Part_2_e-Jan17.pdf

P a r t 2 : R u l e s f o r M a t e r i a l s a n d W e l d i n g

RULES FOR

MATERIALS AND WELDING

PART 2

American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862

2016 American Bureau of Shipping. All rights reserved.

ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA

R u l e C h a n g e N o t i c e ( 2 0 1 7 )

Rule Change Notice (2017) The effective date of each technical change since 1993 is shown in parenthesis at the end of the subsection/paragraph titles within the text of each Part. This date is based on the date of purchase order of the materials. Unless a particular date and month are shown, the years in parentheses refer to the following effective dates:

(2000) and after 1 January 2000 (and subsequent years) (1996) 9 May 1996 (1999) 12 May 1999 (1995) 15 May 1995 (1998) 13 May 1998 (1994) 9 May 1994 (1997) 19 May 1997 (1993) 11 May 1993

Listing by Effective Dates of Changes from the 2016 Rules

EFFECTIVE DATE 1 January 2017 – shown as (2017) (based on the date of purchase order of the materials)

Part/Para. No. Title/Subject Status/Remarks 2-1-1/7.2 Electronic Certification System To mitigate the risk of misrepresentation on ABS approval by the client.

2-1-5/5 Heat Treatment To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-1-6/1.1 General To clearly indicate that the raw material such as ingots or billets or others is to be procured from an ABS approved facility.

2-1-6/5.1 General To clearly indicate that the raw material such as ingots or billets or others is to be procured from an ABS approved facility.

2-3-7/1.1.1 General To clearly indicate that the raw material such as ingots or billets or others is to be procured from an ABS approved facility.

2-3-7/1.5.1 General To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-3-7/1.11.1(c) Small Forgings To specify that in the case of carbon and low alloy steel small forgings, test sampling is based on the furnace mass rather than the

no. of forgings, in line IACS W7.

2-3-7/Figure 1 (New)

Gear Ring Forgings – Test Specimen Locations and Orientations

To clearly indicate the test coupon locations for carbon and low alloy steels.

2-3-7/Figure 2 (New)

Pinion or Gear Forging – Test Specimen Locations and Orientations

To clearly indicate the test coupon locations for carbon and low alloy steels.

2-3-7/Figure 3 (New)

Gear Shaft Forging – Test Specimen Locations and Orientations

To clearly indicate the test coupon locations for carbon and low alloy steels.

2-3-7/1.11.1(g) Surface Hardened Forgings To indicate that the carburized forging requirement is also applicable to other types of surface hardening processes (except for induction hardening).

2-3-7/1.11.1(h) (New)

Continuous Heat Treatment To indicate the continuous heat treatment requirements are to be specially agreed with ABS.

2-3-7/1.5.7 Surface Hardening To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-3-7/3.1.1 General To clearly indicate that the raw material such as ingots or billets or others is to be procured from an ABS approved facility.

2-3-7/3.5.1 General To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-3-7/3.5.8 (New)

Surface Hardening To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-3-7/3.9.3(c) Small Forgings To specify that in the case of carbon and low alloy steel small forgings, test sampling is based on the furnace mass rather than the

no. of forgings, in line IACS W7.

ii ABS RULES FOR MATERIALS AND WELDING . 2017

Part/Para. No. Title/Subject Status/Remarks 2-3-7/Figure 4 (New)

Pinion or Gear Forging – Test Specimen Locations and Orientations

To clearly indicate the test coupon locations for carbon and low alloy steels.

2-3-7/Figure 5 (New)

Gear Shaft Forging – Test Specimen Locations and Orientations

To clearly indicate the test coupon locations for carbon and low alloy steels.

2-3-7/3.9.3(g) Surface Hardened Forgings To indicate that the carburized forging requirement is also applicable to other types of surface hardening processes (except for induction hardening).

2-3-7/3.9.3(h) (New)

Continuous Heat Treatment To indicate the continuous heat treatment requirements are to be specially agreed with ABS.

2-3-7/5.1.1 General To clearly indicate that the raw material such as ingots or billets or others is to be procured from an ABS approved facility.

2-3-7/5.5.1 General To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-3-7/5.9.3(c) Small Forgings To specify that in the case of carbon and low alloy steel small forgings, test sampling is based on the furnace mass rather than the

no. of forgings, in line IACS W7.

2-3-7/5.9.3(e) (New)

Continuous Heat Treatment To indicate the continuous heat treatment requirements are to be specially agreed with ABS.

2-3-7/7.1.1 General To clearly indicate that the raw material such as ingots or billets or others is to be procured from an ABS approved facility.

2-3-7/7.5.1 General To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-3-7/7.11.1(c) Small Forgings To specify that in the case of carbon and low alloy steel small forgings, test sampling is based on the furnace mass rather than the

no. of forgings, in line IACS W7.

2-3-7/7.11.1(e) (New)

Continuous Heat Treatment To indicate the continuous heat treatment requirements are to be specially agreed with ABS.

2-3-9/5 Heat Treatment To clearly indicate that HT facilities can be approved independently, if they carry out the mechanical tests and NDE.

2-4-1/5.19.1 (New)

Repair to Casting Defects Identified after Machining or During Assembly

To specify requirements for repairs of castings by welding and temporary welds made to castings.

2-A1 List of Destructive and Nondestructive Tests Required for Materials and Responsibility for Verifying

To include witness requirements for steels with enhanced corrosion resistance properties.

ABS RULES FOR MATERIALS AND WELDING . 2017 iii

P A R T F o r e w o r d

Foreword For the 1996 edition, the “Rules for Building and Classing Steel Vessels – Part 2: Materials and Welding” was re-titled “Rule Requirements for Materials and Welding (Part 2).” The purpose of this generic title was to emphasize the common applicability of the material and welding requirements in “Part 2” to ABS-classed vessels, other marine structures and their associated machinery, and thereby make “Part 2” more readily a common “Part” of the various ABS Rules and Guides, as appropriate.

