NES 849 Steel Castings For Structural Engineering and Pressure Purposes Category 2

Ministry of Defence
Defence Standard 02-849 (NES 849)

Issue 1 Publication Date 01 April 2000
Steel Castings For Structural,

Engineering And Pressure Purposes
Incorporating NES 849 Category 2

Issue 1 Publication Date May 1989
AMENDMENT RECORD
Amd No
Date
Text Affected
REVISION NOTE
This standard is raised to Issue 1 to update its content.
HISTORICAL RECORD
This standard supersedes the following:
Naval Engineering Standard (NES) 849 Issue 1 dated May 1989.
Signature and Date
Ministry of Defence
Naval Engineering Standard
NES 849
Issue 1 (Reformatted)
May 1989
STEEL CASTINGS FOR STRUCTURAL

ENGINEERING AND PRESSURE PURPOSES
This NES Supersedes

DG SHIPS 6080
DG SHIPS 6081
DG SHIPS 8081
Record of Amendments
AMDT
1
2
3
4
5
6
7
8
9
10
INSERTED BY
DATE
NAVAL ENGINEERING STANDARD 849

ISSUE 1 (REFORMATTED)
STEEL CASTINGS FOR STRUCTURAL
ENGINEERING AND PRESSURE PURPOSES
The issue and use of this Standard

is authorized for use in MOD contracts
by MOD(PE) Sea Systems and
the Naval Support Command
ECROWN COPYRIGHT
Published by:
Director of Naval Architecture
Procurement Executive, Ministry of Defence
Sea Systems, Foxhill, Bath BA1 5AB
i
ii
NES 849
SCOPE
1.
This NES gives the requirements for the manufacture, inspection and testing of steel castings
for structural and engineering purposes for HM Ships and general engineering purposes for
Submarines.
2.
Seven types of steel castings for different combinations of service conditions are detailed
herein under the following designations:
Type A
Carbon steel
Type B
Carbon steel
Type C
Carbon steel
Type D
Carbon molybdenum steel
Type E
Type F
Type G
2.25% chromium1% molybdenum steel
iii
NES 849
iv
NES 849
FOREWORD
Sponsorship
1.
This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Chief Naval Architect (CNA), Section NA 132.
2.
It is to be applied as required to any Ministry of Defence contract for the purchase of steel
castings for general engineering purposes and is applicable to Surface Ships and Submarines.
3.
If it is found to be technically unsuitable for any particular requirement the Sponsor is to be

informed in writing of the circumstances with a copy to CNA, Section NA 145.
4.
Any user of this NES either within MOD or in outside industry may propose an amendment
to it. Proposals for amendments which are:
a.
not directly applicable to a particular contract are to be made to the Sponsor of the NES.
b.
directly applicable to a particular contract are to be dealt with using existing procedures
or as specified in the contract.
5.
No alteration is to be made to this NES except by the issue of a formal amendment.
6.
Unless otherwise stated, reference in this NES to approval, approved, authorized or similar
terms means by the Ministry of Defence.
7.
Any significant amendments that may be made to this NES at a later date will be indicated
by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line
interval.
Conditions of Release
General
8.
This Naval Engineering Standard (NES) has been prepared for the use of the Crown and of
its contractors in the execution of contracts for the Crown. The Crown hereby excludes all
liability (other than liability for death or personal injury) whatsoever and howsoever arising
(including but without limitation, negligence on the part of the Crown, its servants or agents)
for any loss or damage however caused where the NES is used for any other purpose.
9.
This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.
10.
The Crown reserves the right to amend or modify the contents of this NES without consulting
or informing any holder.
MOD Tender or Contract Process

11.
This NES is the property of the Crown and unless otherwise authorized in writing by the MOD
must be returned on completion of the contract, or submission of the tender, in connection
with which it is issued.
12.
When this NES is used in connection with a MOD tender or contract, the user is to ensure that
he is in possession of the appropriate version of each document, including related documents,
NES 849
relevant to each particular tender or contract. Enquiries in this connection may be made of
the local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.
13.
When NES are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contracts and any other statutory requirements.
Compliance with an NES does not of itself confer immunity from legal obligations.
Related Documents
14.
In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:
a.
British Standards
British Standards Institution,

389 Chiswick High Road,
London W4 4AL
b.
Defence Standards
Directorate of Standardization and Safety Policy,

Stan 1, Kentigern House, 65 Brown Street,
Glasgow G2 8EX
c.
Naval Engineering Standards
CSE3a, CSE Llangennech, Llanelli,

Dyfed SA14 8YP
d.
Other documents
Tender or Contract Sponsor to advise.
Note: Tender or Contract Sponsor can advise in cases of difficulty.

