions conforming to those specified in AS 1391, cut from the test specimen. The cross-section location of the test piece shall be as specified in Clause 10.5.2.2 of Clause 10.5.2.3, a8 appropriate (b) A length of the full section test specimen. ‘The test piece shall be aged in accordance with Clause 10.5.4 coPyRIGHTsensed to Mr. Kevin Macartney 0n4 March 2010.1 user personal user licence only. Storage, distribution or use on network protiied (10005427), ASINZS 1163:2009 16 10.8.2.2. Circular hollow sections (CHS) For a length of circular hollow section, the test piece shall be taken at approximately 90° from the weld seam (see Figure 8(@)). The tensile test piece cut from a test specimen shall not be flattened between gauge marks. 10.5.2.3 Rectangular hollow section (RHS} The tensile test piece cut from a test specimen shall be taken from any side midway between and excluding the corners (sce Figure 8(b}). The test picce shall not include @ longitudinal weld seam, 10.8.3 Impact test piece Three test pieces shall be prepared from each test specimen and cut parallel to the longitudinal axis of the hollow section, with the axis of the notch perpendicular to the rolled surface of the section (see Figure 8). For circular and rectangular hollow sections, the cross-section location of the test piece shall be as specified in Figure 8 where, for rectangular hollow sections, it shall also be remote from the weld seam. The test piece shail be prepared in accordance with AS 1544.2 using, where necessary, the largest practicable subsidiary test pioce with a width not less than 5 mm. For standard sized test specimen (i.e, 10 x 10 mm), the finally machined test pieces shall be extracted from the mid-thickness of the hollow section wall ‘The test piece shall be aged in accordance with Clause 10.5.4 Weis Aniernanve positions lat Circular hollow section lb) Rectangular hollow section FIGURE 8 CROSS.SECTION POSITION OF TEST SPECIMEN FOR TENSILE AND IMPACT TESTS. 10.5.4 Ageing treatment to tensile or impact testing, the test pieces shall be aged by hesting to a temperature between 150°C and 200°C for not less than 15 min. 10.8.8 Cold flattening test ‘The test piece shall be taken in the form of a cross-section from one end of a finished length of a circular hollow section which contains a longitudinal weld seam. The length of the test piece shall be not less than 40 mm. 10.6 Mechanical testing 10.6.1. Tensile test ‘The tensile test shall be carried out in accordance with AS 1391 COPYRIGHTLUoensed to Mr. Kevin Macartney on 4 March 2070. 1 user personal user cence ony. Storage, distibution er use on network probit (10085427), nw ASINZS 1163:2009 Elongation results shall be reported on a gauge length L, ~ 5.65¥S,, where S, is the original cross-sectional atea, Conversion of results from a non-proportional gauge length shall be in accordance with ISO 2566-1 10.6.2 Impact rest Impact test requirements shall comply with Clauses 10.6.2. 1 or 10.6.2.2. 10.6.2.1 Hollow sections with nominal thickness of 6 mm or greater Impact tests shall be performed at 0°C in accordance with AS 1544.2 10.6.2.2 Hollow sections with nominal thickness less than 6 mm Impact tests are not required at 0°C in accordance with AS 1544.2 subject to satisfying one or both of the following: (a) Using the same steel supplier, steel grade, steel processing for hollow sections complying with Clause 10.6.2.1 {b) Ensuring that the finished product ferrite grain size is greater than or equal to 6 as verified by the method specified in AS 1733 (ISO 643), when the steel feed is aluminium killed, Alternatively, when aluminium is used as the grain-refining element, the grain size requirement shall be deemed to have been fulfilled if the cast analysis shows the aluminium content to be not less than 0.020% total aluminium, or alternatively. 0.015% soluble aluminium, In these cases, verification of the grain size shall not be required. This method of verification is only acceptable when the following evidence is provided by the manufacturer or supplier’ (Confirmation of compliance with Clause 6 of this Standard. 