Accordingly, the subject booklet, Rules for Materials and Welding (Part 2), is to be considered, for example, as being applicable and comprising a “Part” of the following ABS Rules and Guides:

- Rules for Building and Classing Steel Vessels

- Rules for Building and Classing Steel Vessels Under 90 Meters (295 Feet) in Length

- Rules for Building and Classing Steel Vessels for Service on Rivers and Intracoastal Waterways

- Rules for Building and Classing Mobile Offshore Drilling Units

- Rules for Building and Classing Steel Barges

- Rules for Building and Classing High-Speed Craft

- Rules for Building and Classing Floating Production Installations

- Rules for Building and Classing Offshore Support Vessels (OSV Rules)

- Rules for Building and Classing High-Speed Naval Craft

- Guide for Building and Classing Liftboats

In the 2002 edition, Section 4, “Piping” was added to Part 2, Chapter 4, “Welding and Fabrication”. This Section is applicable only to piping to be installed on vessels to be built in accordance with the ABS Rules for Building and Classing Steel Vessels, the ABS Rules for Building and Classing Offshore Support Vessels, or the ABS Rules for Building and Classing High-Speed Naval Craft.

In the 2004 edition, Part 2 was reorganized to incorporate the new divisions “Rules for Testing and Certification of Materials,” comprised of Chapters 1, 2 and 3 and Appendices 1, 4, 5, 6 and 7, and “Rules for Welding and Fabrication,” comprised of Chapter 4 and Appendices 2 and 3. This reorganization was purely an editorial change intended to clarify the requirements for the materials themselves and for construction, respectively, and does not contain any technical changes.

iv ABS RULES FOR MATERIALS AND WELDING . 2017

P A R T T a b l e o f C o n t e n t s

Rules for Materials and Welding

CONTENTS

Rules for Testing and Certification of Materials

CHAPTER 1 Materials for Hull Construction

Section 1 General Requirements Section 2 Ordinary-strength Hull Structural Steel Section 3 Higher-strength Hull Structural Steel Section 4 Low Temperature Materials Section 5 Hull Steel Castings Section 6 Hull Steel Forgings Section 7 Ordinary and Higher Strength Steels with Enhanced

Corrosion Resistance Properties for Cargo Oil Tanks

CHAPTER 2 Equipment

Section 1 Anchors Section 2 Anchor Chain Section 3 Rolled Steel Bars for Chain, Cast and Forged Materials for Accessories and Materials for Studs

CHAPTER 3 Materials for Machinery, Boilers, Pressure Vessels, and Piping

Section 1 General Requirements Section 2 Steel Plates for Machinery, Boilers and Pressure

Vessels Section 3 Seamless Forged-steel Drums Section 4 Seamless-steel Pressure Vessels Section 5 Boiler and Superheater Tubes Section 6 Boiler Rivet and Staybolt Steel and Rivets Section 7 Steel Machinery Forgings Section 8 Hot-rolled Steel Bars for Machinery Section 9 Steel Castings for Machinery, Boilers and Pressure

Vessels Section 10 Ductile (Nodular) Iron Castings Section 11 Gray-iron Castings Section 12 Steel Piping Section 13 Piping, Valves and Fittings for Low-Temperature

Service [Below -18°C (0°F)] Section 14 Bronze Castings

ABS RULES FOR MATERIALS AND WELDING . 2017 v

Section 15 Austenitic Stainless Steel Propeller Castings Section 16 Seamless Copper Piping Section 17 Seamless Red-brass Piping Section 18 Seamless Copper Tube Section 19 Condenser and Heat Exchanger Tube Section 20 Copper-Nickel Tube and Pipe Section 21 Monel Pipe and Tube

APPENDIX 1 List of Destructive and Nondestructive Tests Required for

Materials and Responsibility for Verifying

APPENDIX 4 Procedure for the Approval of Manufacturers of Hull Structural

Steel Section 1 Procedure for the Approval of Manufacturers of

Semi-finished Products for Hull Structural Steel Section 2 Procedure for the Approval of Manufacturers of Rolled

Hull Structural Steel

APPENDIX 5 Procedure for the Approval of Manufacturers of Hull Structural

Steels Intended for Welding with High Heat Input

APPENDIX 6 Nondestructive Examination of Marine Steel Castings

Section 1 General Section 2 Surface Inspection Section 3 Volumetric Inspection

Annex 1 General Location for the Type of Nondestructive

Examinations of Typical Hull Steel Castings

APPENDIX 7 Nondestructive Examination of Hull and Machinery Steel

Forgings Section 1 General Section 2 Surface Inspection Section 3 Volumetric Inspection

APPENDIX 8 Additional Approval Procedure for Steel with Enhanced

Corrosion Resistance Properties vi ABS RULES FOR MATERIALS AND WELDING . 2017

Rules for Welding and Fabrication

CHAPTER 4 Welding and Fabrication

Section 1 Hull Construction Section 2 Boilers, Unfired Pressure Vessels, Piping and

Engineering Structures Section 3 Weld Tests Section 4 Piping

APPENDIX 2 Requirements for the Approval of Filler Metals

Section 1 General Section 2 Electrodes for Shielded Metal Arc Welding Section 3 Wire-Flux Combinations for Submerged Arc Welding Section 4 Wire and Wire Gas Combinations for Gas Metal Arc

Welding and Flux Cored Wires for Flux Cored Arc Welding

APPENDIX 3 Application of Filler Metals to ABS Steels

APPENDIX 9 Welding Procedure Qualification Tests of Steels for Hull

Construction and Marine Structures Section 1 General Requirements

Annex 1 Location of Charpy V-Notch Impact Test Annex 2 Hardness Test (Typical examples of hardness test) Annex 3 Welding Positions

ABS RULES FOR MATERIALS AND WELDING . 2017 vii

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P A R T C h a p t e r 1 : M a t e r i a l s f o r H u l l C o n s t r u c t i o n

