BAUGRUP - Redefining Facades Worldwide AND TEST PLAN (ITP... · Web view1.4.1 ITP’s overview...
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INSPECTION AND TEST PLANTECHNICAL BULLETIN FOR BINA.THERM, CONTRACTORS AND CLIENTS
QUALITY MANAGEMENT SYSTEMPROJECT QUALITY CONTROL
INSPECTION AND TEST PLAN (ITP) for BAUCLAD & BAUTRIM External Prefabricated Cladding and Decoration Systems
This document is detailing a systematic approach to testing the installation of BAUCLAD & BAUTRIMfaçade system and products (including additional materials) such as a visual inspection, dimension inspection, adhesion/bonding inspection, function test, factory acceptance test and participation of all parties.
The target of the document is to guarantee the product quality and ensure the product function achieved the designed requirements.
Special edition of preliminary PQP for the Customer/General contractor.
Rev
Date
Comments
Prepared by
Reviewed by
Approved by
00
Initial issue
Contractor
Contractor
General Contractor
Customer
Contents:
1. Construction Site Details
1.1 Purpose and scope
1.2 Document Glossary
1.3 Roles and Responsibilities
1.4 Inspection and Test Plan Input Data
1.4.1. ITP’s overview
1.4.2. Work methodology
1.4.3. Characteristics of product quality/correct installation details against acceptance criteria
1.4.4. Stage / frequency
1.4.5. Records
1.4.6. Specification / standard
1.4.7. Acceptance criteria
1.4.8. Inspection / test procedures
1.4.9. Hold / Witness points
1.4.10. Checklists
2. Personnel / Workers training
3. Identification and traceability
4. Amendments to the ITP and additional information
Document appendixes:
· Appendix 1: Inspection and Test Plans
· Appendix 2: Checklists
· Appendix 3: Storage and protection checklist:
· Appendix 4: Incoming inspection checklist:
· Appendix 5: Pre-handover activities
1. Construction Site Details:
Client: _________________________________________________________
General Contractor: _____________________________________________
Project name and site address: ________________________ __________
Site manager: __________________________________________________
Emergency numbers: ___________________________________________
1.1Purpose and scope
The purpose of the present document “Inspection and Test Plan” is to put together a single document that records all inspection and testing requirements relevant to installation of the BAUGRUP Decorative Thermal Insulating Wall Systems. Inspection and Test Plan identifies the components of the system and work activities to be inspected or tested, by whom and at what stage or frequency, as well as Hold and Witness Points, references to relevant standards, acceptance criteria and the records to be maintained. The attached in the Annexes Inspection and Test Plans, being properly implemented, help ensure that, and verify whether, work has been undertaken to the required standard and requirements, and that records are kept.
1.2Document Glossary
Hold Point -A ‘hold’ point defines a point beyond which work may not proceed without the authorisation of a designated service provider, the General Contractor’s or Customer’s representative/authorised person or a regulatory authority representative,.
Witness Point -A ‘witness’ point provides a party such as the Contractor’s service provider, customer, general contractor, and a regulatory authority with the opportunity to witness the inspection or test or aspect of the work, at their discretion.
Surveillance -Intermittent monitoring of any stage of the work in progress (whether by the Contractor, by General Contractor’s representative or customer).
Self-inspection-Where the service provider performing the work verifies the quality progressively - often with the aid of checklists.
Work area -A discrete section of the whole contracted works on the construction project, defined specifically by location in a map as an annex to the Main Agreement, where any installation works would be completed before it moves onto another area. Also delimited areas will be referred to in the Agreement as lots.
1.3Roles and Responsibilities
Contractor
The foreman of Contractor will document and maintain the Inspection and Test Plans and thus will be the ITP Inspector.
The Inspector (the Contractor foreman) is technically instructed and has a good technical and practical knowledge of, and experience in, the activities involved to install the BAUGRUP Facade System. The use, understanding and acceptance of ITPs by the foreman and other personnel is greatly enhanced since he was involved in the document preparation.
