Pilbara Insulation

Quality Manual
April, 2000 Revision

QUALITY

“SAFETY AND QUALITY

ON TIME…ON BUDGET”

Pilbara Insulation is firmly committed to achieving Safe, Quality Assured

results.

Pilbara Insulation has engaged Roy Gay Quality Assurance and

Technical Support as a Quality Assurance Advisor.

The Pilbara Insulation Quality Manual has been designed by Roy Gay,
in collaboration with Darren Hargreaves and Tim Lennox to address
specific Passive Fireproofing requirements and conform to B.S.5750,
A.S.3902 or ISO 9002.

Relevant project and manufacturers specifications are to be inserted in

Section 2 of the manual and the appended inspection process sheets,
report forms and coating procedures will be tailored to these
specifications for each submission.

The appendices included here are written for Passive Fireproofing. The
Pilbara Insulation Quality Manual is equally applicable to grouting,
jointing and various concrete works as detailed under ‘Projects’.
Project specific procedures will be produced for these activities as
required.
 Pilbara Insulation
Quality Manual
April, 2000 Revision

QUALITY
MANUAL
 Pilbara Insulation
Quality Manual
April, 2000 Revision

POLICY STATEMENT

The following document outlines the organisation and procedures that shall be
adopted to ensure the supply and installation of products and services are fit for their
intended purpose and conform with the contract requirements and specifications.

To achieve this, Pilbara Insulation pty ltd have prepared a Quality Manual that shall
be applied to all works performed.

The Quality Manual describes a Quality Assurance Programme which complies with
the British Standard Requirements BS 5750, AS 3902 or ISO 9002. To ensure
quality, safety and reliability, all Pilbara Insulation personnel are required to be fully
conversant with and committed to the implementation of the Pilbara Insulation
Quality Assurance Programme.

The Directors of Pilbara Insulation hereby confirm that the Quality Assurance
Manager has the authority and responsibility to ensure that all personnel involved in
the contract comply with the Quality Assurance Programme.

Tim Lennox
Director
Pilbara Insulation pty ltd
 Pilbara Insulation
Quality Manual
April, 2000 Revision

CONTENTS

SECTION 1 SCOPE AND APPLICATION

1.1 Scope of Quality Manual

1.2 Application of Quality Manual
1.3 Issue and Amendment

SECTION 2 REFERENCES

2.1 Reference Specifications

SECTION 3 JOB DESCRIPTIONS

3.1 Project Management

SECTION 4 QUALITY SYSTEM REQUIREMENTS

4.1 Management Policy and Organisation
4.2 Quality System
4.3 Contract Review
4.4 Document Control
4.5 Purchasing
4.6 Purchaser Supplied Products
4.7 Product Identification and Traceability
4.8 Process Control
4.9 Inspection and Testing
4.10 Inspection, Measuring and Test Equipment
4.11 Inspection and Test Status
4.12 Control of Non-Conforming Materials
4.13 Corrective Action
4.14 Handling,Storage and Preservation
4.15 Quality Records
4.16 Quality Audits
4.17 Training

APPENDICES 1-6

1 Organisation Chart
2 Inspection Process Sheets ( 3 pages )
3 Materials Handling Report / Corrective Action
4 Audit Report
5 Inspection and Test Plan
6 Coating Procedure Specification
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Quality Manual
April, 2000 Revision

SECTION 1 - SCOPE AND APPLICATION

1.1 Scope of the Quality Manual

The Quality Manual describes how Pilbara Insulation will implement and
maintain their Quality Insurance Programme in accordance with British
Standard 5750 Pt.2 (A.S. 3902) to meet the specific quality requirements of
the contract.

The Quality Manual is supported by:-

* Inspection and Test Plans (I.T.P.’s)
* Inspection and Test Procedures
* Method Statements and Work Instructions where applicable.

1.2 Application of the Quality Manual

The Quality Manager is responsible for the initial preparation, issue

distribution and any revisions of the Quality Manual.