15.
All applications to Ministry Establishments for related documents are to quote the relevant
MOD Invitation to Tender or Contract Number and date, together with the sponsoring
Directorate and the Tender or Contract Sponsor.
16.
Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.
Health and Safety

Warning
17.
This NES may call for the use of processes, substances and/or procedures that may be injurious
to health if adequate precautions are not taken. It refers only to technical suitability and in
no way absolves either the supplier or the user from statutory obligations relating to health
and safety at any stage of manufacture or use. Where attention is drawn to hazards, those
quoted may not necessarily be exhaustive.
vi
NES 849
CONTENTS
Page No
TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
v
v
v
v
vi
vi
vi
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
SECTION
DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 1.1 MATERIAL DESIGNATIONS . . . . . .
Elevated Temperature . . . . . . . . . . . . . . . . . . . . . . . .
Low Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.1
1.1
1.1
1.
1.1
1.2
SECTION
2.
CHEMICAL ANALYSIS . . . . . . . . . . . . . . . . . . . . . .
TABLE 2.1 COMPOSITION . . . . . . . . . . . . . . . . . .
2.1
2.1
SECTION
3.
MECHANICAL PROPERTIES . . . . . . . . . . . . . . . .
TABLE 3.1 MECHANICAL PROPERTIES . . . . .
3.1
3.1
SECTION
4.
4.1
MANUFACTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
4.1
SECTION
5.
CLASSIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
SECTION
6.
6.1
6.2
6.3
DELINEATION OF AREAS FOR

NON-DESTRUCTIVE TESTING . . . . . . . . . . . . . . .
Critical Test Region . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Region . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unclassified Region . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1
6.1
6.1
6.1
SECTION
7.
7.1
7.2
DIMENSIONS AND TOLERANCES . . . . . . . . . . .

Schedule of Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1
7.1
7.1
SECTION
8.
QUALITY ASSURANCE DOCUMENTATION . . .
8.1
SECTION
9.
9.1
9.1.1
9.1.2
9.1.3
9.2
TEST METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
9.1
9.1
9.1
9.1
9.1
vii
NES 849
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
Non-destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Particle and Liquid Penetrant . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1
9.1
9.1
9.1
9.2
9.2
9.2
SECTION
10.
10.1
10.1.1
10.1.2
10.1.3
10.1.4
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
ACCEPTANCE STANDARDS . . . . . . . . . . . . . . . . .
Destructive Examination Standards . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensile Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charpy V-notch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Examination Standards . . . . . . . .
Dimensional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Particle and Liquid Penetrant . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1
10.1
10.1
10.1
10.1
10.1
10.1
10.1
10.1
10.1
10.2
10.2
10.2
SECTION
11.
11.1
11.2
11.3
11.4
11.5
DEFECTS AND RECTIFICATION OF DEFECTS

Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limits on Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-welding Requirements . . . . . . . . . . . . . . . . . . . . .
Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impregnation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1
11.1
11.1
11.1
11.1
11.1
SECTION
12.
IDENTIFICATION OF CASTING . . . . . . . . . . . . . .
12.1
SECTION
13.
PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.1
ANNEX
A.
RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .
A.1
ANNEX
B.
DEFINITIONS AND ABBREVIATIONS . . . . . . . .
B.1
ANNEX
C.
ULTRASONIC REFERENCE STANDARD . . . . . .

