Factory Quality Assurance Plan for New York GFRC Project

Factory Quality Assurance/Quality Control Plan
for
540 West 21st Street Project, New York, USA
Revision Date Prepared by Approved by Status
00 2018-4-12 Xu Zhixing For

information
Design and Supply GRC Façade Panel,
st
Ref No: BLD/QC-01 Issue:01 / Rev: 00
540 West 21 Street, New York, USA
Page No.: 1 of 81 Date: 10/Aril/2018
TABLE OF CONTENTS
Summary of Amendments
1.0 Quality Policy (QP)

QP
2.0 Introduction
3.0 Project QA/QC Organization Chart

QA/QC
4.0 Resources Schedule
5.0 Calibration For Measuring Equipment
6.0 Production Setting-Out and In-Plant Control Plan
7.0 Delivery / Storage of Master Model
8.0 Negative Mould Making Procedure
9.0 GFRC Production & Quality Control Procedure

GFRC
10.0 Curing, protection, assembly inspection, packing and shipping of GFRC Products
GFRC
11.0 Product Numbering System
12.0 Technical Data and Specification of Major Raw Materials
13.0 Inspection and Test Plan
Appendix A: Inspection Forms

A
Appendix B:Inspection Criteria of Raw Materials
B
— 1 —
st
Appendix C: Inspection Criteria of Moulds
C
Appendix D: Inspection Criteria of GFRC Production Process
D
Appendix E: Acceptance Standards of Products
E
SUMMARY OF AMENDMENT
Issue Rev Description of Amendment Date Prepared Prepared By

No. (Initial)
01 00 For Information 10/04/2018 Xu Zhixing
— 2 —
st
1.0 QUALITY POLICY (QP)
QP
A Beilida Company is committed to be a GFRC works Sub-contractor in providing high

quality standard of GFRC to meet Specification and statutory requirements.
GFRC
B Beilida Company has established a comprehensive quality management system to meet the
requirement of ISO 9001, ISO 14001 & OHSAS 18001 which must be strictly adhered to by all
employees.
ISO 9001, ISO 14001 &
OHSAS 18001
C Beilida Company has also set up a relative complete quality management system pursuant
to International GRCA Standard and PCI Requirements.
GRCA PCI
D To achieve and sustain our performance in according with our Targets, we are always
committed to: -
Provide consistently high quality of services and products, and continually improving the
effectiveness of the management system.
E It is the responsibility of all employees to ensure that these targets are achieved, as the
satisfactory performance of the Company is a direct result of everyday actions of every staff. In
addition, management objectives shall be established at relevant function with regular reviews to
assess the achievement.
F This policy shall be brought to the attention of all employees.
— 3 —
st
——
1 2
5&6 GRC ISO9001 GRCA AMS
In order to fully illuminate our policies of quality management, our company is intend to
introduce the quality management system of our Zhongshan Factory —Nanjing Beilida New
Materials System Engineering Co. Ltd., Zhongshan Branch (Formerly named “Zhongshan Beilida
Decorative Construction Materials Co., Ltd.), into this project. Zhongshan Branch has successfully
completed the GRC production of Venetian Hotel Parcel 1, 2, 5&6, and has been accredited the
quality management system of ISO 9001 and GRCA AMS certification, as below:
— 4 —
st
— 5 —
st
— 6 —
st
— 7 —
st
— 8 —
st
2.0 INTRODUCTION
2.1 Background
2.1.1 The QA/QC plan edited by Zhongshan Beilida, is applicable to the Design and Supply
of GFRC Façade works to this project.
GFRC
2.1.2 The quality assurance system of Beilida Zhongshan Branch (BLD) has been assessed
and certified by a Hong Kong independent Agent, Hong Kong Quality Assurance Agency
(HKQAA), and will be continuously assessed by the Third independent Agent and by BLD's
Quality Department. BLD will be responsible for the quality management of the factory and the
implementation of practicable measures to mitigate any delay.
HKQAA
2.1.3 To prevent any loss arisen from repeat activities during procurement, fabrication,
delivery and/or installation, testing and inspection, and/or any services, etc., BLD will implement
every appropriate effort to detect and remedy any non-compliance action, to the satisfaction of the
Client or his representatives
2.2 Purpose and Scope of This Document
2.2.1 The purpose of this Quality Plan is to provide confidence and assurance to our Client
(Customer) that BLD will deliver this project with good planning in various aspects and resources
allocation, and with all necessary skills and effective management for quality control.
2.2.2 This Factory Quality Plan complies with the requirements as stipulated in ISO
9001:2008. The quality management system described in this Factory Quality Plan applies to all
works and materials required in this contract. Whenever deemed necessary, this Plan will be
revised at regular intervals to reflect the actual situation of quality management.
ISO 9001:2008
— 9 —
st
2.2.3 The Quality Plan to be described in this document should be read in conjunction with
the Façade Specification and PCI of the follows:
a. Glass Fiber Reinforced Concrete
b. Testing Requirement
c. Quality Assurance Requirement
d. Proposed materials
e. PCI MNL-128:”Recommended Practice for Glass Fiber Reinforced Concrete Panels.”
f. PCI MNL 130:”Manual for Quality Control for Plants and Production of Glass Fiber
Reinforced Concrete Products”
g. BS EN1169:1999: Precast Concrete Products -- General rule for factory production
control of glass-fiber reinforced cement
PCI
A.
B.
C.
D.
E. PCI MNL 128 –
F. PCI MNL 130 --
G. EN1169:1999 --
3.0 Project QA/QC Organization Chart

QA/QC
3.1 The diagram displays the project organization with individual positions, and with a brief
duty description to them following, and indicates the date of revision as necessary in accordance
with ISO 9001. The project organization chart shall be updated when the organization changes if
necessary. The typical project Organization Chart will be set up on the basis of below chart. BLD
QA/QC representative will be on full time on a regular basis, and regular QA audit will be
conducted to ensure compliance of the manufacturing procedure in the production of GFRC
panels.
ISO9001
— 10 —
Design and Su
upply GRC Façaade Panel,
st
Reef No: BLD/QC-01 IIssue:01 / Rev:
R 00
540 West 21 Street, New York,
Y USA
Paage No.: 11 of 81 DDate: 10/Arril/2018
Q
QA G
GFRC
PM
QC//QA
Manaager
QC QC QC
QA
QC
C QC QC QC QC QC
BLD QA
A Organizatio
on Chart
3.2 Liist of Contrrollers
The Project Maanager will assign the following Controllerss for the prroject specific tasks ass
detailed below.
b Eachh assigned Controllers
C shall have minimum two nos. off person if possible, inn
case of abbsence of thhe other, andd each team
m leader shou
uld also havve a deputy..
Controlller no. and

d responsib
bility C
Current Po
osition Titlee(in each faactory/plan
nt facility)
1. Systeematic mannagement of
o QA/QC
Q Manageer QC
QC
system
P
Project Man
nager
— 11 —
st
2. Raw Material Storage Supervisor
Quality Assurance QA
3. Fabrication of masters and molds Production Manager
Mould QC Supervisor QC
4. GFRC Production Production Supervisor
GFRC Process QC Supervisor QC
5. Curing and post treatment (Air
Post treatment Supervisor
curing)
Product QC Supervisor QC
6. Packing and delivery (Logistic Finished product and packing Supervisor

