Welding procedure qualification is a formal requirement on most structural, pressure equipment, and fabrication contracts — but the process is widely misunderstood. Here is what a WPS, PQR, and welder qualification record actually are, what the qualification test involves, who signs what, and what onsite testing looks like in practice.
Why Qualification Is Required
A welding procedure specification (WPS) is a written document that defines the parameters for making a weld: the base material, filler material, preheat, interpass temperature, joint design, welding position, heat input, and post-weld heat treatment if applicable. The WPS tells the welder what to do.
But a WPS on its own is not enough. Before a WPS can be used in production, it must be supported by a procedure qualification record (PQR) — a document that records an actual test weld made to the WPS and the results of the mechanical tests performed on that test weld. The PQR is the evidence that the procedure produces welds with the mechanical properties required.
The Applicable Standards
The standard used depends on the application and the client's requirements:
- AS/NZS 1554 series — structural steel welding, the most common standard for NZ fabrication
- AS/NZS 2980 — quality requirements for fusion welding of metallic materials (ISO 3834 equivalent)
- AS/NZS 9606 / ISO 9606 — welder qualification testing
- ASME Section IX — pressure vessels and boilers, widely used in process plant
- AWS D1.1 — structural steel, common on international and mining projects
- API 1104 — pipeline welding
The standard determines what test pieces are required, what mechanical tests must be performed, and what the acceptance criteria are.
The Qualification Test — What Actually Happens
A test weld is made by the welder (or by an automatic process) in the position and joint configuration specified. For a typical butt weld qualification, the test piece is then cut into specimens and subjected to:
- Tensile testing — to confirm the weld meets the minimum tensile strength of the parent material
- Bend testing — to confirm ductility and fusion, with the specimen bent over a mandrel without cracking
- Macro examination — a cross-section of the weld is etched and examined visually for fusion, penetration, and internal defects
- Impact testing (Charpy) — required for some standards and applications where notch toughness is specified
- Hardness testing — particularly for high-strength steels or when HAZ hardness is a concern
Non-destructive testing — VT and PT or MT at minimum, RT or PAUT for some standards — is carried out on the test piece before it is cut for mechanical testing.
The PQR — What It Must Contain
The PQR records the actual parameters used during the test weld (not the intended parameters — the actual ones, measured during welding) and the results of every test. It must be signed by the examining body — an independent, qualified inspection organisation — and it must be traceable to the test piece and the test reports.
The WPS is then written or revised to sit within the ranges qualified by the PQR. A single PQR can support multiple WPSs if the variables are within the qualified range.
Welder Qualification Records
A welder qualification record documents that a specific welder has demonstrated the skill to make an acceptable weld to a specific procedure, in a specific position, on a specific material group. Welder qualifications have an expiry — typically six months of inactivity in the process and position qualified causes the qualification to lapse.
Who Signs What
The examining body — an organisation approved under the standard to qualify welding procedures and welders — signs the PQR and the welder qualification record. DEG Survey & Inspection is an approved examining body under AS/NZS 2980 for welding procedure and welder qualification testing.
Onsite Testing — What It Looks Like
For fabricators, the most practical option is to bring DEG to the workshop or site. We set up the test, witness the welding, perform the NDT, prepare and send specimens for mechanical testing, and issue the PQR and qualification records as a complete package. Turnaround on the mechanical testing is typically five to seven working days. Where a fabricator has an urgent production need, we can prioritise NDT results the same day to confirm the weld is acceptable before mechanical test results are finalised.
Get in touch: admin@deg.nz