FIGURE C.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C.1
C.1
ANNEX
D.
PROCUREMENT CHECK LIST . . . . . . . . . . . . . . .
D.1
ALPHABETICAL INDEX
viii
NES 849
1.
DESIGNATIONS
a.
Casting material is to be selected from TABLE 1.1 to meet the specific service
environment for which it is intended.
Environment
Room Temperature
Room and Elevated
Temperature
Material Type
UTS
N/mm 2
Reference
C
C Mo.
C
C Mo.
2 Cr. 1 Mo.
430
460
430
460
540
A
D
B
E
G
C
C. Mo.
430
460
C
F
Room and Sub-Zeroed

Temperature
TABLE 1.1 MATERIAL DESIGNATIONS
1.1
Elevated Temperature
a.
1.2
Type E would be selected for engine or machinery castings which require good
impact, shock resistance and elevated temperature properties. Where superior
creep properties are required Type G is to be selected.
Low Temperature
a.
For Type C and Type F the designations LT40 and LT50 indicate the minus
temperature at which impact properties are tested.
1.1
NES 849
1.2
NES 849
2.
CHEMICAL ANALYSIS
a.
The castings supplied to this NES are to conform to the chemical composition
required by TABLE 2.1.
Material to Conform to
Casting
Type A
BS 1504161 Grade 430 A
Type B
BS 1504161 Grade 430 E
Type C
BS 1504161 Grade 430 LT40
Type D
BS 1504245 A
Type E
BS 1504145 E
Type F
BS 1504245 LT50
Type G
BS 1504622E
TABLE 2.1 COMPOSITION
2.1
NES 849
2.2
NES 849
3.
MECHANICAL PROPERTIES
a.
TABLE 3.1 details the minimum mechanical properties and test temperatures
for Types A to G steel castings.
Tensile
Strength
UTS
N/mm 2
Proof Stress 0.2%
Elong
5.65 S O
Average Charpy
V-Notch
N/mm 2
Test
Temp
Room
Room
300 C
500 C
Room
Room
Type A
430
230
20
25
Type B
430
230
148
20
25
Type C
430
230
20
20
Type D
460
260
18
20
Type E
460
260
151
18
20
Type F
460
260
18
20
Type G
540
325
240
17
25
TABLE 3.1 MECHANICAL PROPERTIES
3.1
40 C 50 C
NES 849
3.2
NES 849
4.
4.1
MANUFACTURE
a.
The castings are to be manufactured using the latest techniques and are to be
of such a quality and purity that on completion they have the required
composition and properties when tested in accordance with this standard.
b.
To obtain test results which are representative of the actual casting or batch of
castings all test bars are to be cast attached to the casting to which they refer
and are to remain attached until the completion of the heat treatment cycles.
c.
The test bars are to be representative of the thickest and thinnest sections
within the casting or batch.
d.
Material for retests is not to be machined to the finished test bar size prior to
any further heat treatments.
e.
The location of the test bars is to be agreed between the purchaser and the
manufacturers since their position could adversely affect the casting quality.
f.
Should the design of the casting make it undesirable to provide cast-on test bars
the manufacturer is to consult the QAR to allow in extreme cases the provision
of separately cast keel bars.
Heat Treatment
a.
Each casting is to be supplied in the heat treated condition the details of which
are quoted in BS 1504 under the relevant material specification.
b.
The heat treatment furnaces used are to be fitted with automatic temperature
controls and with graphical temperature recorders.
c.
The manufacturer is required to demonstrate to the QAR that the furnaces used
are capable of providing an even distribution of heat at the correct temperature.
4.1
NES 849
4.2
NES 849
5.
CLASSIFICATIONS
a.
The classification of castings in accordance with NES 745 is as follows:
Class 1
a casting whose failure would lead to uncontrollable flooding, the total

immobilization of the vessel, or a serious hazard to personnel.
Class 2
a casting whose failure would lead to severe but controllable flooding, the
serious disruption of the weapon systems, main propulsion machinery, or
its attendant auxiliaries including generators.
Class 3
all other castings where their failure would not constitute an immediate
significant hazard.
Note:
It is incumbent upon designers to avoid over-classifying castings on the

grounds that doing so adds additional costs to components.
5.1
NES 849
5.2
NES 849
6.
DELINEATION OF AREAS FOR NON-DESTRUCTIVE TESTING

a.
6.1
Critical Test Region

a.
6.2
This will apply to certain areas of a Class 1 casting. The remainder of a Class
1 casting is to be designated as a Test Region.
Test Region
a.
6.3
Each casting is to be divided into regions of criticality, ie critical, test, and

unclassified. These designations will determine the degree of inspection to be
carried out and the standard of acceptance.
This will also apply to certain areas of a Class 2 casting. The remainder of a
Class 2 casting is to be unclassified.
Unclassified Region
a.
This will also apply to the whole of a Class 3 casting.
b.
Critical Test regions and Test regions are to be marked on reference drawings
as follows:
(1)
critical test regions are to be indicated by cross hatching in full lines at 45

