E513 CE Book Cover 20/10/08 15:15 Page 1Guide to the CE Markingof Structural SteelworkBCSA Publication No. 46/08BCSA Publication No. 46/08

E513 CE Marking Book 20/10/08 15:21 Page 1Guide to theCE Marking ofStructural SteelworkE513 CE Marking Book 20/10/08 15:21 Page 2Apart from any fair dealing for the purposes of research or private study or criticism or review, aspermitted under the Copyright Design and Patents Act 1988, this publication may not bereproduced, stored, or transmitted, in any form or by any means, without the prior permission ofthe publishers, or in the case of reprographic reproduction only in accordance with terms of thelicences issued by the UK Copyright Licensing Agency, or in accordance with the terms of licencesissued by the appropriate Reproduction Rights Organisation outside the UK.Enquiries concerning reproduction outside the terms stated here should be sent to the publishers,The British Constructional Steelwork Association Ltd. at the address given below.Although care has been to ensure, to the best of our knowledge, that all data and informationcontained herein are accurate to the extent that they relate to either matters of fact or acceptedpractice or matters of opinion at the time of publication, The British Constructional SteelworkAssociation Limited, the authors and the reviewers assume no responsibility for any errors in ormisinterpretations of such data and/or information or any loss or damage arising from or relatedto their use.Publications supplied to members of BCSA at a discount are not for resale by them.The British Constructional Steelwork Association Ltd.4, Whitehall CourtWestminsterLondonSW1A 2ESTel: +44(0)20 7839 8566Fax: +44(0)20 7976 1634E-mail: postroom@steelconstruction.orgWebsite: www.steelconstruction.orgBCSA Publication No. 46/08ISBN 10 1-85073-562-XISBN 13 978-1-85073-562-5British Library Cataloguing-in-Publication DataA catalogue record for this book is available from the British Library.The British Constructional Steelwork Association LtdPrinted by: Box of Tricks Advertising and Design Limited2

E513 CE Marking Book 20/10/08 15:21 Page 3Guide to the CE Marking of Structural SteelworkTHE BRITISH CONSTRUCTIONALSTEELWORK ASSOCIATION LIMITEDThe British Constructional Steelwork Association Limited (BCSA) is the nationalorganisation for the steel construction industry: its Member companies undertakethe design, fabrication and erection of steelwork for all forms of construction inbuildings and civil engineering. Associate Members are those principal companiesinvolved in the supply to all or some Members of components, materials or products.Corporate Members are clients, professional offices, and educationalestablishments etc., which support the development of national specifications,quality, fabrication and erection techniques, overall industry efficiency and goodpractice.The principal objectives of the Association are to promote the use of structuralsteelwork; to assist specifiers and clients; to ensure that the capabilities andactivities of the industry are widely understood and to provide members withprofessional services in technical, commercial, contractual and quality assurancematters. The Association's aim is to influence the trading environment in whichmember companies have to operate in order to improve their profitability.A current list of members and a list of current publications and further membershipdetails can be obtained from:The British Constructional Steelwork Association Ltd.4, Whitehall CourtWestminsterLondonSW1A 2ESTel: +44(0)20 7839 8566Fax: +44(0)20 7976 1634E-mail: postroom@steelconstruction.orgWebsite: www.steelconstruction.org3E513 CE Marking Book 20/10/08 15:21 Page 4SUMMARYThis document gives guidance on the CE Marking of structural steelwork. It applies to structuralsteel components that are manufactured as welded or non-welded fabrications. The componentsmay be CE Marked individually or collectively as a kit.The general guidance applies to structural steel components to be used in building construction.It can also be applied, with some modification, to components to be used in other constructionapplications including bridges.This publication has been reviewed by Stephen Rein MCIOB, MInstCES, who was a consultant toCEN for five years and is co-author of The Construction Products Directive: A practical guide toimplementation and CE marking.4E513 CE Marking Book 20/10/08 15:21 Page 5Guide to the CE Marking of Structural SteelworkCONTENTSPAGE1 INTRODUCTION AND SCOPE 71.1 Objective71.2 Scope71.3 Overview72 CE MARKING REGULATIONS 92.1 Construction Products Directive 92.2 Harmonised standards92.3 Certification102.4 CE Marking112.5 Construction Products Regulations 112.6 Future developments123 CE MARKING STANDARD FOR STRUCTURAL STEELWORK 133.1 Basis133.2 Scope133.3 Definitions133.4 Requirements203.5 Evaluation methods213.6 Evaluation of conformity213.7 Marking system264 EUROPEAN FABRICATION STANDARD 294.1 Status and scope294.2 Documentation304.3 Constituent products304.4 Tolerances304.5 Welding314.6 Surface treatment325 WELDING QUALITY MANAGEMENT 335.1 Welding as a 'special process' 335.2 Control of welding335.3 Technical instructions345.4 Competence of personnel345.5 Implementation346 RESPONSIBLE WELDING COORDINATORS 356.1 Welding coordination356.2 Tasks for welding coordinators 357 TRACEABILITY377.1 Introduction377.2 Government Circular377.3 Inspection documents387.4 Requirements387.5 Batch or type traceability397.6 Welding395E513 CE Marking Book 20/10/08 15:21 Page 68 SUPPLY CHAIN IMPLICATIONS 408.1 Introduction408.2 Manufacturers408.3 Importers408.4 Distributors408.5 Stockholders418.6 Steel processors418.7 Special products and processes 418.8 Transition period429 EXECUTION CLASS439.1 General439.2 Application to buildings439.3 Wider application4310 FACTORY PRODUCTION CONTROL 4410.1 Introduction4410.2 FPC systems4410.3 System requirements4511 ROUTES TO CERTIFICATION 4811.1 Introduction4811.2 Assessment of the WQMS4811.3 Assessment of the RWC4911.4 Surveillance audits5011.5 Steel Construction Certification Scheme 5112 IMPLICATIONS FOR DESIGNERS,SPECIFIERS AND CONSTRUCTION MANAGERS 5312.1 Introduction5312.2 Designers and specifiers5312.3 Construction managers54APPENDICESA ASSESSMENT OF THE RWC 56B ISSUES ASSOCIATED WITH BRIDGES 57C DOCUMENTARY EXAMPLES 60D SG17 GUIDANCE ON FPC ASSESSMENT 64E ABBREVIATIONS70REFERENCES716E513 CE Marking Book 20/10/08 15:21 Page 7Guide to the CE Marking of Structural Steelwork1 INTRODUCTION AND SCOPE1.1 ObjectiveThe objective of this document is to provide practical guidance on the CE Marking of structuralsteelwork in accordance with the Construction Products Directive (CPD) and the UK'sConstruction Products Regulations (CPR). The guidance is for steelwork contractors, theirpurchasing clients and supply chain including designers, specifiers and construction managers.1.2 ScopeThe guidance in this document applies to the CE Marking of structural components that aremanufactured from carbon steel as welded or non-welded fabrications. The componentsmay be CE Marked individually or collectively as a kit.This document applies to components intended for installation in construction works to bebuilt in the United Kingdom (UK), and applies as appropriate to the Republic of Ireland (RoI).It is addressed principally to components used in structural steelwork for buildingconstruction works undertaken to the BCSA'sNational Structural Steelwork Specification forBuilding Construction (CE Marking Edition). It can also be applied, with some modification,to components to be used in other construction applications including bridges, or tostructural components manufactured from stainless steel or steel castings.As explained in this document, CE Marking is applicable to the manufacture of structuralsteel components, that is to the operations undertaken by steelwork contractors in thefabrication of structural steelwork rather than the erection of structural steel frames on site.1.3 OverviewWith respect to the European Construction Products Directive, CE Marking applies tomanufactured structural components placed on the market individually or as a kit ofcomponents and intended for use in any form of construction works (except marine andoffshore). The basis of the regulatory regimes applicable in the UK and the Republic ofIreland is explained in section 2.Components manufactured from structural steel may be CE Marked once they demonstratecompliance with the relevant harmonised European Standard using the appropriate systemof attestation. The European Standard relevant to structural steel components is EN 1090-1 and this document assumes that the British Standard BS EN 1090-1 will be available bythe end of 2008 from which date CE Marking of structural steel components is possible. ENdocuments are designated with I.S. EN when issued in the RoI with otherwise identical textto BS EN versions.BS EN 1090-1Execution of steel structures and aluminium structures - Part 1:Requirements for conformity assessment of structural componentsdefines themanufacturing controls needed to ensure that structural steel components meet thenecessary technical requirements that are defined in BS EN 1090-2Execution of steelstructures and aluminium structures - Part 2: Technical requirements for steel structures.The contents of these standards are explained in sections 3 and 4.Special provisions apply if welding is used in steel component manufacture, and these areexplained in sections 5 and 6 and Appendix A.The fabrication of structural steelwork is an assembly process that uses constituentproducts (i.e. steel sections, fasteners and welding consumables). Some of these products,7E513 CE Marking Book 20/10/08 15:21 Page 8SECTION 1 : INTRODUCTION AND SCOPEsuch as curved beams, may be part-processed but not ready for incorporation into theconstruction works until after further fabrication. Sections 7 and 8 explain how CE Markingapplies to these supply chain products and the requirements applicable to the fabricationprocess necessary to ensure sufficient traceability.BS EN 1090-2 introduces the concept of Execution Class that enables specifiers to selectthe level of manufacturing quality management appropriate to how safety critical thecomponent will be in the construction works. This is explained in section 9.As structural steel components are safety critical, CE Marking to BS EN 1090-1 requiresthat the component manufacturer's factory production control (FPC) system isindependently assessed and certified by a body notified to the European Commission bythe appropriate national agency (DCLG in the UK). A manufacturer may employ anysuitable notified body (NB) from any member state to undertake initial inspection andcontinuous surveillance of its FPC. Sections 10 and 11 explain this and what manufacturersneed to do. Further guidance issued by the European Group of Notified Bodies is includedin Appendix D.Section 12 explains that, whilst CE Marking of structural steel components is relevantprimarily to manufacturers, it also has implications for designers - whether as specifiers ofthe construction works requirements or as drafters of the manufacturing specification.The general