The Contractor is responsible for ensuring that all the required Inspection and Test Plans are prepared, including those covering work or processes to be carried out by its service providers. While it is preferable that its service providers prepare the ITPs for their own work, in the final analysis some may require the service provider’s involvement.
The senior responsibles of the Contractor will be made responsible for approving Inspection and Test Plans, and any subsequent amendments, prior to their submission or submission of compliance/conformity certification to the customer.
The General Contractor
The General Contractor must appoint and ensure a person who will be available anytime the review or consent from the Contractor Inspector will be requested or intrepelated. The Inspector must sign in due time the necessary documents and agree upon/report the modifications/altertion of the system according to real site situations.
The Client
The Client may also appoint and ensure a person who to review or consent the ITP’s Checklists from the Contractor’s Inspector
1.4Inspection and Test Plan input data
1.4.1ITP’s overview
Because 100% inspection and testing in most cases is neither practical nor desirable, the ITP’s indicate the activities/products to be inspected and tested, as separate activities, and carry out preliminary tests to assist in obtaining an early indication of conformity
The following points describe what needs and control points have been included and considered for each component of the Inspection and Test Plans. They explain the components, possible fails and defects, and the relevant checkpoints have been selected for verification.
The “what to test”, “how to test” and “when to test” is governed by:
· What the work is and how complex it is
· Accessibility for inspections and sampling
· Consequences of failure, including as follows:
· Cost of remedial work
· Effect on construction program
· Accessibility for rectification
· Disruption to use of building or structure
· Consequential damage to other elements
· Threat to safety of workers and public
· Availability of resources
The type, timing and frequency (the what, when and how often) of inspections and tests are best determined in conjunction with the consideration of the characteristics to be verified.
1.4.2Work methodology
General sequence of work and method of erection of the BAUCLAD Wall system:
• Each bundle will be delivered in conforming transport package and lifted to the necessary elevation and stored accordingly to ensure safety.
• The claddings and corniches will be fixed to the walls in sequence and placed in accordance with working drawings.
• The corniches will be mechanically anchored and the claddings will be doweled.
• The proper joinery will be ensured before progress to next element.
• The Quality inspector will verify the quality of the installation, the strength of the joinery, the mechanical fixing order and sequence.
1.4.3Characteristics of product quality / Correct installation details against acceptance criteria
The characteristics of a work item can be defined as “a distinguishable property of an item, material or process”. Examples of characteristics are colour, texture, size, strength, flatness, alignment, capacity and the like.
The characteristics to be verified will be tested regarding the Correct Installation Manner, Conforming product Characteristics and Classification of BAUCLAD & BAUTRIM system defects. This will determine the stage at which the inspection or test must take place if the potential for subsequent nonconformities is to be avoided.
Some characteristics can only be considered after one particular operation and before another, but prior to application of final touch-up works, priming and painting.
Correct Installation Manner:
Substrate requirements
Substrate must be levelled (not to have protruding parts like reinforced concrete over the plane of the wall surface), must be rendered (covered with rough external plastering) and dusted off and clean of debris.
Adhesion of BAUCLAD system
BAUCLAD prefabricated wall decorative claddings
Full surface adhesion with flex cement
Perimeter and beads: adhesion with flex cement
Adhesion with polyurethane foam
BAUTRIM prefabricated decoration corniches
Full surface adhesion with flex cement
Adhesion with Polyurethane foam
Jointing of BAUCLAD system
BAUCLAD prefabricated wall decorative claddings
Connection to Fire transom and construction
BAUTRIM prefabricated decoration corniches – Flexible / Movement joint
Mechanical fixing of BAUCLAD
Mechanical Fixing of BAUTRIM Decoration Profiles
Installation of Window Decoration
Construction of a Flexible Joint
A flexible joint is used in the application of the Big Decoration Profiles (Corniches).
This joint is also used at the formation of movement joints in the wall surface, where necessary and indicated by General Contractor, as per Project Specified lines.
