Information for the certification of weld shops in rail vehicle construction

according to EN 15085-2

Certificate according EN 15085-2 :

Railway applications-Welding of railway vehicles and components-
Part 2 :Quality requirements and certification of welding manufacturers.

Starting 2008-04-01, the series of standards EN 15085 parts 1 to 5 ( issued October 2007 ) has been
introduced by the German National Safety Authority, the Eisenbahn-Bundesamt (EBA) as generally
accepted rules of technology for the area of competence of the EBA.

Workshops intending to carry out welding works in new building, conversion and repair including finishing
welding of rail vehicles must have evidenced their competence according to EN 15085 Part 2. The
evidence is regarded as given if the certificate has been issued by the manufacturer certification body.
These manufacturer certification bodies in Germany are authorised by EBA as a National Safety
Authority.

A certificate based on ISO 3834-2 or –3 does not replace a certificate according EN 15085-2!

The SLV Duisburg, branch of GSI mbH as a manufacturer certification body accredited by the German
Railway Authority undertakes verification of compliance with the requirements on technology and
personnel in the workshop and issues the certificate for the certification level fulfilled.

For issuing a certificate an application for his workshop (s) must be submitted to the manufacturer
certification body by the manufacturer .

Focuses on the verification of compliance are parts 2 to 5 of EN 15085 (requirements to personnel,

procedure specifications, welders examinations, structural requirements, rules on execution, materials,
weld performance classes, planning documents.)

Comparison

DIN 6700-2 (old) EN 15085-2 (new)

Notified body (competent authority – Railway If required :

Authority) Manufacturer certification body
Inspects and issues certificate (National safety authority)
Inspects and issues certificate

Parts classes (BTK) Certification level (CL)

Depending on safety relevance of components Depending on weld performance class (CP) or
and parts on defined components and parts
(weld performance class will be determined by
structural requirements according to DIN EN
15085-3 !!)

C1
Vehicles and components with high safety CL 1
Rail vehicles or parts with welded
relevance, joints classified in weld performance
new build, conversion and repair, classes CP A to CP D
bogies, underframe and (Levels CL 2 to CL 4 included)
vehicle body
Required for:
bogies,
body shell components (underframe, structures),
buffers and draw gear,
C2
Vehicle parts with high safety relevance wheel set components (wheel set mountings, axle
finishing welding boxes, spring supports),
repair of vehicles, components and brake equipment,
parts classes C1 / C2 external fuel tanks,
(large repair shops
C1) supporting frames for heavy components
 (pantographs, traction units),
welded components for drag transmission from
bogie to vehicle,
vibration dampers and their link between
bogie and vehicle or between vehicles,
finishing welding of castings within components
indicated above

CL 2
Components with welded joints of

C3
Vehicle parts with medium safety Weld performance class CP C2 to CP D
relevance CP C1 is possible, if inspected according to
Repair of parts class C3 class of testing CT 1;

Level CL 4 is included for parts according to

CL 2 or CL 3
C4
Vehicle parts with low safety relevance CL 3
Parts with welded joints classified
Repair of parts class C4 according to weld performance class CP D

C5
Welding manufacturer which: CL 4
Welding manufacturer, which:

- designs - designs
- purchases and assembles - purchases and assembles
- purchases and sells - purchases and sells
components and parts to be welded.
______________________________________ __________________________________
Certificate required for: C1, C2, C3, C5 Certificate required for: CL 1, CL 2, CL 4
Not required for parts class C4 Not required for CL 3

Quality requirements to welding Quality requirements to welding

manufacturer manufacturer
Parts class C1 to C3: CL 1: according to EN ISO 3834-2
according to DIN EN ISO 3834-3 CL 2: according to EN ISO 3834-3
Parts class C4: according to DIN EN ISO 3834-4 CL 3: according to EN ISO 3834-4
Parts class C5: according to DIN EN ISO 3834-3 CL 4: according to EN ISO 3834-3
(if QMS according to DIN EN ISO 9001 required:
DIN EN ISO 3834-2)

Welding coordinators Welding coordinators

Parts class C1 CL 1
responsible , level A

responsible welding coordinator, level 1
deputy, level A

deputy , level 1 (not for smaller welding shops)
(not for smaller welding shop)

further deputies, level B or C /

in addition to each welding shop, with one further deputy, level C
level 3 or 4 for each further welding shop

Parts class C2 ( class CL 1 includes the old classes C1 + C2 )

responsible welding coordinator, level 1

deputy, level 2 or 3

in addition per welding shop,
level 3 or 4
(with several manufacturing shops)

Parts class C3
responsible welding coordinator, CL 2
responsible welding coordinator,

level 2 or 3 level B or C

deputy, level 4
deputy, level C
Parts class C4
no requirements CL 3
No requirements