10.6.3. Cold flattening test The flattening test piece shall be flattened at room temperature between two parallel plane surfaces with the weld seam located as follows in relation to the direction of flattening: (@) Ford, $60 mm: 45 degrees (b) For ds > 60 mm: 90 degrees The test piece shall be flattened until the distance between the surfaces is 0.754, or less. 11 MECHANICAL PROPERTIES 111. Tensile test When tested in accordance with Clause 10.6.1, the yield strength, tensile strength and elongation of the test piece shall conform to the limits given in Table 6 for the appropriate grade 11.2 Impact test When tested in accordance with Clause 10.6.2.1, the absorbed energy value resulting from— (@) cach individual test; and (b) the average of three tests, shall conform to the specified values given in Table 7 for the appropriate grade. 11.3. Cold fattening test When tested in accordance with Clause 10.6.3, a test piece taken from a circular section with a longitudinal weld seam shall show no signs of cracks or flaws. Superficial ruptures arising from surface imperfections shall not be cause For rejection, COPYRIGHTLicensed to Mr Kevin Macarney on4 March 2010.1 user personal user licence only. Storage, distribution or use on network prohibited (10006427), ASINZS 1163:2009 18 TABLE 6 TENSILE TEST REQUIREMENTS: Minimum elongation a8 a proportion of the ‘gauge length of 5.6895, Minimom | saimum ee Jed | tenes eee strength | strength Circular hollow Rectangular hollow ue in de MPs MPa sis | 918.<30 | >a0 | sts | >15 <30 | 530 250 | 320 18 20 22 | 16k 35019 30 | ao [i] ss [2| 2] [ue C450, C450LD 450 500 12 14 16 | 10 2 i NOTE: These limit apply tothe fac fom which the ease ests akon, TABLE 7 CHARPY V-NOTCH IMPACT TEST REQUIREMENTS Minimum absorbed energy, Joules test iaiieasaih Sue of test plece Grade 10 mm x 10 mm 10 mm » 7.5 mm 10 mm 5 mm cq. | Average inaiviavat| average [nd Average etdeests [test | attests | test | ofdtess [test casaLo | cso | 0 Fa 2 nan | 6 8 B casei | 12 REMOVAL OF SURFACE DEFECTS 12. Grinding When removal of surface defects by grinding is adopted, the ground area shall be well- transitioned and the remaining wall thickness in the ground areas shall be not less than 90% of the nominal thickness. 12.2, Depositing weld metal Welding used in the repair of surface defects shall be performed in accordance with AS/NZS 1554.1, using low-hydrogen electrodes complying with AS/NZS 4855. Welds shall be sound, the weld being thoroughly fused without underentting or overlap. The ‘weld metal shall project at least 1.5 mm above the rolled surface and the projecting metal shall be removed by grinding flush with the rolled surface. 12,3, Removal of upset Hollow sections produced by electric resistance welding shall have the external upset removed. After removal of the external upset, the remaining weld seam (excluding the upset beyond the inner surface) and wail thickness in the adjacent area shall not be less than 90% of the nominal wall thiekness. coPyRIGHTcence to Me Kevin Macartney on 4 March 2010.1 user personal user cence only. Storage, eistibuton oc use on network pobtited (10005427), 19 ASINZS 1163:2009 13. IDENTIFICATION, CERTIFICATION AND INDEPENDENT TESTS. 13.1 Identification 13.1.1 Individual length markings All hollow section lengths supplied in Australia shall be clearly and legibly identified by suitable and durable methods, such as painting (e.g. ink jet) or stamping with the following: (@) The manufacturer's name or mark, or both (b) ‘The manufacturer's site or mill identification, or both. (©) Traceable text identification which can be in either one or both of the following forms: (i) The time and date of manufacture of the product. (ii) A serialized identification number for quality control/assurance and traceability purposes. (A) ‘The markings specified in Items (a), (b) and (c) shall be placed a each length of ex-mill tube inimum of once on Where identification is by means of die-stamping, low-stress stamps shall be used for impact tested grades. This Clause does not apply to hollow sections supply in New Zealand. NOTES: 1 Products not marked with the provisions specified in this Clause would be considered to be ‘non-compliant with this Standard, 2 If the identified portion of the product is subsequently removed, then these identifications are to be transferred to each remaining portion of the product 3. Manufacturers making a statement of compliance with this Standard on a product, packaging or promotional material related to that product are advised to ensure that such compliance is capable of being verified. 13.1.2 Bundle/pack markings ‘The material shall be marked or tagged for bundles with the following: (a) The manufacturer's name or mark, or both, (b) Reference to this Standard, ie. AS/NZS 1163. (c) The grade of steel (see Clause 5). (4) The product dimensions to be identified with this Standard NOTE: See Appendix D. (©) A traceable identification number. 