Rules for Testing and Certification of Materials

C H A P T E R 1 Materials for Hull Construction

CONTENTS

SECTION 1 General Requirements

1 Testing and Inspection

1.1 General

1.2 Manufacturer Approval

1.3 Test and Test Data

1.5 Certification on the Basis of the ABS Quality Assurance Program for Rolled Products

1.7 Rejection of Previously Accepted Material

1.9 Calibrated Testing Machines

1.11 Structural Pipe

1.13 ASTM References

3 Defects 5 Identification of Materials 7 Manufacturer’s Certificates

7.1 Form of Certificate

7.2 Electronic Certification System

7.3 Other Certificates

9 Marking and Retests

9.1 Identification of Specimens

9.3 Defects in Specimens

9.5 Retests

9.7 Rejected Material

11 Standard Test Specimens

11.1 General

11.3 Test Specimens Orientation

11.5 Tension Test Specimens, Plates and Shapes

11.7 Tension Test Specimens for Castings (other than Gray Cast

Iron) and Forgings

11.9 Bend Test Specimens, Castings and Forgings

11.11 Impact Test Specimens

11.13 Tolerances

13 Definition and Determination of Yield Point and Yield Strength

13.1 Yield Point

13.3 Yield Strength

13.5 Tensile Strength

14 Elongation

ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017 1

15 Permissible Variations in Dimensions

15.1 Scope

15.3 Plates and Wide Flats

15.5 Shapes and Bars

16 Rolled Plates over 100 mm (4 in.) Thick 17 Steel Plates and Wide Flats with Specified Minimum Through

Thickness Properties (“Z” Quality)

17.1 Sampling

17.3 Number of Tensile Test Specimens

17.5 Tensile Test Specimen Dimensions

17.7 Tensile Test Results

17.9 Retests

17.11 Ultrasonic Inspection

17.13 Marking

17.15 Certification

19 Formed Materials 21 Ultrasonic Examination of Plate Material 23 Fracture Toughness Testing

TABLE 1 Batch Size Depending Upon Product and Sulfur Content TABLE 2 Reduction of Area Acceptance Values

FIGURE 1

FIGURE 2 Standard Tension Test Specimen FIGURE 3 Standard Round Tension Test Specimen with 50 mm (2 in.)

Gauge Length FIGURE 4 Charpy V-notch Impact Test Specimens FIGURE 5 Plate and Wide Flat Sampling Position FIGURE 6 Diagram Showing Acceptance/Rejection and Retest

Criteria

SECTION 2 Ordinary-strength Hull Structural Steel

1 Ordinary-strength Hull Structural Steel 3 Process of Manufacture

3.1 Plates Produced from Coils

5 Chemical Composition

5.1 Ladle Analysis

5.3 Product Analysis

5.5 Special Compositions

5.7 Fine Grain Practice

7 Condition of Supply

7.1 As Rolled – AR

7.3 Heat Treatment

7.5 Controlled Manufacturing Process

7.7 Quenching and Tempering – QT

2 ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017

9 Tensile Properties

9.1 Required Tensile Properties

9.3 Tension Test Specimens

9.5 Exceptions

9.7 <No Text>

9.9 Omission of Elongation Requirements

9.11 Retests

9.13 Unsatisfactory Tests

11 Impact Properties

11.1 Impact Tests

11.3 Impact Test Frequency

11.5 Initial Test Requirements

11.7 Retests

11.9 Unsatisfactory Tests

11.11 Thin Plates

13 Marking

13.1 Stamped or Stenciled Material

13.3 Coils, Lifts and Bundles

13.5 Flanging-quality Identification

13.7 Special Stamping and Marking

13.9 Special Impact Testing

13.11 Steel with Improved Through Thickness Properties

13.13 Steel with Ultrasonic Examination

13.15 Shipping Procedure

13.17 Steel at Secondary Sources

15 Surface Finish

15.1 Surface Examination

15.3 Treatment of Surface Defects – Plates

15.5 Treatment of Surface Defects – Shapes

15.7 Bar-stock Repairs

15.9 Rivet Steel and Rivets

TABLE 1 Chemical Properties of Ordinary Strength Hull Structural

Steel 100 mm (4.0 in.) and Under TABLE 2 Tensile Properties of Ordinary Strength Hull Structural

Steel 100 mm (4.0 in.) and Under TABLE 3 Elongation Requirements for Alternative B Specimen TABLE 4 Impact Properties of Ordinary-Strength Hull Structural Steel

100 mm (4.0 in.) and Under TABLE 5 Condition of Supply and Frequency of Impact Tests

Ordinary Strength Hull Structural Steel

SECTION 3 Higher-strength Hull Structural Steel

1 Higher-strength Hull Structural Steel 3 General 5 Fine Grain Practice

ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017 3

7 Additional Requirements of TMCP Steel

7.1 Carbon Equivalent

7.3 Cold Cracking Susceptibility

TABLE 1 Chemical Properties of Higher-strength Hull Structural

Steel 100 mm (4.0 in.) and Under TABLE 2 Tensile Properties of Higher-strength Hull Structural Steel

100 mm (4.0 in.) and Under TABLE 3 Elongation Requirements for Alternative B Specimen TABLE 4 Impact Properties of Higher-strength Steel 100 mm (4.0 in.)

and Under TABLE 5 Condition of Supply and Frequency of Impact Tests –

Higher-strength Hull Structural Steel TABLE 6 Carbon Equivalent for Higher-strength Hull Structural Steel

100 mm (4.0 in.) and Under Produced by TMCP

SECTION 4 Low Temperature Materials

1 General 3 Marking 5 Toughness Tests

5.1 Charpy V-notch

5.3 Drop-weight Test

7 Service Temperature 0°C (32°F) or Above 9 Service Temperature at or Above -55°C (-67°F) up to 0°C

(32°F) 11 Service Temperature at or Above -196°C (-320°F) up to -55°C

(-67°F) 13 Service Temperatures below -196°C (-320°F)

