AS 4458—1997

Australian Standard®

Pressure equipment—Manufacture
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 This Australian Standard was prepared by Committee ME/1, Pressure Equipment. It
was approved on behalf of the Council of Standards Australia on 17 January 1997 and
published on 5 June 1997.

The following interests are represented on Committee ME/1:

A.C.T. WorkCover
Australasian Corrosion Association
Australasian Institute of Engineering Inspection
Australian Aluminium Council
Australian Building Codes Board
Australian Chamber of Commerce and Industry
Australian Institute of Energy
Australian Institute of Petroleum
Australian Liquefied Petroleum Gas Association
Boiler and Pressure Vessel Manufacturers Association of Australia
Bureau of Steel Manufacturers of Australia
Department for Industrial Affairs, S.A.
Department of Labour, New Zealand
Department of Training and Industrial Relations, Qld
Electricity Corporation of New Zealand
Electricity Supply Association of Australia
Institute of Metals and Materials, Australasia
Institution of Engineers, Australia
Institution of Professional Engineers, New Zealand
Insurance Council of Australia
Metal Trades Industry Association of Australia
National Association of Testing Authorities, Australia
New Zealand Engineering Federation
New Zealand Heavy Engineering Research
New Zealand Institute of Welding
New Zealand Petrochemical Users Group
New Zealand Timber Industry Federation
Victorian WorkCover Authority
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Welding Technology Institute of Australia

WorkCover, N.S.W.
Work Health Authority, N.T.
Workplace Standards Authority, Tas.
WorkSafe, W.A.

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amendments thereto.
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This Standard was issued in draft form for comment as DR 94387.

 AS 4458—1997

Australian Standard®

Pressure equipment—Manufacture

First published as AS 4458 — 1997.

Incorporating:
Amdt 1—1999
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PUBLISHED BY STANDARDS AUSTRALIA

(STANDARDS ASSOCIATION OF AUSTRALIA)
1 THE CRESCENT, HOMEBUSH, NSW 2140
ISBN 0 7337 1009 3
 AS 4458 — 1997 2

PREFACE

This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee ME/1 on Pressure Equipment.
This Standard is the result of a consensus among Australian and New Zealand
representatives on the Joint Committee to produce this document as an Australian
Standard. Consensus means general agreement by all parties. Consensus includes an
attempt to remove all objections and implies much more than the concept of a simple
majority, but not necessarily unanimity. It is consistent with this meaning that a member
may be included in the Committee list and yet not be in full agreement with all clauses of
this Standard.
This Standard is one of the ‘core’ documents which form part of the revised arrangement
of the pressure equipment Standards; and is intended to unify and revise the
manufacturing requirements for the pressure equipment Standards, AS 1210, Pressure
vessels, AS 1228, Pressure equipment — Boilers and AS 4041, Pressure piping.
In this way misunderstanding, cost and delay in manufacture can be reduced and safety
can be improved. It is intended to avoid unnecessary duplication and promote greater
confidence in reciprocal acceptance of qualified procedures.
This Standard is based largely on AS 1210, with due allowance for practices or
requirements of AS 1228 and AS 4041.
Requirements have been formulated with a view to maximum compatibility with
recognized International Standards.
Statements referred in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral
part of a Standard, whereas an ‘informative’ appendix is only for information and
guidance.
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The use of material in print form or in computer software programs to be used commercially, with or without payment, or in
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 3 AS 4458 — 1997

CONTENTS
Page

SECTION 1 SCOPE AND GENERAL

1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 2 MATERIAL GROUPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 3 DRAWINGS AND PRODUCT QUALITY

3.1 CONSTRUCTION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 COMPETENCE OF MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 MANUFACTURE AND WORKMANSHIP . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 INDEPENDENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 4 MATERIAL IDENTIFICATION

4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 TYPES OF IDENTIFICATION OF MATERIALS . . . . . . . . . . . . . . . . . . . 14
4.3 MATERIAL NOT FULLY IDENTIFIED . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 IDENTIFICATION AND MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 DEFECTS IN MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 5 MATERIAL CUTTING

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . ............. . . . . . . . . . . . . . 17
5.2 THERMAL CUTTING . . . . . . . . . . . . ............. . . . . . . . . . . . . . 17
5.3 MECHANICAL CUTTING AND EDGE PREPARATION . . . . . . . . . . . . . 19
5.4 EDGE EXAMINATION . . . . . . . . . . . ............. . . . . . . . . . . . . . 19
5.5 EDGE FINISH . . . . . . . . . . . . . . . . . . ............. . . . . . . . . . . . . . 19

SECTION 6 FORMING OF PRESSURE EQUIPMENT COMPONENTS

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6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 HOT FORMING OF PRESSURE EQUIPMENT COMPONENTS . . . . . . . . 22
6.3 COLD FORMING OF PRESSURE EQUIPMENT COMPONENTS FROM
PLATES AND SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.4 COLD FORMING OF PIPES AND TUBES . . . . . . . . . . . . . . . . . . . . . . . 30
6.5 INDUCTION BENDING OF PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.6 REPAIR OF SURFACE IMPERFECTIONS AFTER FORMING . . . . . . . . . 33