13.2 Test reports and test certificates 13.2.1 Qualifications on test reports and test certificates A test report or test certificate shall provide results in relation to the following: (a) Tests performed by a laboratory accredited by signatories to the International Laboratory Accreditation Corporation (ILAC) through their Mutual Recognition Agreement (MRA), in the field and class of testing, om behalf of the manufacturer for the purpose of establishing compliance with this Standard, The appropriate logo or further details of the ILAC (MRA) signatory shall be also noted on the document. aser and () Additional tests not considered in thi ‘manufacturer, NOTE: In Australia, ILAC (MRA) accredited bodies include National Association of Testing Authorities (NATA) and in New Zealand they include International Acereditation New Zealand (ANZ). Standard as agreed between the puré COPYRIGHT‘ruse on network prohibited (10085427), Lensed to Mr, Kevin Macartney on 4 Mach 2010. 1 user personal user cence only. Storage, si ASINZS 1163:2009 20 13.2.2 Minimum requirements for reports and test certificates In alphanumeric characters, @) (b) © @ © © @ (hy (i) a tk) o any report of test certificate shall be written in English by the manufacturers and shall have the following: addition to Clause 13.2, st Manufacturer's, supplier's and testing authority's name. Test certificate number and test number Date Product, testing specification and grade, e.g. AS/NZS 1163-C350L0 (see Clause 5). Produet dimensions and size, c.g, 200 x 100 x 5.0 RHS. NOTE: See Appendix D. Product steelmaking process, e.g. basic oxygen continuously cast, fine-grained, fully killed steels, and the like (see Clause 6) Length, bundle, pack or unique identifier to which the test certificate applies (see this Clause), Heat number (from steel feed casting). Chemical analysis type, eg. ladle and cast analy: ct “PP (see Clauses 7.1, 7.2 and 7.3), Chemical composition of carbon (C), silicon (Si), manganese (Mn), phosphorus (P), sulphur (S), chromium (Cr), molybdenum (Mo), aluminium (Al), titanium (Ti), niobium (Nb), vanadium (V), copper (Cu), nickel (Ni), carbon equivalence (CE) (see Clauses 7.1, 7.2 and 7.3) and any other element intentionally added, * or prod Where relevant, mechanical or alternative information as noted below (Tensile tests to Clause 10.6.1: Orientation, i.e. longitudinal ‘L* (see Clause 10.2.1), treatment, ie. aged ‘A’ (see Clause 10.5.4) and results, ie. yield strength in MPa, tensile strength in MPa and % elongation (sce Clause 11.1). (ii) Impact tests to Clause 10.6.2.1: Orientation, ie. longitudinal *L’ (see Clause 10.2.1), treatment, ie. aged ‘A’ (see Clause 10.5.4) and results (see Clause 11.2) ii) Impact test reporting to Clause 10.6.2.2(a): Statement of steel feed supplier name, grade/type, mill location, and other sizes with nominal thickness greater than or equal to 6 mm using the same steel feed type for compliance with Clause 10.6.2.1 pact test reporting to Clause 10,6.2.2(b): Statement of compliance with Clauses 6 and 10.6,2.2(b) with further statements of finished product ferrite grain size, use of aluminium killed steel feed and/or aluminium content in total or soluble form. (iv) Additional tests agreed between the purchaser and the manufacturer, (in) Statement acknowledging material being supplied in accordance with Items (a) to (I) @) above. Signatory from manufacturer, supplier or testing authority attesting to Items (a) {0 (m) above. NOTE: Test certificates may be requested by the end purchaser or at the time of manufacture, ‘COPYRIGHTLicensed to Me Kevin Macartney on 4 March 2010, + user personal user ence only. Storage, distribution or use on network peohbited (19008427), 2 ASINZS 1163:2009 13.3 Independent tests In the event of a dispute as to the compliance of the steel with this Standard, the purchaser and the manufacturer, or the supplier, shall agree 10 have referee testing carried out by independent laboratories acoredited by signatories to ILAC (MRA). 14 ROUNDING OF NUMBERS 14.1 General For the purpose of deciding whether a particular requirement of this Standard is complied with, the determined value, observed or calculated, shall be rounded off in accordance with AS 2706. The number of significant places retained in the rounded-off values shall be the same as that of the specified value in the appropriate material Standard. 