Control)
Product QC Supervisor QC
7. Calibration Operator
Process QC QC
4.0 Resources Plan
4.1 Personnel
The required labor forces during GFRC production will be in line with the approved human
resources plan, which shall be submitted to the façade main contractor of GFRC works. Every
worker will be trained before taking his duty. To continuously improve the implementation of
quality plan, a periodic internal audit will be carried out by project quality representatives in
factory stated in the project quality plan.
GFRC
GFRC
This project will be set up 4~8 production lines according to its large quantity and programme,
each production line will be equipped with 15 personnel, which is consisted of spray gun operators,
consolidation, compaction and trowelling workers, workers for mixing and blending, QCs (2
persons), repairing workers and post-finishing workers. At the beginning and non-peak production
period, we will set up 4 production lines, and daily capacity of each line will be 80~100m2; when
— 12 —
st
at peak production time, production line will be increased to 8 lines at most, so as to meet the
progress.
3~4 15
1 +1 QC 2
3
50~80m2/ 4
4.2 Material
Submission and procurement will be in compliance with GFRC production schedule specified
in the contract. The project team will issue a list and schedule to procurement department to order
related materials according to the master programme and GFRC production schedule.
GFRC
GFRC
In order to meet the requirement of GFRC elements specified in the Specification and by the
Client, we will specify the brand and source of origin of all the raw materials used, so that the
source and quality can be controlled and maintained, for instance:
1. Cement
Cement shall be ordinary Portland Cement to BS EN 197-1: 2000 or ASTM C150 and shall be
obtained from one source.
2. Glassfiber
Glassfiber shall be alkali-resistant, continuous filament fiber developed and formulated
specifically to have high strength retention in ordinary Portland cement environments. The
glassfiber quality shall contain a minimum of 16% ZrO2 by weight, in accordance with
internationally recognized standards, and shall have a minimum strength retention (determined by
strand in cement (SIC) testing) of 300 MPa (test method: GRCA SO 104/0184). The producer shall
provide certification to show that the glass fiber conforms to EN 15422:2008.
3. Aggregate
The aggregate shall be suitable graded silica sand, limestone, granite or other stable fine
material which is hard, durable and clean. It shall not contain deleterious materials in such a form
or in sufficient quantity that affects adversely the strength or durability of the GFRC.
The aggregate shall comply with the following requirements:
Silica Content > 96%
— 13 —
st
Moisture Content < 2%
Soluble Salts < 1%
Loss On Ignition < 0.5%
Sulphate Ion < 4,000ppm
Chloride Ion < 600ppm
4. Water
The water shall be clean and free from deleterious matter that may interfere with the colour,
setting, or strength of concrete. Refer BS EN 1008, Mixing water for concrete.
GFRC
1 BS EN197-1:2000 BS 6588:1966
2
16% SIC 300MPa EN 15422: 2008
3
Raw materials used for our GFRC products can be classified to two types according to their
origin, domestic materials and imported materials.
The domestic materials stated in this plan refer to those materials that are necessary for
production and their sources are within the People’s Republic of China, exclusive of Hong Kong,
Macau and Taiwan. To save transportation energy, the equivalent alternatives with nearer supply
source and convenient supply conditions will be applied.
The import materials in this document refer to the required materials whose supply location is
beyond the region of China.
— 14 —
st
Main raw Materials used for this project such as cement will be imported from Thailand,
Elephant white cement or equivalent domestic brand Aalborg white cement, fiberglass will be
firstly chose of Cem-Fil glassfiber from Taishan Fiberglass Manufacturer.
52.5 52.5 Cem-Fil
4.3 Plant
Major Machinery such as spraying machines, high-speed mixer, and other equipments which
are necessary for GFRC production will be planned and ordered before GFRC production, and the
quantity will be based on our production capacity arrangement and the requirement of the project.
For better quality control of the panels, all the spray machines will be calibrated prior to
commencement of GFRC production. Calibration and maintenance records for those plants being
in use will be kept for record and can be submitted upon request.
GFRC
5.0 Equipment Calibration
Basically all equipments have to be maintained and calibrated periodically, especially the
measuring tools and equipments have to be calibrated daily, or calibrated and checked by
independent testing laboratory while the spraying equipment should be calibrated before each
fabrication. The calibration or checks frequency shall be annually or as stated otherwise.
For all test certificates, only English version and the certificates that were issued by HOKLAS
or accredited laboratory authorized by Standardization Administration of China will be accepted in
this project. The certificates will be maintained at quality control department for monitoring and
checking. The quantity of each type of equipment should be determined by the output of the
— 15 —
st
factory to ensure equipments are sufficient for this project.
HOKLAS
Testing equipment photos and calibration certifications are as following:
6.0 Production Setting-out and In-plant Equipments Control Plan
The Production Manager and the Yard Manager shall prepare a Production layout plan for
each workshop for GFRC production, clearly identifying allocation of storage space for GFRC raw
materials and production area(s). Purpose of this production yard layout plan is to mitigate damage
of material and to facilitate material handling and production through proper storage and
arrangement, and thus the yard can be maintained in a tidy and clean environment
GFRC
GFRC
Production Plan has to be reviewed and assessed carefully by the Production Dept and Project
Team whether it can be realized in accordance with the factory actual capability. After assessment,
this plan will be submitted to the Façade Main Contractor and/or the representative of the Client.
Façade Main Contractor and/or the representative of the Client will review and comment the plan
and/or revise the plan accordingly based on the master program of the project, and discuss with
factory the feasibility of the plan. The approved plan will be an action object for all parties and
shall be performed by all related parties. Moreover, this plan shall also be adjusted and updated in
accordance with Job site progress.
The Material Controller shall review and up-date the production layout plan at least every two
weeks or as required, in order to cope with different stages of GFRC production. The site layout
plan shall identify the following:
— 16 —
st
GFRC
a. Mould fabrication area

b. GFRC fabrication area GFRC
c. Trimming, repairing and inspection area
d. Packing area
e. Mould storage area
f. Mould fabrication and production storage area
g. Raw material storage area
h. Site access arrangement
i. Testing Laboratory
j. Loading / Unloading area /
k. Curing Area
l. Assembly area
m. Sealant Application area
— 17 —
st
Layout Plan of ZS BLD Factory
Factories other than Zhongshan which would be used particular for this project should be
equipped and planned in the same way as Zhongshan factory.
— 18 —
st
Mould Fabrication area
The mould area should be large enough for fabrication of masters, timber moulds, silicone
moulds and FRP moulds and be equipped with necessary platforms, transferring devices and
cranes as well as free passageways.
FRP
GFRC Production Area

