ISO 3834-2:2021 defines the highest level of quality requirements for fusion welding of metallic materials, applicable both in workshops and at field installation sites. It is designed for critical or high-risk welding applications, typically found in industries such as:

• Pressure vessels
• Structural steel
• Pipelines
• Aerospace and nuclear components

EN ISO 3834-2 for Class 1, EN ISO 3834-3 for Class 2 or EN ISO 3834-4 for Class 3.

Key Elements of ISO 3834-2:2021

1. Review of Requirements and Technical Review
2. Sub-contracting
3. Welding Personnel
   • Welders and welding operators
   • Welding coordination personnel
4. Inspection and Testing Personnel
   • Including qualified non-destructive testing (NDT) personnel
5. Equipment
   • Production and test equipment
   • Suitability, description, commissioning, and maintenance
6. Welding and Related Activities
   • Production planning
   • Welding procedure specifications and qualifications
   • Work instructions and document control
7. Welding Consumables
   • Batch testing, storage, and handling
8. Storage of Parent Materials
9. Post-Weld Heat Treatment
10. Inspection and Testing
    • Before, during, and after welding
    • Inspection and test status
11. Non-Conformance and Corrective Actions
12. Calibration and Validation of Measuring and Testing Equipment
13. Identification and Traceability
14. Quality Records

ISO 3834-5: Documentation for Conformity

ISO 3834-5 specifies the documentation required to demonstrate compliance with ISO 3834-2:2021.

1. Review of Requirements and Technical Review

The manufacturer must:

• Review contractual, technical, and in-house requirements before starting work.
• Confirm that all necessary manufacturing information is complete and available.
• Ensure proper planning of quality-related activities.
• Demonstrate capability to meet all specified requirements.

The review verifies that:

• The work is within the manufacturer’s capabilities.
• Resources are adequate to meet deadlines.
• Documentation is clear and unambiguous.

In requirement review the following aspects may be considered:

• • the product standard to be used, together with any supplementary requirements.statutory and regulatory requirements.any additional requirement determined by the manufacturer.
  • the capability of the manufacturer to meet the prescribed requirements.

Technical reviews are part of early planning activities and the following may be considered:

• Parent material specifications and welded joint properties
• Quality and acceptance requirements for welds
• Location, accessibility, and sequence of welds, including accessibility for inspection and non-destructive testing
• Specifications for welding, non-destructive testing, and heat treatment procedures
• Approach for the qualification of welding procedures
• Qualification of personnel
• Selection, identification, and traceability (e.g., for materials and welds)
• Quality control arrangements, including the involvement of any independent inspection body
• Inspection and testing
• Sub-contracting
• Post-weld heat treatment
• Other welding requirements, such as batch testing of consumables, ferrite content of weld metal, ageing, hydrogen content, permanent backing, peening, surface finish, and weld profile
• Use of special methods (e.g., achieving full penetration without backing when welded from one side only)
• Dimensions and details of joint preparation and the completed weld
• Welds to be made in the workshop or on site
• Environmental conditions relevant to the welding process (e.g., low ambient temperatures or the need for protection against adverse weather).
• Handling of non-conformances.

2. Sub-Contracting

When a manufacturer plans to engage sub-contracted services or activities (such as welding, inspection, non-destructive testing, or heat treatment), they must provide the sub-contractor with all necessary information to meet the applicable requirements. The sub-contractor, in turn, is required to supply the manufacturer with the relevant records and documentation of the work performed as specified. Note the following:

• Provide all relevant technical and quality information.
• Ensure the subcontractor complies with ISO 3834-2 requirements.
• Take responsibility for the subcontractor’s performance and records.

3. Welding Personnel

• Welders and operators must be certified.
• Welding coordination personnel must be appropriately qualified.

4. Inspection and Testing Personnel

• NDT personnel must be qualified.
• For visual testing, formal qualification may not always be required.

5. Equipment

• Production and test equipment
• Description of production equipment
• Suitability of equipment
• New equipment
• Maintenance of equipment

6. Welding and related activities

• Production planning
• Welding procedure specifications
• Qualification of the welding procedures
• Work instructions
• Procedures for preparation and control of documents

7. Other Key Requirements

• Proper maintenance and calibration of production and testing equipment.
• Controlled storage and handling of consumables and parent materials.
• Comprehensive inspection and testing at all welding stages.
• Clear procedures for non-conformance management, traceability, and record keeping.

In summary

ISO 3834-2:2021 sets a rigorous framework for welding quality assurance.
ISO 3834-5 complements this by defining the documentation required to demonstrate conformity – ensuring traceable, consistent, and high-integrity welded structures in critical industries.