14.2 Tensile properties The determined value of tensile strength shall be rounded off to the nearest 10 MPa antd the determined value of yield strength shall be rounded off to the nearest 5 MPa. 18 MANIPULATION Galvanized circular hollow sections of outside diameter less than ot equal to 60.3 mm and other shaped hollow sections of equivalent dimensions, shall be capable of withstanding a 90° bend around a grooved mandrel having a root radius of 6 times the outside diameter of the circular hollow sections or the section dimension in the plane of the bend for nom circular hollow sections. On completion of the bending operation, the galvanized coating shall show no signs of cracks or flaws. 16 NOMINAL DIMENSIONS, SECTION PROPERTIES AND MASS NOTE: Appendix D provides information on nominal section dimensions and, coupled with first Principles, also provides the listings and basis for the evaluation of nominal section properties and mass, 17 SAMPLING AND TESTING TO DEMONSTRATE PRODUCT CONFORMITY. As a minimum, the sampling and testing procedures shall conform to Appendix B. Additional testing may be agreed between the manufacturer and the purchaser. copyaicHTLicensed te Mr. Kevin Macartney on 4 March 2010.1 user personal user licence ony. Storage, ditibuton o use on network protie (10095427) ASINZS 1163:2009 APPENDIX A PURCHASING GUIDELINES (Informative) AL GENERAL Australian/New Zealand Standards are intended to inchide the technical provisions. necessary for the supply of materials referred to in the particular Standard, but do not purport to comprise all the necessary provisions of @ contract. In a number of cases, the purchaser is asked to state the requirements or is given a choice of optional requirements. These ate contractual matters to be agreed upon between the purchaser and the manufacturer, or the supplier ‘This Appendix contains detailed explanations, advice and recommendations on the information to be supplied by the purchaser at the time of enquiry and order, Its aims are to avoid misunderstandings and to result in the purchaser receiving satisfactory products and A2_ INFORMATION TO BE SUPPLIED BY THE PURCHASER ‘The purchaser should consider and supply the following information at the time of enquiry and order, after making due reference to the explanation, advice and recommendations contained in this Appendix: (a) Quantity and delivery instructions (dates, schedules, delivery point. (6) Dimensions of section, e.g. nominal length of long and short side, nominal outside diameter and nominal thickness (see Appendix D). (e) Designation of grade and Standard number (see Clause 5). (4) Any limitations in respect of packaging, e.g. number or sections per pack, packaging materials, (e) Whether a test certificate or test report is required (see Clause 13.2) (©) Whether it is the intention of the purchaser to inspect the steel at the manufacturer's works (see Paragraph A3). (@) Any information concerning processing or end use that the purchaser considers would assist the manufeeturer (ha) Whether a product analysis is required (see Clause 7.3), (i) Particular position of the weld seam (see Clause 9.2.1), if required (i) Special mill finish or coating, e.g. galvanized, (k) End finish () Special tolerances. (im) Length of seotions (including length tolerance type ~ see Table 5). (a) Zine coating requirements (see Clause 7.4) NOTE: Any special or supplementary requirements of this Standard are to be subject to agreement between the purchaser and the manufacturer, or the supplier at the time of enquiry and order, and stated on the order. coPyaIGHTUonnsed to Mr. Kev Macaftney on 4 Match 2070.1 user personal usar Ieence only. Strago,distibuton or use on network prohibited (10005427) 23 ASINZS 1163:2009 A3_ INSPECTION If it is the purchaser's intention to undertake any of the following functions at the manufacturer's works, this should be notified at the time of enquiry and order, and should be accomplished in a manner which will not interfere with the operation of the works, The functions are as follows’ (a) Inspect the product during manufacture (b) Select and identify the test samples. (©) Witness the tests being made. ‘The manufacturer should provide all reasonable facilities to enable the purchaser 10 be satisfied that the produet complies with this Standard Ad HEAT TREATMENT ‘The mechanical properties