1.6 QUALITY ASSURANCE/ QUALITY CONTROL
1.6.1 The Fabricator shall provide and document all inspection, testing and quality control
for structural steelwork throughout the fabrication and erection of the works.
1.6.2
Materials and workmanship
shall be submitted
for inspection
and testing in
mill, shop and/or field by SCI and/or Testing Agency. Such inspection and testing does not relieve the Contractor of his responsibility to provide his own inspection, testing and
quality control as necessary to furnish materials and workmanship in accordance with
requirements of the Agreement.
1.6.3
The
fabricator shall maintain the inspection and quality control of his shop and field work. Quality control and inspection of welding work shall consist of meticulous supervision by
the
Contractor's welding inspector using non-destructive spot testing at not less than but not limited to the following rates and depending upon performance, the percentage of inspection shall be increased.
1.6.4 The Testing Agency shall carry out the following tests on the welds as directed by SCI
in accordance with the British Standards indicated:
a) Radiographic test
to
BS EN 1435 as appropriate.
b) Ultrasonic test
to
BS EN 1714.
c) Magnetic-particle test
to
BS EN ISO 9934-1. d) Dye-Penetration test to BS EN
571-1.
|
Weld Type
|
Test
|
|
Full
penetration butt
welds
|
50% radiographic (RT) or ultrasonic testing (UT)
and 50%
magnetic
particle (MT) or dye
penetrant testing (PT). (for site welds the above
will be 100%)
|
|
Partial
penetration
butt
welds
|
Minimum 25%
ultrasonic
(UT) and
25% magnetic particle (MT) or dye penetrant testing
(PT). (for site welds the above will be 50%)
|
|
Fillet
welds
|
Minimum 20% magnetic particle (MT) or dye penetrant testing (PT). (for site welds the above
will be 50%)
|
1.6.5
Non-destructive testing shall be done by
radiographic, magnetic particle or ultrasonic method, whichever is the most effective for the joint to be tested. Testing of welds
shall be carried out by qualified personnel.
All the results of such tests shall be submitted to SCI.
1.6.6
The fabricator shall notify SCI and the Testing Agency prior to the commencement of
any fabrication, erection, or other phases of work so as to allow them
reasonable opportunity to inspect
the work.
1.6.7 The fabricator shall facilitate inspection and testing by SCI and shall, at his own expense,
furnish the following, upon request:
a) Complete
sets of approved
Shop Drawings and
corrective work procedures at fabricating shop(s) and in the field.
b) Cutting lists, order
lists, material
bills, and shipping lists.
c) Information as to time and place of all rollings and shipments of material to shops and field.
d) Representative sample pieces requested for
testing as selected by SCI.
e)
Full and ample means and assistance for testing materials, and proper facilities for inspection of work, in mill, shop and field including access
ladders, scaffolding, lighting and protective gear.
1.6.9 The fact that steelwork has been accepted at the shop shall not prevent its final rejection at the job site, or even after it has been erected if it is found to be defective in any
way.
1.6.10
The fabricator shall
provide all necessary arrangement
for SCI and his representatives
to inspect
the production
in
the factory, place of assembly
and erection on site. Any
work or material found to be of sub-standard shall be rejected and removed from site.
These
defective work or materials shall be replaced with corrective work/ materials to
the
satisfaction of SCI
1.6.11 In addition to conforming to
the
requirements of the British Standards and Codes of Practice listed in this specification, all bolting in workshop shall
be in accordance with the following requirements.
General
a) Connections to be bolted shall be secured in close contact by service bolts or
a sufficient number of permanent bolts before the connections are finally bolted.
b) Hardened tapered washers shall be provided at taper flanges to compensate for
the
lack of parallelism.
c) A minimum of one washer to be supplied per
bolt, positioned under
the
nut.
d) Taper washers shall
have
a minimum thickness of 3mm at the thin end.
Black and Precision Bolts
a) Bolts shall show not less than three clear threads through the nuts, and the threaded portion shall not bear upon the thickness of connected plies in
a tightened condition.
b) Drilled holes shall be accurately positioned to
template and burrs shall be
removed from edges of holes before parts are assembled.
Punching of holes shall be restricted to
the limitations as highlighted in this specification.
Drift
pins will
be allowed only for bringing together the several parts of the structure and shall not be used in such a way as to distort the work or enlarge the
holes.
1.6.12 Independent Testing Agency (ITA)
1.6.12.1 The ITA
shall act on
behalf of and represent SCI
in matters
relating
to the interpretation of this section of the Specification and the monitoring,
auditing and verifying of the Contractor’s systems and hardware within the scope of this Contract.
1.6.12.2 ITA
monitoring and auditing activities
shall be undertaken
generally within the
guidelines of
BS 5750, and at
whatever frequency and
depth of involvement as agreed by the ITA and SCI to be necessary to verify that the Contractor’s work
satisfies the Contract Specification. The
ITA personnel shall carry out work under the guidance of a manager who shall be responsible to and report to SCI.
