EN 15085-4
Documentations
Qualifications
15085-4 Welding Preparation Documents: How Do Welder Qualifications Support Quality Railway Production Worldwide?
By First Welding Certification Technical Editorial Team
6 Min Read Time
12 Oct 2026
Table Of Contents
EN 15085 Certifications
EN 15085 - 1
Welding of Railway Vehicles and Components (General)
EN 15085 - 2
Welding of Railway Vehicles and Components (Requiremets For Welding Manufacturer)
EN 15085 - 3
Welding of Railway Vehicles and Components (Design Requirements)
EN 15085 - 4
Welding of Railway Vehicles and Components (Production Requirements)
Introduction
Before welding starts on a railway component, the manufacturer must know what to weld, how to weld it, who will perform the work and how the final joint will be checked. Poor preparation can lead to weld defects, unnecessary rework, dimensional problems and gaps in production records.
EN 15085-4 preparation before welding addresses these requirements through welding planning documents, Welding Procedure Specifications (WPS), personnel qualification and supplementary production weld tests.
For railway vehicle and component manufacturers in India, understanding these requirements is important when establishing controlled welding production for projects involving EN 15085.
This blog explains the main preparation requirements and the different types of production weld tests in practical terms.
Welding Planning Documents
Welding planning documents establish how the manufacturer will carry out and control welding activities. Under EN 15085-4:2023, the manufacturer prepares these documents with the involvement of the responsible welding coordinator. Where the technical specification requires approval, the manufacturer must obtain it before welding begins.
General Requirements
The welding team should review the approved drawings, joint details, materials, welding requirements and inspection arrangements before production starts.
Manufacturing changes must remain controlled. For example, the manufacturer must not independently change the weld type, base material, weld location or specified consumables where the standard requires design department permission.
Any permitted manufacturing adaptations must be documented in the welding planning documents.
Working Plans
Working plans describe the manufacturing operations required to produce a railway component or assembly.
These plans are particularly relevant to components such as bogie frames, underframes, car body structures and safety-critical subassemblies.
A practical working plan may identify:
The sequence of manufacturing operations.
Component preparation and assembly stages.
Welding activities and relevant drawings.
Inspection stages and required records.
Responsibilities for carrying out and checking the work.
The plan should match the actual manufacturing process and remain under document control.
Additional Welding Planning Documents
Series production may require additional documents to control assembly and welding activities.
Welding sequence plans establish the order of welding operations. Correct sequencing can reduce distortion, weld shrinkage, residual stresses and the risk of missing welds.
Other documents may include tacking plans, repair plans, fixture and tooling documents, and instructions for removing damaged parts. An inspection and test plan must also be prepared in accordance with the applicable requirements of EN 15085-5.
Welding Procedure Specification (WPS)
A Welding Procedure Specification defines the welding conditions and essential parameters that the welder or operator must follow.
Depending on the welding process, the relevant specification may follow standards such as EN ISO 15609, EN ISO 14555 or EN ISO 15620.
A WPS typically identifies:
Welding process and joint configuration.
Parent material and thickness range.
Welding consumables.
Welding position and relevant parameters.
Joint preparation and applicable technique.
Other process-specific requirements.
The manufacturer must select the applicable WPS and ensure that the procedure has the required qualification for the work. A WPS does not automatically qualify every material, joint or welding condition.
Training and Qualification of Welders and Operators
Qualified personnel for EN 15085-4 are essential for consistent welding quality.
Before starting any work, the manufacturer must ensure that every welder or welding operator is qualified for the specific welding process, type of joint, material being used, and the production conditions involved.
For example, manual welding qualifications and welding operator qualifications for mechanised or automatic processes may follow different standards.
The manufacturer should maintain current qualification records and verify their validity under the applicable rules. Where necessary, additional production weld tests may demonstrate a person’s ability to perform a particular welding task.
Supplementary Weld Tests
Supplementary production weld tests demonstrate that the design, welding conditions, personnel skills or completed welded joints meet the specified requirements.
EN 15085-4 does not mean that every railway weld automatically requires every type of production test. The welding coordinator who is responsible decides if testing is needed and figures out how much testing is required during the design review or manufacturing process.
Objectives of Production Weld Tests
Production weld tests may demonstrate:
Whether a design is suitable for welding.
Whether the chosen welding settings are suitable for a particular joint.