guidance in this document applies to structural steelwork used in buildingconstruction. It can also be applied, with some modification, to components to be used inother construction applications, and the different issues applicable to bridgework areexplained in Appendix B.Appendix C provides example of the documents that support CE Marking.Appendix E lists the abbreviations used in this document.8E513 CE Marking Book 20/10/08 15:21 Page 9Guide to the CE Marking of Structural Steelwork2 CE MARKING REGULATIONS2.1 Construction Products DirectiveThe Construction Products Directive (CPD) came into force in 1988 and introduced the conceptof CE Marking for all construction products permanently incorporated into 'construction works'.This includes steel products such as steel sections, bolts, welding consumables and fabricatedsteel components that are used in buildings, bridges, highways or other civil engineeringprojects. The CPD is a piece of European legislation that is considered as one of the 'NewApproach' Directives, though the CPD differs in certain significant ways from the typical NewApproach Directive. Like all New Approach Directives the CPD was created to remove barriersto trade by providing a common set of 'tools' across Europe to address the different rules onconstruction products in the various member states; specifically the CPD establishes thefollowing framework:A system of harmonised standards (sometimes referred to as hENs);An agreed system for demonstrating the suitability of products;A framework of certification bodies (known as Notified Bodies); andThe ability to CE Mark products.This is explained in summary in the documentCE marking under the Construction ProductsDirective, published by the Department for Communities and Local Government (DCLG) andcurrently available from the DCLG website.A more detailed guide is:The Construction Products Directive - A practical guide toimplementation and CE marking, authored by Adam Pinney and Stephen Rein, two UK expertswho have acted as consultants to CEN and the European Commission in this area. Furtherinformation can be found on http://www.apsrconsultantsltd.com.As the CPD relates to public safety, enforcement is by means of a criminal prosecution againstthe company and its relevant employee. Some enforcement proceedings have beenundertaken by UK regulators over the period since 1988.2.2 Harmonised standardsThe CPD lists six 'essential requirements' that apply to all civil engineering works, these arelisted below:1. Mechanical resistance and stability.2. Safety in case of fire.3. Hygiene, health and the environment.4. Safety in use.5. Protection against noise.6. Energy economy and heat retention.These essential requirements derive from a comparison of what public safety provisions areincluded in the building and construction regulations of the EU's member states. In essence,meeting the provisions should ensure that the products meet the regulatory requirements of allEU member states, including, for instance, the provisions on materials and workmanship inRegulation 7 of the Building Regulations applicable to England and Wales.For steel products and ancillaries only mechanical resistance and stability and safety in case offire apply. The harmonised product standards break down these general requirements intospecific measurable properties termed essential 'performance characteristics' (e.g. yieldstrength, toughness and load bearing capacity) and establishes the values to be met.9E513 CE Marking Book 20/10/08 15:21 Page 10SECTION 2 : CE MARKING REGULATIONSThe harmonised product standards establish common test methods and reporting styles fordeclaring the essential characteristics of a product in the information accompanying CE Marking- for example the required yield strength of nominal S275 steels reducing with thickness. Theyalso define the test methods and the testing frequency if sampling is to be adopted.For steel products the main harmonised product standards are:Steel sections and plates - BS EN 10025-1;Hollow sections - BS EN 10210-1 and BS EN 10219-1;Preloadable bolts - BS EN 14399-1;Non-preloadable bolts - BS EN 15048-1;Fabricated structural steelwork - BS EN 1090-1.Providing the attestation of conformity procedures have been complied with, then CE Markingis possible after the harmonised standards are cited in the Official Journal (OJ) and the date ofapplicability given on the NANDO website has passed.(See http://ec.europe.eu/enterprise/newapproach/nando/index.cfm?fuseaction=cpd.hs).The Commission and much of Europe consider CE Marking is compulsory once the date of theend of the coexistence with national technical specifications has passed: the date is also givenon the NANDO website.For EN 10025-1 the date of applicability was 1st September 2005 and the date for the endof the coexistence period was 1st September 2006 giving a year's transition period formanufacturers to implement CE Marking against the standard. For EN 1090-1 it is expectedthat the standard will be published by CEN around December 2008. The date of applicabilitywill then be published on the NANDO website. This is likely to be around August 2009. It hasbeen agreed that there will be a two year coexistence period which would then end aroundAugust 2011. By then the amended Construction Products Regulations are likely to be inforce and, as explained below, these are likely to make CE Marking mandatory throughoutthe European Union.2.3 CertificationThe CPD gives four different systems (with two additional sub-systems) for attesting that aproduct conforms to the performance characteristics given in the harmonised standard (this iscalled attestation of conformity). The system which applies to a product is published as aCommission Decision in the OJ and is also given in a mandate from the European Commissionto CEN and is chosen on the basis of the nature of the product, its intended end use and therole it plays in the structure. In the case of structural steelwork this is covered in mandate M/120for structural metallic products and ancillaries that also covers rolled steel products, fastenersand welding consumables.Safety critical products like structural steel components and fabricated structural steelworkare at attestation of conformity system 2+. This means that the manufacturer is not allowedto fix the CE Marking without having a suitable factory production control (FPC) system inplace. This is verified by a notified inspection body (NB) after initial inspection and subject tocontinuing surveillance who issues a certificate confirming that the manufacturer's FPC isadequate to give confidence that the manufacturer's processes can produce products thatcomply with the relevant harmonised standard.For a body to be a NB for the purposes of BS EN 1090-1 it must be notified as an FPCinspection body by a member state to the Commission and to other member states. Thisnotification confirms the NB as competent to assess the manufacturer's FPC as capable ofensuring conformity of products to BS EN 1090-1 and that the NB meets the criteria set out10E513 CE Marking Book 20/10/08 15:21 Page 11Guide to the CE Marking of Structural Steelworkin Annex IV of the CPD. This notification is therefore specific to each harmonised standard,and once this is done the NB can undertake the tasks for which it has been notified. The SteelConstruction Certification Scheme is seeking notification and will act as a notified body forthe harmonised standard for structural steel components to BS EN 1090-1. Even before BSIpublishes BS EN 1090-1, as soon as CEN publishes EN 1090-1 it will be available forcertification bodies and steelwork contractors to use to implement and assess FPC systems.NBs can apply for notification concurrently with the final stages of the EN, which can be madeas soon as the EN passes its formal vote and is ratified. The CE Marking of products cannotcommence, however, until the date of applicability given on the NANDO website.2.4 CE MarkingThe CE Marking signifies that the products are in conformity with the relevant harmonisedtechnical specification (e.g. harmonised standard) and that the relevant conformity assessmentprocedures have been complied with: hence the product has the declared performance for theessential characteristics in the information accompanying the CE Marking.CE Marking under the CPD shows purchasing clients, the authorities and others that theproduct complies with the appropriate harmonised European Standard. In the case of steelproducts (such as sections, bolts and fabricated steelwork) the CE Marking is a declaration bythe manufacturer that the product is in conformity with the relevant harmonised standard(s) andmeets any threshold values required by the harmonised standard and has the values declaredin the information accompanying the CE Marking.CE Marking and its accompanying information is a legal declaration by the manufacturer onmatters concerning health and safety about how the product performs in an intended use andits impact is less about changing what the manufacturer has to do, and more about placinggreater onus on the manufacturer to get it right. To that end the manufacturer needs to satisfya notified body about the adequacy of its FPC system to avoid producing non-conformingproduct.2.5 Construction Products RegulationsThe CPD is implemented in the UK by the Construction Products Regulations (CPR) andmanufacturers obey the CPR rather than the CPD directly. The CPR came into force in 1991and describes two ways of complying with the legal provisions - by CE Marking products andby not CE Marking products. Under the regulations CE Marked components are presumedto comply with the harmonised technical specification and have the characteristics declaredwhen meeting building requirements/regulations, whilst other declarations about the productdo not carry this explicit presumption and the manufacturer may need to demonstrate to thebuilding control authorities etc that it does comply with the building regulations/requirements.Under the non-CE Marking route, if asked, the manufacturer must supply to the authority allthe information it has on the product to enable the authority to satisfy itself whether theproduct complies with the building regulations/requirements and hence can be placed on themarket for use in the works. CE Marking is therefore not mandatory in the UK but by optingfor the CE Marking route the legal position is much clearer and BCSA is recommending thatall of its members CE Mark the steel frames and components they fabricate.The authorities responsible for enforcing the CPR are Trading Standards Officers in England,Wales and Scotland, Environmental Officers in Northern Ireland and authorised officers in theRepublic of Ireland. The penalties for not complying with the CPR can be a 5,000 fine, 3months in prison or both.11E513 CE Marking Book 20/10/08 15:21 Page 12SECTION 2 : CE MARKING REGULATIONS2.6 Future developmentsThe European Commission is proposing to replace the CPD by a new Regulation with theaim of further improving the free trade of construction products in the European Union andsimplifying the CE Marking process.Unlike a European Directive, a European Regulation is