SECTION 5 Hull Steel Castings

1 Process of Manufacture

1.1 General

1.3 Chemical Composition

3 Marking and Retests

3.1 Marking

3.3 Retests

5 Heat Treatment 7 Mechanical Properties

7.1 Ordinary Grade Castings

7.3 Special Grade Castings

9 Test Specimens

9.1 Material Coupons

9.3 Separately Cast Coupons

11 Number of Tests 13 Inspection and Repair

13.1 General

13.3 Minor Defects

4 ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017

13.5 Major Defects

13.7 Welded Repair

13.9 Post Weld Repair Heat Treatment

13.11 Nondestructive Testing

15 Certification

SECTION 6 Hull Steel Forgings

1 Process of Manufacture

1.1 General

1.3 Degree of Reduction

1.5 Discard

1.7 Chemical Composition

3 Marking and Retests

3.1 Marking

3.3 Retests

5 Heat Treatment

5.1 General

5.3 Cooling Prior to Heat Treatment

5.5 Annealing

5.7 Normalizing

5.9 Tempering

7 Tensile Properties 9 Test Specimens

9.1 Location and Orientation of Specimens

9.3 Hollow-drilled Specimens

9.5 Small Forgings

9.7 Specimen Identification

11 Number of Tests

11.1 Tension Test

11.3 Brinell Hardness Test

11.5 Special Situations

11.7 Examination

11.9 Rectification of Defective Forgings

13 Certification

SECTION 7 Ordinary and Higher Strength Steels with Enhanced Corrosion

Resistance Properties for Cargo Oil Tanks 1 Scope 3 Approval 5 Method of Manufacture 7 Chemical Composition 9 Condition of Supply 11 Mechanical Properties 13 Freedom from Defects 15 Tolerances 17 Identification of Materials

ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017 5

19 Testing and Inspection

19.1 Facilities for Inspection

19.3 Testing Procedures

19.5 Through Thickness Tensile Tests

19.7 Ultrasonic Inspection

19.9 Surface Inspection and Dimensions

21 Test Material 23 Test Specimens

23.1 Mechanical Test Specimens

25 Number of Test Specimens 27 Retest Procedures 29 Marking 31 Documentation

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P A R T S e c t i o n 1 : G e n e r a l R e q u i r e m e n t s

C H A P T E R 1 Materials for Hull Construction

S E C T I O N 1 General Requirements

1 Testing and Inspection

1.1 General

All materials subject to test and inspection, intended for use in the construction of hulls and equipment of vessels classed or proposed for classification, are to be to the satisfaction of the Surveyor and in accordance with the following requirements or their equivalent. Materials, test specimens and mechanical testing procedures having characteristics differing from those prescribed herein may be approved upon application, due regard being given to established practices in the country in which the material is produced and the purpose for which the material is intended, such as the parts for which it is to be used, the type of vessel and intended service, and the nature of the construction of the vessel.

1.2 Manufacturer Approval (2003)

1.2.1 (2010)

All products for hull construction are to be manufactured at steel works approved by ABS for the type and grade of steel contemplated. The suitability of the products for welding and assumed forming is to be demonstrated during the initial approval test at the steel works. Approval of the steel works for rolled products is to be in accordance with Part 2, Appendix 4.

1.2.2 (2006) It is the manufacturer’s responsibility to assure that effective procedures and production controls are implemented during the production, and that the manufacturing specifications are adhered to.

Should any deviation from the procedures and controls occur that could produce an inferior product, the manufacturer is to carry out a thorough investigation to determine the cause of the mishap and establish countermeasures to prevent its recurrence. The complete investigation report is to be submitted to the Surveyor. ABS reserves the right to request a closer survey until the cause is resolved to the satisfaction of the Surveyor. Each affected piece is to be tested to the satisfaction of the attending Surveyor prior to distribution from the steel works. In addition, the frequency of testing for subsequent products may be increased to gain confidence in the quality.

1.2.3 Where the steel is not produced at the rolling mill, the procedures in 2-1-1/7.3 are to be followed.

1.2.4 (2011) It is the manufacturer’s responsibility to ensure that raw materials used/semi-finished/finished cast or wrought steel products produced are within radioactive contamination limits as permitted by an appropriate regulatory body/agency, as applicable to the place of manufacture. Radiation level and reference to the allowed limits are to be specified and documented in manufacturer’s QA/QC procedures.

ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017 7

Part 2 Rules for Materials and Welding Chapter 1 Materials for Hull Construction Section 1 General Requirements 2-1-1

1.3 Test and Test Data

1.3.1 Witnessed Tests

The designation (W) indicates that a Surveyor is to witness the testing unless the plant is enrolled and product is manufactured under ABS’s Quality Assurance Program.

1.3.2 Manufacturer’s Data

The designation (M) indicates that test data is to be provided by the manufacturer without verification by a Surveyor of the procedures used or the results obtained.

1.3.3 Other Tests

The designation (A) indicates those tests for which test data is to be provided by the supplier and audited by the Surveyor to verify that the procedures used and random tests witnessed are in compliance with Rule requirements.

See Part 2, Appendix 1 for a complete listing of indicated designations for the various tests called out by Part 2, Chapter 1 and Part 2, Chapter 2 of this Part.

1.5 Certification on the Basis of the ABS Quality Assurance Program for Rolled Products Upon application, consideration will be given to the acceptance of plates, shapes and bars without witnessing of mechanical tests by the Surveyor, on the basis of compliance with ABS’s Quality Assurance Program.

1.7 Rejection of Previously Accepted Material

In the event of any material proving unsatisfactory in the process of being worked, it is to be rejected, notwithstanding any previous certificate of satisfactory testing.