from upper left to lower right;
(2)
test regions are to be indicated by cross hatching in short chain dotted

lines at 45 from upper right to lower left.
6.1
NES 849
6.2
NES 849
7.
DIMENSIONS AND TOLERANCES

a.
7.1
Schedule of Inspection
a.
Following agreement of the design features and the issue of casting drawings,
the purchaser is to provide a complete Schedule of Inspection prepared by the
designer and agreed by the founder which will include a marked up drawing
indicating the extent of Critical Test Regions and Test Regions, where
applicable, in accordance with Section 6.
b.
The Schedule of Inspection is to define:
c.
7.2
Before finalizing a design, the designer is to consult a foundry methods engineer

to allow incorporation of any modifications or change in design which might
assist in the production of sound castings.
(1)
surface finish;
(2)
classification;
(3)
any restriction on the repair of the castings;
(4)
non-destructive testing and pressure test requirements.
The designer is to make allowances in the factors of safety of the component to

take account of the reduced strength which occurs within the acceptance levels
detailed in Section 10.
Tolerances
a.
The casting tolerances are to be agreed between the purchaser and the
manufacturer and the minimum wall thickness after final machining is to be
stated on the drawing. The casting is to be capable of being machined to finished
dimensions within leaving evidence of the cast surface and accepted in
accordance with Section 10.
7.1
NES 849
7.2
NES 849
8.
QUALITY ASSURANCE DOCUMENTATION

a.
It is a requirement for Class 1 and Class 2 castings that each consignment of

castings is to be accompanied by Quality Assurance Documentation. This is to
include the actual results of the tests required by Section 9. together with
Certificates of Conformity with the relevant acceptance standards detailed in
Section 10. and a copy of the print out from the heat treatment furnace
temperature recorder.
b.
Class 3 castings are to be accompanied by a Statement of Compliance only,

unless further Quality Assurance Documentation is specified in the Contract
Documents.
8.1
NES 849
8.2
NES 849
9.
TEST METHODS
9.1
Destructive Tests
9.1.1
Analysis
a.
9.1.2
9.1.3
9.2
A full chemical analysis is to be made from each cast.
Mechanical Tests
a.
One set of tests is required from each cast and it is advised that extra material
be available to enable retests in the event of failure of the initial test.
b.
Tensile tests at room temperature are to be carried out in accordance with BS 18

and are to include the determination of the proof stress.
c.
Tensile tests at elevated temperatures are to be carried out in accordance with

BS 3688 Part 1 for the determination of the proof stress.
d.
Charpy V-notch impact tests are to be carried out in accordance with BS 131
Part 2 at the temperature quoted in TABLE 2.1. A minimum of three impact
tests are to be made for each test.
Test Pieces
a.
All test pieces are to be permanently marked with the cast and batch numbers
or a number which will ensure unique traceability of the material.
b.
To ensure representative results all machined test pieces require a surface

finish of 0.8m Ra or better.
c.
Unless authorized by the QAR all test pieces are to be retained for a period of
two months after completion of the contract or delivery of the material.
Retests
a.
Should any of the original mechanical test pieces fail to satisfy the requirements
of TABLE 2.1 the manufacturer is to take one of the following actions:
(1)
carry out two additional tensiles, if the original failed or an additional set
of charpy V-notch tests if they originally failed, or
(2)
reheat-treat the casting with suitable test material securely attached and
then carry out new mechanical tests.
9.3
Non-destructive Tests
9.3.1
Dimensional
a.
9.3.2
Visual
a.
9.3.3
Checks are to be carried out on each casting to ensure that the design drawing
requirements can be met (see Section 7.).
All castings are to be subjected to 100% visual examination assisted when

necessary by the use of 5 magnification optics. All imperfections are to be
identified and recorded on the Quality Assurance Documentation.
Magnetic Particle and Liquid Penetrant