Whether a welder can perform the required operation.
Whether the welded joint meets the required quality standards.
One production weld test may address more than one objective when the evidence satisfies the relevant requirements.
Realisation and Amount of Production Weld Testing
When production weld testing is necessary, the test should use manufacturing conditions representative of the actual product and take place under the welding coordinator’s supervision.
The test may use a separate test piece, a production assembly mock-up or an extension of the production weld.
The welding coordinator should define the test type and quantity in the weld test plan. The manufacturer must document the results and ensure that the welding coordinator reviews and approves them.
Types of Production Weld Tests
Suitability of the Design
Design-related tests assess whether the proposed joint and component design for EN 15085 can achieve the required weld quality and mechanical properties.
A representative mock-up can help assess weld accessibility, material selection, inspectability and the practical feasibility of the joint design.
Suitability of Welding Conditions
Some joint configurations may differ from those covered by the existing welding procedure qualification. Production weld tests can then establish whether the selected conditions achieve adequate fusion and weld quality.
The welding coordinator determines the appropriate testing based on the joint geometry, applicable qualification rules and technical requirements.
Skill of the Welder
Welder-related production tests can demonstrate practical ability for specific tasks, particularly where a joint is difficult to weld or requires special skill.
The welding coordinator defines the test and acceptance requirements in the weld test plan. The validity of a test demonstrating welder skill must follow the applicable rules.
Quality of the Welded Joint
Where the required volumetric examination cannot be performed, production weld tests may be necessary to demonstrate joint quality.
Depending on the application, fracture testing or macrosectionsmayform part of the assessment. The weldingcoordinator must establishsuitable test methods, frequencyand acceptance criteria.
Electron Beam, Laser Beam and Laser-Arc Hybrid Welds
These processes require appropriate production testing where specified to demonstrate weld quality under representative manufacturing conditions.
Changes to the design, material or manufacturing conditions may require further assessment if they can affect weld quality.
Resistance Spot, Roll Seam and Projection Welds
Production tests for resistance welding assess whether the welded joints achieve the required quality. The test method and acceptance criteria must reflect the welding process and applicable requirements.
Flash Welds
Flash welding joins components through a controlled heating and upsetting process. Production tests, where required, verify that the joint meets the relevant quality criteria.
Stud Welds
Stud welding requires control of the applicable process conditions and joint performance. Production tests may demonstrate that the stud weld achieves the specified requirements.
Friction Stir Welded Joints
Friction stir welding uses a rotating tool to create a joint without conventional fusion of the parent materials. Production tests may assess joint quality and verify the suitability of the selected manufacturing conditions.
For all these specialised processes, the manufacturer must select test methods and acceptance criteria based on the applicable standard, product requirements and welding coordinator’s assessment.
Frequently Asked Questions
What is EN 15085-4 preparation before welding?
It covers the planning activities required before welding railway vehicles and components, including working plans, welding sequence plans, WPS documentation, personnel qualification and applicable production weld tests.
Is a WPS mandatory for every railway weld?
The manufacturer must establish and apply the relevant welding procedure documentation and qualification required by the applicable standards, contract and production conditions. The exact requirements depend on the welding process and application.
Are production weld tests required for every welded component?
No. The welding coordinator determines whether production weld tests are necessary and specifies their type and quantity based on the design, joint configuration, welding conditions and required quality.
Which manufacturers should review EN 15085-4?
Manufacturers of railway vehicles and welded railway components should review the applicable production requirements alongside the relevant parts of the EN 15085 series and their project specifications.
Why are welding sequence plans important?
They establish the order of welding operations and can reduce distortion, shrinkage, residual stresses and missed welds during series production.
Conclusion
EN 15085-4 Certification preparation before welding establishes a controlled approach to railway welding production. Manufacturers need appropriate planning documents, qualified personnel, applicable WPS documentation and a clear approach to production weld testing.
The key is to prepare the work before welding begins, document changes, verify personnel qualifications and retain test evidence that demonstrates compliance with the specified requirements.
For railway manufacturers in India, these practices can improve production consistency, traceability and readiness for the applicable EN 15085 certification requirements.
Planning EN 15085 certification for your railway manufacturing operations?
First Welding Certification Pvt Ltd (PRVÁ ZVÁRAČSKÁ, a.s.) can be contacted to discuss the applicable certification requirements for railway welding activities.