1.9 Calibrated Testing Machines (2005)

The Surveyor is to be satisfied that the testing machines are maintained in a satisfactory and accurate condition.

Additionally, the Surveyor is to keep a record of the dates and by whom the machines were rechecked or calibrated. All tests are to be carried out to a recognized national or international Standard by competent personnel.

1.11 Structural Pipe (2016)

Unless otherwise indicated (e.g., 3-1-4/1.1 of the ABS Rules for Building and Classing Mobile Offshore Drilling Units), pipes intended for structural use are to be tested to the applicable specification or physical requirements of Section 2-3-12, as applicable.

1.13 ASTM References (1998)

Frequent references will be found within Part 2, Chapter 1 through Part 2, Chapter 3 to various American Society for Testing and Materials (ASTM) specification designations without year notations. Unless otherwise noted, the current issue of the ASTM specification is to be used.

3 Defects All materials are to be free from cracks, injurious surface flaws, injurious laminations and similar defects.

Except as indicated for specific materials, welding or dressing for the purpose of remedying defects is not permitted unless sanctioned by the Surveyor. In such cases where sanction is required for materials to be so treated, the Surveyor may prescribe further probing and necessary heat treatment; then, if found satisfactory, the part treated is to be stamped with the Surveyor’s identification mark and surrounded by a ring of paint.

5 Identification of Materials The manufacturer is to adopt a system for the identification of ingots, slabs, finished plates, shapes, castings and forgings which will enable the material to be traced to its original heat and the Surveyor is to be given every facility for so tracing the material.

8 ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017

7 Manufacturer’s Certificates

7.1 Form of Certificate

Unless requested otherwise, four copies of the certified mill test reports and shipping information (may be separate or combined documents) of all accepted material indicating the grade of material, heat identification numbers, test results and weight shipped are to be furnished to the Surveyor. One copy of the mill test report is to be endorsed by the Surveyor and forwarded to the Purchaser, and three are to be retained for the use of ABS. Before the certified mill tests reports and shipping information are distributed to the local ABS office, the manufacturer is to furnish the Surveyor with a certificate stating that the material has been made by an approved process and that it has satisfactorily withstood the prescribed tests. The following form of certificate will be accepted if printed on each certified mill test report with the name of the firm and initialed by the authorized representative of the manufacturer:

“We hereby certify that the material described herein has been made to the applicable specification by the ________ process (state process) and tested in accordance with the requirements of ___________ (the American Bureau of Shipping Rules or state other specification) with satisfactory results.”

At the request of manufacturers, consideration may be given to modifications in the form of the certificate, provided it correspondingly indicates compliance with the requirements of the Rules to no less degree than indicated in the foregoing statement.

7.2 Electronic Certification System (2017)

An electronic certification system may be used to issue certified mill test reports, which may be electronically signed and stamped by the attending Surveyor, subject to the following conditions.

• All relevant information regarding the customer order, including the electronic certification request, is to be provided to the attending Surveyor by the manufacturer.

• Procedures are to be established to control handling and distribution of certified mill test reports among the manufacturer, ABS, and the purchaser.

• In order to implement the electronic certification system, the steel mills are to be under mandatory ABS QA program.

• The mills under ABS QA program shall implement security provisions that appropriately control electronic storage and protect unauthorized use of all electronic signatures provided by ABS.

• These provisions shall be assessed at the time of periodic and annual QA audits at the mill.

7.3 Other Certificates (2015)

Where steel is not produced in the works at which it is rolled or forged, a certificate is to be supplied to the Surveyor stating the process by which it was manufactured, the name of the manufacturer who supplied it, the number of the heat from which it was made and the ladle analysis. The number of the heat is to be marked on each ingot, bloom, slab or billet for the purpose of identification.

Where the product is not heat treated in the works at which it is rolled, a certificate is to be supplied to the Surveyor by the works at which it is finally heat treated, stating the process by which it was rolled, the name of the manufacturer who supplied it, the heat number from which it was made and the ladle analysis.

All heat treatment facilities are to be ABS approved, in association with qualification testing being carried out on the final product after final heat treatment. The heat treatment works should also supply the record of heat treatment, including heat treatment curves, indicating time and temperature, and heating and cooling rates.

9 Marking and Retests

9.1 Identification of Specimens

Where test specimens are required to be selected by the Surveyor, they are not to be detached until stamped with his identification mark, nor are they to be detached until the material has received its final treatment.

ABS RULES FOR TESTING AND CERTIFICATION OF MATERIALS . 2017 9

9.3 Defects in Specimens

If any test specimen shows defective machining or develops defects, it may be discarded and another specimen substituted, except that for forgings a retest is not allowed if a defect develops during testing which is caused by rupture, cracks or flakes in the steel.

9.5 Retests

If the percentage of elongation of any tension test specimen is less than that specified and any part of the fracture is more than 19 mm (0.75 in.) from the center of the gauge length of a 50 mm (2 in.) specimen, or is outside the middle half of the gauge length of a 200 mm (8 in.) specimen, as indicated by scribe scratches marked on the specimen before testing, a retest is to be allowed.

9.7 Rejected Material

In the event that any set of test specimens fails to meet the requirements, the material from which such specimens have been taken is to be rejected and the required markings withheld or obliterated.

11 Standard Test Specimens

11.1 General (2005)

The tension test specimens are to be of the full thickness or section of material as rolled, except as otherwise specified. The specimens are to receive no other preparation than that prescribed and are to receive similarly and simultaneously all of the treatment given the material from which they are cut. Straightening of specimens distorted by shearing is to be carried out while the piece is cold. The accuracy of the tensile test machines is to be within ±1% of the load.

11.3 Test Specimens Orientation

Tension test specimens are to be taken longitudinal to the final direction of rolling for plates equal to or less than 600 mm (24 in.) in width and transverse to the final direction of rolling for plates wider than 600 mm (24 in.), except for shapes and bars which are to be taken longitudinal to the final direction of rolling.