Note: Due to big size and considerable weught of corniches it is strongly recommended to form the joint between corniches by the method of a movement joint. The joint may be placed at each connection of the corniches (once in 2 meters) or after each 2 corniches (once in 4 meters).
The Hourglass proportion A to A/2 must be always respected.
Conforming Product Characteristics:
BAUCLAD prefabricated wall decorative claddings:
Plain, respected planarity (+/- 2% tolerance acceped), uniformly covered with BAUCOAT Acrylic Coating.
According to producer’s Technical documentation.
BAUTRIM prefabricated decoration corniches
Plain, respected planarity (+/- 2% tolerance acceped), uniformly covered with BAUCOAT Acrylic Coating.
According to producer’s Technical documentation.
Installation materials: Flex cement based adhesive – according to producer’s Technical DatasheetPolyurethane Foam – according to producer’s Technical DatasheetModified Silane Polymer – according to producer’s Technical Datasheet
Accessories for installation:
Helix Dowels – according to producer’s Technical Datasheet
Prepainted Rebars – according to producer’s Technical Datasheet
Tools used for installation:
Hammer drill, Hand saw, Circular cutting machine, Hammer – according to producer’s documents.
Classification of general wall system defects:
Defects in the direct adhered wall system BAUCLAD & BAUTRIM can be generally classified as:
Aesthetic defects:
· Lost vertical/horizontal level during installation
· Lost planarity
· Staining
· Efflorescence
Note: The BAUCLAD & BAUTRIM wall system components allow to correct minor surface irregularities. However the products are dependent on substrate quality, evenness, leveling and rigidity. Before determining whether the aesthetic defects come from improper installation, or product/component defects, the surface and integrity of the substrate must be evaluated.
Functional defects:
· Cracking
· Delamination and bond failure
· Movement joint failure
The location of the defect is also critical in evaluation and recommendation of corrective action. Note: The BAUCLAD & BAUTRIM wall system components bear thermal differences, humidity differences and some mechanical movement of the substrate. However the products are dependent on substrate quality, and rigidity. Before determining whether the functional defects come from improper installation, or product/component defects, the strength and integrity of the substrate must be evaluated and other factors that might have affected the BAUCLAD & BAUTRIM system must be considered.
The BAUCLAD & BAUTRIM system generally consists of five distinct layers:
Location of defects:
· Substrate and back-up wall construction layer (offered by General Contractor)
· Rendering / rough external wall plastering (offered by General Contractor or can be agreed for subcontracting with BAUCLAD & BAUTRIM on the necessary surfaces under specifically determined areas)
· Adhesive layer
· Outer cladding/decoration prefabricated material layer
· Joint forming materials and touch-up mortar
· Final paint treatment (including primer)
1.4.4Stage/frequency
The inspection/test stage/frequency will be determined by each installation lot, according to the requirements of the contract documents or by the type of inspection and/or test and the characteristics under consideration, as outlined in the ITP and ITP Checklists.
Generally, the stage of verification is a predefined assembled lot (portion of façade) assigned and specified exactly as lot in the Contract drawings.
The Frequency of testing is once for each installed lot.
Thereafter, frequencies may be increased and processes reviewed for ‘problem’ work activities and decreased where consistent conformity was evidenced.
1.4.5Records
Records provide the documented evidence necessary to verify that the BAUCLAD & BAUTRIMproduct/service is used in accordance with the contract requirements.
The records will be in various forms, but mainly ITP checklists. Additionaly where necessary the General Contractor or Client may request test certificates, certificates of compliance/conformity, written approvals.
1.4.6Specification/standard
The standards against which conformity is measured against the contract technical specification.
Other standards may include:
· Contract documents/specification generally
· Contract drawings / Project design
· Approved workshop drawings and/or calculations
· Approved technical details/procedures
· Approved samples
· Approved Mock-up
· Manufacturers’ recommendations, Assembly Instructions and Technical Data Sheets
· Regulatory requirements
· International Standards
1.4.7Acceptance criteria
Respecting the manufacturer’s Manufacturers’ recommendations, Assembly Instructions and Technical Data Sheets is the main acceptance criteria which is taken as a benchmark for evaluating the application quality and conformity.