enforceable as law in all memberstates without the need for national legislation. In many ways a European Regulation isequivalent to an 'Act of Parliament of the European Union'. A consequence of replacing theCPD with a European Regulation is that CE Marking will become mandatory in the UK andthe Republic of Ireland.The proposed regulation places legal obligations on Manufacturers, Importers andDistributors and on those companies in the supply chain who either place a product on themarket under their own trademark or modify a construction product already placed on themarket so as to change its essential characteristics. If the regulation becomes law it will haveimplications for all parts of the structural steelwork supply chain including the fabricationservices provided by steel stockholders and steel benders.The proposal also replaces the six 'essential requirements' with seven 'basic worksrequirements'. These will apply to all construction works. The first six 'basic worksrequirements' are identical to the six 'essential requirements' given on page 9. The seventhreflects the European Community's drive for a more sustainable built environment. The draftwording of this requirement is:7. Sustainable use of Natural ResourcesThe construction works must be designed, built and demolished in such a way that the use ofnatural resources is sustainable and ensure the following:a) Recyclability of the construction works, their material and parts after demolition;b) Durability of the construction works;c) Use of environmentally compatible raw and secondary materials in the constructionworks.The European Commission is keen for the proposed regulation to pass all stages by spring2009, i.e. sufficiently before the European elections in early 2009. This will mean that theRegulation will come into UK and RoI laws in July 2011 with some provisions coming intoforce sooner.12E513 CE Marking Book 20/10/08 15:21 Page 13Guide to the CE Marking of Structural Steelwork3 CE MARKING STANDARD FOR STRUCTURAL STEELWORK3.1 BasisThe basis of CE Marking is that the manufacturer declares that its products meet specifiedperformance characteristics that are defined as essential to the application of the productsin the field of construction. In order to do this the manufacturer needs to:Know the requirements in terms of defined essential performance characteristics andrequired values to be met. For structural steel components theserequirementsaredefined in clause 4 of BS EN 1090-1.Use specified test methods that can evaluate whether products conform to thespecified requirements. For structural steel components theseevaluation methodsare defined in clause 5 of BS EN 1090-1.Implement a system for controlling regular production. For structural steelcomponents the system forevaluation of conformityis defined in clause 6 of BSEN 1090-1.Mark its products in the correct way using a suitable classification and designationsystem. For structural steel components themarking systemis defined in clauses 7and 8 of BS EN 1090-1.These four aspects of BS EN 1090-1Execution of steel structures and aluminium structures- Part 1: Requirements for conformity assessment of structural componentsare explainedin detail below.BS EN 1090-1 is one of a suite of harmonised European Standards dealing with structuralmetallic products and ancillaries. All harmonised standards include anAnnex ZAand theimplications of this are explained in detail below.3.2 ScopeBS EN 1090-1 deals with the manufacture of load bearing components and kits ofcomponents for use in structures. The components can be made of steel that is hot rolled, coldformed or produced with other technologies. They may be produced of sections/profiles withvarious shapes, flat products (plates, sheet, strip), bars, castings, forgings made of steel oraluminium materials, unprotected or protected against corrosion by coating or other surfacetreatment, e.g. anodising of aluminium. The standard does not cover conformity assessmentof components for suspended ceilings, rails or sleepers for use in railway systems.3.3 DefinitionsSome important principles may be drawn from the definitions given in clause 3 ofBS EN 1090-1.3.3.1 Constituent productsThe scope of BS EN 1090-1 acknowledges that the fabrication of structural steelwork is anassembly process that uses constituent products such as steel sections, fasteners andwelding consumables. Importantly, the application of BS EN 1090-1 relies on using theharmonised product standards for these constituent products.For instance, BS EN 10025-1Hot-rolled products of structural steels - Part 1: Generaltechnical delivery conditionsis a harmonised standard and it requires that steel products13E513 CE Marking Book 20/10/08 15:21 Page 14SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKproduced to the standard possess defined levels of strength - e.g. as S275. These strengthvalues then underpin the evaluation of the load bearing capacity of a component producedto BS EN 1090-1.In welding standards such as BS EN 1011Welding - Recommendations for welding ofmetallic materials, constituent products are referred to as parent materials or parent metaland weld metal.3.3.2 Component specificationBS EN 1090-1 applies to both series and non-series production. These terms are explainedby Pinney & Rein in their practical guide. Although fabricated steel components aregenerally bespoke, being one-offs or to a limited number typically of less than 10 identicalitems this may be series or non-series production.Whether a component is made in series or non-series production, specific details arerequired before manufacture can be undertaken. The document giving all necessaryinformation and technical requirements for manufacture is termed thecomponentspecification. For structural steelwork the suite of relevant component specifications wouldcomprise the fabrication drawings defined in theNational Structural Steelwork Specificationfor Building Construction (CE Marking Edition) (NSSS).One principle to be observed in CE Marking is that the manufacturer should be clear and notconfusing in its declarations. The simplest way this can be achieved is to start from a definitivecomponent specification and then to warrant that the component has been made inaccordance with that specification. This procedure differs little from how steelwork contractorshave been used to satisfying their purchasing clients and the national building regulations.3.3.3 KitsA kit is defined as a construction product when it is a set of at least two separate componentsthat need to be put together to be installed permanently in the works. For a "kit" to come withinthe scope of the CPD, the following conditions must be satisfied:The "kit" must be placed on the market, allowing a purchaser to buy it in one transactionfrom a single supplier,The "kit" must have characteristics that allow the works in which it is incorporated tosatisfy the essential requirements, when the works are subject to regulations containingsuch requirements.It is thus possible to consider structural steel components as a kit when they are supplied ascomponents of a whole building project or as defined phases of the whole project. Two CEMarking options are thus open to the steelwork contractor:To apply CE Marking to the individual components as they are delivered from themanufacturing works, using the component specifications issued for manufacture asthe reference;To apply CE Marking to a defined set of components as a kit, using as a reference acollection of component specifications linked to, say, and erection marking plan ordelivery list.For example, a manufacturer making bridges or bridge components of all sizes and shapes, where no twoare ever the same, is still involved with series production. This is because the work is making bridges/bridgecomponents. If the manufacturer were asked to make a steel door and this was not part of normal productionline then that would be non-series production. If the manufacturer did not normally make purlins but thenmade several of a common type as a special order then that would also be non-series production.14E513 CE Marking Book 20/10/08 15:21 Page 15Guide to the CE Marking of Structural SteelworkGenerally the steelwork contractor will also be the manufacturer and hence this distinction isnot generally an issue. However, if the steelwork contractor alters components or a kit suppliedby another manufacturer, or adds to such a kit in any way and then relies upon CE Markingas a demonstration of conformity then the steelwork contractor becomes the manufacturer ofthat kit or those components.3.3.4 Design briefFabricated steel components are generally bespoke because they are made for specificprojects. In the NSSS the termproject specificationis used for the specification prepared fora specific building project. With respect to those parts of the construction works described inthe project specification as structural steelwork, the NSSS anticipates that theengineerwhois responsible for the design of structural members will preparedesign drawingsthat includeall information necessary for the design of connections and completion of the fabricationdrawings. Irrespective of whether the engineer is working directly for theemployeror for thesteelwork contractor, the NSSS assumes that the steelwork contractor will undertake thedetailing of the steelwork and the design and detailing of connections.Thus, it is generally necessary for the steelwork contractor to undertake some design workin preparing the details needed for the component specification. This design work will beundertaken to what BS EN 1090-1 terms adesign briefwhich would in essence comprisethe design drawings and the other appropriate information itemised in Tables 1.1 to 1.7 ofthe NSSS.3.3.5 Structural characteristicsBS EN 1090-1 defines some of the essential performance characteristics as structuralcharacteristics. These are governed in part by the design approach used to evaluate themand refer to:Load bearing capacity;Fatigue strength; andResistance to fire.The essential performance characteristics itemised in BS EN 1090-1 that are not defined asstructural characteristics are:Tolerances on dimensions and shape;Weldability;Fracture toughness;Reaction to fire;Emission of radioactivity; andRelease of cadmium.The extent to which these essential characteristics may depend on the constituent productsused in manufacture can be identified by checking the essential performance characteristicsitemised in the harmonised standard for the constituent product. For instance, BS EN10025-1 includes the following essential characteristics:Tolerances on dimensions and shape;Elongation;Tensile strength;Yield strength;15E513 CE Marking Book 20/10/08 15:21 Page 16SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKImpact strength;Weldability.The tolerances relevant to a constituent product continue to apply to componentsmanufactured from such products, unless BS EN 1090-2 (which is invoked for suchrequirements by BS EN 1090-1) specifies more stringent criteria. Elongation is not directlyspecified as an essential characteristic in BS EN 1090-1, but the evaluation of structuraldesign characteristics will depend