11.5 Tension Test Specimens, Plates and Shapes (1996)

11.5.1 Flat Specimens

Tension test specimens for rolled plates, shapes and flats are to be cut from the finished material and machined to the form and dimensions referred to in 2-1-1/Figure 2 or tension test specimens of dimensions other than described may be approved at the request of the manufacturer.

11.5.2 Round Specimens

For material over 19 mm (0.75 in.) in thickness or diameter, tension test specimens may be machined to dimensions referred to in 2-1-1/Figure 2. The axis of each round specimen is to be located as near as practicable midway between the center and the surface of the material. Tension test specimens of dimensions other than described above may be approved at the request of the manufacturer.

11.7 Tension Test Specimens for Castings (other than Gray Cast Iron) and Forgings (2006) Tension test specimens for castings and forgings are to be machined to the form and dimensions shown in for the round specimen alternative C in 2-1-1/Figure 2 or in accordance with 2-1-1/Figure 3.

11.9 Bend Test Specimens, Castings and Forgings (2005)

When required, bend test specimens for castings and forgings may be machined to 25 mm × 20 mm (1 in. × 0.790 in.) in section. The length is unimportant, provided that it is enough to perform the bending operation. The edges on the tensile side of the bend test specimens may have the corners rounded to a radius of 1–2 mm (0.040–0.080 in.).

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11.11 Impact Test Specimens (2013)

An impact test is to consist of three specimens taken from a single test coupon or test location. Impact test specimens are to be machined to the form, dimensions and tolerances shown in 2-1-1/Figure 4. Full size standard specimens are to be used unless the section thickness of the product is less than 11 mm (7/16″) or the absorbed energy is expected to exceed 80% of the test machine full scale capacity. For plates, flats and bars, the specimens are to be located with their edges within 2 mm (0.08 in.) from the surface, except that where the thickness exceeds 40 mm (1.57 in.), the longitudinal axis of the specimen is to be located at a point midway between the surface and the center of the thickness. These test specimens are to be cut with their longitudinal axes either longitudinal or transverse to the final direction of rolling of the material at the option of the steel manufacturer, unless a specific orientation is specified. The length of the notch is to be perpendicular to the original rolled surface. Also see 2-1-2/11.1 and 2-1-4/5.1, as applicable.

11.13 Tolerances (1998)

The tolerances of the tension test specimen dimensions are to be in accordance with a recognized national standard.

13 Definition and Determination of Yield Point and Yield Strength

13.1 Yield Point (2005)

The yield point is the first stress in a material, less than the maximum obtainable stress, at which an increase in strain occurs without an increase in stress. The value of stress is measured at the commencement of plastic deformation at yield, or the value of stress measured at the first peak obtained during yielding even when that peak is equal to or less than any subsequent peaks observed during plastic deformation at yield.

Yield point may be determined by the halt of the pointer, or autographic diagram. The 0.5% total extension under load method will also be considered acceptable.

The test is to be carried out with an elastic stress within the following limits:

Modulus of Elasticity of the Material (E), N/mm2

Rate of Stressing, N/mm2-s-1 Min. Max.

< 150,000 2 20 ≥ 150,000 6 60

13.3 Yield Strength (2005)

The yield strength is the stress at which a material exhibits a specified limiting deviation from the proportionality of stress to strain. When no well-defined yield phenomenon exists, yield strength is to be determined by the 0.2% (Rp 0.2) offset method. Alternatively, for material whose stress-strain characteristics are well known from previous tests in which stress-strain diagrams were plotted, the 0.5% extension under load method may be used. When agreed upon between the supplier and purchaser for austenitic and duplex stainless steel products, the 1% proof stress (Rp 1) may be determined in addition to Rp 0.2.

The rate of loading is to be as stated in the limits above.

13.5 Tensile Strength (2005)

After reaching the yield or proof load, for ductile material, the machine speed during the tensile test is not to exceed that corresponding to a strain rate of 0.008 s-1. For brittle materials, such as gray cast iron, the elastic stress rate is not to exceed 10 N/mm2 per second.

14 Elongation (2005) The elongation value is, in principle, valid only if the distance between the fracture and the nearest gauge mark is not less than one-third of the original gauge length. However, the result is valid irrespective of the location of the fracture if the percentage elongation after fracture is equal to or greater than the required value.

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Generally, the elongation, A5, is determined on a proportional gauge length, dS 565.5 0 = , but may also be given for other specified gauge lengths.

If the material is a ferritic steel of low or medium strength and not cold worked, and the elongation is measured on a non-proportional gauge length, the required elongation, A0, on that gauge length, L0, may after agreement be calculated from the following formula:

40.0

50 2

L S

AA

15 Permissible Variations in Dimensions (1994)

15.1 Scope (2002)

The under tolerance specified below represents the minimum material certification requirements and is to be considered as the lower limit of the usual range of variations (plus/minus) from the specified dimension.

The responsibility for meeting the tolerances rests with the manufacturer who is to maintain a procedure acceptable to the Surveyor. Where any tolerance (including over thickness tolerance) to be used is more stringent than the normal commercial tolerance, ABS is to be advised before the steel is presented for acceptance to assure that the thickness measuring procedure is appropriate.

In all cases, the thickness of the steel is to comply with the under tolerance specified below. The steel mill is to consider the effect of mill scale on the resulting measurement.

For classification purposes, including the assessment of deterioration at future thickness gaugings, the thickness indicated on the approved plan is to be used.

15.3 Plates and Wide Flats (1 July 2013)

These requirements apply to the tolerance on thickness of steel plates and wide flats with widths of 600 mm (24 in.) or greater (hereinafter referred to as: product or products) with thicknesses of 5 mm (0.2 in.) and over, covering the following steel grades:

i) Normal and higher strength hull structural steel.

ii) Higher strength quenched and tempered steels for welded structure according to Appendix 3-1-A3 of the ABS Rules for Building and Classing Mobile Offshore Drilling Units.