Acceptance criteria can be defined additionally in the contract documents (either directly or by reference to international/local standards), but these criterias must mot come in contradiction with the Manufacturers’ recommendations, Assembly Instructions and Technical Data Sheets. Thus in these cases the acceptance criteria with the customer (where they are not specified or clear) must be specified in the main Agreement to agree the yardsticks (such as test panels/sections or previous work) against which a product/service is to be declared conforming or nonconforming.
1.6.8Inspection/test procedures
For many inspections/tests, the methods employed will be specified or self evident and determined by the characteristics being examined.
A typical test procedure using statistical techniques might, for example, cover:
· reference to work areas/lots or batches
· frequency of sampling
· method of taking samples
· method of conducting a test (including conditions)
· qualifications of test personnel and equipment calibration/condition/specification
· method of documenting results
In some cases it may be possible to satisfy the requirements simply by referencing the requirements of Australian Standards and the like.
1.4.9Hold and Witness Points
The Contractor identifies the Hold and Witness Points with the people responsible for the inspection /test /endorsement and other requirements that are required for its service providers and employees doing the work. Contractor will do this to the extent that is necessary to be confident that the work is being carried out to the standards required.
The General Contractor and Customer retain the option to inspect the work at any stage and may identify Hold and Witness Points requiring the customer’s attendance.
The word “Surveillance” will be indicated in the ITP against all selected inspection or test points that are not otherwise covered by Hold or Witness Points.
1.4.10Checklists
Checklists will be completed with each inspection and test - where they will, in effect, summarise the procedures that have, and should have, taken place up to the particular point in the work process. They will be used to confirm all the matters have been attended to. They will also remind to the Inspector and participating parties of all the matters that should be checked.
The checklists will refer exactly to the installed lot (predefined facad area).
The fact that checklists exist, are used and are stored and content have been verified, will give the General Contractor and Customer confidence that the person doing the work at the Contractor’s Company is aware of all the important steps, attributes and matters to be addressed, and the standards that should be complied with, and that conformity is being verified.
2. Personnel / workers training
The Inspector – Is the Contractor’s foreman instructed as a QA/QC Engineer. The Inspector is trained to maintain and register of all Inspection and Test Plan (ITP) including Checklists. The Inspector will be responsible and the appointed person to be in control of quality control of the installation works. The person will be appointed in the main Agreement documents. The Contractor’s senior of the Inspector shall maintain, keep and archive the approved Inspection and Test Plans, Checklists and related papers.
Other site operations / 3rd parties: The responsibles from the General Contractor and Client will be introduced into the application of the System and system components, including tolerances and acceptability of installed product for a correct evaluation/inspection/evaluating test results of the BAUCLAD & BAUTRIMproducts / wall system.
Installers: The installers of the BAUCLAD & BAUTRIMWall Systems are instructed for the correct application and verification of installation conformity during installation. The installers are offered the contract drawings, installation patterns and drawings, assembly instructions and are introduced in the contents of the ITP, verification of Control points and Critical Control Points and the ITP’s Checklists.
Helpers: Helpers are instructed into main helping operations, labor safety and correct handling of materials. Inspection and testing plans hereinbelow do not include them as relevant parties to participate in evaluation and verification processes.
3. Identification and traceability
The Inspector – Is the Contractor’s foreman instructed as a QA/QC Engineer. The Inspector is trained to maintain and register of all Inspection and Test Plan (ITP) including Checklists. The Inspector will be responsible and
4. Amendments to the ITP and additional information
Amendments to the IPT: Should any part of this ITP require amendment or alteration, this will be notified for agreement by all relevant parties prior to it being enforced.
Communicate ITP: Communicated to all relevant parties and signed by all personnel.
End of document.
