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 covers welding work done on railway vehicles and parts.The evaluation looks at the welding done by the maker, how important the welded part is for safety, and how skilled the workers are.Special care should be taken with EN 15085-2, which is for the maker, because it sets the different levels of classification and what needs to be shown to prove everything is up to standard.
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 main problem is that it’s unclear 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 included in the certification.
A broader scope can lead to unnecessary questions during the assessment.
2.Incorrect Classification
Classification under EN 15085 is based on the safety importance of welded parts.
Therefore, manufacturers should classify their products and welding activities properly instead of just choosing a higher classification level.The current system has three classification levels, based on the safety importance of the welded parts.
For more information about classification and certified scope, you can refer to our EN 15085 certification requirements article.
3.Misunderstanding of EN 15085-2
Another issue is the confusion about EN 15085 being a single document.
In reality, EN 15085 includes different parts, each covering various requirements.EN 15085-2 focuses on the welding manufacturer, whereas other parts cover design, production, and inspection/testing.
It’s important to know which requirements apply to your specific manufacturing activities before beginning the assessment.
4.Lack of WPS and WPQR Documents
Manufacturers may have WPS (Welding Procedure Specification) documents, but there could be a gap between what is written in them and what actually happens in the production process.
The WPS should detail the welding activity, and a suitable WPQR (Welding Procedure Qualification Record) should be used for qualification of the welding procedure.
Common problems in this area are:
– WPS that doesn’t cover actual production
– Poor qualification records
– Gaps between WPS and WPQR
– Uncontrolled WPS revision process
– Missing support documents
For more information about WPS and WPQR qualification, manufacturers can visit WPS and WPQR certification.
5.Not Clear Who Is Responsible for Welding Coordination
Welding coordination plays a major role in the controlled production of rail vehicles.
Issues often arise because of unclear responsibility allocation, incorrect personnel qualifications based on their 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 duties are carried out.
6.Lack of Controlled Welder Qualifications
Even if welders are qualified, it’s not enough if their qualifications are outdated, incomplete, or not relevant to the job.
Manufacturers should check:
– Welder qualifications
– Welding processes
– Material groups
– Welding positions
– Applicable ranges
– Validity and continuity records
If individual qualification is needed, then welder certification is separate from manufacturer certification.
7.Incomplete Material Traceability
Traceability is especially important if the manufacturer has to show the connection between incoming materials and the final welded components.
A practical traceability chain could look like this:
Material → Heat/Batch Identification → Cutting/Fabrication → Welding → Welder → Inspection → Final Component
Missing identification at any stage makes it hard to show the production process during an audit.
Manufacturers may also need to comply with EN 10204 Type 3.2 documents 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 type of inspections and tests applied to the welded components and collect proper documentation.
For qualification of NDT personnel, ISO 9712 is responsible for certification and qualification.
9.Inconsistent Documentation
Sometimes, documentation describes a method that is not followed in actual production.
This creates a big gap between the documented controls and what happens on the shop floor.
When preparing for certification, manufacturers should compare the following areas:
– Procedure
– WPS
– Personnel
– Production
– Inspection
– Records
If there is inconsistency between these areas, the documentation should be reviewed before the assessment.
10.Treating Certification as a One-Time Event
Certification is not just about getting a certificate once.
To maintain a certified welding system, manufacturers have to manage the welding system and related records throughout the certification period.Changes in products, welding procedures, personnel, equipment, or production processes can affect the certification scope and control.
Therefore, the controlled system must continue to work effectively even after the initial assessment.
EN 15085 and Other Certifications
Railway makers might face different welding and standards, but each one covers something different.
EN ISO 3834 is about the quality needed for welding metals together.
It helps check if the whole welding system is good.
WPS and WPQR are about making sure the welding process is right, not about certifying the company.
Welder certification is for making sure the people doing the welding are qualified.
ISO 9712 is for people who test welds using non-destructive methods.
If a company makes structures from steel or aluminum that aren’t part of railway work, then EN 1090 might be needed.
This helps prevent 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, a manufacturer can do an internal check in five areas:
Scope – Are the products, activities, places, 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 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 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 who want EN 15085 certification need to prepare their audits by looking at how the whole welding process works, not just checking if documents exist.Common issues during audits include the certification scope, classification of work, how welding is coordinated, WPS and WPQR procedures, qualifications of welders, tracking of materials, inspection processes, non-destructive testing, and making sure documents match real production practices.The current valid version is EN 15085-2:2020+A2:2025, which is available from BSI and replaces the earlier A1:2023 version.
Is Your Railway Welding System Ready for EN 15085 Certification?
First Welding Certification Private Limited (PRVÁ ZVÁRAČSKÁ, a.s.) offers EN 15085 certification through the manufacturer’s approved Manufacturer Certification Body (MCB) process.Railway manufacturers can share details about their company and production methods to figure out the right scope and requirements for certification.
Before the assessment, check your railway welding process, certification scope, and related requirements.