GFRC
This area should include all the equipments and services necessary for production, and should
have a clear system to keep the area clean, including drainage system, settlement pits, rinse area
etc. Moulds will be placed at wheeled trolleys or turntables in a certain height, which will make
spraying process easier, and thus increase productivity and reduce over-spray wastage.
Trimming, Repairing and Inspection Area
Trimming, Repairing and Inspection Area is very important and should not be taken as a
passageway. It should be used for remedial and/or repairing works where there is any units need to
be repaired and/or remedial, i.e. edges, corner etc.
— 19 —
st
Patch up
QC
Semi-finished Product Inspection by QC
— 20 —
st
Raw material storage area
This area should be close to but separate from the Mould/GFRC fabrication area and it is
important to keep the cement, pigment, metakaolin, sand and fiberglass in a dry condition.
Maintain ventilation within the storage area. Note: All materials shall be stored on timber pallets.
/GFRC
The location of yard arrangement, date of revision of the production layout plan shall be
clearly indicated and updated.
7.0 CONTROL OF MASTER MODEL
7.1 We will fabricate the necessary master models in accordance with the approved Master
Model shop drawing and / or construction shop drawing. Inspection Record of master models
will be submitted together with the Master Model Buyoff Form.
/
buyoff
— 21 —
st
— 22 —
st
7.2 Flow Chart for Inspection and Acceptance of Master Cast: -
Beilida will carry out the Inspection of

Mast Cast with the representative of
Client at site in accordance with MSD.
Master Cast Zhong Shan Beilida undertakes initial

Handover Form visual inspection and checking
according to approved master cast
Taking record /
Acceptable photos and
returning to
Supplier
Yes
Negative Mould
Making
Control Point
7.5 Allowable Tolerances of Master Cast ( Refer to following tables)
7.5.1 Detail dimensions have a +/– 1 mm tolerance, maximum 2 mm tolerance; factory

tolerance is +/- 0.5 mm, maximum 1 mm overall tolerance in detail dimension.
1 mm 2 mm 0.5 mm
1mm
7.5.2 Moulds that to be joined at both ends must have the same profile and be jointed at the
center. Tolerance should be +/- 0.5 mm. Other parts must be matched exactly in dimensions.
0.5 0.5
— 23 —
st
The checking items are as follows:
1. Check all details of the profiles and dimensions.
A. Height
B. Width
C. Diagonal
D. Radius size
Notes: Identity defects with marker and record the 1 mm allowable tolerance.
Non- critical tolerances may vary at a tolerance of 1mm/1m
1 mm
1 mm
2. Check surface smooth finish.
A No polyester putty residue. Bumps on the surface finish make indentations on the mold
surface.
B No grooves from sanding on the part or the flanges.
C No reverse in the profiles.
D Check draft angle through the length of the master and each profile.
E Check the flat surfaces for straight and plane.
F Sanding paper to be not more than 240 grit.

240
G Check for details of parallel lines which shall be the same length.
I Repeat details such as dentils, acanthus leaves must be symmetrical and free of distortion
and misalignment.
— 24 —
st
J Sculpture work should be conforming to original reference material or alternative
information provided by owner.
K Allowable tolerance in the master cast dimensions is shown above and will be in
accordance with MOF Specifications and relevant drawings: -
MOF
Master cast Handover Form or Inspection Form shall be prepared for each master model
and master model must be complied with all requirements as specified in related shop drawings
and specification.
— 25 —
st
8.0 NEGATIVE MOULD FABRICATION PROCEDURE
Mould fabrication and inspection diagram
Dispatcher
Mould worker
QAQC NO
Buyoff
QAQC inspection with client representative Yes
Mould worker
QAQC YES NO
QAQC inspection with client

representative when necessary
— 26 —
st
9.0 GFRC Production & Quality Control Procedure
GFRC
9.1 Flow Chart for QA / QC Plan for Mould Making and GFRC Production
GFRC QA/QC
Negative Mould
inspection by the mould
supervisor assistant
Mould Controlling NO
Acceptable Rework
Sheet3
Check Point
YES
Check Point
GRC Daily GRC YES
Acceptable
Production Sheet Production
Curing
NO
Scrap
Demoulding Sheet Demoulding
Check Point
Patch Up & Trimming
NO
Rework
Acceptable
YES YES
Acceptable
Packing
Delivery
— 27 —
st
9.2 Raw Material Usage for GFRC Production:
Raw Material Brand Supplier

(i) White Cement White Elephant SCT Co. Ltd.
Aalborg White Cement (Anqing)
Company Limited
(ii) Silica Sand N/A Hop Shing Silica Sand Co.

( )
(iii) Alkali Resistant Cem-FIL Taishan Fiberglass Inc

Glass Fiber
NEG ARG Fiber Nippon Electric Glass Co. Ltd
(iv) Water Reducer Sikament NN Sika (China ) Ltd.
Sika Formol EX Sika (China ) Ltd.

(v) Release mould agent
Bayferrox Bayer Pigments Co. Ltd.

(vi) Pigment
(vii) Acrylic polymers Dow Chemical Company

Primal MC-76 LO
(viii) Potable Water
(ix) Sealer CS4001 Dow Chemical Company
CTC United Coating
(x) Backing steel frame BS Standard or Equivalent

Chinese Standard Grade
Steel
— 28 —
st
9.3 Formulations and Mixing Ratio: - Standard ratio
1.
Standard mix design for face mix
* Pigment
White Silica sand Admixture
Type Water Metakaolin Polymer
cement #6, 40/70 Sika NN
Face
40kg 40kg 15Kg 300-400ml 2~3kg 2~3Kg <5%
mix
(1)
NOTE: Proportion of water can be adjusted slightly, subjected to current weather conditions when casting.
(2) —
Silica sand- Pure colored silica sand should be used for particular textures
(3) The amount of pigment is subject to the approved sample.
1. 2. B
Standard mix for backing mix Batching record B
*
Type White Silica sand Water Admixture
cement #6,40/70 Polymer Metakaolin AR glass fiber
SikaNN
Backing 40kg 40kg 15kg 300-500ml 2~3kg 2~3kg 5~6kg
NOTE: Proportion of water can be adjusted slightly, subjected to current weather conditions when casting.
9.4 Material Mixing Sequence:
The cementitious slurry should be batched/weighed using proper equipments and mixed in a
‘High Shear Mixer’, both of them must be operated by specialist operators, so that a smooth,
flowing and uniform consistency will be achieved.
— 29 —
st
9.5 Method of testing of raw material before GFRC production:-

GFRC
9.5.1 Slump test (BSEN1170-1:1998)

(BSEN1170-1:1998)
This is a useful check on the spray ability of a mix.