1.6.12.3 The ITA’s quality monitoring activities shall
include, but not limited to,
the
following:
(a) Assessment of the QA/QC facilities and the organisation of
the
Contractor
and his sub-contractor’s, if applicable.
(a) Assessment of approval of the Contractor’s Quality Manual.
(b) Checking of the accuracy and calibration of Contractor’s measuring and test
equipment.
(c) Review
and approval of the Contractor’s personnel training and certification, including welder qualifications before commencement of work.
(d) Welding shall be performed only by approved welders as tested to BS 4872.
The welders shall pass the qualifying test for the type of welding and welding position they will perform in the work
(e) Verification that the Contractor’s documentation of materials and process is adequate,
and satisfies the requirements of this section.
(f) Verification that the
Contractor’s
receipt and
storage of incoming materials is controlled such that the correct
materials are employed in the correct locations.
(g) Confirmation that all materials, including part and fully finished components, welding consumables and paints, etc., comply
with the requirements of this section.
(h) Confirmation by way of Non-Destructive Testing (NDT) and documentation
cross checking
that
welds placed during
fabrication
and erection have
mechanical properties and defect levels that satisfy
the
requirements of this
section.
(i) Confirmation that the painting and coating processes used are appropriate and that the
resulting corrosion protection systems are in accordance with the requirements of this section.
1.16.12.4 The
ITA
shall undertake only
whatever steps that are
agreed by
SCI to be necessary to confirm that
the fabricator is
discharging his
responsibilities
in this respect. It is emphasised that the activities of the ITA in no way relieve the Contractor of his responsibility to satisfy all provisions of the Contract Documents.
1.6.12.5 On despatch of each finished item from the fabricator’s works, the ITA shall confirm
to SCI, in writing, that the said items, as far as it is known, have been fabricated to
the
requirements of the Quality Manual and satisfy the requirements of this section
of
the Specifications.
1.6.13.1 The Contractor shall
ensure that
all personnel from
their proposed
Inspection Authority
performing the inspections and tests have the appropriate qualifications, experience and
training.
1.6.13.2 The resumes of these personnel shall be submitted to SCI
for approval.
1.16.14 Test Pieces
1.6.14.1 The Contractor shall prepare two sets of test pieces representative in all relevant
respects of the work to be carried out.
1.6.14.2 The Contractor shall confirm, by
the
means of tests, on one set of the test pieces that
the
proposed method will result in work that complies with the Specification. The
second set of
test
pieces shall be protected and retained until the issue
of the Certificate of Completion by SCI.
1.6.14.3 No work is to be carried out until the Contractor has confirmed, in writing, that the
results of the tests comply with this section of the Specification. The
quality standards
established by the test pieces shall be the minimum standard for
the
work.
1.16.15 Inspection Status
1.6.15.1 The Contractor shall
operate a system
for
identifying the inspection status at all stages
of
fabrication and erection.
1.6.16 Inspection & Test Records/ Certificates
1.6.16.1 The
Contractor shall
keep
records
of all
tests on materials
and
workmanship,
procedural trials. Records shall
be made available to SCI and the ITA for examination.
1.6.16.2 Test certificates demonstrating that the steelwork
and bolts
used conform to the requirements of the Specifications shall be submitted to SCI
for record.
1.6.17 Period of Notice
1.6.17.1 The Contractor shall agree with SCI the period of notice for all tests and any trial
assembly before commencement
of
such works.
1.6.18 Quality Manual
1.6.18.1 The Contractor’s quality programme shall be defined in a Quality Manual in which the organisational plan, systems and procedures are
fully described to ensure that all
essential quality control activities as described in the Clauses above are consistently and accurately carried out throughout all
phases of the work.
1.6.18.2 As a minimum, the
Quality
Manual shall include information and
procedures under the
following headings:
- Organisation and Management
- Facilities, Measuring and Test
Equipment
- Personnel Training and Certification
- Documentation
- Receipt, Storage, Handling and Transportation
- Materials
- Welding
- Fabrication and Erection
- Painting and Coating
- Inspection
- Non-Conforming Items
1.6.18.3 The Contractor shall produce the fully comprehensive Quality Manual within 3 weeks
of
the award of the Contract to the approval
of
SCI and ITA.
1.6.19 Quality Audits
1.6.19.1 The Contractor shall make all facilities available to the ITA such that quality audits
may
be carried out at any time prior to the Issue of the Completion Certificate by SCI.
1.6.19.2 The Contractor shall make available to the ITA all requested documentation to allow the ITA to discharge his duties and to witness significant stages in the
fabrication and
erection process.
1.6.19.3 Any deficiencies in
the work or steel
fabricator’s QA/QC
system detected by the ITA shall be reported to SCI. These items
shall be considered as being of suspect quality
and shall be physically quarantined in a separate holding area. No work may be
carried out on these items until SCI issues a Direction or Instruction in accordance
with the Conditions of Contract.
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