The thickness tolerances for products below 5 mm (0.2 in.) may be specially agreed.

Note: Tolerances for length, width, flatness and over thickness may be taken from national or international standards.

Class C of ISO 7452 may be applied in lieu of 15.3.2, in which case the requirements in 15.3.3 and 15.3.4 need not be applied. If Class C of ISO 7452 is to be used, the portion of the footnote of ISO 7452, Table B.2, which reads “Also a minus side of thickness of 0,3 mm is permitted.” is not to be applied.

Additionally, if ISO 7452 is applied, it is required that the steel mill demonstrate to the satisfaction of ABS that the number of measurements and measurement distribution is appropriate to establish that the mother plates produced are at or above the specified nominal thickness.

15.3.1 Responsibility

The responsibility for verification and maintenance of the production within the required tolerances rests with the manufacturer. The Surveyor may require that he witness some measurements. The responsibility for storage and maintenance of the delivered product(s) with acceptable level of surface conditions rests with the shipyard before the products are used in fabrication.

15.3.2 Thickness Tolerances

15.3.2(a) Thickness tolerances of a given products are defined as:

• Minus tolerance is the lower limit of the acceptable range below the nominal thickness.

• Plus tolerance is the upper limit of the acceptable range above the nominal thickness.

Note: Nominal thickness is defined by the purchaser at the time of enquiry and order.

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15.3.2(b) The minus tolerance on thickness of products in the scope of 2-1-1/15.3 is 0.3 mm (0.012 in.) irrespective of nominal thickness.

15.3.2(c) Thickness tolerances are not applicable to areas repaired by grinding in accordance with 2-1-2/15.3.

15.3.2(d) Plus tolerances on nominal thickness are to be in accordance with a recognized national or international standard such as ASTM A6.

15.3.3 Average Thickness

15.3.3(a) The average thickness of a product is defined as the arithmetic mean of the measurements made in accordance with the requirements of 2-1-1/15.3.4.

15.3.3(b) The average thickness of the product is not to be less than the nominal thickness.

15.3.4 Thickness Measurements

15.3.4(a) Thickness is to be measured at locations as defined in 2-1-1/Figure 1. Automated or manual method is applied to the thickness measurements.

15.3.4(b) The procedure and records of measurements are to be made available to the Surveyor and copies provided on request.

FIGURE 1 (1 July 2013)

: Measurement points Rolling direction

Line 3

Line 2

Line 1 A1 A2 A3

B1 B2 B3

C1 C2 C3

a) Locations of Thickness Measuring Points for the Original Steel Plates

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FIGURE 1 (continued) (1 July 2013)

Rolling direction

Line 3

Line 2

Line 1 A1 A2 A3

Rolling direction

Line 3

Line 2

Line 1 A1 A2 A3

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FIGURE 1 (continued) (1 July 2013)

Rolling direction

Line 3

Line 2

Line 1 A1 A2 A3

b) Locations of Thickness Measuring Points for the Cut Steel Products

Notes:

1 (1 July 2013) At least two lines are to be selected from Lines 1, 2, or 3 as shown, and at least three points on each selected line are to be selected for thickness measurement. If more than three points are taken on each Line, the number of points on each line is to be the same.

The measurement locations apply to a product rolled directly from one slab or steel ingot even if the product is to be later cut by the manufacturer. Examples of the original measurements relative to later cut products are shown in 2-1-1/Figure 1b). It is to be noted that the examples shown are not representative of all possible cutting scenarios.

2 For automated measuring, peripheral points are to be located 10-300 mm (0.375-12.0 in.) from the edge.

3 For manual measuring, peripheral points are to be located 10-100 mm (0.375-4.0 in.) from the edge.

15.5 Shapes and Bars

The under tolerance of cross sectional dimensions for shapes and bars are based on the ordered dimensions and are to conform to those given in ASTM A6 or other recognized standards as may be specified in the purchase order.

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16 Rolled Plates over 100 mm (4 in.) Thick (2016) When ABS and non-ABS grade rolled plates of over 100 mm (4 in.) thickness are used for vessel hull structural application, in addition to chemical analysis the following test data is to be obtained at one-quarter and mid thickness locations:

• Tensile properties, and

• Impact properties in the longitudinal or transverse directions

Also, each plate is to be UT inspected in accordance with either ASTM A578 Level B or another equivalent recognized standard to evaluate the internal soundness.

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FIGURE 2

Standard Tension Test Specimen (1) (1995) d a b

Lo

Lc

A

R

= diameter in mm = thickness in mm = width in mm = (2005) original gauge length in mm = (2005) parallel length in mm = (2005) original cross sectional area in mm2 = transition radius in mm

Round Specimen

Flat Specimen

A

A

O

R

R d b a

L

L C d a b Lo Lc R

Flat specimen Alternative A

– t (2) 25 5.65 A Lo+ 2 A 25

Flat specimen Alternative B

– t (2) 25 200 225 25

Round specimen Alternative C

14 – – 70 85 10

Notes:

1 Standard specimen in accordance with ASTM E8/E8M or A370 will also be acceptable in conjunction with the corresponding elongation requirements in 2-1-2/Table 2 or 2-1-3/Table 2.

2 t is the full thickness of the material as produced. If the capacity of the testing machine does not allow full thickness specimens to be broken, the thickness may be reduced by machining one surface only.

3 (2005) Lo, the proportional gauge length, is to be greater than 20 mm.

FIGURE 3

Standard Round Tension Test Specimen with 50 mm (2 in.) Gauge Length (2008)

50 mm ± 0.125 mm (2 in. ± 0.005 in.)

10 mm ± 0.25 mm (0.375 in. ± 0.010 in.)

Reduced Section 60 mm (2.25 in.) min.

Radius 10 mm (0.375 in.) min.