on assumptions about elongation. For instance,Eurocode designs apply to steels with minimum elongation of 15%.Steel products to BS EN 10025-1 are designated with a steel grade, e.g.S275, whichsignifies both the permitted range of tensile strength and the minimum yield strength. To theextent that these values are affected by subsequent processes used in manufacture (e.g.welding, hot or cold bending, or thermal cutting used in fabrication), BS EN 1090-2 specifiesrestrictions on how these processes may be used.BS EN 1090-1 defines fracture toughness and impact resistance as the same requirement.BS EN 10025-1 refers to the impact strength of steel products which is assessed using CharpyV-notch (CVN) impact tests, and BS EN 10025-1 defines weldability in terms of chemicalcomposition using the carbon equivalent value (CEV). Both these characteristics may beaffected by subsequent processes used in manufacture of steel components, especially in theheat affected zone (HAZ) of the parent metal during welding. Thus BS EN 1090-2 specifiesparticular requirements for the CEV of steel products that may be welded, as well as theminimum CVN and maximum hardness permitted in the HAZ and the weld metal.3.3.6 Load bearing capacityThe determination of the load bearing capacity of a structural component can be a complexissue as it may involve, for instance, member design for buckling, connection design forbearing, crushing etc. as well as an understanding of the behaviour of welds andmechanical fasteners such as preloadable bolts. Prior to the advent of a harmonisedstandard for structural steel components, steelwork contractors and/or their purchasingclients have been undertaking such design evaluations on all steelwork projects. It is not theintention of the CPD to change this way of working or to place unnecessary impediments inhow such design matters have been undertaken in meeting the existing national regulationsfor building construction etc.Parties undertaking design in support of developing the component specification should notexpect to alter their ways of working. The only supplementary change is that themanufacturer undertaking (some of the) design work has the option of including a warrantyon that element of the design when declaring that the component meets the componentspecification (see the optional methods for preparing the component specification explainedbelow).The simplest way of looking at the issues associated with load bearing capacity is that thecomponent derives its capacity from that of its constituent products and the way those areassembled. Typically the shape and yield or tensile strength of, say, a steel beamdetermines its load bearing capacity - and values for safe loads are given in membercapacity tables. What the manufacturer is charged with is that the processes used infabrication do not impair the properties of the plain member.BS EN 1090-1 requires the manufacturer to address how structural characteristics aredependent on the manufacturing characteristics of the product. Most importantly for loadbearing capacity in quasi-static building construction, this depends on the yield strength ofthe constituent products, and, as noted above, this can be affected by subsequent16E513 CE Marking Book 20/10/08 15:21 Page 17Guide to the CE Marking of Structural Steelworkprocesses used in manufacture such as welding. Hence, the manufacturer needs toobserve the provisions of BS EN 1090-2 with respect to welding and to have a suitablewelding quality management system (WQMS) in place. This enables the manufacturer to beconfident that any impairment of the yield strength of, say, parent materials in the HAZ iswithin defined limits as evidenced by the limits on hardness etc. measured during the testingin support of the Welding procedure qualification record (WPQR).Then, in effect, the manufacturer may declare the equivalent of load bearing capacity bywarranting that the component has been made in accordance with its componentspecification (i.e. fabrication drawing) on which appears the grade, shape, configuration etc.of the constituent products from which load bearing capacity can be evaluated bycalculation to, say, the Eurocodes.3.3.7 Evaluation methodsIn most harmonised standards, essential characteristics are evaluated by physical testing toa supporting European Standard. For instance the test method specified in BS EN 10025-1for evaluating impact strength is BS EN 10045-1Charpy impact test on metallic materials -Part 1: Test method (V-and U-notches). Physical testing is applicable to products of astandard or standardised type but is not easily applied to bespoke products. Whilst the safeload bearing capacity of a lifting beam might be established by a physical test, such non-destructive proof load testing of bespoke structural components is impractical; and it may beimpossible to establish fatigue strength or resistance to fire by other than destructive testing.Hence, BS EN 1090-1 allows measurement of geometry and/or structural calculations to beused as evaluation methods, as well as structural testing supported by calculations.3.3.8 Preparation of the component specificationBS EN 1090-1 includes an informative Annex A that provides guidelines for preparation ofthe component specification. The annex distinguishes the following typical cases:Manufacturer provided component specification (MPCS).This case is typical ofsteelwork contracting in general whereby the detailing and connection design areundertaken by the steelwork contractor. In this case BS EN 1090-1 allows two options:Option 1:The manufacturer only declares the geometry and the material properties of thecomponent. The manufacturer attaches the component specification to thecomponent and provides a CE Marking that warrants that the as-manufacturedcomponent complies with its component specification. The manufacturer providesno warranty with respect to the design work that it has undertaken to develop theMPCS from the design brief.BS EN 1090-1 relates this option to Method 1 in Guidance Paper 'L' Application anduse of Eurocodes. If this is the option that the manufacturer always uses then thislimitation should be clear on the scope statement on the manufacturer's declarationof conformity.Option 2:In this case, the manufacturer declares not only the geometry and the materialproperties of the component but also the structural characteristics (such as loadbearing capacity) resulting from design of the component. The manufacturer needsto undertake the design. The manufacturer thus includes in the CE Marking awarranty that its design work has been undertaken according to the design brief.17E513 CE Marking Book 20/10/08 15:21 Page 18SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKBS EN 1090-1 relates this option to Method 2 in Guidance Paper 'L' and assumesthat such a design brief would be wholly based on the relevant parts of theEurocodes. This would be particularly useful for manufacturers of standardisedproducts, such as cold-formed purlins, intended for sale throughout Europe. Then theproduct could be supplied against a component specification showing dimensionsand giving constituent material properties, together with an attached data sheetgiving, for example, Eurocode-based load bearing capacities in relation to spans andfixings. The parameterisation would need to cater for National Annex values adoptedfor the nationally determined parameters (NDPs) allowed by the Eurocodes.Alternatively, Method 3 in Guidance Paper 'L' allows CE Marking of structuralcharacteristics to a design brief that is bespoke to a client's project. Thus BS EN1090-1 defines an MPCS to Method 3b as one that includes structural characteristicsevaluated by design to a brief issued by the purchaser or one developed by themanufacturer to meet the purchasing client's order. Method 3a to BS EN 1090-1 thusallows CE Marking of components with design values evaluated at least in part to,say, an American standard provided that this is explicitly agreed in the purchasingclient's order. For instance, the component may be designed to the Eurocodes forstatic design, but to the AISC code for seismic design resistance. It should be notedthat Method 3b is not applicable to products placed on the European market wherethe purchaser is not known in advance of product delivery. In such cases it isimperative that component specification is clearly linked to the design basis used forcalculations.Purchaser provided component specification (PPCS). In this case the manufacturerundertakes no design and simply provides a product that meets the fully definitive PPCStogether with the necessary supporting documentation. BS EN 1090-1 defines this asMethod 3a to Guidance Paper 'L', as this allows components to be supplied to a PPCSbased on the purchasing client's choice of design code that may be other than theEurocodes.However, this case is more typical of a steelwork contractor subcontracting fabrication toanother fabricator/supplier on the basis that the purchasing steelwork contractorprovides fully detailed fabrication drawings for the manufacture of the sublet work. Thepurchasing steelwork contractor will usually require the components to be supplied withappropriate CE Marking, which will mean that the subcontract fabricator/supplier musthave a suitably certified FPC.3.3.9 Use and locationIn the case of a PPCS the use and location of a component are known in advance.However, for a MPCS there is an important distinction to be made between componentsmade for a use and location that is known in advance and those whose use and locationare unknown at the time the component is placed on the market. For design to theEurocodes under Method 2 (Option 2) above, BS EN 1090-1 describes the former case asMethod 2a and the latter case as Method 2b. Under Method 2a the relevant NDPs in theNational Annex for the location and use will be known. Under Method 2b the structuralperformance characteristics for the component will be application neutral. Hence a productdata sheet containing, say, load-span tables for such a component would need to becarefully drafted to avoid a potential purchaser/user making a mistake about, say, thecomponent's load bearing capacity that is safe in the actual location and use decided bythe purchaser/user.18E513 CE Marking Book 20/10/08 15:21 Page 19Guide to the CE Marking of Structural Steelwork3.3.10 Reaction to fireReaction to fire refers to issues such as surface spread of flame, and uncoated steelconstituent products are classified as Class A1 with respect to reaction to fire. No furtherdocumentation is required to support this classification for an uncoated steel componentmanufactured to BS EN 1090-1.There is currently no harmonised standard covering how reaction to fire for coatings applied tosteel components shall be declared. BS EN 1090-1 anticipates that this will be dealt with byspecifying the applied coating in the component specification, and providing supportinginformation using the coating manufacturer's product data sheet as evidence of the coating'sproperties. In due course, a standard format for declaring the properties of applied coatings islikely to be prepared as the basis for CE Marking