The slump is measured by the number of rings covered by the slurry. The standard
formulations 4-7 rings are the normal range to be aimed for depending on relevant ambient
temperature.
2~5
4-7
— 30 —
st
9.5.2 Wash-Out Test :Measuring the fiber content in flesh GRC (BS EN1170-2:1998)
GRC (BSEN1170-2:1998)
Before the daily production, test boards should be prepared; one of the test boards will be
used for wash-out test so as to determine the ratio of fiber content.
9.5.3 Measuring fiber content of sprayed GRC (BSEN 1170-3:1998):

GRC (BSEN 1170-3:1998):
The test shall be carried out under the same conditions as actual production. Such kind of
tests can be carried out at any time as per QC requirement in order to check the consistency
of fiber content and sprayed slurry volume.
BAG TEST & BUCKET TEST
The tests can be randomly conducted by QC to check the output from the slurry spray as well
as the fiber content.
QC
— 31 —
st
9.6 Moulds preparation and inspection before GRC Production:

GRC
1 Moulds should be inspected before daily production. Only the qualified ones can be put
into service. Attached is the inspection list of moulds.
2 Prepare the inspection tools and drawings. Make sure that the serial numbers of the moulds
must be unique and correct.
3 One should refer to MSD, PSD and inspection list to check the dimensions, appearance and
flatness of moulds. During inspection, he/she should make a well inspection record. After
inspection, he/she should sign and hand over the inspection record as well as mark on the moulds.
MSD PSD
4 Confirm all fixing jigs are complying with the PSD drawing
PSD
5) Make sure there is enough space for spraying and demoulding between moulds.
6) Provide a safe working area between each mould for spray up, hand packing, compaction
work and fixing jig installation.
— 32 —
st
9.6.5 GRC Production Process
GRC
1 Check/Verify the mould number, drawing and relevant texture as well as raw materials
2 Clean and apply the water based demoulding agent onto the mould
3 Weight the mixture and additives as per standard mixing ratio. The weight accuracy
should be within +2%, a record of which should be prepared and provided.
+2%
4 The mixing of both face coat and aggregate material should be done as per requirement
of operation instruction which is compiled by technical department. Before production, the
instruction should be well explained to the factory managers who will train the operators in
accordance this instruction.
5 Mixing should be conducted as per standard procedure and the mixing material should
be sprayed within the specified time. It is strictly forbidden to conduct any non compliance
operations such as adding the water into the mix for a second time.
6 The slump test should be carried out and recorded during each mixing. Production can only
be carried out based on qualified slump tests (reaching the certain loops), otherwise, correction
measures like adding cold water to control the slurry temperature or adjustment of mixing
equipment should be provided to remove the deviations. It is imperative to provide consistent
slurry in order to guarantee good quality.
7 Mixing should be strictly in line with the production instructions, so that slurry consistency
can be maintained and the qualified slurry can be applied in time.
— 33 —
st
8 In accordance with specifications, we shall carry out slump test, test board fabrication as
well as equipment calibration before daily production.
9 A face coat shall be sprayed according to operation instruction, at the beginning of which a
dedicated QC will check the spray gun, volume, distance and atomization to make sure these are
all in line with the specification.
QC
10 A process QC coupled with the spray operator should check the thickness, spray intervals
and setting time of face coats. The QC is responsible for providing an inspection record.
QC
11 During face coat fabrication, all of the quality risks such as slurry slumps, dried or even
cracked coats should be removed immediately. The materials should be removed and the
production should be conducted once again.
12 The production capacity of every machinery shall be tested and verified in a scientific way,
so that the best match of personnel, machinery, production capacity and quality control can be
maintained.
13 We will reasonably consider the production of components with different textures from
the production planning to placement of moulds in a comprehensive way. .
14 Before spray of aggregate slurry, on one hand, one should prepare the test boards used for
wash out test and test of other physical/mechanical properties, on the other hand, he/she should
prepare buckets/bags for calibration of spray volume and determination of fiber content.
— 34 —
st
15 Mixing, application and spray of aggregate slurry should be in accordance with the
operation instruction, which is compiled strictly in line with relevant standards of PCI 128 and
GRCA.
PCI 128 GRCA

16 In order to guarantee a good spray quality, process QCs should be endowed with higher
authorities and trained more professionally, so that they will perform the quality control duties
better in the fabrication process.
QC
17 The thickness of every aggregate layer together with the total thickness of the component
should be well controlled and maintained, so that the good compaction quality can be provided.
Such kind of inspections should be executed by both process QC and spray operator. The process
QC will also conduct random inspection and recording.
QC
18 Sufficient and well trained compaction operators should be equipped for fabrication, so
that a good GFRC compaction quality can be guaranteed. The component bulk dry density should
not be lower than1800kg/m3.
GFRC
1800kg/m3
The thickness of each spray layer should be kept within 4mm (when compacted). The
aggregate slurry should be sprayed in three layers in minimum.
4mm 3
19 In order to improve the precise positioning of embedded parts and steel structures, the
auxiliary positioning devices as well as other measures can be adopted. Steel structures shall be
inspected one by one when received by the factory according to the drawings. The client
representative shall come to the factory during fabrication.
20 The lifting hooks should be embedded into GFRC product as specified in the design and
PSD drawing.
PSD GFRC
— 35 —
st
21 When the fabrication finishes, the QC will check the main dimensions, including product
surface dimension, diagonal dimension and steel structure positioning in order to make sure that
there are no deviations during fabrication. Later on, the component should be cured for 16 to 24
hours without removing of any auxiliary positioning devices.
GFRC QC
16-24
22 Adequate demoulding professionals and a perfect demoulding plan based on the

components features will be provided in order to remove the accidents, structural damages and
minimize the surface minor damages.
23 After taken out from the mould, the components will be immediately transferred to
patching and processing areas, where patches and inspections will be provided. The components
further movement should be avoided.
24 Adequate and well trained teams/professionals should be provided for patches, acid wash,
sandblasting and protection coat application so as to make sure we can catch up the project
schedule.
25 The raw material quality, process quality and test board quality should be inspected and
recorded daily by dedicated QA/QC. The test/inspection records should be submitted for approval
regularly. The Client Representative can require inspection/test at any time.
26 Professional QC should be provided to supervise/monitor the protection coat quality,

patching quality, acid wash and other surface treatment quality constantly. The qualified
components should be immediately submitted for approval by the client representative who shall
sign his/her name if bought off.
QC
— 36 —
st
27 In order to minimize the product secondary contamination and damages, enough mobile
protective devices should be equipped based on project characteristics.
10.0 Curing, protection, Assembly, packing and transportation of GFRC Products