a.
All Class I and Class 2 castings are to be subjected to 100% of either magnetic
particle or liquid penetrant examination in accordance with NES 729 Part 2 or
Part 4 before any machining operations are commenced. All casting surfaces
which are subsequently machined are to be subjected to a further examination
on completion.
9.1
NES 849
9.3.4
Radiography
a.
9.3.5
Ultrasonics
a.
9.3.6
The manufacturer can opt to subject designated Critical Test and Test Regions
to either 100% radiography or 100% ultrasonic examination. Radiography is to
be carried out in accordance with NES 729 Part 1, all subsurface imperfections
found by this examination are to be identified for subsequent assessment in
accordance with the acceptance standards in Section 10.
When it is proposed to use ultrasonic examination the manufacturer is to

forward the inspection technique and procedure to the QAR for approval with
NES 729 Part 5. To confirm the findings of the ultrasonic examination a
minimum of 10% of the area of the casting examined is to be radiographed.
Pressure Tests
a.
When required by the Contract Documents the castings are to be subjected to

a pressure test for the minimum duration of 15 minutes. Certain castings may
require longer periods of test and these together with test pressures will be
specified in the Contract Documents.
9.2
NES 849
10.
ACCEPTANCE STANDARDS
10.1
Destructive Examination Standards
10.1.1
Analysis
a.
10.1.2
Tensile Tests
a.
10.1.3
Each tensile test result is to meet the requirements laid down in TABLE 2.1 for
the appropriate material and test temperature.
Charpy V-notch
a.
10.1.4
The chemical analysis is to conform to the relevant material specification

quoted in BS 1504.
The average of three impact tests made is to be no less than the value quoted
in TABLE 3.1. No single value is to be lower than 70% of the value quoted in
TABLE 3.1.
Retests
a.
b.
The two tensile retest specimen results are to conform to the requirements in
TABLE 3.1. The additional set of charpy V-notch impact tests together with the
results of the original tests are to satisfy the following:
(1)
the average of the six is to be not less than the specified value in
TABLE 3.1;
(2)
no more than two of the individual values is to be less than that specified
in TABLE 3.1;
(3)
no more than one is to be less than 70% of the value specified in

TABLE 3.1.
Where test pieces are found, on testing, to have visually obvious casting defects,
the results are to be ignored and a new test piece prepared.
10.2
Non-Destructive Examination Standards
10.2.1
Dimensional
a.
10.2.2
Visual
a.
10.2.3
The castings are to be dimensionally within the tolerances stated on the

contract drawings and when no tolerances are given, subject to agreement
between the purchaser and manufacturer, a tolerance of 10% or 6mm
whichever is the lesson the designed wall thickness will be permitted on all
casting dimensions. The reduced wall thickness is to be free from sub-surface
defects in both Critical Test and Test Regions. The total area of reduced
thickness is not to exceed 10% of each individually designated test region.
The finished surface of the casting is to be free from cracks, hot tears, cold shuts
or linear defects. The surface finish is to meet the standard specified in the
Contract Documents and drawings.
Magnetic Particle and Liquid Penetrant

a.
All surfaces are to be free from cracks, hot tears or chain like porosity. Isolated
pin-point porosity is acceptable. Where porosity is present, indications which
are larger than pin-point are limited as follows:
10.1
NES 849
10.2.4
(2)
the sum of the diameter of indications in an area of 5000mm2 must not

exceed 24mm.
Cracks, hot tears and cold shuts in any area of the casting and lack of fusion in
weld repair areas are not acceptable. Internal porosity and shrinkage are
acceptable when:
(1)
in Critical Test Regions the local reduction in wall thickness does not
exceed 5% of the designed wall thickness and the total defective area does
not exceed 500mm2 or 10% whichever is the smaller and,
(2)
in Test regions the local reduction in wall thickness does not exceed 10%
of the designated wall thickness and the total defective area does not
exceed 1000mm2 or 20% whichever is the smaller.
Ultrasonics
a.
10.2.6
the maximum number of indications is not to exceed 8 of 8mm diameter

in any 5000mm2;
Radiography
a.
10.2.5
(1)
Any defect which causes a signal greater than or equal to the signal produced
by the approved reference standard shown in Annex C. is to be deemed
unacceptable and the casting rejected. Where the backwall echo is attenuated
by 40% or greater, the examination by ultrasonics is unacceptable and
radiography in accordance with Clause 9.3.4a. is to be employed.
Pressure Tests
a.
Each casting is to show no evidence of leakage.
10.2
NES 849
11.
DEFECTS AND RECTIFICATION OF DEFECTS
11.1
Defects
a.
11.2
11.3
Limits on Repair
a.
The limits on the extent of repairs for dimensional, surface and subsurface are
to be in accordance with NES 745.
b.
All welding is to be in accordance with NES 706 with regard to welding process,
weld procedure, weld preparation and consumable selection.
Pre-welding Requirements
a.
11.4
After excavation the weld area is to be examined to ensure the defect has been
removed. Welding is only to be carried out on sound material.
Heat Treatment
a.
11.5
In the event of subsequent manufacturing operations revealing unacceptable