such products supplied for use in construction.3.3.11 Dangerous substancesThe CPD requires manufacturers to declare whether their products emit radioactivity orrelease cadmium. In general, BS EN 1090-1 requires no testing for these dangeroussubstances if the steel component is manufactured from steel constituent products and isnot coated. If the steel is coated the manufacturer may have to make a separate declarationconcerning the coating as with reaction to fire.3.3.12 No performance determinedUnless an essential characteristic is regulated in the European member state where thecomponent is to be used, a manufacturer's CE Marking may state No performancedetermined (NPD - not to be confused with a National Annex NDP) for that characteristic.For instance, structural steelwork undertaken to the NSSS is intended for buildingconstruction where fatigue is not a factor in design. It would then be in order to stateFatigue strength - NPD. The manufacturer may however wish to declare performancecharacteristics not regulated in certain member states for marketing purposes or foreconomy reasons to facilitate easier movement of products within all member states.In Annex ZA of BS EN 10025-1, for instance, some essential performance characteristicsare noted as threshold values (a minimum value below which the product is not fit for use).Where performance characteristics for structural steel components are declared using theproperties of constituent products which are in turn based on threshold values, then therestriction still applies that NPD cannot be stated for those characteristics as a minimum orthreshold value must always be met.Although BS EN 1090-1 allows NPD to be declared for weldability for non-weldedcomponents, it should be noted that the harmonised standards for most constituent steelproducts include weldability as a threshold value (e.g. see BS EN 10025-1). In such cases,whether the steel component is welded or not, NPD may not be declared for the componentif the declaration relies upon properties transmitted from those of its constituent products.All the examples of CE Marking given in Annex ZA of BS EN 1090-1 state that NPD is usedfor release of cadmium, and emission of radioactivity. In practice, steel products do not emitor release either dangerous substance, and hence rather than NPD it is practical to declareNo release of cadmium and No emission of radioactivity.19E513 CE Marking Book 20/10/08 15:21 Page 20SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORK3.4 Requirements3.4.1 GeneralThe basis of how the essential performance characteristics defined in BS EN 1090-1 arespecified as requirements for manufacture of a steel component is as follows:Steel components are manufactured from steel constituent products with essentialcharacteristics that are defined in the harmonised standards for those products.The manufacturer incorporating those products into a structural steel componentneeds to ensure that:Incoming materials to be used as constituent products comply with the relevantspecification by documentary check supplemented by re-testing if necessary (seesection 8 on how this affects the supply chain);The use of those constituent products in manufacture meets the necessarytraceability requirements (see section 7);The modification of the essential characteristics of the constituent products by theprocesses of steel component manufacture, such as by welding, is controlled tomeet the requirements of BS EN 1090-2Execution of steel structures andaluminium structures - Part 2: Technical requirements for steel structures(seesection 4 below which explains the content of BS EN 1090-2 in detail).Structural characteristics are established by suitable design calculations and/orphysical testing.3.4.2 DurabilityThe CPD requires that the durability of the essential characteristics is established. It shouldbe noted that the durability required is related to the essential performance characteristicsidentified in the harmonised standard.As there is no applicable direct method for testing durability, BS EN 1090-1 introduces thefollowing principles to establish the durability of a steel component. The durability dependson the constituent products. The essential characteristics of steel constituent products areimmune from degradation over time with the major exception that atmospheric corrosioncan impair cross-sectional dimensions.Some products use structural steels with improved atmospheric corrosion resistance, forwhich the required chemical composition is specified in the relevant supporting standard.Otherwise, durability is defined in terms of the corrosion protection applied to the surface ofa steel component.The selection of a method for protecting steel components from corrosion is covered by BSEN 1090-2. This allows the indirect evaluation of durability in terms of the classifiedexposure of the component linked to specified requirements for surface protection in thecomponent specification. The NSSS offers six standard specifications for applied surfacecoatings that may be invoked in component specifications.It is arguable that in two other respects - fatigue and fracture - the properties of constituentsteel products are less than permanently durable as over the longer term steel can besusceptible to failure due to externally applied cyclic stresses or low temperatures. As boththese properties are explicitly defined as essential structural characteristics in BS EN 1090-1, the issue of durability can be addressed by declaring values that are related to the stresscycling or working temperature as relevant.20E513 CE Marking Book 20/10/08 15:21 Page 21Guide to the CE Marking of Structural Steelwork3.5 Evaluation methodsThe evaluation methods to be used are related to the manufacturing requirements to beevaluated that are derived from the essential performance characteristics defined in BS EN1090-1. A combination of three methods is included in BS EN 1090-1 and the harmonisedstandards for constituent products:Physical testing - used for example to establish fracture toughness of steel materialsusing the CVN impact test.Measurements of geometry - used for tolerances on dimension and shape, andcovered in BS EN 1090-2.Structural calculations - which may be used to evaluate load bearing capacity, fatiguestrength and resistance to fire.BS EN 1090-1 allows the use of physical testing instead of or in support of calculations. Forinstance, the supplementary rules in the Eurocodes for the design of steel cold-formedmembers and sheeting specifies testing procedures to be used. BS EN 1990Eurocode -Basis of structural designdefines various types of test and specifies the proper statisticalmethods for the evaluation of test results.It is also worth noting that BS EN 10025-1 relies wholly on physical testing andmeasurements of geometry to establish conformity and the introduction of structuralcalculations as a third evaluation method in BS EN 1090-1 is linked to the fact that it coversbespoke products and non-series production.3.6 Evaluation of conformity3.6.1 Initial type testingThe general principles behind the evaluation of conformity are the use of initial type testing(ITT) and factory production control (FPC). The basis of ITT is:A manufacturer develops a product type.What might be termed prototype examples of the new product type are tested toestablish their properties against the essential performance characteristics.The new product type is commissioned into production and representative samplesfrom new production are tested to establish that the production methods used canproduce conforming product.Thus ITT is necessary at the commencement of production of a new product type includingproduction using new constituent products, and at the commencement of new or modifiedmethods of production.As BS EN 1090-1 applies to the manufacture of bespoke components that may be uniqueexamples of their type, it is impractical to apply the simple concept of ITT described above.Hence, the concept of initial type calculation (ITC) is introduced as a conformity evaluationmethod. What this builds on is the wealth of physical testing undertaken in researchlaboratories that has been codified into the design rules that underpin the ITC. Thus even aunique example of a structural component is built up in the calculations from what might betermed sub-types - for instance the behaviour and bearing resistance of an end plate in abolted connection.ITC is built up wholly on what might be termed historical data, and BS EN 1090-1 allowshistorical data from both ITC and ITT to be used. This reduces the amount of type testingthat the manufacturer needs to perform. However, the application of historical data needs21E513 CE Marking Book 20/10/08 15:21 Page 22SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKto be carefully considered when, say, test results obtained in support of a product meetingBritish Standards are extended to meet a European Standards. BS EN 1990 provides thestatistical basis for using such prior information.The steel constituent product standards, such as BS EN 10025-1, measure the essentialperformance characteristic of weldability in terms of chemical composition as a carbonequivalent value (CEV). Welding to BS EN 1090-2 builds on this concept of weldability byapplying the concepts behind ITT in the methods used to evaluate conformity of weldedcomponents, as follows:A manufacturer wishes to develop a welding procedure specification (WPS) anddefines parent and weld materials, welding process, joint design and preparation,welding position and technique etc. in a preliminary welding procedure specification(pWPS).Using the pWPS as the reference document, the manufacturer carries out a weldingprocedure test, which is then subjected to destructive and non-destructive tests(NDT) to specified standards. The results of the testing and the actual weldingparameters used are recorded in a welding procedure qualification record (WPQR).The WPQR is used to support application of the WPS in practice and the qualificationof other WPS to be used in production within a defined range of essential variables,for example material type/thickness, joint types, welding position etc.The fact that the WPS may be used over a range of actual welds that differ somewhat fromthe initial type tested is an example of the allowance in BS EN 1090-1 to extend applicationof ITT to other situations in a family. The range of qualification allowed in the weldingstandards defines how big the family may be, which in terms of parent materials is doneusing steel groups cited in BS EN 1090-2.BS EN 1090-2 also builds on the ITT concept with respect to using a qualified WPS inproduction as it specifies that the first five joints made to the same new WPS must meetquality levels comparable to those in the procedure test when subjected to NDT. Thisestablishes that a WPS can produce conforming quality when implemented in production.Thereafter the NDT on production welding is reduced to sampling as part of FPC.BS EN 1090-1 restricts the application of a given ITT programme to a production ofcomponents within a defined Execution Class (EXC). This concept is explained furtherbelow, but it has