GFRC
10.1 Curing
1 Because of the acrylic polymer additive, the components can be cured in a natural in house
conditions. Excessive exposure to sunshine and rainfalls will increase the risk of cracks and
discoloration of panels; therefore, after being taken out of the moulds, the components should be
prevented from rainfalls and strong sunrays within one week.
GFRC
2 In order to remove the discoloration, the patched places should be cured in a wet manner
and proper measures should be adopted.
GFRC
2 Proper measures shall be adopted to minimize the curing environment changes due to
abnormal climate.
10.2 Protection
1 Application of protection coat should be line with the standard practice. Besides comparing the
sample color, the component moisture should also be tested, the protection coat application can be
carried out in accordance with the operation instruction only when the color compare and moisture
test are success.
GFRC
2 The selection of protection agent should be based on well consideration of waterproof

performance, durability, pollution resistant and cleaning performance.
— 37 —
st
3 Sufficient dry time and condition should be provided after the protection agent is applied.
Inspection and bought off of the client representative shall go before delivering.
10.3 Pre-assembly in factory

1 Since some of the components should be assembled and inspected inside the factory, therefore, a
dedicated team of operators will be established for assembly. The components shall be inspected
independently by QC before assembly; only qualified ones will be assembled. After assembly, the
QC shall work together with the client representative to inspect the modular texture, appearance
and quality. Later on, the sealant and protection agent can be applied respectively before packing
and delivering.
QC
2 A dedicated assembly zone will be provided. The assembly will be carried out by the
professional operators/installers according to the shipment schedule so as to avoid the secondary
damages.
10.4 Packing and Protection of Finished Products

1 All the components shall be fixed and stored on steel pallets, which will be designed as per
component profiles in order to make sure the component gravity is stable, the pallet structure and
supports are of good strength.
2 A dedicated packing team shall be established who will be trained professionally and equipped
with proper packing devices/equipment, so that the component damage risks will be minimized.
3 The components shall be protected at the corners with soft materials. Waterproof and
contamination resistant functions should be provided. The components shall be firstly packed by
foams of certain strength and later be fixed firmly on the pallets by packing tapes.
— 38 —
st
10.5 Shipping
1 A contract will be signed with a large professional shipping company who has rich shipping
experience of large GFRC components. A dedicated team will be organized to coordinate packing
and shipping.
GFRC
2 A barcode system will be utilized to manage finished products, through which one may read all
of the relevant information from design to installation by scanning, including complete set of
drawings, mold, steel structure, fabrication, process quality control and inspections etc., The
barcode will also be referred when numbering the product and drawing. The barcode will be sealed
and labeled at the eye-catching places on surface of the component.
3 The site shipment directive shall be strictly abided by (deliver only when required as per
priorities) so that the installation requirement will be satisfied.
11.0 Product Numbering System
11.1 Parts No.
All GFRC parts no. will be marked with an oil pen on its back or at either end. The consistent
coding system illustrated as follows will be specifically applied to all the GFRC panels for this
project.
GFRC
GFRC
Information Code
Project No. ------------------------------------------------------- 52310
PSD. No --------------------------------------------------- MU2-M6

PSD .
Manufacture Date ------------------------------------------- 4/14/2018
— 39 —
st
Mould Identification No. --------------------------------------------- A
Example 52310/MU2-M6 10/8/07 A
11.2 Mould Code
Each Mould is assigned a record sheet and has a sequential number system. As the MSD
reflects a part that may be utilized in different locations a number that refers to the PSD drawing
will be utilized,
MSD
PSD
The numeric code will identify the following
Project No.---------------------------------------------52310
PSD No----------------------------------------------- MU2-M6

PSD
Mould Identification No -----------------------------B
Date of Manufacture----------------------------------1/8/07
Example 52310/MU2-M6 /B/1/8/07
11.3 Model Code
Same to MSD drawing

MSD
— 40 —
st
12.0 Technical Data and Specification of Major Raw Materials
12.1 CEMENT
— 41 —
st
— 42 —
st
12.2 SILICA SAND
— 43 —
st
12.3 ALKALI RESISTANT GLASS FIBERS
— 44 —
st
— 45 —
st
12.4 POLYMER
— 46 —
st
— 47 —
st
12.5 Cast-in Items
— 48 —
st
— 49 —
st
12.6 Typical Fixing Details
— 50 —
st
13.0 Inspection and Test Plan
— 51 —
st
— 52 —
st
Appendix A :
Inspection Form
Register Summary of Inspection &Fabrication QA/QC Checking Record Form
Item Content Page

1 Form 1 Batching Record A of Daily Production( Face Mix) P54
2 Form 2 Batching Record B of Daily Production( Back Mix) P55
3 Form 3 Square rule Calibration Report P56
4 Form 4 Steel Tape Calibration Report P57
5 Form 5 In-coming Materials Inspection Record P58
6 Form 6 Mould Inspection Record P59
7 Form 7 Process Quality Control Testing Report P60
8 Form 8 Equipment Maintenance Records P61

9 Form 9 Finished Production Inspection Record P63
— 53 —
st
A
Form 1: Batching record A of daily production(Face mix)
Factory:__________ Manufacture date:________________ Record No._______________
1 2 A
Standard mix for face coat Batching record A
Pigment
*
White Silica QC
Batch Type Water Admixture Metamax Polymer Operator
cement sand inspector
F/C
2Kg
Explain: *Water may vary up to 2kg depending on cyclical weather conditions.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
— 54 —
st
B
Form 2: Batching record B of daily production(Backing mix)
Factory:____________ Manufacture date:________________ Test board No.: ___________ Record No._________
1 2 B
Standard mix for Backing Batching record B
*
QC
White Wate AR glass
Batch Type Silica sand Admixture Polymer Metamax Operator inspector
cement r fiber
Backing
2Kg
Explain: *Water may vary up to 2kg depending on cyclical weather conditions
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
— 55 —
st
Form 3: Square rule Calibration Report
Appearance
0-300mm
Serial Smoothness Degree

Angle Calibrati
Square No Level of side readability Degree Conclus Inspecto Appro
Tolera on Remarks
ruler Tolerance ion r val
nce Date
model
1
Note: Standard equipments Standard Square rule
2 ±1mm , ±0.1° 300 mm 0.5 mm
Calibration Standard: Scale: ±1mm Degree: ±0.1° ( i.e. Distance between right angle side and
right angle side is 0.5mm)
(3)
The expired Date of Square Rule should be 6 mouths from the date first used.
— 56 —
st
Form 4: Steel Tape Calibration Report
Tolerance(mm)
Serial
Model No NO 0-1000 1000-200 2000-300 3000-400 4000-500 Total Calibrat
Tolerance Conclus Inspecto Date Approva Remarks
(1) 1 2 1mm/1000mm (3)
Note (1) Standard Equipment:1mm Steel Tape; ( 2 ) Stand Calibration: 1mm/1000mm; (3) The expired Date of Square Ru
be 6 mouths from the date first used.
— 57 —
st
Form 5:
In-coming Material Inspection Record
Cement sand ARClassFiber Other