Proceed to document appendixes.
Document appendixes
Appendix 1
Inspection and Test Plans:
Use the following forms for inspecting and testing the products and systems of BAUCLAD & BAUTRIMWall Systems.
Customer:
Contract Number:
Contract/Project Name:
INSPECTION AND TEST PLAN for: BAUCLAD & BAUTRIMCladding and Decoration
Work area: (Insert work area)
Contractor’s logo
Ref
Operation or stage of work
Stage/ frequency
Records
Requirement/ standard/ specification
Acceptance criteria
Inspection/ test procedure
Inspection
Description
Characteristics
Employee
Contractor
G.C./ Client
1
Proceeding to assembly (requires General Contractor’s Permit)
Approvals required obtained
Each work area
Checklist
Contractor’s written permit
Permit
-
H
H
H
2
Order of BAUCLAD & BAUTRIMprefabricated materials
To specification
Each delivery
Copy of order
Specification, as attached
Reflects spec./ safe, secure
Review
H
H
S
3
Preliminary to installation inspection:
Substrate evaluation for installation of claddings and decorations
Substrate quality
Each work area
Checklist
General requirements to rendered walls
Substrate is even, level and rendered/ plastered.
The wall blocks are holding strong
Right levels & dimensions/ clean/ safe
Visual
H
H
S
4
Mixing of adhesive
Workability of flex glue mix
Each work area
Checklist
Producer’s instructions
Evenly mixed and viscous
Measure
H
W
S
5
Cladding and Decoration application
Adhesion and level
Each work area
Checklist
BAUCLAD & BAUTRIMinstruction for application
At least 50% adhesion of each element
Visual
H
W
S
6
Adhesion & glue curing
To specification
Each work area
Checklist
Producer’s instructions
Finish/ curing/ maintained
Visual
X
W
S
7
Joint formation
To specification
Each work area
Checklist
BAUCLAD & BAUTRIMinstruction for application
Shop Drawing
Presented joint formation type
Correct placement and construction
Visual
X
W
S
8
Touch-up Works
To specification
Each work area
Checklist
Specification, as attached
Correct placement
Visual
X
W
S
9
Priming and painting
Ready to paint, clean and smooth
Each work area
Checklist
Specification, as attached
Correct placement
Visual
X
W
S
10
Pre-handover activities
All matters finalised, clean and tidy
Each work area
Checklist
Specification, as attached
Completed to spec./ clean and tidy
Final visual inspection
H
H
H
*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring; X = Self inspection by performer of work.
Appendix 2
ITP Checklists:
Use the following checklists for tracking verified parameters of the inspection and testing procedures of the products and systems of BAUCLAD & BAUTRIM.
The following typical checklist for Inspection and Test Plans has been designed to assist interested parties in assessing Contractor’s ITPs. The customer may specify other items that would be addressed in the service providers’ ITPs to support the control of risks, but the items must be agreed before usage and introduced into reviewed redaction of document. The Clause references are to those in the current ISO 9001 Quality management systems – Requirements.
Key to symbols to be used in check-boxes is: ( = Yes ( = No O / - = Not applicable
INSPECTION AND TEST PLAN CHECKLIST for:
BAUCLAD & BAUTRIM FAÇADE THERMAL INSULATION, DECORATION AND FINISHING WORKS
(To be completed by Contractor’s Inspector)
Contract Number:
Contract/Project Name:
Contractor:
Subcontractor:
Work area:
Checklist Number:
Work
Items/activities to be verified
Reference
Initialled
/ OK
Comments / Explanations / References
Proceeding to assembly
Access permission obtained
Access obtained
Equipment approved/on site -
Scaffold/ladders
Signage/barricades
Application Instruments
Materials approved/on site -
BAUCLAD & BAUTRIM prefabricated claddings/decoration
Paints/ glues/ caulks
Extra:
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Order of BAUCLAD & BAUTRIM prefabricated materials
BAUCLAD & BAUTRIM Claddings
BAUCLAD & BAUTRIM main Corniche profiles (parts)
BAUCLAD & BAUTRIM Window decoration plate
BAUCLAD & BAUTRIM Window decoration profile
Application materials
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Preliminary to installation inspection:
Substrate evaluation for installation of claddings and decorations
Notification of power disruption
Protective measures
Isolate appropriate circuits
Verify smoothness and planarity of substrate
Verify lack of uneven / protruding surface parts
Free of oil/grease
Free of dirt and loose particles
Washed down
Repaired spots cured
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Mixing of adhesive
Humidity/temperature appropriate
Protective measures
Adhesive validity (check expiry date)
Water mixing ratio respected
1 part water to 5-6 parts of glue
Water impurities missing
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Cladding and Decoration application
Check product integrity – generally top coat free of imperfections such as runs, patchiness, pinholes, misses etc.
