Quality & Inspections · Mandatory · Construction

Weld Inspection Record

A record of weld inspections including visual inspection, NDT results, and welder qualifications.

Last reviewed: 29 March 2026 — This guide reflects UK law as of this date. BS EN ISO 3834 remains current with no amendments enacted as of 29 March 2026. Next scheduled review: 29 March 2027.

Legal basis	BS EN ISO 3834 (quality requirements for fusion welding) + BS EN 1090 (execution of steel structures)
BS EN 1090	Requires CE marking, welding coordination by certified EWE/IWE, Welding Procedure Specification (WPS), WPQR, welder qualification certificates (BS EN ISO 9606-1)
BS EN ISO 3834	Quality requirements at three levels (comprehensive / standard / elementary)
Inspection types	Visual (VT) 100% on all structural welds; MT for surface defects; PT for cracks; UT for volumetric defects; RT for cross-section view
Execution Classes	EXC1–EXC4 with increasing quality requirements. EXC2 minimum for most structural steelwork

1. Weld Inspection — Ensuring Structural Integrity Cannot Be Seen by the Naked Eye

A weld that appears sound to the naked eye may contain internal defects — lack of fusion, porosity, slag inclusions, or cracks — that create stress concentrations and can lead to catastrophic failure under load. The weld inspection record provides systematic evidence that every structural weld has been inspected using the appropriate methods and meets the required acceptance standard.

The inspection regime is determined by the Execution Class (EXC1-EXC4) assigned to the structure. EXC2 is the minimum for most structural steelwork and requires 100% visual inspection plus a specified percentage of non-destructive testing (NDT). The weld inspection record must trace every weld from the welder who made it, through the WPS used, to the inspection results and final acceptance.

Check qualifications before work starts

Never allow an unqualified person to carry out structural welding — welder qualification certificates must be checked before work starts. Each welder must hold a valid BS EN ISO 9606-1 certificate for the relevant welding process, material, and position.

2. Weld Inspection Record — Content

The weld inspection record must provide full traceability from the individual weld through to the welder, the procedure, and the inspection results. Each row represents a single weld or weld joint, and the columns capture every dimension of quality assurance required under BS EN 1090.

Column	Description
Project / element	The project name and the specific structural element (e.g. primary beam B12, column splice C5)
Weld ID	Unique identification number for each weld, referenced to the weld map or fabrication drawing
Date of welding	Date the weld was made — links to welder shift records and environmental conditions
Welder	Name and qualification certificate number of the welder (BS EN ISO 9606-1)
WPS reference	Reference number of the Welding Procedure Specification used, which must be validated by a WPQR
Weld process	Welding process used (e.g. MMA/111, MIG/MAG/135, TIG/141, FCAW/136)
Joint type	Type of joint (butt, fillet, T-joint, corner) and weld configuration (single-V, double-V, full penetration)
Material	Parent material grade and thickness (e.g. S355J2+N, 20mm flange to 12mm web)
Visual inspection (VT)	Result of 100% visual inspection — accept/reject against BS EN ISO 5817 quality level
NDT type	Non-destructive testing method applied (MT, PT, UT, RT) as required by the inspection plan
NDT date	Date the NDT was carried out — must allow for any required cooling period after welding
NDT operator	Name and PCN certification level of the NDT operator (minimum Level 2 for the relevant method)
NDT result	Result of the NDT examination — accept/reject with reference to any indications found
Acceptance standard	The acceptance standard applied (e.g. BS EN ISO 5817 Level B for EXC3, Level C for EXC2)
Overall result	Final assessment of the weld — accept, reject, or accept subject to repair and re-inspection
Reviewed by	Name and role of the responsible welding coordinator (EWE/IWE) who reviewed and signed off the record

3. Common Mistakes

Using a WPS not validated by a WPQR

Every Welding Procedure Specification (WPS) used on structural steelwork must be validated by a Welding Procedure Qualification Record (WPQR) that demonstrates the procedure produces welds meeting the required quality level. A WPS without a supporting WPQR is unvalidated and non-compliant with BS EN 1090.

Structural welding without a qualified welding coordinator

BS EN 1090 requires that structural welding is supervised by a qualified welding coordinator — either an International Welding Engineer (IWE) or European Welding Engineer (EWE) depending on the Execution Class. Welding carried out without welding coordination is a fundamental non-conformance.

Not maintaining a weld map for traceability

A weld map is a drawing or diagram that shows the location and identification of every structural weld on the project. Without a weld map, inspection records cannot be related to specific welds on the structure, and traceability is lost. The weld map must be maintained as a permanent project record.

NDT conducted by uncertified operators

All NDT on structural welds must be carried out by operators holding PCN Level 2 certification (minimum) for the relevant test method. Results from uncertified operators are invalid and must be repeated by a certified operator. Certification must be current and cover the specific method and sector.

Not recording pre-heat temperature where specified

Pre-heating is required for certain material grades and thicknesses to prevent hydrogen-induced cracking. Where the WPS specifies a minimum pre-heat temperature, this must be verified (typically by contact thermometer) and recorded before welding commences. Failure to pre-heat or to record the temperature is a non-conformance against the WPS.

4. Frequently Asked Questions

What is the difference between BS EN ISO 3834 and BS EN 1090?▾

BS EN ISO 3834 is the quality management standard for fusion welding — it defines the quality system requirements that a welding fabricator must have in place (comprehensive, standard, or elementary level). BS EN 1090 is the execution standard for structural steel and aluminium structures — it defines the technical requirements for fabrication and erection, including welding, bolting, surface treatment, and tolerances. A fabricator needs both: 3834 for the welding QMS and 1090 for the execution requirements.

What are the BS EN ISO 5817 acceptance levels?▾

BS EN ISO 5817 defines three quality levels for imperfections in fusion welds: Level B (stringent) is required for Execution Classes EXC3 and EXC4; Level C (intermediate) is required for EXC2; Level D (moderate) is the least stringent and applies to EXC1. The quality level determines the maximum permitted size of each type of imperfection (porosity, undercut, misalignment, excess weld metal, etc.).

What PCN certification is required for site NDT?▾

PCN Level 2 is the minimum certification required for an NDT operator to independently set up, carry out, and interpret the results of non-destructive testing on structural welds. The certification must be for the relevant method (MT, PT, UT, or RT) and must be current. Level 1 operators can only work under the supervision of a Level 2 or Level 3 operator.

Is visual inspection sufficient for structural welds?▾

Visual inspection (VT) is mandatory for 100% of structural welds and is an essential first step in the inspection process. However, VT alone cannot detect internal defects such as lack of fusion, root defects, or sub-surface porosity. For Execution Class EXC2 and above, additional NDT (MT, UT, PT, or RT) is required on a specified percentage of welds to detect defects that are not visible at the surface.

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