Parts class C5
for parts class C1, one CL 4
For CL 1: level A

welding coordinator for level 1
For CL 2: level B or C

for parts class C2, one welding
coordinator, level 1
(design only: DVS-welding designer) See annex B

for parts class C3 one welding Tasks and areas of competence of welding
coordinator 2 or 3 coordinator
(design only: like parts class C2)

Involvement in organization Welding coordination organization

Also see DVS-code of practise 1617

Description of the job: DIN EN ISO 14731 Description of the job: EN ISO 14731

tasks, responsibilities and areas of competence
tasks, responsibilities and areas of competence

rules for the areas of competence
rules for the areas of competence

when must a responsible welding coordinator be
when must a responsible welding coordinator be
present present

measures in case of absence of a responsible
measures in case of absence of a responsible
welding coordinator welding coordinator

authority to issue instructions
authority to issue instructions

making decisions independent of manufacturing
making decisions independent of manufacturing
pressures pressures

CL 1: Owners, managing directors,

Parts class C1: Owners, managing directors, works manager, manufacturing manager
works manager, manufacturing manager are not admitted as welding coordinator,
are not approved as welding coordinator, no approval possible,
deputy may be approved (Yes, in case of smaller shops, if welding
coordinator has level A and deputy has
level C),
deputy may be approved

External welding coordinator Subcontracted welding coordinator

(in special cases) (special cases)

see also DVS-guideline 1619 and Welding coordinators who are not employed.
A-Z-collection of KoA Valid for responsible welding coordinator

for CL 1 to CL 4 possible

for parts classes C2, C3 and C5 possible
only one subcontract per manufacturing plant,

also valid for welding coordinators who are deputy must be employed with manufacturer
employed by another part of the same
work contract and working times regulated,
manufacturer(holding, head office, administration) running of a production log

work contract and working time ruled
if subcontracted welding coordinator is to be

description of the job active in more than two plants,
(when must a welding coordinator be present) approval of customer is required,

running of a work book for CL 4 exceptions in accordance with

maintenance: Welding coordinator of level 1 of a manufacturer certification body
maintenance works can be approved for 2 further
also valid for welding coordinator who is employed
smaller works of the same owner as the responsible with another plant than that of the manufacturer
welding coordinator (for parts class C2) (holding, head office, administration)

Welders, operators, setters Welders, operators, setters


DIN EN 287-1, DIN EN ISO 9606-2,
EN 287-1, EN ISO 9606-2,
DIN EN ISO 9606-3, DIN EN 1418 EN ISO 9606-3, EN 1418

per welding process, material group, dimension,
for all welding processes, types of material, types
min. 2 according to the applicable standards of seams and welding positions in manufacture

for fillet weld separated evidence required
for fillet weld separated evidence required
(butt weld does not include fillet weld) (butt weld does not include fillet weld)

Aluminium-material groups 21 to 23:
with TIG and MIG principally radiography of the
butt weld; for fillet weld additional macro-section

Welding coordinator level 1 is allowed to
responsible Welding coordinator level 1 is

take examinations allowed to take examinations
(if approved by the notified body) (if approved by the notified body)

Minimum number not stated!!

Inspection personnel Inspection personnel

quality inspections within welding manufacture:
quality inspections within welding manufacture:
Inspection personnel must be instructed Inspection personnel must be instructed
by the welding coordinator by the welding coordinator
e.g. for visual testing for external evaluation of the
welds

if required: ndt (VT, PT, MT, ET, UT, RT)
according to DIN EN 473
if required: PT, MT, ET, UT, RT according to
inspectors with level 1 / inspection coordinator EN 473 with instruction by welding coordinator,
with level 2; Inspector with level 1 / inspection coordinator
subcontracted inspection personnel possible with level 2;
subcontracted inspection personnel possible

All inspections of the welded joints are to be
carried out and evaluated under the
Inspections of the welded joints by the
responsibility of the responsible welding responsible welding coordinator ! Or by
coordinator !! IWIP or EWI, level 1 or inspection personnel
according to EN 473, level 3

Welding Procedure Specifications (WPS) Welding Procedure Specifications (WPS)

for parts class C1 to C3 required
for welded joints of the weld performance class
for parts class C4 only if required by the customer CP A to CP C3 required,
CP D only if required by the customer

Evidence of the WPS: Evidence of the WPS:

manual / partly automated processes in
CL 1 / CL 2: Inspection report WPQR required

materials groups 1.1, 1.2, 8, 9, 21-26 according to according to EN ISO 15610, EN ISO 15611,
DIN EN ISO 15614-1 and -2 or EN ISO 15612, EN ISO 15613,
DIN EN ISO 15611 or DIN EN ISO 15613; EN ISO 15614, EN ISO 14555, EN ISO 15620
repair according to DIN EN ISO 15613 (for CP D only if required by the customer)
directly before start of production
CL 3: only if required by the customer

fully automated processes or material groups Details see EN 15085- 4, 4.1.4

1.3-7 and 31-36
according to DIN EN ISO 15614-1 and -2 See annex C ( EN 15085-2)

