RAILWAY WELDING
AUDIT READINESS
CERTIFICATION
EN 15085 Certification in Chennai: 10 Common Audit Problems Railway Manufacturers Face
By First Welding Certification Technical Editorial Team
10 Min Read
21 Aug 2026
Table Of Contents
Key Takeaways
Identify audit requirements before assessment
Review welding procedures and quality records
Verify personnel competence and qualifications
Maintain consistent welding quality and traceability
Why EN 15085 Audit Preparation Is Important
EN 15085 is about welding done on railway vehicles and their parts.The standard checks how the welding is done by the manufacturer, how important the welded part is for safety, and how skilled the workers are.Special attention is needed for EN 15085-2, which is for the manufacturer.This part sets different levels of classification and what needs to be shown to prove that everything meets the required standards.
When preparing for an audit, the main question a company will face isn’t:
“Are our welding steps written down?”
But rather:
“Can we show that our written welding plan is followed the same way every time in our production?”
When getting ready for an audit, the main question a company will face isn’t:
“Are our welding steps written down?”
But rather:
“Can we show that our written welding plan is used the same way every time in our production?”
10 Common EN 15085 Audit Issues
1.Scope of Certification Not Clearly Defined
The biggest issue is that it is not clear what exactly needs to be certified.
The certified scope should include railway products, different types of components, welding tasks, materials, welding methods, and production locations covered by the certification.
If the scope is too broad, it can cause unnecessary confusion during the assessment.
2.Incorrect Classification
Classification under EN 15085 depends on how important the welded parts are for safety.
Manufacturers should classify their products and welding activities correctly, not just pick a higher classification.
The system has three classification levels based on the safety importance of the welded parts.
For more information on classification and certified scope, you can refer to our EN 15085 certification requirements article.
3.Misunderstanding of EN 15085-2
One problem is the confusion about EN 15085 being just one document.
In reality, EN 15085 includes different parts, each covering specific requirements.
EN 15085-2 focuses on the welding manufacturer, while other parts deal with design, production, and inspection.
Before starting the assessment, it is important to understand which requirements apply to your specific activities.
4.Lack of WPS and WPQR Documents
Some manufacturers may have WPS (Welding Procedure Specification) documents, but there may be a mismatch between what is written and what actually happens in production.
The WPS should describe the welding process, and a suitable WPQR (Welding Procedure Qualification Record) should be used for welding procedure qualification.
Common problems in this area include:
– WPS that does not cover actual production
– Poor qualification records
– Mismatch between WPS and WPQR
– Uncontrolled revisions of WPS
– Missing supporting documents
For more information on WPS and WPQR, manufacturers can visit the WPS and WPQR certification page.
5.Not Clear Who Is Responsible for Welding Coordination
Welding coordination is a key part of controlling the production of rail vehicles.
Issues often arise because of unclear responsibility, incorrect qualifications for roles, and lack of documentation for welding coordination activities.
A manufacturer must be able to show who is responsible for welding coordination and how their responsibilities are handled.
6.Lack of Controlled Welder Qualifications
Even if welders are qualified, it isn’t enough if their qualifications are outdated, incomplete, or not relevant to the job.
Manufacturers should check the following:
– Welder qualifications
– Welding processes
– Material groups
– Welding positions
– Applicable ranges
– Validity and continuity records
If individual qualification is needed, welder certification is different from manufacturer certification.
7.Incomplete Material Traceability
Traceability is important if a manufacturer must show the link between incoming materials and the final welded parts.
A clear traceability chain could look like this:
Material → Heat/Batch Identification → Cutting/Fabrication → Welding → Welder → Inspection → Final Component
Missing identification at any step makes it harder to show the production process during an audit.
Manufacturers may also need to follow EN 10204 Type 3.2 for material inspection records.
8.Inconsistency Between Inspection/NDT Plan and Records
A common problem is when the inspection and non-destructive testing (NDT) plan does not match the production records.
Manufacturers should identify the types of inspections and tests used on the welded parts and collect proper documentation.
For NDT personnel qualification, ISO 9712 is responsible for certification.
9.Inconsistent Documentation
Sometimes, the documentation describes a method that isn’t actually followed in production.