of these grades can be affected by any reheating that may be applied for its end use. If it is intended to reheat these grades above 620°C, the purchaser should discuss the application and the proposed reheating treatment with the manufacturer. NOTE: Welding to AS/NZS 1554 does not affeet the mechanical properties of hollow sections ‘manufectured to this Standard, copvaicrloaned to. Kevin Macariney cn 4 March 2010, 1 user personal ier cence only. Storage, distribution or use on network proheited (10085427). ASINZS 1163:2009 m4 APPENDIX B PRODUCT CONFORMITY (Normative) BI SCOPE This Appendix sets out the minimum sampling and testing plan for Product Conformity to this Standard which shall be demonstrated by the hollow section manufacturer or supplier, ‘The Product Conformity requirements shall enable Conformity Assessment to be made by a manufacturer or supplier (first party), a user or purchaser (second party), ot an independent body (third party), and shall not be dependent on a quality management systems standard (c.g. 180 9001, cte.). To meet this requirement the manufacturer or supplier shall also ‘maintain all records relating to product conformity in @ form suitable for second or third party assessment NOTE: These provisions are based on— (a) ISOMEC Directives, Part 2, Rules for she structure and drafting of International Standards, Sth Edition, 2004, (b) ISO/IEC Directives, Supplement ~ Procedure specific to IEC, 4th Edition, 2009, (©) TEC, Conformity Assessment Bosrd (CAB/S22/INF, 2009-05-27), Agenda item 7.2, ISO/IEC Directives, text concerning conformity assessment: ctrrent status, B2_ SAMPLING AND TESTING B21, General Sampling and testing shall be carried out by the manufacturer in accordance with Paragraphs B2.2 or B2.3 as appropriate. For every batch, the chemical composition shall be obtained in accordance with Clauses 7.1, 7.2 oF 7.3, as appropriate The manufacturer or supplier shall ensure that product which does not mect the requirements of the Standard are identified, deemed nonconforming and controlled to prevent unintended use or delivery. The results from the nonconforming tests shall be excluded from the long-term conformance calculations. Should a failure on retesting occur, then the quarantined batch shall be rejected or satisfy the provisions of Paragraph B2.2.3. B22. Minimum batch sampling and testing B2.2.1 Batch sampling For tensile, impact and flattening tests, the test samples shall be taken as follows: (a) One sample for a batch not exceeding 50 tonnes for— () circular hollow sections (CHS) with outside diameter less than 168.3 mm; and Gi) _all other (non-CHS) shapes. (b) One additional sample from the balance of the batch as described in (a) above. (©) For CHS with outside diameter equal to or greater than 168.3 mm, one sample per heat for a specific outside diameter and thickness. 82.2.2 Conformity Each batch conforms with this Stendard if all of the samples tested give results that are within the specified limits coPvRIGET.Licensed to Me. Kevin Macartney on 4 March 2010.1 user personal user ence ony. Storage, dstibuton or use on network prohibited (10086427), 25 ASINZS 1168:2009 If any of the properties of the tested samples provide results outside the specified limits, the requirements of Paragraph B2.2.3 apply B2.23° Rerests B2.23.1 Tensile test and cold flasening rest Ifa retest is carried out, one or more of the following procedures shall be adopted (a) Make two additional tests on test pieces from samples teken from the same unit at a position as near as practicable to the failed sample. The unit conforms to this Standard provided both additional test pieces conform to Clauses 10.2, 10.5, 10.6 and I (b) Make two test samples at random from the remainder of the batch. If the test pieces from both additional samples conform to Clauses 10.2, 10.5, 10.6 and II, the remainder conforms to this Standard. If one of these samples fails to conform, the steel of the applicable batch does not conform to this Standard (©) Make test samples from each rolled unit of steel and individually test in accordance with this Standard. If the test piece from the additional sample conform, to Clauses 10.2, 10.5, 10.6 and 11, the rolled unit of steel conforms to this Standard. B2.2.3.2 Impact tests If a retest is carried out, one or more of the following procedures shall be adopted: (a) Ifthe average value of the three impact test results is less than the specified minimum