a particular implication for production welding in that requirements for thewelding quality management system (WQMS), the methods of qualification, the extent ofFPC testing and the production quality levels required differ for EXC2, EXC3 and EXC4. ForEXC4, BS EN 1090-2 requires production welds to meet a higher quality than thatestablished by ITT in the WPQR.3.6.2 Factory production controlFactory production control (FPC) is needed to establish that a manufacturer can produceconforming product in regular ongoing production. In essence what the manufacturer doesis to establish the key control checks during the ITT phase and then to sample test actualproduction to compare it with necessary quality levels established by ITT. FPC is thus usedto prove that products conform to the product type, given that ITT has been used to provethat the product type meets the required essential performance characteristics.As FPC is based on sampling, the minimum frequency and extent of sample testing isdefined in the harmonised standard. For products to BS EN 10025-1, this can be specific toa lot or cast (type 3.1 inspection certificate) or non-specific (type 2.2 test report). Specific22E513 CE Marking Book 20/10/08 15:21 Page 23Guide to the CE Marking of Structural Steelworktesting is required for all steel products except those of the following qualities: S275JR,S275J0, S355JR or S355J0.As BS EN 1090-1 covers bespoke non-series production the required number of samplesis specified as only one (i.e. the component may be its own unique type) when applied tocalculations of structural characteristics, dimensional measurements, and the checking ofCEV and CVN values for the constituent steel products. More extended sampling is requiredwhen the conformity evaluation is established by physical testing rather than calculation.In practice, production to BS EN 1090-2 as a supporting standard for BS EN 1090-1 meansthat many requirements relating to production are specified. As noted above this hasparticular application to the use of NDT to establish that production continues to produceconforming welds treating further joints welded according to the same WPS as a singlecontinuing production lot. The NSSS uses the term routine testing for this aspect of FPC.In many ways FPC may be seen as a sub-set of the controls necessary in a qualitymanagement system based on BS EN ISO 9001, and BS EN 1090-1 allows (but doesnot require) an FPC conforming to BS EN ISO 9001 to be used as the basis for therequired system.The detailed requirements for the FPC are explained in section 10, and it should be notedthat the system is defined in terms of written procedures, regular/routine inspection (i.e.quality control) supported by competent personnel and suitable equipment for productionand testing.3.6.3 Attestation levelsAttestation of conformity is the term used to define the whole system needed to ensure thatonly conforming products are placed on the market. This allocates certain tasks to themanufacturer and others to an independent organisation that the manufacturer appoints tocertify defined aspects of its operations as meeting the required standard.Certification organisations themselves need to be suitably competent to undertake theirallotted tasks. Their competence is established against BS ISO/IEC 17021Conformityassessment - Requirements for bodies providing audit and certification of managementsystemsand the scope of competence of the organisation is accredited by, say, UKAS. Thisaccreditation is then used by the competent authority (DCLG in the UK) to notify theEuropean Commission and the certification organisation then becomes a notified body (NB).Depending on the attestation level which has been chosen by the European Commission,the NB may be involved as a third party in certifying:The FPC system, as is required for all structural steel components and explainedbelow with respect to BS EN 1090-1. This is system 2+ and it permits themanufacturer to issue a Declaration of Conformity related to its products. The role ofthe NB under system 2+ is defined as that of an inspection body rather than that of acertification body as the latter implies that product or product type certification isinvolved (as below);The product type by involvement in the ITT/ITC. This would be system 1+ and wouldresult in the NB issuing a Certificate of Conformity related to the manufacturer'sproduct types; orThe products themselves. Outside of the CE Marking requirements, BS EN 10025-1allows this option for certain higher quality steels whereby the purchaser's authorisedinspection representative endorses the declaration that the products supplied are incompliance with the requirements of the order.23E513 CE Marking Book 20/10/08 15:21 Page 24SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKThe attestation level specified for all structural steel components is level 2+ which allocatesthe tasks as follows:Tasks under the responsibility of the manufacturer: ITT, FPC and product testing.Tasks for the NB: Certification of the manufacturer's FPC on the basis of both initialinspection and continuous surveillance.3.6.4 Product testingBS EN 1090-1 specifies the amount of product testing by the manufacturer as follows:Checking those essential dimensions that are critical to use of the component oneach component or a suitable sample if components are manufactured under similarconditions. The requirements for dimensions that are essential are listed as essentialtolerances in BS EN 1090-2.Checking the manufactured components against the component specification withrespect to the requirements for surface treatment for corrosion protection as specifiedin BS EN 1090-2.Checking that the inspection documents for constituent products conform to therequired values for CEV, CVN, and yield, proof or tensile strengths as specified in BSEN 10025-1 or other relevant harmonised standards for steel products.For design undertaken by the manufacturer, verifying that the calculations used todevelop the component specification are relevant and have been carried out inaccordance with the design brief.Checking that manufacturing processes that affect structural characteristics are beingundertaken to BS EN 1090-2. This is relevant to processes that may alter theessential performance characteristics of constituent products. Hence, BS EN 1090-2specifies the relevant procedure and production testing for welding, bending, andthermal cutting.3.6.5 Laboratory testingThe possibility for third party endorsement of the product type is comparable to third partyendorsement of actual laboratory test results as opposed to endorsement that the systemfor control of laboratory testing has been checked within the scope of the FPCendorsement. In terms of BS EN 10025-1 laboratories undertake material tests to establishCEV, CVN etc., and the system for control of laboratory testing requires;A direct check of the performance of the manufacturer's own laboratory within thescope of the FPC;Accreditation of the laboratory under BS EN ISO/IEC 17025General requirements forthe competence of testing and calibration laboratories(or equivalent) with theaccreditation being specific for the tests carried out; orDirect assessment of an external laboratory by the NB.In terms of BS EN 1090-1 there are similar requirements that treat laboratory testing as partof the manufacturer's FPC. For EXC2 and above this applies to tests associated withwelding, and the NSSS thus requires a competent examiner or examining body to verify theWPQRs, to witness welder qualification tests (WQTs) and to endorse the WQT certificates.These responsibilities are distinct from those of a possible project-specific third partyinspection authority that may be appointed.24E513 CE Marking Book 20/10/08 15:21 Page 25Guide to the CE Marking of Structural Steelwork3.6.6 Design controlAs noted above, control of design is seen as part of FPC to the extent that the manufacturerchooses to warrant the design work it undertakes to develop the component specificationfrom the design brief. The NB is not required to verify the content of the design or that thecomponent specification complies with the design brief as this would be equivalent toproduct type certification to attestation system 1.The NB is required to certify during initial inspection and continuous surveillance thatsuitable design control procedures are in place (e.g. for revising drawings), and that designwork is being undertaken using suitable equipment and other resources (e.g. suitablecomputer programs and latest copies of design codes). During initial inspection the NB isalso asked to certify that that design work is being undertaken by suitably competentpersonnel with defined job descriptions.3.6.7 Certification of the FPCBS EN 1090-1 defines those minimum aspects of the FPC that must be assessed by theNB. During initial inspection these relate to checking whether the resources (premises,personnel and equipment) are adequate for the manufacture of steel components to BS EN1090-2. This also comprises:Checking that the FPC has procedures for checking conformity and handlingprocedural non-conformities and non-conforming product.Evaluation of job descriptions (e.g. based on an organogram) and requirements forcompetence of personnel (e.g. for weld inspection personnel).During continuous surveillance the NB:Checks that the manufacturer is undertaking the specified product testing describedabove that is associated with execution work.Checks that the FPC procedures for checking conformity and handling proceduralnon-conformities and non-conforming product are being operated properly.3.6.8 Welding certificationSpecifically for those manufacturers who use welding and following the initial inspection, theNB is required to identify the scope of certification of the FPC in terms of the weldingprocesses and parent materials covered. The manufacturer can establish the basis for thisscope by using its portfolio of WPSs, WPQRs and WQTs as those documents underpin theoperation of the FPC for welding. In this regard it is required that for each main weldingprocess the manufacturer shall have available welder(s) with suitably qualified weldingprocedures.As the NB also needs to confirm on the certificate which Execution Class is relevant to themanufacturer's FPC for welding, the NB needs to assess the welding quality managementsystem (WQMS), the methods of qualification, the extent of FPC testing and the productionquality levels and to relate these to the Execution Class using the requirements specified inBS EN 1090-2 (see section 5).Unless the scope of certification is limited to EXC1, the Responsible Welding Coordinator(RWC) also needs to be identified on the certificate. The certification of the FPC for weldingmay be identified within the general FPC certificate or issued as a separate welding certificate.Although it is not required, it may also be agreed between the manufacturer and the NB thatthe WQMS is certificated according to the appropriate level of BS EN ISO 3834. If the25E513 CE Marking Book 20/10/08 15:21 Page 26SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKmanufacturer already has its WQMS certified to BS EN ISO 3834, then