Gauge length for measuring elongation after fracture

Note:

(2008) The gauge length and fillets are to be as shown, but the ends may be of any shape to fit the holders of the testing machine in such a way that the load is to be axial. The reduced section may have a gradual taper from the ends towards the center, with the ends not more than 0.13 mm (0.005 in.) larger in diameter than the center.

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FIGURE 4

Charpy V-notch Impact Test Specimens (2015)

10 mm (0.394 in.)

m m (0

.3 in m m (0

.3 in

(0.295 in.)

7.5 mm 5.0 mm

(0.197 in.) (0.098 in.)

2.5 mm

0.25 mm (0.010 in.) Radius

Full size Subsize

90°

45°

55 mm (2.165 in .) Length

L/2

Notes (2005)

Adjacent Sides are to be at 90 Deg ± 10 min. Centering of notch ± 1 mm (0.039 in.)

Width:

Standard Specimen 10 mm ± 0.11mm (0.004 in.)

Subsize Specimen 7.5 mm ± 0.11 mm (0.004 in.)

Subsize Specimen 5 mm ± 0.06 mm (0.0024 in.)

Subsize Specimen 2.5 mm ± 0.06 mm (0.0024 in.)

Thickness ± 0.06 mm (0.0024 in.)

Angle of Notch ± 2 Degs.

Angle between plane of symmetry of notch and longitudinal axis of test specimen is to be at 90 Deg. ± 2 Deg.

Radius of Notch ± 0.025 mm (0.001 in.)

Length of specimen ± 0.60 mm (0.024 in.) Dimension to Bottom of Notch ± 0.06 mm (0.0024 in.)

Surface Finish Requirements on:

Notched surface and opposite face Other surfaces

2 µm (63 µin.)

4 µm (125 µin.)

All impact tests are to be carried out on Charpy machines complying with the requirements of ISO 148 or other national and international recognized Standards, and having a striking energy of not less than 150 J.

(2015) Where the test temperature is other than ambient, the temperature of the test specimen at the moment of breaking is to be the specified temperature within ± 2°C (± 3.6°F).

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17 Steel Plates and Wide Flats with Specified Minimum Through Thickness Properties (“Z” Quality) (2013) “Z” quality steel is employed in those structural details subject to strains in the through thickness direction in order to minimize the possibility of lamellar tearing during fabrication.

These requirements are intended for material with a thickness greater than or equal to 15 mm (0.60 in.)

where a specified minimum ductility in the through thickness or “Z” direction is specified. Products with a thickness less than 15 mm (0.60 in.) may also be included.

Two “Z” quality steels are specified:

Z25 for normal ship applications

Z35 for more severe applications.

Through thickness properties are characterized by specified values for reduction of area in a through thickness tension test.

The steel works are to be approved by ABS for the manufacture of “Z” quality steels, in accordance with Part 2, Appendix 4. In addition, the maximum sulfur content is to be 0.008%, determined by ladle analysis.

When steels with improved through thickness properties are specified, special steel-making processes are to be used. The following processes used either singly or in combination would be considered to meet this requirement.

i) Low sulfur practices

ii) Addition of elements known to control the shape of nonmetallic inclusions.

iii) Electroslag or vacuum arc remelting.

iv) Control of centerline segregation during continuous casting

17.1 Sampling

The samples for preparing test specimens for plates and wide flats are to be taken as follows:

One test sample is to be taken close to the longitudinal centerline of one end of each rolled piece representing the batch. See 2-1-1/Table 1 and 2-1-1/Figure 5.

TABLE 1

Batch Size Depending Upon Product and Sulfur Content (2005)

Product Sulfur > 0.005% Sulfur ≤ 0.005% Plates Each piece (parent plate) Maximum 50 t of products of the same cast, thickness and heat treatment

Wide flats of nominal thickness ≤ 25 mm (1.0 in.)

Maximum 10 t of products of the same cast, thickness and heat treatment

Maximum 50 t of products of the same cast, thickness and heat treatment

Wide flats of nominal thickness > 25 mm (1.0 in.)

Maximum 20 t of products of the same cast, thickness and heat treatment

Maximum 50 t of products of the same cast, thickness and heat treatment

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FIGURE 5

Plate and Wide Flat Sampling Position (2005)

Principal rolling direction

Centerline of product

Test Sample

Test Specimens

17.3 Number of Tensile Test Specimens

The test sample must be large enough to accommodate the preparation of six (6) specimens. Three (3) test specimens are to be prepared while the remaining samples are set aside for possible retest.

17.5 Tensile Test Specimen Dimensions

Round test specimens, including built-up type by welding, are to be prepared in accordance with a recognized national standard.

17.7 Tensile Test Results

The minimum average value for the reduction of area of at least three (3) tensile test specimens taken in the through thickness direction must be that shown for the appropriate grade given in 2-1-1/Table 2. Only one individual value may be below the minimum average but not less than minimum individual value shown for the appropriate grade. See 2-1-1/Figure 6.

A value less than the minimum individual value is a cause for rejection

The test is considered invalid and a further replacement test is required if the fracture occurs in the weld or heat-affected zone.

TABLE 2

Reduction of Area Acceptance Values (2005)

Grade Z25 Z35 Minimum Average 25% 35% Minimum Individual 15% 25%

17.9 Retests

2-1-1/Figure 6 shows the three cases where retest is permitted. In these instances, three more tensile tests are to be taken from the remaining test sample. The average of all six (6) tensile tests is to be greater than the required minimum average with no greater than two results below the minimum average. In the case of failure after retest, either the batch represented by the piece is rejected or each piece within the batch is required to be tested.

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FIGURE 6

Diagram Showing Acceptance/Rejection and Retest Criteria (2005)

Acceptable Results

Acceptable RetestResult where retest is permitted

Results Above Minimum Average

Results Below Minimum Average

Minimum Average

Minimum Individual

= Individual result = Average result

17.11 Ultrasonic Inspection…