defects capable of detection by the inspection techniques prior to delivery the
casting can be rejected.
Welding is only to be carried out on castings which have been fully heat treated
and after acceptance mechanical testing has been completed. The casting is to
be subjected to a post weld stress relief and the temperature is to be as quoted
for the relevant material specification in BS 1504.
Impregnation
a.
Impregnation is not to be used as a recovery procedure for Class 1 castings. Class

2 and 3 castings can be recovered using impregnation in accordance with
DEF STAN 031 when approved by the Design Authority.
11.1
NES 849
11.2
NES 849
12.
IDENTIFICATION OF CASTING
a.
For identification purposes, all castings are to be legibly marked by the

manufacturer with the following particulars:
(1)
The material designation and NES 849 Type X.
(2)
Class of casting, ie C1, C2 or C3.
(3)
Unique cast number which can be related to the Quality Control

Documentation.
b.
The markings detailed in Clause 12.a. are to be cast-on, stamped, using low
stress stamps in a non-critical area, engraved or vibro-etched in the position
indicated on the drawings. Markings are to be as conspicuous as the nature of
the casting allows and provision is to be made for transferring identification
markings during manufacture such that traceability is maintained throughout
the service life of the casting. The markings are not to be made on the highly
stressed regions, eg Critical Test Region of the casting.
c.
Where difficulty is being experienced in satisfactorily applying identification

symbols it is to be resolved by consulting the QAR.
12.1
NES 849
12.2
NES 849
13.
PACKAGING
a.
Except where otherwise stated in the Contract Documents packaging is to be

in accordance with the contractors normal trade practice which is to ensure
that no damage occurs during transit.
b.
Each package is to carry a label marked with the following additional

identification details:
(1)
NATO stock number when applicable.
(2)
Description of castings.
(3)
Quantity.
(4)
Contract number.
13.1
NES 849
13.2
NES 849
ANNEX A.
RELATED DOCUMENTS
A.1
Reference is made to:

Referred to in
Clause
BS 18
Methods for tensile testing of metals
9.1.2b.
BS 131 Part 2
The Izod impact test on metals

Pt 2 The Charpy V-Notch impact test on
metals
9.1.2d.
BS 1504
Steel castings for pressure purposes
2.a., 4.1a.,
10.1.1a., 11.4a.
BS 3688 Part 1
Methods for mechanical testing of metals 9.1.2c.

at elevated temperatures
Pt 1 Tensile testing
DEF STAN 031
Impregnation of porous castings
NES 706
Welding and fabrication of ship structure 11.2b.
NES 729
Requirements for Non-Destructive

Examination Methods
Part 1 Radiographic
9.3.4a.
Part 2 Magnetic Particle
9.3.3a.
Part 4 Liquid Penetrant
Annex B., 9.3.3a.
Part 5 Ultrasonic
9.3.5a.
Classification, Inspection Requirements

and Acceptance Standards of Steel and
Copper-base Alloy Castings
5.a., 11.2a.
*NES 745
(DG Ships/
PS/9010)
Note:
11.5a.
*In course of preparation. When published will supersede stated

document.
A.1
ANNEX A.
NES 849
ANNEX A.
A.2
NES 849
ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1
For the purpose of this NES the following definitions apply:

Acceptance Authority
the Design Authority for the systems or

equipments concerned.
Cast
a cast is:
a. the product of one furnace melt, or
b. the product of one crucible melt, or
Certificate of Conformity
c. the product of a number of furnace or crucible

melts where such are aggregated prior to sampling.
this is supplied with material of which traceability
during manufacturing is required and is issued on
the basis of the required tests having been carried
out on the casts from which the material supplied
has been taken.
Contractor
the firm, Company Organization or Establishment

working within the scope of this NES.
Design Authority
the relevant Section of Sea Systems Controllerate,