this may be relied uponas relevant when the NB issues the general certificate for the FPC.During continuous surveillance, the NB is not specifically required to re-certificate the FPC forwelding, but in practice re-certification of the FPC will include a review of the WQMS for amanufacturer of welded components. The NB also has the authority to undertake a surveillanceaudit if circumstances change. In this respect, the manufacturer is required to inform the NB ofchanges that could affect the validity of the certificate, such as:New or changed essential facilities;Change of Responsible Welding Coordinator;New welding processes;New essential equipment.3.7 Marking system3.7.1 GeneralThe basis of the marking system is that the component shall be identifiable against the relevantessential performance characteristics that are to be warranted by the manufacturer ascomplying with the requirements of BS EN 1090-1. This requires that the component is linkeduniquely to its component specification, and if this is in the form of a fabrication drawing theinformation required by BS EN 1090-1 can be given on the drawing.In addition, BS EN 1090-2 specifies certain requirements related to traceability (see section 7)and identification methods applicable to component manufacture, and links these to themarking necessary for correct use of the component in terms of erection.Most often bespoke steel components are supplied to a given project for eventual erection asa complete structural frame for, say, a building. In such cases the components may be seen asa kit, and the marking can be done on a collective basis for them all. Typically this might bedone using the erection marking plan as a central reference point to define the kit, and then toattach the necessary CE Marking information to the whole kit via the marking plan. This methodhas an obvious extension for steelwork contractors undertaking design-and-build projects andwho wish to warrant the design as well as the manufacture of all the components by referenceto the design calculation sheets.3.7.2 Classification and designationBS EN 1090-1 requires that the Execution Class relevant to its manufacture is given on thecomponent specification.The requirements for dimensions that are essential performance characteristics are listed asessential tolerances in BS EN 1090-2. For some essential tolerances, such as those forcylindrical and conical shells, more than one class is specified. In which case, the componentspecification needs to identify the class that is relevant to the component.3.7.3 CE MarkingBS EN 1090-1 includes an informative Annex ZA related to the application of the CPD tostructural steel components. It is informative as it pertains to application of national regulationswhich cannot be made mandatory by a European Standard. Instead the framework is given inthe informative annex which is then mandated in practice by the appropriate regulations in eachEuropean member state.26E513 CE Marking Book 20/10/08 15:21 Page 27Guide to the CE Marking of Structural SteelworkThe annex links together the following elements of the required CE Marking system:The FPC certificate issued by the NB (as described above).The declaration of conformity made by the manufacturer. This is a document that themanufacturer prepares and maintains which then entitles the manufacturer to affix theCE Marking. It must be signed by an appropriate employee of the manufacturingcompany, and is the basis for criminal proceedings if the regulators believe that the CEMarking has been wrongly applied by the manufacturer. Appendix C illustrates anexample of a declaration of conformity.The CE Marking of the component. This includes the CE Mark itself (literally the lettersC and E in a particular type style and size) as well as other information as illustrated inAppendix C.BS EN 1090-1 allows the CE Marking to be done on one of four templates linked to thepreparation of the component specification via the methods defined in Guidance Paper 'L' asfollows:By reference to component geometrical data and the material properties of constituentproducts with NPD for structural characteristics determined by design (Method 1 usingMPCS Option 1);As above but including values for structural characteristics determined by design to therelevant Eurocodes (Method 2 using MPCS Option 2);As above but including values for structural characteristics determined by design to thepurchaser's design requirements (Method 3b using MPCS Option 2); orBy reference to component geometrical data and the material properties of constituentproducts with a cross-reference to the purchaser's design but no specific values forstructural characteristics determined by design (Method 3a using PPCS).As noted previously, at the present time CE Marking under the CPD is not mandatory under thenational regulations implemented in the UK and the RoI. Most often CE Marking of structuralsteel components to BS EN 1090-1 applies to production intended for a bespoke project-specific application that is known in advance of manufacture. In such cases, even if CE Markingwere mandatory or adopted voluntarily, it would be reasonable to apply BS EN 1090-1 to thefinal completed component that is directly ready for site assembly and/or erection. Whether thesteelwork contractor as manufacturer of the completed component requires CE Marking to beused by its supply chain (see section 8) then depends on how the manufacturer wishes toexercise FPC. Clearly the steelwork contractor will require most constituent products to be CEMarked, but might control the operations of some sublet suppliers undertaking steel processingwithin the purchasing steelwork contractor's own FPC system. This has particular relevance forthe WQMS and the control of welding by sublet suppliers.3.7.4 Affixing the CE MarkingThe CE Marking may be located in one of the following places:on the product;on the packaging; orin the manuals or other supporting commercial literature accompanying the product.It is likely that for bespoke project-specific items the CE Marking would be located on theIn this context accompanying means unambiguously linked to, it does not mean that the commercialliterature has to physically be attached to the product.27E513 CE Marking Book 20/10/08 15:21 Page 28SECTION 3 : CE MARKING STANDARD FOR STRUCTURAL STEELWORKfabrication drawings that comprise the component specification. The component itself thenonly needs an identity mark (such as the piece marks in use currently) that links itunambiguously to the relevant drawing, perhaps via a delivery list or marking plan ascurrently.For series items, such as proprietary purlins, it is more likely to be placed on the productlabel. For steel products it is generally on the inspection document, and for fasteners andwelding consumable it is generally on the packaging.3.7.5 PackagingIn principle the importance of packaging for a product with CE Marking is that themanufacturer produces conforming product ex-works and the obligation on themanufacturer is to use packing that is sufficient to preserve the essential performancecharacteristics for a reasonable time reflecting the period until the purchaser is ready toinstall the product in the construction works.For structural steel components, the context is somewhat different, as the components arenearly always made to order, and the essential performance characteristics are largelyunaffected by exposure during the period between leaving the manufacturer's works andbeing installed on site. Furthermore, in bespoke cases a steelwork contractor would beliable to rectify any damage that the component received before it was finally handed overas part of the construction works.For these reasons, BS EN 1090-1 is largely silent about packaging requirements, and BSEN 1090-2 includes the requirements for rectification of any damage sustained in deliveryor erection.28E513 CE Marking Book 20/10/08 15:21 Page 29Guide to the CE Marking of Structural Steelwork4 EUROPEAN FABRICATION STANDARD4.1 Status and scopeBS EN 1090-2Execution of steel structures and aluminium structures - Part 2: Technicalrequirements for steel structuresis not a harmonised standard but it supports theapplication of BS EN 1090-1 by providing the technical requirements relevant tomanufacture of steel components. This is analogous to BS EN 10045-1 being a supportingstandard giving the test methods for CVN in support of the harmonised standards for steelproducts BS EN 10025-1 etc. As well as building on these test methods used to establishthe characteristics of constituent products, BS EN 1090-2 includes its own test methods forsuch items as measuring geometrical dimensions of components. It also makes referenceto other test methods in further supporting standards such as those specifying requirementsfor welding.The scope of BS EN 1090-2 is wider than simply the technical requirements for manufacture(e.g. by fabrication including welding), as it also covers all execution requirements for steelstructures including erection. Erection and other operations (such as bolting) that take placeon a project site where the construction works are being built are not relevant to the CEMarking process which merely assumes that the works will be otherwise properly designedand built.In addition, the scope of BS EN 1090-2 is much wider than the individual British Standardsthat it will replace as it includes requirements for all types of steel structure: buildings,bridges, towers, masts, chimneys, shells, sheeting in carbon manganese steels up to S690and stainless steels up to S700. It applies to structures subjected to fatigue or seismicactions.Despite this extremely wide scope, the requirements related to steel structures used inbuilding construction are very close to those in previous British Standards and those in theNational Structural Steelwork Specification for Building Construction (NSSS). To assiststeelwork contractors and specifiers, BCSA is preparing a CE Marking Edition of the NSSSthat includes only those provisions relevant to the majority of steel-framed buildings.Undertaking projects to the NSSS should ensure that the steelwork complies with theprovisions relevant to all types of building construction designed for static loading in EXC2according to BS EN 1090-2.With respect to CE Marking the relevant clauses of BS EN 1090-2 are as follows:Documentation (clause 4 and Annex A);Constituent steel products (clauses 5, 12.1 and 12.2);Geometrical tolerances (clauses 11 and 12.3 and Annex D);Welding and other fabrication operations (clauses 7, 6 and 12.4);Surface treatment for corrosion protection and durability (clauses 10 and 12.6 andAnnex F).With respect to their application as requirements for BS EN 1090-1 these clauses form threegroups as follows:Potentially there could be situations (such as on a major stadium, power station or bridge project) where asubstantial amount of manufacture takes place on the construction site. Arguably this is outside the scope ofthe CPD as the fabrication (assembly and welding) work is not undertaken in a works/factory covered by themanufacturer's FPC certification. It would, however, generally be the case that the WQMS and the