QCS 03.

02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

Page 1 of 8
1. PURPOSE

The purpose of this procedure for inspection and testing activities in order to
verify that the specified requirements for the product or services in
accordance with the Customer requirements.

2. SCOPE

This procedure shall cover the raw material and consumable receiving inspection,
in process inspecting and testing, non-destructive testing, final inspection,
inspection and test records.

3. REFERENCES

3.1 ISO 9001:2015 clause 8.2.4

3.2 AWS D1.1 Edition 2015

3.3 AISC. 2005 – American Institute of Steel Constructions

3.4 MBMA. 2002- Metal Building System Manual

3.5 IBC. 2006.-International Building Code

3.6 Quality Manual

3.7 Fabrication Procedure

3.8 N.D.T Procedure

3.9 Hot Dip Galvanization Procedure

3.10 Blasting & Painting Procedure

3.11 Non-Conforming Product Control Procedure

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

3.12 Non-Conforming Product Control Procedure

3.12 Corrective and Preventive Action Procedure

3.14 Quality Records Control Procedure

4. DEFINITION

4.1 TPI Third Party Inspection

4.2 NDT Non-Destructive Testing
4.3 RT Radiography Test
4.4 UT Ultrasonic Testing
4.5 MPI Magnetic Particle Inspection
4.6 DPT Dye Penetrant Testing
4.7 DFT Dry Film Thickness
4.8 WFT Wet Film Thickness
4.9 QC Quality Control
4.10 QA Quality Assurance
4.11 SSPC Steel Structure Painting Council
4.12 WPS Welding Procedure Specification
4.13 PQR Procedure Qualification Record
4.14 ASNT American Society for Non-Destructive Testing
4.15 NCR Non-Conformance Report

5. RESPONSIBILITY

5.1 The Storekeeper/QC Supervisor shall be responsible for material receiving

inspection and verification.
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

5.2 The Fitter Foreman/Supervisor shall be responsible for inspection of marking,

material identification and transfer of identification number during marking and
cutting process.

5.3 The QC Supervisor shall be responsible for inspecting the dimensional

conformance with shop drawing during Fit-up/Assembly process.

5.4 The Welding Supervisor shall be responsible for selection of appropriate welding
consumables, compliance of welding procedure specification (WPS), welding
procedure qualification record (PQR) and to ensure that only qualified welders are
used for welding work.

5.5 Quality Control Supervisor shall be responsible for visual welding inspection and
Non-Destructive testing of weld joints in accordance with the Quality Plan and its
relevant International Code of Practice.

5.6 Quality Control Engineer shall be responsible for ensure that the inspection and test
are carried out in accordance with Quality Plan and appropriate quality records are
maintained.

6. PROCEDURE

Whatever the product is supplied to the customer, repaired, rebuilt, modified or

otherwise changed, shall be subject to verification that it conforms with the
prescribed as per the customer drawing and specification requirements and any
deficiencies corrected before being released.

Requirement details of the inspection and test shall be documented in the Quality
Plan or Inspection and Test Plan. These shall be reviewed and approved by the
customer, when required by the contract.

6.1 Receiving inspection and testing

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

In coming product or materials including customer supplied items shall not be used
or processed until it has been inspected or verified as conforming to specified
requirement as such verification shall be in accordance with the quality plan or
inspection and test plan.

In order to relate the degree of receiving inspection to the importance of the item
shall categorise purchases, as follows:

 If the subsequent discovery of a non-conformance will not cause design,

production, installation or operational problem of any nature then a simple
identity, quantity and damage check will sufficient.

 If the subsequent discovery of a non-conformance will cause minor

design, production, installation or operational problem then the product shall
be subject to a complete inspection to verify compliance with all prescribed
requirements.

In case of product or materials inspected at the subcontractor's premises by the

company representative or the customer representative and accepted by them, it
may not required to carry out receiving inspection before processes. The documents
evidence of inspection at subcontractor's premises shall be the record of receiving
inspection.

When incoming product is released for urgent production purposes, prior to

carry out the receiving inspection, it shall be positively identified and recorded in
order to permit immediate recall and replacement in the event of non-conformance
detected during the in-process inspection.

6.1.1 Raw material receiving inspection

6.1.1.1 Quality Control Section shall ensure that incoming raw material not use or issued
for production process until it has been inspected and verify as conforming to the
specified requirements. Verification and inspection of conformance to specified
requirements shall be in accordance with project quality plan and inspection and
test plan.
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

6.1.1.2 When incoming raw material is released for urgent production purposes prior to
verification and inspection and it shall be positively identified and recorded in order
to permit immediate recall and replacement in the event of non-conformity to
specified requirements.