average, or if one value is less than the specified individual test value given in Table 7, then test three additional test pieces from the original sample in accordance with Clauses 10.2, 10.5 and 10.6, and add the results to those previously obtained and calculate a new average. If the average value of the six tests is not less than the specified minimum average, and not more than one result of the six tests is below the minimum specified individual test value given in Table 7, then the unit conforms to this Standard. (b) Take two further test samples at random from the remainder of the test batch, If the test pieces from both additional samples conform to Clauses 10.2, 10.5, 10.6 and 11.2, then the remainder conforms to this Standard. If one of these additional samples fails to conform, the steel of the applicable batch does not conform to this Standard (c) Take test samples from each rolled unit of steel and individually test in accordance with this Standard. If the test piece from the additional sample conforms to Clauses 10.2, 10.5, 10.6 and 11.2, then the rolled unit of steel conforms to this Standard B2.3. Statistical Sampling B23. General Process verification by statistical sampling or alternate methods can be used to demonstrate produet conformity where the conditions required by Paragraph B2.3 are met (See also Note 1). Where it can be demonstrated that the type test (see Note 2) of any group of products (see Note 3) manufactured under the same conditions of steel supplier, steel grade, steel processing and tube processing ate distributed normally, then it shall be permissible to adopt statistical sampling to verify process acceptanice for each product in accordance with 180 7966. copyRiGHToan! o Mr. Kevin Macartney on 4 March 2010.1 user personal user Keenca any Storage, dstributon of use on network prohibited (10085427), ASINZS 1163:2009 26 For produet conformance to this Standard via statistical sampling, the inputs of provess acceptance verification, ongoing testing and statistical sampling must be demonstrated and, where applicable, also maintained, To ensure that the process being assessed is in control (see Note 1), a statistically significant number of samples must be obtained within « rationally determined time period that is reflective of typical manufacturing practice (see Note 4). Within a defined group, each type of test sample randomly selected shall not exceed a sampling period of three months. Additionally, any sample or sampling that indicates a predicted proportion of non- conforming product in excess of an amount considered within the demonstrated statistical sampling method, shall cause the sampling for that combination of size, thickness and grade to revert to batch sampling rules until it can be demonstrated that the conditions of statistical sampling are valid for that combination In the event of actual non-conforming test results, the retest provisions of normal batch testing shall also apply. NOTES: 1 Statistical sampling is a procedure that enables decisions to be made about the quality and conformity of batches of items after inspecting or testing only a portion of those items. This procedure will only be valid if the sampling plan has been determined on a statistical basis and the following requirements are met: (@) The sample is drawn randomly fom a population of product of known history that enables verification that the product was made from known materials at essentially the same time by essentially the same processes and under essentially the same system of control. {b) For each different situation, a suitable sampling plan is defined. A sampling plan for fone manufacturer of given capability and product throughput may not be relevant to another manufacturer producing the same items. In order for statistical sampling to be meaningful to the customer, the manufacturer or supplier needs to demonstrate how the above conditions have been satisfied. Sampling and the establishment of a sampling plan should be carried out in accordance with recognized Standards (¢.g. AS 2490, AS 1199) and methods. Under this approach, ongoing sampling and testing of product shall be disected primarily at monitoring the process to ensure that product outcomes are acceptable, within characteristic ranges as well as stable and under control (e.g. normally distributed. 