Foxhill, Bath, responsible for the system
concerned. Where this is not known by the
Contractor, enquiries are to be forwarded to DCW,
Section NA 132, Foxhill, Bath.
Pinpoint Porosity
any circular bleed out of less than 0.5mm diameter

revealed during liquid dye penetrant examination
in accordance with NES 729, Part 4.
Quality Assurance
Authority (QAA)
the authority designated in a contract as

responsible for quality assurance matters relating
to that contract.
Quality Assurance
Representative (QAR)
any officer duly authorized to act on behalf of the

QAA and the Project Manager.
Statement of Compliance
this is supplied with material of which traceability

during manufacture is not required. It ensures
that the material complies with the conditions of
this NES in accordance with the manufacturers
quality control procedures.
B.1
ANNEX B.
NES 849
ANNEX B.
B.2
NES 849
ANNEX C.
ULTRASONIC REFERENCE STANDARD
FIGURE C.1
T = Thickness to be tested 10%
{ = the block may be cut to this line to facilitate drilling where a single block
is required for use. Alternatively a number of separate reference blocks
may be employed.
Thickness to be examined (mm)
Dia of FBH (mm)
Up to and incl 50
1.5
Over 50 to 75 (incl)
2.5
Over 75 to 100 incl
3.0
Over 100
4.0
NOTES:
1. The flat bottom of the holes (FBH) is to be parallel to the entrant surface.
2. The reference standard is to be wide enough to permit sound transmission
to the flat bottom holes without side effects.
3. The reference standard material is to be ultrasonically free from obvious
defects and similar to the material being tested. The surface finish is to
be comparable to the test surface and of similar contour.
4. The test frequency is to be the same as the calibration frequency.
5. The equipment is to be set to show a minimum echo of 20% full screen
deflection from each hole within the thickness to be inspected.
C.1
ANNEX C.
NES 849
ANNEX C.
C.2
NES 849
ANNEX D.
PROCUREMENT CHECK LIST
TITLE ......................................................
REFERENCE ......................................................
Notes:
1.
This Check List is to ensure that certain aspects of this Naval

Engineering Standard are consulted when preparing a Statement of
Technical Requirements for a particular application.
Clauses where a preference for an option is to be used or where specific
data is to be added are included in the Check List.
List
Each item is to be marked either
2.
3.
= included
NA
= not applicable
CHECK
CHECK
No
1
Steel Designation
CLAUSE
No
1.1a., 1.2a.
Elevated Temp, Properties
3.a.
Low Temp, Properties
3.a.
Classification of Casting
5.a.
Delineation of Test Area
Quality Assurance Documentation
6.a., 6.1a.,
6.2a., 6.3a.
8.a., 8.b.
Pressure Test
Packaging
! or NA
9.3.6a.
13.a.
D.1
ANNEX D.
NES 849
ANNEX D.
D.2
NES 849
ALPHABETICAL INDEX
A
Analysis, 9.1, 10.1
C
Certificate of compliance, 8.1
Charpy V-notch, 10.1
Chemical composition, 2.1
Controls on thermal treatment, 4.1
Critical test Region, 6.1
D
Defect rectification, 11.1
Defects, 11.1
Destructive tests, 9.1
Dimensional, 9.1
Dimensions, 7.1
E
Elevated temperature, 1.1
H
Heat treatment, 4.1, 11.1
I
Identification, 2.1
Impregnation, 11.1
L
Labels, 13.1
Limits on repair, 11.1
Liquid penetrant, 9.1, 10.1
Low temperature, 1.1
INDEX.1
INDEX
NES 849
M
Magnetic particle, 9.1, 10.1
Manufacture, 4.1
Marking, 12.1
Mechanical tests, 9.1
N
Non-destructive examination standards, 10.1
Non-destructive tests, 9.1
P
Packaging, 13.1
Pre-welding requirements, 11.1
Pressure tests, 9.2, 10.2
Q
Quality assurance, 8.1
R
Radiography, 9.2, 10.2
Retests, 9.1, 10.1
S
Schedule of inspection, 8.1
Statement of compliance, 8.1
T
Temperature, 1.1
Tensile tests, 10.1
Test pieces, 4.1, 9.1
Test region, 6.1
Tests, destructive, 9.1
Tests, non-destructive, 9.1
Thermal treatment, 4.1
Tolerances, 7.1
INDEX
INDEX.2
NES 849
U
Ultrasonics, 9.2, 10.2
Ultrasonics reference standard, C.1
Unclassified test region, 6.1
V
Visual, 9.1, 10.1
W
Welding, 11.1
INDEX.3
INDEX
NES 849
INDEX
INDEX.4
Inside Rear Cover
Crown Copyright 2000