6.1.1.3 All the receiving inspection shall be carried out upon receipt of materials or before
used for production. Method and level of receiving inspection shall be described in
the Inspection and Test Plan in accordance to the nature of contract or Customer
requirement.

6.1.1.4 Storekeeper shall verify the quantity, number of packing, type of materials,
general appearance of materials and conformance against the Requisition Order
purchase documents, packing list and delivery order upon receiving materials or
Customer supplied products.

6.1.1.5 Storekeeper shall make arrangements to request QC for inspection.

6.1.1.6 QC Supervisor shall carry out the following visual inspection:

a) General appearance

b) Corrosion or pitting conditions

c) Dimension conformance to purchase order of material list

d) Material identification (Heat number) conformance to mill certificate

e) Verification mill certificate conformance to material standard, manufacturing

code and Client specification.

6.1.1.7 When material identification numbers (Heat number) are not in compliance with the
mill certificate, or the mill certificates are not in compliance with the required
specification material manufacturing code, the QC Supervisor shall fix “HOLD”
label on the non-compliance material OR WRITE DOWN BY YELLOW CRAYON
and raise a NCR for further investigation and corrective actions. On completion
corrective action, the “HOLD” label shall be removed by QC Supervisor.
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

6.1.1.8 When material specification, dimensional, corrosion condition and general

appearance are not in compliance with the requirement, the QC Supervisor shall
reject the materials and such materials shall be identified and segregated from
other materials and “REJECT” label shall be affixed and NCR shall be raised for
necessary corrective action.

6.1.1.9 When it becomes necessary to release materials for urgent production purposes
prior to receiving inspection, it shall be identified by material request code number
and recorded by the Storekeeper and report to QC Section for further recall
when necessary. However, “HOLD” and “REJECT” materials shall not be
released for urgent production.

6.1.2 Consumable receiving inspection

6.1.2.1 All the consumable which directly affect the quality of the product such as welding
electrode, flux, welding filler wire, drilling and punching tools, cutting nozzles and
pressure regulators shall be verify and inspect upon receiving from the supplier.

6.1.2.2 The following items to be verify and inspect for welding consumables:

a) Conditions of the packing and protection

b) Manufacturer brand name

c) Specification comply to AWS standard

d) Quantity in accordance with the purchase order

e) Material test certificate when necessary

6.1.2.3 All the receiving verification and inspection report and necessary records shall be
established and maintained in accordance with quality record control procedure.

6.2 In-process inspection and testing

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

In-process inspection shall be carried out in order to verify the conformance of

the product against the specification and requirement of each process concerned.

Acceptance criteria and the standard shall be defined in detail in the quality plan or
inspection and test plan. The inspection and test plan shall:

 Identify the process to be carried out In-process inspection and

testing.

 Define the specification and acceptance criteria to be used.

 Define any special test equipment to be used.

 Identify the person responsibility to whom perform the

inspection and test.

Product shall be hold until the required in-process and test have been completed
and shall be released for next process only after acceptance by the QC Inspector
and issue of report or put Inspection & Test identification mark on the product. If any
product found non-conformity during in-process inspection & test shall be identified,
segregated and hold until the product to be re-inspected and accepted by the QC
Inspector.

6.2.1 Marking and Cutting

a) Inspection during marking and cutting process includes:

* Checking of marking

* Verification of product mark number

* Transfer of heat number, when necessary

* Edge Preparation
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

b) Inspection during marking and cutting shall be carried out by the Fitter
Foreman / Assembly Supervisor and QC Supervisor may witness the transfer
of heat number.

c) Acceptance criteria and conformance of marking and cutting inspection shall

be in accordance with the shop drawing cutting plan, Customer quality
standard and mill certificates, where appropriate.

6.2.2 Fit-up / Assembly Inspection

a) Inspection during Fit-up/ Assembly inspection shall include the followings:

1) Piece mark number

2) Material profile

3) Thickness

4) Overall length

5) Roof gap

6) Number of holes

7) Hole’s pitch dimension

8) Hole distance from reference point

9) Diameter of hole

10) Gusset location and orientation

11) Thickness and profile of gusset plates

12) Straightness of the base plates and gusset plates etc.