This creates a big gap between what is written and what is done.
When preparing for certification, manufacturers should check the following areas:
– Procedure
– WPS
– Personnel
– Production
– Inspection
– Records
If there is a mismatch between these areas, the documentation should be reviewed before the assessment.
10.Treating Certification as a One-Time Event
Certification is not about getting a certificate once.
To keep the welding system certified, manufacturers must manage the system and related records throughout the certification period.
Changes in products, welding methods, workers, equipment, or production steps can affect the certification scope and control.
The controlled system must continue to work effectively after the initial assessment.
EN 15085 and Other Certifications
Railway manufacturers may have different welding practices and standards, but each one covers a unique area.
EN ISO 3834 talks about the quality required when joining metals with welding.
It helps check if the entire welding process is up to standard.
WPS and WPQR are about making sure the welding method is correct, not about certifying the company itself.
Welder certification ensures that the people doing the welding are properly trained and qualified.
ISO 9712 is for people who test welds without damaging them, using non-destructive methods.
If a company makes steel or aluminum structures that are not part of railway projects, then EN 1090 might be needed.
This helps avoid confusion because some companies think all welding certifications are the same.
Comparison of Certification
| Certification / Standard | Main application | Main focus |
|---|---|---|
| EN 15085 | Railway vehicles and components | Railway welding manufacturer |
| EN ISO 3834 | Fusion welding | Welding quality requirements |
| WPS & WPQR | Welding procedures | Procedure qualification |
| Welder Certification | Welding personnel | Individual qualification |
| ISO 9712 | NDT personnel | NDT competence |
| EN 1090 | Steel and aluminium structures | Structural execution |
| EN 10204 Type 3.2 | Metallic products | Inspection documentation |
How Chennai Manufacturers Can Review Their Readiness
Before the assessment begins, a manufacturer can do an internal check in five areas:
Scope – Are the products, activities, locations, and welding process clearly defined?
People – Are the welding coordinator, welders, and other NDT staff properly trained and qualified?
Procedures – Do the WPS and WPQR records match what’s actually happening in production?
Materials – Is there a way to track and prove the identity of the materials used?
Records – Are there proper records showing what was made, inspected, and tested?
This kind of check can help find problems before the certification starts.
Frequently Asked Questions
What are the EN 15085 certification requirements?
Requirements may be comprised of the certification scope, applicable classification, welding coordination, competent staff, WPS and WPQR, traceability of materials, production controls, inspection, testing, and documentation. The applicable requirements depend on the manufacturing scope.
What is the EN 15085 certification process?
The process generally involves defining the intended scope, submitting relevant company information, certification registration, assessment activities, review of assessment results and certification when the applicable requirements have been demonstrated.
How do manufacturers choose a suitable certification body in India?
A manufacturer shall take into account such certification body’s recognition, MCB status, technical competence, certification scope and applicable registration schemes. PZVAR acts as a Manufacturer Certification Body for EN 15085 certification.
How much does railway welding certification cost?
There is no single certification cost as it depends on such criteria as certification scope, classification, welding processes, production sites, assessment time and others.
What classification level is applied to a railway manufacturer?
Classification level is determined based on the significance of the safety of welded railway parts and applicable classification criteria. The existing system includes three classification levels. The manufacturer should decide which level applies to his organization.
Conclusion
Manufacturers in Chennai wanting EN 15085 certification should prepare for audits by looking at how the entire welding process works, not just checking if documents are there.Common issues found during audits include things like the scope of certification, how work is classified, how welding is organized, the WPS and WPQR procedures, welder qualifications, tracking of materials, inspection processes, non-destructive testing, and making sure all documents match what actually happens during production.The current valid version of the standard is EN 15085-2:2020+A2:2025, which is available through BSI and replaces the previous version A1:2023.
Is Your Railway Welding System Ready for EN 15085 Certification?
First Welding Certification Private Limited (PRVÁ ZVÁRAČSKÁ, a.s.) provides EN 15085 certification through the manufacturer’s approved Manufacturer Certification Body (MCB) process.Railway manufacturers can provide information about their company and production methods to determine the correct scope and requirements for certification.Before the assessment, review your railway welding process, certification scope, and related requirements.