_____________ _____________
Supplier JobNo
_____________ _____________
DateReceived DeliveryOrderNo
Material name quantity Unit weight Quality
Recordofselectiveinspectionofweight
kg %
Standardweight Selectiveinspectionrate Selectiveinspectionquantity Acceptancerate
kg %
tolerance Standardacceptancerate Acceptance quantity
0 1 2 3 4 5 6 7 8 9
0-
1-
2-
3-
4-
5-
Conclusion
Prepared by Inspector QC Supervisor
Date Date Date
— 58 —
st
Form 6:
Mould Inspection Record
Mould I.D. Name:_________ Job No: __________
Mould Serial No:___________ Date Fabricated: _________
(mm) (mm) Measurement /

Item Design Allowable tolerance Acceptable(A)/ Unaccept
1st measur Re- measure
3mm
Length Max: 3mm
3mm
Width Max: 3mm
Height
Cast-in Positio
1.0 mm/1000mm
Warpage
1.o mm
Surface flatnes
2.0 mm
Edge straightne
5
Diagonal Max: 5mm
1
2
3
Result
4
5
Final conclusion:
Prepared by Inspector QC Supervisor
Date Date Date

— 59 —
st
Form 7:
Quality Control Testing Report
Job No: Manufacture Date
Spray mixing Ratio
Silica Sand___kg / While / Grey Cement:____kg Fiber:____kg water:__kg
Admixture__kg GFRC Power ___kg
Qualuty Standard Refer to “Quality Control Handout”
Fiber Content :4.8%-5.3% Slump 4-7 rings
Slump Test Tests

Testing time
Slump (ring)
3
Note It is passed when meet the requirement in 3 testing .If normal range, the admixture should be varied and test
again
Test method for fiber content of sprayed GFRC(BSEN1170-3:1998)

tester equipment sprayer
+30 fiber
Testing time Blank Fiber roll blank fiber roll content(%) compressor
backet before spray backet+spraying afer spray m - m4/m3- m record
m (g) m2 (g) 30scc m3 (g) m4 (g)
+ +
Sample position Sieve m Sieve+ Fiber content Average renarks
(g) sample Sieve+ fiber (%) value
m2 (g) m3 (g) M - m1/m2- m
T upper
T middle
t lower
Ration of water absorption & immersion and porosity density
testing date tester
Testing no dimension Volume Quality after Quality after dry Absorption Density
cm3 mmersion Md (g) Mwl - Md /Md Kg/m3
Mwl
T1 ----- ------ -----
T2 ----- ------ -----
B1 ----- ------ -----
----- ------ -----
Average value
— 60 —
st
Form 8: Equipment Maintenance Record
Date:
Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Item
clean nozzle
Checking abrasion state

Every Day
of rubber tire and blade

45
1 Spray Gun 1
Atmosphere Checking
(>45 ponds)
wind
power motor refueling
Rotor
and Stator Cleaning
Every
Current
Week
Checking
clean nozzle

Every Day

2 Spray Gun 2
45
Atmosphere Checking
(>45 ponds)
wind
Rotor
and Stator Cleaning
Every
Current
Week
Checking
clean nozzle

Every Day

3 Spray Gun 3
45
Atmosphere Checking
(>45 ponds)
wind
Rotor
and Stator Cleaning
Every
Current
Week
Checking
— 61 —
st
Equipment Maintenance Record
Date:
Date 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Item
clean nozzle

Every Day

45
4 Spray Gun 4
Atmosphere Checking
(>45 ponds)
wind
Rotor
and Stator Cleaning
Every
Current
Week
Checking
propeller
Every Day
Blade Screw Checking
Cleaning
1 Mixer 1
Blade
annex
Every Week
lubricant
Current
Checking
propeller
Every Day
Blade Screw Checking
Cleaning
1 Mixer 2
Blade
annex
Every Week
lubricant
Current
Checking
— 62 —
st
Form 9:
Finished Product Inspection Record
1 2 3
4
Product Serial Acceptable
Date length width height Cast-in diagonal Surface Surface Backing Remark
name no colour /unacceptable
produced position flatness finish finish
length width height diagonal

0-3m Cast-in Surface
5mm 2.5mm/2m
— 63 —
st
Appendix B:
Inspection Criteria of Raw Materials
— 64 —
st
1
Cement
1)
General
a. GFRC
Two types of cements used in BLD: Portland grey cement and Portland white cement.
b. 42.5 42.5R GB175-1999 28
42.5MPa
Grade of cement: 42.5, 42.5R or above (National standard GB175-1999).
c.
Before choosing one cement brand, should obtain the physical properties test and chemical
composition test report from manufacturer, and send the sample to test if the clients require
2)
Inspection items of cement that pass test
a.
Appearance: date of production (validity within in 3 months); packing condition; indicating of
intensity grade.
b.
Weight inspection (selected)
2% 100
Min selected rate: 2% (If quantity is 100bags, select 2 bags to inspect and record)
2 2%
Deviation standard of weight inspection: 2%:
50kg 1kg
Grey cement: 50±1 kg
40kg 0.8kg
White cement: 40 ±0.8 kg
3) 4% 50%
When find discrepancy. Reselect 4% for inspection, if there are 50% bags of selected quantity fall
short of standard; return this lot material to supplier.
2
Silica Sand
1)
General description
a. GFRC
using quartz sand (silica sand) for GFRC product
b. 1.1.3
Before choosing one quartz send supplier, should choose the sample to test its chemical
composition test (requirement: please refer to the specification: 1.1.3)
2)
Inspection items of quartz sand in the factory
— 65 —
st
a
Weight inspection (selected)
1 2%
Min. selected rate: 2%
2 4% 50kg 2kg
Deviation standard of weight inspection is ±4%, that is: 50 ±2kg
3 4% 50%
When find discrepancy. Reselect 4% for inspection, if there are 50% bags of selected quantity
fall short of standard; return this lot material to supplier.
b
Inspection of water content
2%
Approval standard: water content < 2%
:
Inspection method:
1 200g W W1
Select M1N 200g quartz sand and put it on a dry metal salver (Wmetal) which is W1: sand and
salver
2 100 1 W2
put it in oven ( 100 ) for baking at least 1 hour, which is W2: dry sand and salver
W1 W 2
3 = 100
W 2 Wmetal
W1 W 2
3 water content = 100
W 2 Wmetal
c
Particle diameter grading limit of quartz sand
Content Percentage Content Percentage Diameter passing