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

b) Acceptance criteria and conformance of fit-up/Assembly inspection is in

accordance with shop drawing, Customer technical specification and
appropriate International Code and Standards.

c) Any non-conformance observed during inspection, the QC Supervisor shall

fix a “HOLD” label OR WRITE DOWN BY YELLOW CRAYON and
subsequently raise NCR.

d) Appropriate corrective action shall be carried out within the period stated in
the NCR reports. Upon completion of satisfactory corrective action, the same
item shall be re-inspected again in accordance with the requirements.

e) If any items are not in conformance with the requirements after necessary
repair and re-inspection, the QC Supervisor shall fix “REJECT” label and
separate the item from the production line and further investigation to be
conducted for the failure.

6.2.3 Welding Inspection

a) QC Supervisor shall check the following conditions for conformity to the

applicable specification, Code and Project Quality Plan prior to welding:

1) Review of welding procedure specification (WPS)

2) Review of welding procedure qualification record (PQR)

3) Review of welder performance qualification test record

4) Verify the list of qualified welder

5) Joint preparation, dimensions and cleanliness

6) Fit-up root clearance, dimension of backing strips, rings, or consumable

inserts

7) Alignment and fit-up of the pieces being welded

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

8) Welding process and consumables

9) Welding procedure

10) Condition of welding power sources and machines

11) Welding parent material specification

12) Pre-heat temperature

13) Tack welding

b) Visual Inspection during welding process is the primary method for

controlling weld quality. Some of the aspects that Welding QC Supervisor
shall check are as follows:

1) Treatment of tack welding

2) Check the correct usage of electrode and classification.

3) Certify the welder qualification badge

4) Verify the welder identification number written near the weld joint

5) Quality of the root pass and the succeeding weld layers

6) Pre-heat and interpass temperature

7) Sequence of welding

8) Inter pass cleaning of weld

9) Root condition prior to welding a second side

c) Items that are inspected by visual inspection after welding include the
followings:

1) Final weld appearance

2) Final weld size

3) Dimensional accuracy

4) Amount of distortion
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

5) Surface cracks

6) Undercut

7) Overlap

8) Exposed porosity and slag inclusions

9) Unacceptable weld profile

10) Roughness of the weld faces

d) Acceptance criteria and conformance of welding inspection in accordance with

the shop drawing, inspection and test plan, Customer technical specification
and International codes which ever applicable.

e) Any minor welding defect observed, the QC supervisor shall mark the
unacceptable area and subsequently the welding. Foreman/ Supervisor shall
take necessary correction action.

f) Any non-conformity observed, the QC Supervisor shall fix a “HOLD” label

and subsequently raise NCR.

g) Appropriate corrective action shall be carried out within the specified period
and when necessary a repair procedure to be established depend on the
complexity of repair works. Necessary record shall be maintained.

6.2.4 Non-Destructive Testing of Welding

a) Most of the internal welding defect may not be observed during visual welding
inspection and they shall be detected by Non-Destructive Testing methods.
Particularly for PEB’s type structures, the Non-Destructive Testing methods as
Magnetic ParticleTesting and Ultrasonic Testing are applicable for butt joint
and T-joint in web and flange of heavy beams and crane beams.
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

b) Non-Destructive Testing shall be carried out by approved NDT subcontractor

and the approval shall be based on the Quality Assessment Record and past
performance of the subcontractor and their capability to meet the customer
requirements.

c) Magnetic Particle Testing (MPT) shall be used for inspecting the welding
cracks, material lamination, inclusion, quenching cracks, thermal cracks,
seams, laps, grinding cracks, overlaps, non-metallic inclusion, fatigue
cracks, and segregations.

d) Ultrasonic Testing (UT) shall be carried out to detect and locate internal
defects such as cracks, porosity, inclusions, lack of fusion and incomplete
penetration.

g) All the NDT shall be carried out by the qualified operator and the qualification
shall meet and conform to the ASNT.

h) QC Engineer shall verify the qualification of NDT operator and ensure that
equipments are calibrated and have the records.

i) Non-Destructive Test reports shall be reviewed and verified by the QC

engineer and when necessary as agreed in the contract or in accordance with
the inspection and test plan, NDT reports shall be submitted for Customer
review.

j) Any non-conformance found through NDT report and the defect shall be
identified in the product by QC Supervisor in co-ordination with NDT Sub-
contractor and a “HOLD” label shall be fixed to the product OR WRITE
DOWN BY YELLOW CRAYON and NCR to be raised for necessary
corrective action.

6.2.5 Blasting and painting inspection

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

a) Painting Supervisor shall inspect for any imperfections of product surface such
as sharp fins, sharp edges, weld spatter, burning slag, etc. prior to shot
blasting the surface of the product.

b) Painting Supervisor shall inspect the followings upon completion of blasting

and prior to start painting:

1) Oil or grease remaining on the surface

2) Dirt, soil, chalk’s mark etc.