2. The type test is the measured parameter such as tensile testing, impact testing, ete, These are Jong term testing plans based on initial testing undertaken to determine overall conformance and other required controls to be put into place (e.g. same steel supply, same manufacturing, process) to ensure ongoing compliance. To reduce sempling frequencies, @ group of products can consist of an aggregation of batch data from a range of produets if it can be demonstrated to be normally distributed 4) See Appendix C for an example on statistical sampling, B23.2 Tensile tests B23.241 General Testing to AS 139) as noted in Paragraph 10.6.1 is only considered within Paragraph B2.3.2 for produet conformance assessment to tensile testing requirements, B2.3.2.2 Sampling conditions In conjunction with the provisions of Paragraph B.2.3.1, statistical sampling shall only be used for a combination of size, thickness and grade where the statistically predicted proportion of non-conforming product is less than 5% at a confidence level of 90%. COPYRIGHT(0098427). 1 on network prohb Loaner to Mr Kevin Macartney on & March 2010. user personal usr Heance nly. Storage, distin or a ASINZS 1163:2009 Changes in steel supplier, steel grade and significant changes in steel or tube processing (e.g, mill) shall necessitate a re-evaluation of the conditions in this Paragraph (B2 3.2.2), NOTE: For further information on the basis for staistial sampling, refer to Appendix C. B2.3.3. Impact tests B2.3.3.1 General Testing and assessments to— (a) Clause 10.6.2.1; (b) Clause 10.6.2.2(a); and (©) the grain size provisions of Clause 10.6.2.2(b). are only considered within Paragraph B2.3.3 for product conformance assessment to impact testing requirements. B2.3.3.2 Sampling conditions In conjunction with the provisions of Paragraph B.2.3.1, statistical sampling shall only be used for a combination of size, thickness and grade where the statistically predicted proportion of non-conforming product is less than $% at e confidence level of 90%, Changes in steel supplier or steel grade and significant changes in steel or tube processing shall necessitate a re-evaluation of the conditions in Paragraph B2.3.3.2. NOTE: For further information on the basis for statistical sampling, refer to Appendix C. COPYRIGHTLUoensed fo MK. Kevia Macarney on 4 March 2070.1 user personal user loence only. Storage, cstbution o use on network prohibited (10005427) ASINZS 1163:2009 28 APPENDIX C BASIS FOR ASSESSMENT OF COMPLIANCE OF MECHANICAL PROPERTIES, BY STATISTICAL SAMPLING (Informative) cl SCOPE ‘This Appendix provides background information and the methodology used in the application of ISO 7966, Amongst other aspects, this Standard permits the use of statistically based sampling of product for the assessnent of the tensile properties and toughness conformance. 2 BACKGROUND It is common practice for an ERW tube manufacturer to use the same steel grade for a range of product sizes. The strength and ductility of ERW tube supplied in the as-rolled condition is largely dependent on the properties of the steel used and the amount of cold deformation that occurs during tube forming, As the amount of cold deformation will vary with the nominal size and thickness of the finished tube, the mechanical properties will vary significantly between product sizes for the same steel grade, This is iMlustrated in Figure Cl, where the actual distribution of yield strength test results obtained from two different product sizes over a period of 5 years and using the same steel grade for both products, which shows the normal curves appropriate to the average and standard deviation for each product. AAs the steel grade is designed for the lowest strength product size there will be many produet sizes that will easily meet the specification limit Count 250 200 350 400 450 600 Yield strength, MPa} FIGURE C1 DISTRIBUTION OF YIELD STRENGTH FOR TWO PRODUCTS Also, as the normal curve is a close approximation to the actual distribution of yield strength test results, statistical formulae based on the normal distribution may be used to predict the proportion of product that would be expected to be above or below any nominated value. For example, for a hypothetical specification of 300 MPa it can be shown that product A has a statistically negligible expected failure rate while product B has an expected failure rate of 1%. Similarly, the likelihood of results below 290 MPa is of the order of | in 3 x 10° for product A and | in 1000 for product B. COPYRIGHTg t ; i 5 i & i : i