(sand for spraying) (Sand for precast) Standard
90% 0.15, 1.2
10% 10% 0.15
90% 0.15, 2.4
If the sand do not comply with the above standards, factory should return materials to the
supplier.
d
The sand should be in close co/or and luster for using as the surface slurry
— 66 —
st
3 Alkali resistant Glass Fiber
1) General
GFRC
GFRC products use alkali resistant glass fiber, should provide the technical specification and
testing report of the manufacturer.
:
Inspection items in the factory:
a.
Appearance inspection: check damp-proof packing whether it's damage, open carton to see
whether it is disposed in sound order.
b. 5 5
A carton of a batch has been selected randomly and chosen 5 boxes for carrying out the above
inspection items. If 5 cartons are passing, a batch is then passed. Otherwise, the entire boxes of the
cartons should be inspected if any one of the boxes is failed. Return those disqualified to supplier
for replacement.
4
Cast-in products
1)
Material quality:
1 SS GMS
Divided into Stainless steel (SS) and Galvanized Mild Steel (GMS)
2 SS 202 304 316L 316H
According to various project requirements, normal SS has been divided into: grade 202, grade 304,
grade 316L, grade 316H etc.
3
/
Ease for estimation is:
Stainless Steel: non-attractive of magnet
Galvanized Mild Steel /Stainless Iron: attractive of magnet
4
The receipt of Material standard:
SGS
Acceptance standard of material quality: the approval certificate (such as SGS report) should
comply with project specification.
2)
5% 20 3
— 67 —
st
10% 40 6
AQL (Acceptable Quality Level)

5% of the batch or 20nos, whichever is greater, take at random from the batch, will be
inspected first. If 3nos or above in the first batch were rejected, then further 10% of the batch or 40
nos will be inspected. Should any rejection more than 6nos of the batch, further inspection will not
be carried out and the supplier will be informed to collect the entire batch for replacement
immediately.
3)
Inspection of appearance: welding crack, welding point, surface condition of plating
4)
Inspection of dimension
Allowable tolerance should comply with the dimension requirement of installation.
5
Inspection of other material
1)
Water reducing agent
a
Appearance: exam name and label on the packing bucket; check its expiration date.
b
Quantity: count the number of bucket
2)
Polymer
a
Appearance: exam name arm label on the bucket; check its expiration date
b
Quantity: count the number of bucket
3)
De-mould oil (mould release agent)
a
Appearance: examine name and label on the packing bucket.
b
Quality: count the number of buckets
4)
Foam
Appearance: cheek whether there is breakage damage
— 68 —
st
Appendix C:
Inspection Criteria of Moulds
— 69 —
st
1
Scope
GFRC
Mould used for GFRC product manufacture
2
Content of inspection and allowed deviation of dimension
1) Side length
2) Board height
3) Position of embedded parts
4) Surface Warpage
5) Surface smoothness
6) Side bending
7) Diagonal deviation
4.4
Inspection methods and test apparatus depend on specific condition of each mould, which could
be referred to general measuring methods 1.3.3 of product in section 7.3.4.
3
Allowed dimension tolerance of the mould
Items Range of allowable tolerance

1. 3 (10 ft. or under): 3mm
Overall Height & Width 3 (10 ft. or above): 3mm per 3m
2. +6.3mm, -0mm
Thickness
3. Not to exceed 118.5kg/m2
Weight of finished panels
4. 6mm
Position of embeds
5. 1.5mm per 300mm of distance from nearest adjacent
Maximum Warpage corner
6. 3mm per 3m
Local Smoothness
7. Not to exceed L/360, maximum 25.4mm
Surface Bowing
8. 3mm per 1.8m, total 6mm, whichever is less
Diagonal tolerance
Note: Others fabrication tolerances refer to Specification.
4
Inspection of appearance
— 70 —
st
1
Swage (Iron mould)
Exam surface smoothness, restness, welding poison, iron sheet connection

2
Wood mould, GRP mould,
Exam surface smoothness, glaze, rustuess, welding poison, interstice, crack, iron sheet connection
3 FRP
FRP mould
Check the flatness,smooth surface,fixing,and welding condition of surface.
— 71 —
st
Appendix D:
GFRC
Inspection Criteria of GFRC Production
— 72 —
st
1 Process
GFRC
Inspection of GFRC production process.
2 : BS EN 1170-1 1998
Slump test BS EN 1170-l: 1998
1 3-5 4 7
Standard: Face xix: 3-5 rings, Backing mix: 4-7 rings
2
Amendment
If exceed standard requirement, adjust mixture ratio and test again

3 GRC BSEN1170-2 1998
GRC mixture fiber content test BSEN1170-2 1998(for reference)
1
Standard
GRC 4.8% 5.3%
Fiber content range in spray process: 4.8%-5.3%
2
Allowable Fiber content tolerance
GRC
Fiber content tolerance in the Deviation Assessment Fiber content tolerance in
Spraying method precast method
1% 0.5%
Low, acceptable
1% 1.5% 0.5% 1%
High, Fair acceptable
1.5% 1%
Unacceptable
3)
Amendment:
If unacceptable, should re-inspect production process and readjust fiber output ration, test again.
4 GRC BS EN 1170-3 1997 GRC

Test method for Fiber content of sprayed GRC BS EN 1170-3:1997
1
Standard (calculate in minute unit)
4.8% 5.3%
Fiber output quantity range: 4.8%-5.3%
2
— 73 —
st
Amendment
If failed, should adjust fiber or cement mortar output rating, then test again.
5
Fiber Length test
2 3
Use spray gun to spurt for 2 seconds, select 3 fiber bunches randomly, and measure its length.
1
Standard:
28-32mm
For spraying: 28-32 mm
12-25mm
For precast: 12-15 mm
2
Amendment
When exceed standard. Adjust fiber length according to below measures:

A
Cheek cutting knife, should timely change if crack or damage
B
Check if there is resistance from exterior to block fiber deliver in to spray gun.
C
Check attrition rate of rubber ring, and replace the rubber ring and blade timely if they can not
driving fit.
6
Thickness test
GFRC
Use roller to consolidate the product, then use probe to test GFRC spray layer thickness.
1)
Standard
-0/+2mm
Designed thickness: -0/+2 mm
2)
Amendment
GFRC 2mm
GFRC
Spray GFRC to the designed thickness. When designed thickness exceed +2mm, remove the
oversprayed material, and use roller to consolidate the sprayed material, and then test again.
— 74 —
st
Remark:
The product should be consolidated again after thickness test.
7
Ratio of water absorption & immersion and dry density
BSEN1170-6 1998
Testing method should be carried out according to BS EN1170-6:1998, and is at the discretion
of Architect and is subjected to the requirement of the Specification whether this test is necessary.
1
Standard
12%
Water absorption should not exceed 12%
2
Dry bulk density should not exceed
GFRC 2300kg/m3
2300 kg/m3 for GFRC spraying method
3
Wet bulk density should not exceed
GFRC 2600kg/m3
2600 Kg/m3 for GFRC spraying method
If there is any non-compliance (below specified requirement), cut a test coupon from finished
product and test it again, if failed again in the second test, all product produced in that day should
not be delivered.
8 GFRC
Inspection standard on GRC flexural strength
8.1 7 BS EN 1170-4 1998
Simplify Bending Strength test (at 7days) : BS EN l170-4:1998
1
Standard (characteristic value)
a
7 LOP 4.2Mpa
7 MOR 7.0Mpa
Precast:
7 days LOP: 4,2 MPa
7 days MOR: 7.0 Mpa
— 75 —
st
b
7 LOP 4.9 Mpa
7 MOR 12.6 Mpa
Spray process
7 days LOP: 4.9 MPa
7 days MOR: 12.6 Mpa
8.2 7 28 BE SN1170-5 1998