SECTION 7 DIMENSIONAL TOLERANCES ON FORMED COMPONENTS AND

PRESSURE EQUIPMENT
7.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 TOLERANCES ON SHELL AND ENDS OF PRESSURE VESSELS
AND BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.3 GENERAL DIMENSIONAL TOLERANCES ON HEAT EXCHANGERS . . 38
 AS 4458 — 1997 4

Page

7.4 DIMENSIONAL TOLERANCES FOR BOILER TUBES AFTER

BENDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5 DIMENSIONAL TOLERANCES FOR PIPE AND TUBE AFTER
BENDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

SECTION 8 WELDED CONSTRUCTION—ASSEMBLY OF JOINTS

PRIOR TO WELDING
8.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2 ASSEMBLY OF PARTS FOR WELDING . . . . . . . . . . . . . . . . . . . . . . . . 41
8.3 WELDED JOINTS—BOILERS AND PRESSURE VESSELS . . . . . . . . . . . 42
8.4 WELDED JOINTS—PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SECTION 9 WELDING QUALIFICATIONS, CONSUMABLES AND EQUIPMENT

9.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........... 48
9.2 WELDING PROCEDURE QUALIFICATION . . . . . . . . . . . ........... 48
9.3 WELDER QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . ........... 48
9.4 RECORD OF WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . ........... 48
9.5 WELDING CONSUMABLES AND EQUIPMENT . . . . . . . ........... 48

SECTION 10 WELDING PREHEAT

10.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.2 METHOD OF PREHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.3 TEMPERATURE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4 CONTINUITY OF PREHEAT DURING WELDING . . . . . . . . . . . . . . . . . 51
10.5 INTERRUN TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.6 PREHEAT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 11 WELDED JOINTS

11.1 CONDITIONS FOR WELDED JOINTS PRIOR TO AND DURING
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.2 STRIKING OF ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.3 INTERRUN CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.4 SURFACE OF FINISHED WELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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11.5 PEENING OF WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

11.6 REMOVAL OF TEMPORARY ATTACHMENTS AND ARC STRIKES . . . 55
11.7 WELD REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11.8 THERMAL STRAIGHTENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11.9 STRUCTURAL WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SECTION 12 NON-WELDED JOINTS

12.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . 57
12.2 THREADED JOINTS . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . 57
12.3 FLANGED JOINTS . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . 57
12.4 FLARED, FLARELESS AND COMPRESSION JOINTS . . . . . . . . . . . . . . 57
12.5 CAULKED JOINTS . . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . 58
12.6 SPECIAL FITTINGS . . . . . . . . . . . . . . . . . . ....... . . . . . . . . . . . . . . 58
 5 AS 4458 — 1997

Page

SECTION 13 WELD NON-DESTRUCTIVE EXAMINATION AND REPAIR

13.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
13.2 NON-DESTRUCTIVE EXAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
13.3 REPAIR TO WELDS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 59
13.4 PRODUCTION TEST PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

SECTION 14 HEAT TREATMENT

14.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.2 TYPES OF HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.3 PRESSURE EQUIPMENT REQUIRING POSTWELD HEAT
TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
14.4 STAGE OF POSTWELD HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . 64
14.5 THICKNESS FOR POSTWELD HEAT TREATMENT . . . . . . . . . . . . . . . 64
14.6 METHODS OF HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
14.7 POSTWELD HEAT TREATMENT PROCEDURE FOR FERRITIC STEELS 68
14.8 REDUCED HOLDING TEMPERATURES FOR POSTWELD HEAT
TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
14.9 POSTWELD HEAT TREATMENT PROCEDURE FOR HIGH CHROMIUM
ALLOY STEELS (MATERIAL GROUPS J AND L) . . . . . . . . . . . . . . . . . 69
14.10 POSTWELD HEAT TREATMENT OF AUSTENITIC AND FERRITIC-
AUSTENITIC CHROMIUM-NICKEL STEELS . . . . . . . . . . . . . . . . . . . . . 69
14.11 EXEMPTIONS TO POSTWELD HEAT TREATMENT OF
ATTACHMENTS TO POSTWELD HEAT TREATED EQUIPMENT . . . . . 70
14.12 POSTWELD HEAT TREATMENT OF CLAD AND LINED
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
14.13 POSTWELD HEAT TREATMENT OF DISSIMILAR MATERIAL JOINTS 71
14.14 HEAT TREATMENT OF ELECTROSLAG WELDS . . . . . . . . . . . . . . . . . 71
14.15 HEAT TREATMENT OF NON-FERROUS METALS . . . . . . . . . . . . . . . . 71
14.16 HEAT TREATMENT OF TEST PLATES . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.17 RECORDING OF HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14.18 HEAT TREATMENT VERIFICATION TESTS FOR EQUIPMENT
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CONSTRUCTED IN MATERIAL GROUPS F AND G . . . . . . . . . . . . . . . 72