Approval of the WPS using WPQR by:

Inspection report of an inspection board (not
 necessarily the notified body according to DIN
6700) or

the approved welding coordinator, level 1 if the

shop has an accredited testing laboratory

Supplementary area of validity of the WPS: No supplementary fields of validity have been

Materials groups see A-Z collection described !!

Test piece thickness t ≤ 3 mm:
manufacturing range 1.0 mm to 2t is valid

Fillet weld thickness of the work piece a<10 mm:
manufacturing range 0.5a to 2a is valid

Fillet weld: Test piece for t≥ 3 mm required

see DIN 6700-2, annex A, D, E, F

Lasting validity for EN 288ff Lasting validity for EN 288ff

Technical equipment Technical requirements

Suitable equipment depending on the extent of the
Suitable equipment according to

welding works: EN ISO 3834, in particular storage of
Storage of materials (dry) materials (dry)
Suitable welding machines Suitable tools and similar corresponding to
Suitable tools and similar corresponding to the the worked materials (aluminium, stainless
materials worked (aluminium, stainless steels) steels)
Welding equipment Welding equipment
Rotating fixtures / clamping devices

for parts class C1 and C2: Working platforms / lifting devices
Rotating fixtures / clamping devices Straightening equipment
Working platforms / lifting devices Special areas for working with aluminium and
Straightening equipment stainless steels
Special areas for working with aluminium and
stainless steels

Approval of the weld shops Certification procedure

See also DVS-guideline 1619

Audit
Audit

Evidence of WPS
Evidence of WPS

Evidence of work specimens according to

Expert discussion (Welding coordinators) EN 15085-4

Expert discussion (welding coordinators)

Welding quality assurance according to
the applicable part of EN ISO 3834

Certificate of welding:
Issuing of a certificate
bound to the location of the weld shop and its bound to the location of the weld shop and its
welding coordinators welding coordinators

Validity Validity

Maximum 3 years
Maximum 3 years
Surveillance by notified body Valid only for the location the shop stated in the
(see DVS-guideline 1619), certificate,
 Modifications are to be disclosed, annual surveillance by manufacturer certification
Extension must be applied for in time body (it is permitted to take into account reports
on internal audits in special cases)

Withdrawal of the certificate Modifications are to be disclosed,
Extension must be applied for in time

Repair Repair

out of the certified shop for production
see DIN 27201-6 of workability (transfer)

in case of warranty or maintenance of its own
vehicles welding works are admissible under the
same conditions regarding personnel, technical
and qualitative requirements
(the other shop need not be stated in the
certificate)

certified body is permitted to carry out welding

works in another workshop if the workshop is
inspected in a verification procedure and the
workshop is indicated in the certificate

Verification of conformity Verification of conformity

according to order: No requirements included in EN 15085

to be declared by the body agreed upon

by the manufacturer:
Inspections and documentation according to the But:
specified weld performance class according to EN 15085-5,
DIN 6700-5 Chapter 9 , Declaration of conformity

by body agreed upon: Manufacturer must submit certificate of compliance
Inspections and documentation according to with the determined contract requirements;
specified weld performance class according to
DIN 6700-5 and attestation of conformity or Guidelines for issuing:
instead of inspections, the body agreed upon see EN ISO/IEC 17050-1 and -2
performs surveillance of the QMS
(certificate will not be issued) Certificate according to EN 10204 shall be agreed
between customer and manufacturer

Evidence of welding procedure specifications – EN 15085-4

Chapter 4.1.4

Weld performance class CP A:

WPQR according to EN ISO 15614 or EN ISO 15620;

According to EN ISO 15613 only if a WPQR according to EN ISO 15614 is present;
For materials with Reh > 500 MPa or for fully automated welding only
EN ISO 15614 is possible
Test pieces must fulfill the requirements of weld performance class CP A (EN 15085-3,
tables 5 and 6)

for weld performance class CP B, CP C1, CP C2:

WPQR according to EN ISO 15613, EN ISO 14555, EN ISO 15620;

If required by component or material: according to EN ISO 15614

Note: EN ISO 15610, EN ISO 15611, EN ISO 15612 not possible


for weld performance class CP C3:

WPQR according to EN ISO 15610, 15611, 15612, 15613, 14555, 15620

If required by component or material: according to EN ISO 15614

for weld performance class CP D: only if requested by customer