3) Rust

4) Rust scale

5) Mill scale

6) Residue from cleaning operation

c) QC Supervisor shall perform random inspection on the profile of the surface

preparation. The blasting surface inspection shall be in conformance to the
required standard and may use comparison with pictorial surface preparation
for structure. Surface profile comparator shall be used to check the surface
profile conformance.

d) The following items shall be inspected on painted products:

1) Dry film thickness

2) Dryness

3) Completeness of coverage

4) Correct usage paint and colour

5) Brushmark, runs, sags etc.

6) Wrinkling of dried paint indicates faulty paint or too thick application

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

7) Adhesion of dried paint

8) Identification marks

9) In-accessible surfaces were they painted

10) Specified number of coats

11) Blisters, pores, crazing etc.

6.3 Final inspection and testing

6.3.1 The last inspection and testing which carry out before despatch to the customer is
the final and such final inspection and testing shall be carried out in accordance with
the quality plan or documented procedure which is approved by the customer and
as per the contractual requirements to complete the evidence of conformance of the
finished product to the specified requirements in the design drawing.

6.3.2 The Quality Plan or Inspection and Test Plan and the procedure for final inspection
and testing require that all specified inspection and tests, including those specified
either on receipt of product and materials, or in-process, have been carried out and
that appropriate data and records shall meet the specified customer / contractual
requirements.

6.3.3 No product shall be despatched until all the activities specified in the quality plan or
inspection and test plan or documented procedures have been satisfactorily
completed and the appropriate data and documentation are established and an
authorised signature or the stamp of an approved stamp holder who has checked
that the particular product, the evidence and the requirement are complete.

6.3.4 Unless specified, final inspection shall be carried out after blasting and painting.

6.3.5 When specified in the contract or inspection and test plan, QC Engineer shall invite
the Customer Engineer for final inspection and review of reports.

6.3.6 The final inspection and test check shall detect whether:
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

 All previous inspection and checks have been performed.

 The product bears the correct identification, part numbers, serial numbers,
modification status etc.,In addition, the metal tag to be tied with items with all
the punched data for easy identification by end user or at site.

 The as-built configuration is the same as the issue status of all parts, sub-
assemblies, assemblies etc. specified by the design standard.

 All recorded nonconformances have been resolved and remedial action taken
and verified.

 All concession applications have been approved.

 All inspection and test results have been collected.

 Any result outside the stated limits is either subject to an approved concession,
an approved specification change or a retest which shows conformance with
the requirements.

 All documentation to be delivered with the product has been produced and
conforms to the prescribed standards.

6.4 Inspection and test records

6.4.1 Inspection and test records called Quality Control records shall be maintained for
all the contracts or individual job or equipments which provide evidence that the
product has been inspected and tested.

6.4.2 All the Inspection and Test records (Quality Control records) shall define clearly
the result of final inspection and test whether the product is failed / passed /
accepted according to the defined acceptance criteria. Records shall define the
acceptance criteria, the limits between which the product is acceptable and beyond
which the product is unacceptable and therefore non-conforming.

6.4.3 Having carried out and completed of final inspection and test activities, the Quality
Assurance Manager / Engineer shall declare that the product has been inspected
and tested and objective evidence produced that will demonstrate that the product
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

meets the specified requirements. Any concession given against the requirements
shall also be identified. These documents are called "Certificate of

Conformance and Product release Note". As required by the customer

specification and contract this document shall be countersigned by the customer
representative.

6.4.4 Quality Assurance/ Quality Control Section shall establish and maintain records/
reports which provide evidence that the product has been inspected and/ or tested.

6.4.5 The following records shall be maintained for the evidence of inspection and
testing:

a) Material Receiving Inspection record

b) Material mill test certificate (From the Manufacturer)

c) Visual & Dimensional Inspection Report

d) NDT Inspection Report (as applicable)

g) Painting Inspection Report

h) Hot Dip Galvanizing Inspection Report

h) Non-conformance Report (As applicable)

i) Welding procedure specification (WPS) (As applicable)

j) Procedure qualification Record (PQR) (As applicable)

k) Welder qualification Record (As applicable)

l) Inspection and Test plan (I.T.P)

 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

7. FLOW CHART
 QCS 03.02 (R00)
QUALITY CONTROL Dated: 25.10.2017
PROCEDURE
Issued By: QC Mgr

8. DOCUMENTATION

QC documents as appropriate for the project/Fabrication.

9. APPENDICES

9.1 General responsibility structure for inspection and testing.

9.2 All the sample records