SECTION 15 CLAD AND LINED CONSTRUCTION

15.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
15.2 CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
15.3 WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
15.4 POSTWELD TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

SECTION 16 BRAZED CONSTRUCTION

16.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.2 MATERIAL FOR BRAZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.3 ASSEMBLY OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.4 PREPARATION OF SURFACES FOR BRAZING . . . . . . . . . . . . . . . . . . . 75
16.5 BRAZING PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
16.6 BRAZING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
 AS 4458 — 1997 6

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16.7 BRAZING PERSONNEL . . . . . . . . .... . . . . . . . . . . . . . . . . . . . . . . . . 76

16.8 SURFACE OF FINISHED JOINT . . .... . . . . . . . . . . . . . . . . . . . . . . . . 76
16.9 POST-BRAZING OPERATIONS . . . .... . . . . . . . . . . . . . . . . . . . . . . . . 76
16.10 REPAIR OF DEFECTIVE BRAZING ... . . . . . . . . . . . . . . . . . . . . . . . . 76

SECTION 17 FORGED CONSTRUCTION

17.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
17.2 METHODS OF FORMING FORGED ENDS . . . . . . . . . . . . . . . . . . . . . . . 77
17.3 TOLERANCES ON PRESSURE VESSEL CYLINDERS AND ENDS . . . . . 77
17.4 HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
17.5 NON-DESTRUCTIVE EXAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.6 ATTACHMENT OF FORGINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.7 WELDING OF FORGED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
17.8 REPAIR OF IMPERFECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

SECTION 18 CAST CONSTRUCTION

18.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
18.2 ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
18.3 NON-DESTRUCTIVE EXAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . 80
18.4 REPAIR OF IMPERFECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

SECTION 19 TUBE HOLE DRILLING AND TUBE EXPANSION

19.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . 81
19.2 TUBE HOLES — DIAMETER AND FINISH . . . . . . . . . . . ...... . . . . . . 81
19.3 LOCATION OF TUBE HOLES IN WELDED JOINTS FOR BOTH
BOILERS AND HEAT EXCHANGERS . . . . . . . . . . . . . . ...... . . . . . . 81
19.4 CONDITION OF TUBES . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . 82
19.5 TUBEPLATE LIGAMENT . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . 83
19.6 EXPANSION OF TUBES . . . . . . . . . . . . . . . . . . . . . . . . ...... . . . . . . 83

SECTION 20 PRESSURE TESTING

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20.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
20.2 TEST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

SECTION 21 FINAL CLEANING, SURFACE TREATMENT AND

DIMENSIONAL CHECKS
21.1 CLEANING AND SURFACE TREATMENT . . . . . . . . . . . . . . . . . . . . . . 86
21.2 DIMENSIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
21.3 PROTECTION FOR TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

SECTION 22 NON-METALLIC PRESSURE EQUIPMENT

22.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
22.2 GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
 7 AS 4458 — 1997

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APPENDICES
A LIST OF REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
B TYPICAL FERROUS MATERIAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 91
C MANUFACTURER’S DATA REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
D DESCALING OF AUSTENITIC AND FERRITIC-AUSTENITIC
Cr-Ni STEEL VESSELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
E SUGGESTED PRACTICE ON PEENING OF WELDS . . . . . . . . . . . . . . . . . 97
F RECOMMENDED DIMENSIONAL TOLERANCES FOR PRESSURE
VESSELS AND PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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 AS 4458 — 1997 8

STANDARDS AUSTRALIA

Australian Standard
Pressure equipment—Manufacture

S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPE This Standard sets out requirements for the manufacture of pressure
equipment as specified in the pressure equipment Standards AS 1210, AS 1228 and
AS 4041. Fabrication, heat treatment, forged construction, cast construction and testing
are covered.

1.2 APPLICATION This Standard is intended for use by designers, manufacturers,

fabricators, inspection bodies, inspectors and all persons concerned with the manufacture
of pressure equipment.
This Standard applies to pressure equipment covered by AS/NZS 1200 and AS 3920.1.
The relevant requirements of AS/NZS 1200 apply to this Standard.

1.3 REFERENCED DOCUMENTS A list of the documents referred to in this

Standard is given in Appendix A.

1.4 DEFINITIONS For the purposes of this Standard, the definitions below apply.
1.4.1 Construction — design, manufacture and supply. (See Figure 1.1).
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FIGURE 1.1 TERMS USED IN CONSTRUCTION

1.4.2 Designer — a person who designs pressure equipment or is responsible for the
design.
1.4.3 Fabrication — the forming and joining of pressure equipment components which
includes cutting, bending, rolling, pressing, swaging, upsetting, threading, welding,
brazing, machining and any other operation on these components, but which is not part of
installation.
NOTE: Fabrication may be carried out in the shop or on site.

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 AS 4458-1997 Pressure equipment - Manufacture
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