RWC'sscope of responsibility would include such site-based operations anyhow. In special circumstances where thesite facility existed for a long enough time, it would be possible for those facilities to be certified by the NB,and hence for CE Marking to be applied to the components produced from those facilities.29E513 CE Marking Book 20/10/08 15:21 Page 30SECTION 4 : EUROPEAN FABRICATION STANDARDThose associated with inspection, testing and corrections (in clause 12 of BS EN1090-2) that support quality control of product conformity;Those associated with documentary controls (in clause 4 and 5) that support qualityassurance of product conformity; andThe rest which underpin the procedural controls of processes of fabrication.It is assumed that clauses 8 and 12.5 on mechanical fastening, clauses 9 and 12.7 onerection and Annexes E, G, H, J, K and M generally have little or no relevance to the CEMarking of structural steel components.4.2 DocumentationBS EN 1090-2 uses the term execution specification for the set of documents coveringtechnical data and requirements for a particular steel structure. This equates to the projectspecification referenced in the NSSS, and both include the portfolio of componentspecifications that are the key documents referred to in BS EN 1090-1.Annex A of BS EN 1090-2 lists all those requirements that may need specifying for aparticular project and hence for specific components. Annex A.3 lists several that are linkedto the choice of Execution Class. The application of the concept of Execution Class isexplained in section 9 below which notes how the NSSS requires who is responsible for thestructural design to review A.3 for its implications.In terms of documentation and as part of FPC, the manufacturer should review theextensive list of supporting standards given in clause 3 of BS EN 1090-2 to ensure that itslibrary contains up-to-date versions of those relevant to its scope of operations.4.3 Constituent productsSection 3 above explains the concept of constituent products. The manufacturer needs toknow that it is using the right products and to ensure that its manufacturer's processes donot impair those properties that underpin the declared essential characteristics of thefinished component. Many of the requirements in BS EN 1090-2 for traceability and weldingrelate to these needs.4.4 TolerancesThose geometrical tolerances that are essential to the evaluation of the strength of acomponent (e.g. straightness required to avoid premature strut buckling) are defined in BSEN 1090-2 as essential requirements. It is those and only those tolerances that themanufacturer warrants when CE Marking under the CPD. As noted in section 3 above, it isnecessary to choose which class applies for some essential tolerances and to include thisin the component specification.It should be noted that BS EN 1090-2 also gives requirements in two tolerance classes forwhat are termed functional tolerances. The functional tolerances are outside the applicationof the CPD to structural steel components, but they are relevant to the contractualobligations that the manufacturer has to its purchasing client. Thus the manufacturer maychoose to link the component to the relevant functional tolerance class by showing thisinformation on the fabrication drawings. To simplify this process, a statement on the markingplan that the component is manufactured in accordance with the NSSS makes the link tofunctional tolerance class 1.30E513 CE Marking Book 20/10/08 15:21 Page 31Guide to the CE Marking of Structural Steelwork4.5 WeldingBS EN 1090-2 covers fabrication requirements in clauses dealing with preparation ofconstituent products, assembly and welding. The implications of BS EN 1090-2 for CEMarking of welded structural components are widely discussed throughout this documentas welding is a special process and has the most relevance to the potential impairment ofthe properties of the constituent products. Similar procedural restrictions apply to otherprocesses used in manufacture that have such a risk if not properly controlled (e.g. hot orcold bending, or thermal cutting used in fabrication).In terms of welding, it should be noted that the NSSS applies the requirements of BS EN1090-2 to building structures to EXC2. These requirements are broadly similar to therequirements in the previous editions of the NSSS except that the conceptual principle isnow made clear that welding of a given type (as defined by a given WPS) may beconsidered as a single continuing production lot in quality management terms.BS EN 1090-2 includes a National Foreword that explains that whilst the Service Category(see section 9) differentiates between quasi-static (SC1) and fatigue (SC2) applications, thisis too coarse a differentiation with respect to the control of weld quality in fatigue. BS EN1090-2 uses the quality levels in BS EN ISO 5817 in four steps as listed below:EXC1: Quality level D.EXC2: Quality level C generally;EXC3: Quality level B (i.e. as required for WQTs and WPQRs);EXC4: Quality level B+.Whilst the levels above may be partly suitable for use in the manufacturer's WQMS toestablish, prequalify and certificate the general quality level of the manufacturer's weldingoperations, they are incomplete as follows:Using informative Annex B of BS EN 1090-2, low consequences risk structures inCC1 (see section 9 for explanation) that are designed for fatigue are in EXC2 andhence the suggested quality level is C generally. This quality level is unsafe for anybut the most modest levels of fatigue, and reduced consequences do notcompensate for inappropriate specification.The EXC4 level is impractical as it requires the manufacturer to demonstrate thegeneral capability of meeting quality level B+ which is more stringent than thatrequired for WQTs and WPQRs. The only way of assuring a quality level above theprequalification standards is to undertake 100% testing on the (minority of) weldswhich the designer specifies as demanding such a high standard and individuallyassess them for acceptance.The conclusion from the above is that the specifier needs to identify the fatiguedemand placed on individual welds subjected to dynamic loads and to decide theacceptance criteria that are relevant on a fitness-for-purpose basis using fracturemechanics based on the function of the component and the characteristics of theimperfections (type, size, location). Whilst this procedure is allowed by BS EN 1090-2 after non-conformities are identified, it is more sensible to start with a properlyclassified set of values. This is available in ISO 10721-2 which specifies a suite ofacceptance criteria appropriate to a series of fatigue classes. These acceptancecriteria are consistent with those used in previous British Standards and the NSSS,and should be used by specifiers in fatigue applications rather than relying on thecoarse SC2 categorisation.31E513 CE Marking Book 20/10/08 15:21 Page 32SECTION 4 : EUROPEAN FABRICATION STANDARD4.6 Surface treatmentAs explained in section 3 above, for structural steel components there is no applicable directmethod for testing durability of the essential characteristics defined in BS EN 1090-1.Provided it can be protected from corrosion, there is no tendency for the properties of steelto decay over time; it is stable chemically and does not creep.Hence, the simplest ways to ensure durability are to make the component from stainless orweather-resistant steel (e.g. with improved atmospheric corrosion resistance), or to protectits surface from atmospheric corrosion by paint, galvanizing or sprayed metal. In terms ofdeclared characteristics, it is simple enough in principle to specify the required surfacecoating and the surface preparation necessary in the component specification and for themanufacturer to warrant that the component conforms to its component specification. Thisis the basis that BS EN 1090-2 provides, allowing the manufacturer to check themanufactured components against the component specification according to the specifiedtesting requirements for surface preparation and treatment.It is less simple to warrant that the component is durable for a specified time as this involves asimultaneous specification of a corrosivity category for the expected environment in the intendedcomponent application and a measure of the durability of the surface protection material.Thus, a direct warranty on the durability of the steel component would be dependent on awarranty on the durability of the surface coating material. Even though there are standardtests that can be used to establish the long term performance of, say, paints, none of theseyet form the test standards supporting harmonised product standards for paints. In thiscircumstance, BS EN 1090-2 allows purchasing clients and steelwork contractors to agreethe execution specification durability in more prescriptive terms and for this to be used todevelop the component specification. Thus, whilst the standard coating specifications givenin the NSSS are scientifically related to particular environmental classifications, there is nowarranty on the coatings.32E513 CE Marking Book 20/10/08 15:21 Page 33Guide to the CE Marking of Structural Steelwork5 WELDING QUALITY MANAGEMENT5.1 Welding as a 'special process'For many years welding has been classed as a 'special process' as defined in BS EN ISO9000 and it is widely recognised that welding normally requires continuous control and/orthat specified procedures are followed since the end result may not be capable of beingverified by testing. In light of this, a fundamental requirement of CE Marking is that themanufacturer using welding needs to implement an appropriate welding qualitymanagement system (WQMS).The CE Marking fabrication standard, BS EN 1090-2, states that all welding shall beundertaken in accordance with the quality requirements of the relevant part of BS EN ISO3834 which identifies the controls and procedures required. Determination of the relevantpart of BS EN ISO 3834, and the stringency of requirements, is ultimately dependent on theExecution Class declared by the manufacturer for its product. With respect to the WQMS,BS EN 1090-2 invokes BS EN ISO 3834Quality requirements for fusion welding of metallicmaterialsas follows:EXC3 and 4: Comprehensive quality requirements to BS EN ISO 3834-2.EXC2: Standard quality requirements to BS EN ISO 3834-3. (The quality levelrequired by the NSSS is BS EN ISO 3834-3 appropriate to EXC2.)EXC1: Elementary quality requirements to BS EN ISO 3834-4.BS EN ISO 3834 is not a quality system standard to replace BS EN ISO 9001. It can beused independently but it is often best used to complement BS EN ISO 9001 requirements.It is also important to note that, whilst some steelwork contractors may choose to have theirWQMS certified by a certification body independently of the notified body, the standards forCE Marking do not require this. Compliance with the requirements of BS EN ISO 3834 canbe verified by the notified body during assessment of a steelwork contractors FPC system.Routes to certification of the FPC system are described in section 11.The basic principles of a welding quality management system to BS EN ISO 383