Assessment of Production

APPROVAL INSPECTION TESTING

TECHNICAL APPROVALS FOIq CONSTRUCTION UK Member of EOTA (European Organisation for Technical Approvals)

UK Member of the UEAtc (European Union of Agr~ment)

Assessment of Production Agreed Quality Plan

for

Promat TL board

Agr~ment Certificate 09/4646

Note to the inspector: all documents referenced in this qp are without any dates. Hence it is imperative please that BBA inspector to report nature of all changes

made in these reports at the next visit. If this proves to be unworkable then we will need the actual dates of these documents in eth quality plan, please.

Document reference Promat AQPKingspan LocationSeptember2017

Date of issue September 2017

BBA Section responsible Construction Products

BBA Project Manager Gayetree Ramkorun

Other products covered by All insulations certificates for Kingspan

BBA Certificates manufactured on this site:

Qualit~ Plan (18-06-42) Iss8 of 8 Job number: Product:

BBA00011241 0001 BBA00011241/1

Product name: Promat TL board which is a calcium silicate board (Promatect HD) bonded to the foil faced Phenolic insulation (Kingspan Kooltherm K10) board which is glass tissue faced on the other side.

Product range:

Bonding Line

Name Application Components Length Width Thickness (mm) (mm) (mm)

Promat TL board An insulated Calcium silicate soffit board

Kooltherm K10 phenolic (foil faced on one side and the other glass tissue)

Calcium silicate board (Promatect H D)

24OO 1200 20-120mm

6mm

Phenolic Line

Medium to high density phenolic foam core faced with tissue or foam

Kooltherm K10 Tissue / foil faced soffit insulation

Kooltherm K10 phenolic (foil faced on one side and the other glass tissue).

24OO 1200 20-120mm

Production location:

Produced by: Kingspan Insulation Limited

Address: Pembridge

Leominster

Herefordshire

Postcode: HR6 9LA

Telephone:

Fax:

Contact:

Title:

E-mail:

Steve Mesham

Management Representative

Is the above production site covered by /SO 9001 Registration?

If YES, Registration No: 388 issue 4

Assessed by (organisation): LPCB

Yes

Qualit~ Plan (18-06-42) Iss8 of 8 Product:

Job number:

BBA00011241 0002 BBA00011241/2

Scope of assessment: Design and Manufacture of insulation and composite insulation materials for the construction industry.

Purchasing data & receiving inspection and testing: All materials are purchased to agreed specifications as laid down in our ISO9001 Quality System. Bonding Line materials are visually checked and processed in accordance with Works Procedure No 4 latest version. If a delivery of any material does not appear to meet the specification set out in the Raw Material Database, then a concession is raised and authorised by the Technical Processing Manager.

Incoming product, raw Original supplier Acceptance limits materials and Components

Apollo Chemicals- spec no. C of A 474

Bonding Line Adhesives (SIKA UK) spec no. 578 C of A

Phenolic Insulation Kingspan Insulation Ltd Internal Specification

Promat Conditionally accepted against

substrate delivery notes and

customer free issues

Identification (type, class, grade, specification, etc)

A9368 GREEN

(Sikamelt-9677)

K10

Promatect HD TP C4E

The raw materials are checked before offloading as per Works Procedure 3 and 4 latest issues. Any raw materials that are outside of specification are dealt with as per Works Procedure 24 latest issue.

The following table is an example of the style, format and content that is required. However it can be modified for proportions, orientation (portrait or landscape*) or converted to other non table formats. * Please note that landscape orientation can be irritating to the reader (client) and therefore should be used with caution.

Product identification and traceability:

Every order that is placed is given an Order Number. The Production Programmes (QSP8b for Bonding Line Line) are then formulated to incorporate all the necessary orders, quoting the respective Order Numbers.

Line 1 - Pembridge

Board Production: Before use, phenolic resin is taken from the bulk tank and pumped into the resin day tank. The acid, blowing agent and resin are pumped at a pre-set rate to the mixing head. When a stable flow is achieved the machine goes from recirculation to dispense and foam exits the dispense nozzles onto the base substrate. The top layer of substrate is also supplied from a roller at the rear of the lay down. This layer is applied to form the top of the substrate. The whole of the ’wet end’ is controlled by a fully automated system

The board then passes into a fixed gap conveyor contained within an oven between 50 and 75 °C (depending on thickness). The partially cured board then passes through a second oven to complete curing.

After packing/wrapping, the stacked boards are placed in temperature controlled curing chambers and left to condition for a minimum period of 48 hours a representative sample is placed with each produced product.

Product identification and traceability: Bonding Line

All blank boards that are made in house are inkjet printed on the edge with product type, date and time of manufacture. This allows traceability to the production records for that board

Bonding line: line 3 Pembridge

Quali~ Plan (18-06-42) Iss8 of 8 Job number: Product:

BBA00011241 0003 BBA00011241/3

The process is fully described in the IMS Pb/Sb/Bs IMP 250 Latest Issue.pem 12.05.2014.Basildon-08.07.2015

Line 1

Board Cutting: The boards are cut to the required dimensions by a two-stage operation:

and selby-

(1) Side trimming: by use of a hogging cutter in conjunction with a scoring blade. The unit is adjusted manually to achieve the correct width.