i 5 ; & : Macartney on 4 March 2010. Lense to Me Ke 29 ASINZS 1163:2009 Both product A and produet B can be considered to be stable and in control and consistently meeting the hypothetical yield strength requirement, although with different margins of safety. Ongoing testing of these products may be conducted with the objective of monitoring and acceptance of the process rather than the acceptance of each manufactured batch. Using this approach, the process is periodically sampled to ensure that it has not changed to an extent that it is no longer acceptable. This can be achieved through the application of statistical principles with considerably less testing than is required for batch testing, particularly where there is a good margin of safety, C3. APPLICATION OF ISO 7966 C31 General ISO 7966 provides a method by which samples from a process may be used to verify the process acceptability against a specification. For any sample size a minimum ‘acceptance control limit’ is determined which will ensure, with 2 nominated risk, that no more than a nominated proportion of the product will fail to conform with the specification limit. As the sample size decreases, the acceptance control limit increases and the manufacturer faces an increasing risk that their process will be falsely rejected due to chance, particularly if the process fas @ low safety margin, e.g. product B in Figure Cl; this is an incentive for the manufacturer to take a large sample size for products with smaller safety margins, C32. Basic To apply ISO 7966, the following example on tensile testing should be considered: (a) The proportion of non-conforming product that is considered rejectable. In this example, this has been nominated as 5%, i.e. the process is considered rejectable if any sample indicates that $% or more of the product may not conform. (b) The maximum tolerable risk of not detecting a rejectable process, ie. the likelihood that the sample will not identify a process that is producing 5% or mote of non- conforming product. In this example, this has been nominated as 10% risk. €3.3 Additional criteria In addition to the items nominated in Paragraph C3.2, the following should be established: (a) For this example it is eonsidered appropriate that— (the assessment to be based on a minimum of $00 tests obtained over a minimum of one (1) year; the distribution of properties for any combination of steel grade and product size to approximate a normal distribution; and (iii) only a combination of size and steel grade where the predicted proportion of non-conforming product does not exceed 2% ate considered suitable for process acceptance sampling, (b) ‘The maximum acceptable time between sampling, i.e. the longest period over which the process may go unchecked. This has been specified as 3 months. (©) The actions to be taken iff a sample indicates that the process is producing more than 5% of non-conforming product. In this instance it is appropriate to revert to batch sampling rules to— (i) increase the sample size in order to verify that the sample average is above or below the acceptance control; and (i) verify that no test results are below the specification limit. copyRIGHT‘Uoenses to Mr. Kevin Macarnay 0n 4 March 2010, 1 user percaral user Keanca any. Storage, dtbition or use an network prohibited (10005427), ASINZS 116322009 50 APPENDIX D. DIMENSIONS AND PROPERTIES OF CROSS-SECTION (nformative) ‘This Appendix provides lists of dimensions and properties of cross-section for information only. Figures D1 to D4 are not restrictive nor exhaustive, Other sizes in various grades are also available in Australia and New Zealand. Although they appear in the following tables, certain sizes may not always be available in all grades, Users are advised to check availability before incorporating hollow sections in major designs, NOTE: The following information was used to generate the data in this Appendin: (0) First principles as typically used in calculating seetion properties. 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Storage, distbution ar use-on network probit (10095427). AS 1199 1199.0 1199.1 2490 a ASINZS 1163:2009 BIBLIOGRAPHY Sampling procedures for inspection by attributes Part 0; Inttoduction to the ISO 2869 attribute sampling system Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot- by-lot inspeetion Sampling procedures and charts for inspection by variables for percent non- conforming copyricHt