Delivered product conforms for installation area
The BAUCLAD & BAUTRIM application Instructions are respected
The project design and elevation placing are respected when assembling
Different work areas combine evenly between them into forming a full visual assembly
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Adhesion & glue curing
Humidity/temperature appropriate
Adhesive correctly prepared and suitable for use (open time – 30 mins)
Adhesive applied on the back side of claddings and decorations according to application patterns
Glue strength and adhesion to substrate are verified on 2 areas of the work area
Specify test result: ___________________(Breaking – EPS Layer – good adhesion. Breaking in Glue, or render layer – bad adhesion)
Drying time of the main adhesive (24 hours) is respected
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Joint formation
Humidity/temperature appropriate
Protective measures
Special adhesive Thixocoll applied in rigid joints
MS-Polymer adhesive is correctly applied in flexible/movement joints
Drying time between joints (24 hours) of each component is respected
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Touch-up Works
Humidity/temperature appropriate
Touch-Upo mortar repaired accordingly
Each coat free of imperfections such as runs, patchiness, pinholes, misses etc.
Drying time of touch-up appropriate (24h)
Surface sandpapered to level
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Priming and painting
Humidity/temperature appropriate
Protective measures
Paint applied to manufacturer’s instructions
Each coat free of imperfections such as runs, patchiness, pinholes, misses etc.
Drying time between coats appropriate
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Pre-handover activities
Replace fixtures
Touch up
Remove protective measures
Final inspection confirms conforming
Clean up working area
CONTRACTOR’s INSPECTOR
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
GENERAL CONTRACTOR APPOINTED REPRESENTATIVE
I have carried out all necessary inspections and verify that the above work for this work area has been completed and conforms to the contract specification/documents
Name:
Signature:
Date:
Appendix 3:
Storage and protection checklist:
INSPECTION AND TEST PLAN CHECKLIST for: STORAGE AND PROTECTION
(To be completed by the person(s) directly responsible for the work)
Contract Number:
Contract/Project Name:
Contractor:
Subcontractor:
Work area:
Checklist Number:
Materials/ components/ equipment
Location of storage
Date
Initials
Comments
Pass
Fail
Appendix 4:
Incoming inspection checklist:
INSPECTION AND TEST PLAN CHECKLIST for: INCOMING INSPECTION
(To be completed by the person(s) directly responsible for the work)
Contract Number:
Contract/Project Name:
Contractor:
Subcontractor:
Work area:
Checklist Number:
Materials/ components/ equipment
Purchase Order No.
Delivery Docket No.
Quantity/size verified
Inspected for
Date
Initial
Against PO
Against DD
Damage
Technical details
Marketing
Appendix 5:
Pre-handover activities:
Use the following forms for pre-handover verification activities.
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
Pre-handover activities
Appearance / Finish
Levels/ dimensions / Installation
Equipment cleaned and site clean
Test results for concrete cylinders
Inspected areas / Sectors
I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents
Name:
Signature:
Date:
I have carried out all necessary inspections and verify that the above work for this work area has been completed and conforms to the contract specification/documents
Name:
Signature:
Date:
CONTRACTOR LOGO