(2) Cut to length: by use of a traversing across cut saw which moves in relation to the board. Control of the unit is via an encoder which the operator sets to the required length.

Method of production and process control:

Bonding Line: line 3 - Pembridge

Calcium Silicate board is lifted with suction pads and placed onto the horizontal conveyor. From the loading station, the board is conveyed into the laydown area were a prescribed amount of hot melt adhesive and one part moisture curing adhesive applied in beads. Insulation panels (K10) are manually placed onto the adhesive coated Calcium Silicate board. These composite boards then travel through a press. These then enter the lifting area where using suction pads the composite is placed onto a pallet, labelled, wrapped and banded.

Process Control:

Bonding Line

Alignment is by the operative’s fingertips. The laminate then passes between a set of compressive rollers (compresses the foam by approx 3mm) before moving on to an automatic stacking unit.

As per IMS PEMBRIDGE/SELBY/BASILDON IMP 250 Latest Issue-pembridge and selby- 12.05.2014.Basildon-08.07.2015

Phenolic Line

Works procedure No. 33

In-process inspection and testing:

As per IMS Pb/Sb/Bs IMP 250 Latest Issue.pem and selby-12.05.2014.Basildon-08.07.2015.

Results are recorded on form - SAP based PI Sheet viewed through SAP QA33 format.

Bonding Line

Property measured Action on rejection

Adhesive coating Weight

Width (Insulation) Length (Insulation)

Method used

Line side weigh scale

Steel tape

Acceptance limits

60-80 gsm (As SOP)

1195mm (+ 0,-2)

2397mm (+ 0,-2)

Frequency

At start up and hourly

Every 30 minutes

Every 30 mins Squareness Steel tape <0.3% of Length

Inform Team Leader


Job number:

BBA00011241 0004 BBA00011241/4

t Alignment Visual inspection } Continuous Inter laminar Strength On Line Continuous

Visual

Visual (At lifting station)

Final inspection and testing:

Phenofic Line

Property measured Works Frequency Acceptance limits Action upon procedure (minimum) rejection

Thermal Conductivity (@ 10 Deg C mean)

Compressive strength

Density

QC11p

One per production run

One per production run

Every 30mins

Max 0.0210 Wm-IK-1

K10 _>100 kPa

None (result recorded)

Board Rejected

Board downgraded

Bonding Line

As detailed in the in-process inspection and testing section. No further testing occurs

Calibration:

Calibration procedures are described in Pb IMP 206 - Calibration latest issue.

t Equipment Identification Calibration date / Due date Bonding Line Adhesive Scales Serial No. SCA-08 - Ext. Cert. 7010 Last 13/05/15 Next due 05/16 - 12 MThs

Packaging:

Boards are automatically stacked and polyethylene shrink-wrapped. Each pack bears a label showing relevant information regarding product description and traceability; including works order number, and bearing the appropriate BBA identification mark (where applicable). Phenolic boards packed with corner protectors.

Bonding Line

Number of laminates per stack is in accordance with Works Procedure No 9 Latest Issue. Each palletised stack employs cardboard corner protectors, polythene shrink wrapping, 3 plastic bands across the width, and a piece of plywood on top, a label which bears Promat HD, dimensions and date of manufacture.

Labelling: Packs are labelled with a product identification label showing the following information:

¯ Thickness of product No of boards per pack


BBA00011241 0005 BBA00011241/5

¯ Product name ¯ Board dimensions ¯ Blank Label used ¯ No BBA logo displayed on label on packs

wrapped at Pembridge ¯ Promat to add to product label/re label upon

delivery (1) Lamination date where applicable

Batch No ProduclJon date (1)

Use of the BBA symbol:

BBA logo is not currently in use for the labelling.

Training:

Training procedures are described in QM 6 Resource Management and IHSEPM Latest issues.

Complaints: Complaints procedures are described in WP20 Customer Complaints Procedure latest issue.


Job number:

BBA00011241 0006 BBA00011241/6

Quality policy: We undertake to have the product produced and placed on the market as described above. We will advise the BBA of any changes and receive agreement from the BBA before the changes are implemented.

Signed ............................................... QC Manager UK & Ireland

Title ................................................

05.09.2017 Dated ..............................................

End of Quality Plan

For BBA internal use only

BBA Cert(s): 09/4646 Approved by: Date:

Qualit~ Plan (18-06-42) Iss8 Product:

of 8 Job number:

BBA00011241 0007 BBA00011241/7

Appendix - Document Revisions

Revision No Reason for re-issue Date


BBA00011241 0008 BBA00011241/8

Assessment of Production

Documents

Transcript of Assessment of Production