Complete Bending Strength test: (7days or 28 days) BS EN l170-5:1998
a
28 LOP 6.0 Mpa
28 MOR 10Mpa
b
28 LOP 7.0 Mpa
28 MOR 18.0 Mpa
b. Spray cast:
28 days LOP: 7.0 MPa
28 days MOP: 18.0 MPa
8.3 MOR
Relationship of MOR value (same in precast and spraying) is as below:
= 0.8 ~ 1.25
moulding plate face down

ratio 0.8 ~ 1.25
moulding plate face up
— 76 —
st
8.4
Reference Strength Standard
Item Precasting Spraying

LOP 4 7.25Mpa 8.00Mpa
4 consecutive mean
5.00Mpa 6.00Mpa
Single value should not
under
MOR 4 12.00Mpa 21.00Mpa
4 consecutive mean
8.50Mpa 15.00Mpa
Single value should not
under
P S
P.S If the test results are below the standard, cut a test coupon from finished product and test
again, if fail again in the second test, all product produced in that day should not be delivered.
— 77 —
st
Appendix E:
Acceptance Standard for GFRC products
GFRC
— 78 —
st
1 Dimension Tolerance
Item Allowable Tolerance

0~3m: ±3mm
Long side 3~6m: ±1mm/m
5mm
Short side Max. not exceed 5mm
Height
Diagonal
0-2mm
Thickness
±5mm
Position of cast-in elements
±2.5mm/m
Side mold Distortion
±3mm
Surface warpage
Notes: Tolerances not mentioned hereinabove should be referred to Specification.
2
Inspection of appearance
The appearance of products shall be consistent and match approved samples approved. by
Client/Achitect.
We shall also identify the defects shown in the following table, where appropriate treatment
shall be undertaken.
Item Inspection Acceptance standard and repairing measurement

1
Crack 1 obvious crack
2
Do not accept product with crack, but if QA
2 part craze or more department confirm that the crack won’t affect
shout & small crack load bearing of product and it won’t enlarger, then
can repair it directly. Otherwise, treat it as scrap
— 79 —
st
1 1
Break corner and 1 Discard panels that its structure were affected
holes 1 obvious break corner 2
and hole
2 2 repair those that only affect appearance and
waterproof layer; any impact on structure can’t be
2 position, frequency and repaired.
size of break corner &
holes
Pinhole Any pinhole Repair immediately
Processing surface Refer to approved samples

Polished surface and
other special surfaces
GFRC
Surrounding of GFRC, filler Do not accept gaps around embedded parts, need
cast-in products to repair
Cast-in Products Screw thread

Do not accept damaged screw thread; any stuffing
within screw thread should be cleaned..
Finish Comply with approved Compare to Client’s Approved sample

finish by Client
— 80 —

Factory Quality Assurance Plan for New York GFRC Project

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Factory Quality Assurance Plan for New York GFRC Project

Загружено:

Авторское право:

Доступные форматы

Factory Quality Assurance/Quality Control Plan

Revision Date Prepared by Approved by Status

00 2018-4-12 Xu Zhixing For

1.0 Quality Policy (QP)

3.0 Project QA/QC Organization Chart

5.0 Calibration For Measuring Equipment

6.0 Production Setting-Out and In-Plant Control Plan

7.0 Delivery / Storage of Master Model

8.0 Negative Mould Making Procedure

9.0 GFRC Production & Quality Control Procedure

12.0 Technical Data and Specification of Major Raw Materials

13.0 Inspection and Test Plan

Appendix A: Inspection Forms

Issue Rev Description of Amendment Date Prepared Prepared By

A Beilida Company is committed to be a GFRC works Sub-contractor in providing high

F This policy shall be brought to the attention of all employees.

2.2 Purpose and Scope of This Document

3.0 Project QA/QC Organization Chart

3.2 Liist of Contrrollers

Controlller no. and

6. Packing and delivery (Logistic Finished product and packing Supervisor

4.0 Resources Plan

52.5 52.5 Cem-Fil

5.0 Equipment Calibration

Testing equipment photos and calibration certifications are as following:

6.0 Production Setting-out and In-plant Equipments Control Plan

a. Mould fabrication area

Layout Plan of ZS BLD Factory

GFRC Production Area

Trimming, Repairing and Inspection Area

7.0 CONTROL OF MASTER MODEL

Beilida will carry out the Inspection of

Master Cast Zhong Shan Beilida undertakes initial

7.5 Allowable Tolerances of Master Cast ( Refer to following tables)

7.5.1 Detail dimensions have a +/– 1 mm tolerance, maximum 2 mm tolerance; factory

The checking items are as follows:

1. Check all details of the profiles and dimensions.

2. Check surface smooth finish.

B No grooves from sanding on the part or the flanges.

C No reverse in the profiles.

E Check the flat surfaces for straight and plane.

F Sanding paper to be not more than 240 grit.

Mould fabrication and inspection diagram

QAQC inspection with client representative Yes

QAQC inspection with client

Patch Up & Trimming

Raw Material Brand Supplier

(ii) Silica Sand N/A Hop Shing Silica Sand Co.

(iii) Alkali Resistant Cem-FIL Taishan Fiberglass Inc

(iv) Water Reducer Sikament NN Sika (China ) Ltd.

Sika Formol EX Sika (China ) Ltd.

Bayferrox Bayer Pigments Co. Ltd.

(vii) Acrylic polymers Dow Chemical Company

(viii) Potable Water

(ix) Sealer CS4001 Dow Chemical Company

CTC United Coating

(x) Backing steel frame BS Standard or Equivalent

9.4 Material Mixing Sequence:

9.5 Method of testing of raw material before GFRC production:-

9.5.1 Slump test (BSEN1170-1:1998)

This is a useful check on the spray ability of a mix.

9.5.3 Measuring fiber content of sprayed GRC (BSEN 1170-3:1998):

BAG TEST & BUCKET TEST

Factory: Manufacture date: Record No._____

Factory:__ Manufacture date: Test board No.: _ Record No._____

Mould I.D. Name:_ Job No: __

Mould Serial No:___ Date Fabricated: _