Copying Only as Agreed with DStan
Defence Standards are Published by and Obtainable from:

Defence Procurement Agency
An Executive Agency of The Ministry of Defence
Directorate of Standardization
Kentigern House
65 Brown Street
GLASGOW G2 8EX
DStan Helpdesk
Tel 0141 224 2531/2
Fax 0141 224 2503
Internet e-mail enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/69/02/849.
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with
a Defence Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by up issue or amendment. It is important that
users of Defence Standards should ascertain that they are in possession of the latest issue or
amendment. Information on all Defence Standards is contained in Def Stan 00-00 Standards
for Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of Defence
Standards and Defence Specifications published annually and supplemented regularly by
Standards in Defence News (SID News). Any person who, when making use of a Defence
Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of
Standardization (DStan) without delay in order that the matter may be investigated and
appropriate action taken.

NES 849 Steel Castings For Structural Engineering and Pressure Purposes Category 2

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Ministry of Defence

Defence Standard 02-849 (NES 849)

Steel Castings For Structural,

Incorporating NES 849 Category 2

Signature and Date

Naval Engineering Standard

STEEL CASTINGS FOR STRUCTURAL

This NES Supersedes

NAVAL ENGINEERING STANDARD 849

The issue and use of this Standard

Carbon molybdenum steel

Carbon molybdenum steel

Carbon molybdenum steel

2.25% chromium1% molybdenum steel

If it is found to be technically unsuitable for any particular requirement the Sponsor is to be

No alteration is to be made to this NES except by the issue of a formal amendment.

MOD Tender or Contract Process

British Standards Institution,

Directorate of Standardization and Safety Policy,

Naval Engineering Standards

CSE3a, CSE Llangennech, Llanelli,

Tender or Contract Sponsor to advise.

Note: Tender or Contract Sponsor can advise in cases of difficulty.

Health and Safety

DELINEATION OF AREAS FOR

DIMENSIONS AND TOLERANCES . . . . . . . . . . .

QUALITY ASSURANCE DOCUMENTATION . . .

DEFECTS AND RECTIFICATION OF DEFECTS

DEFINITIONS AND ABBREVIATIONS . . . . . . . .

ULTRASONIC REFERENCE STANDARD . . . . . .

PROCUREMENT CHECK LIST . . . . . . . . . . . . . . .

Room and Sub-Zeroed

TABLE 1.1 MATERIAL DESIGNATIONS

BS 1504161 Grade 430 A

BS 1504161 Grade 430 E

BS 1504161 Grade 430 LT40

Proof Stress 0.2%

TABLE 3.1 MECHANICAL PROPERTIES

The classification of castings in accordance with NES 745 is as follows:

a casting whose failure would lead to uncontrollable flooding, the total

It is incumbent upon designers to avoid over-classifying castings on the

DELINEATION OF AREAS FOR NON-DESTRUCTIVE TESTING

Critical Test Region

Each casting is to be divided into regions of criticality, ie critical, test, and

This will also apply to the whole of a Class 3 casting.

critical test regions are to be indicated by cross hatching in full lines at 45

test regions are to be indicated by cross hatching in short chain dotted

DIMENSIONS AND TOLERANCES

The Schedule of Inspection is to define:

Before finalizing a design, the designer is to consult a foundry methods engineer

any restriction on the repair of the castings;

non-destructive testing and pressure test requirements.

The designer is to make allowances in the factors of safety of the component to

QUALITY ASSURANCE DOCUMENTATION

It is a requirement for Class 1 and Class 2 castings that each consignment of

Class 3 castings are to be accompanied by a Statement of Compliance only,

A full chemical analysis is to be made from each cast.

Tensile tests at room temperature are to be carried out in accordance with BS 18

Tensile tests at elevated temperatures are to be carried out in accordance with

To ensure representative results all machined test pieces require a surface

All castings are to be subjected to 100% visual examination assisted when

Magnetic Particle and Liquid Penetrant

When it is proposed to use ultrasonic examination the manufacturer is to