The Quality Manual shall cover the activities of Pilbara Insulation and their
sub-contractors to ensure that all materials, works and services are carried out
in a planned and systematic manner.

1.3 Issue and Amendment

The Quality Manual is issued under the authorisation of the Directors of

Pilbara Insulation and the acceptance of the clients representative. The
procedures and methods defined in the Quality Manual shall be complied with
by all Pilbara Insulation personnel.

The Quality Manual shall be subject to periodic review and when required,
will be amended as necessary. Approved amendments will be formally issued
to controlled copy holders. It is the responsibility of recipients to ensure
amended pages are incorporated into their copy of the Quality Manual.
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Quality Manual
April, 2000 Revision

SECTION 2 - REFERENCES

2.1 Reference Documents / Specifications

Project and Manufacturers Specs. to be inserted here.

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Quality Manual
April, 2000 Revision

SECTION 3 - JOB DESCRIPTION

3.1 Company Director

Company Directors shall be responsible for the thorough application of the

Pilbara Insulation Quality Statement and Plan. An ongoing commitment to
Quality shall be maintained by the application of the most stringent
procurement, recruitment and training standards, with regular revision of the
quality plan.

3.2 Project Manager

The Project Manager shall be responsible to Pilbara Insulation Directors for

the efficient management, execution and completion of the project works
including QA/QC aspects as follows:-

• liase with Quality Manager to prepare, implement and monitor the QA/QC
programme.
• ensure that all personnel involved in the project works are aware of the
QA/QC requirements and that procedures detailed in the QA Manual are
understood and followed.
• participate in the regular review of the QA/QC Programme and implement
any appropriate recommendations.

3.3 Quality Manager

The Quality Manager shall be responsible to Pilbara Insulation Directors and

the Project Manager for establishing an appropriate QA/QC Programme for
the project and in conjunction with the Project Manager, ensure that it is
effectively implemented and maintained.

This shall include:-

• conducting regular and required inspections of the works in accordance

with the Inspection and Test Plan
• monitoring any review of QC documentation progressively compiled
during the project
• auditing and evaluating the overall effectiveness of the QA/ QC
Programme and recommending any appropriate action
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Quality Manual
April, 2000 Revision

3.4 Supervisor

Supervisors shall be responsible to the Project Manager for the day to day
progress of the works in a safe and efficient manner and maintain an effective
liaison with the Quality Manager.

Supervisors shall ensure that all required inspections be carried out and that
standards of quality are maintained during all stages of the works including:-

• that work carried out is in accordance with established work procedures

• that all personnel liase with the Quality Manager and co-operate in the
interpretation of the QA/QC Programme.
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Quality Manual
April, 2000 Revision

SECTION 4 - QUALITY SYSTEM REQUIREMENTS

4.1 Management Policy and Organisation

It is the policy of Pilbara Insulation to consistently carry out the requirements

of the referenced specifications, Standards and Codes. The quality Practices
to be implemented are described in this Quality Manual and are based on the
requirements of B.S. 5750.

Conformance with the requirements of this Quality Manual and Referenced

Documents is mandatory.

Disputes which cannot be resolved at the lowest project management level

shall be referred to the Directors of Pilbara Insulation.

4.1.1 Project Organisation

An organisation Chart showing the company structure is attached in

Appendix 1. The quality function is independent of the construction
function to ensure that full quality control procedures, as outlined in
the Quality Manual, are achieved.

4.1.2 Principal Quality Responsibilities

The site Project Manager shall ensure that all Pilbara Insulation
personnel and sub-contractors personnel, where applicable,
undertaking works are provided with appropriate work instructions to
ensure:-

• the prevention of any occurrence of non-conformity of supplied

products and services.
• the identification and recording of any quality problems and initiate
appropriate Corrective Action
• the correction of the result and cause of any such quality problems

The Project Manager shall ensure, by way of quality audits and product
verification activities, that the practices outlined in the Quality Manual
are properly implemented and maintained.

4.1.3 Management Reviews

The site Project Manager and other department heads shall review the
effectiveness of the Quality Manual by conducting regular meetings.
These meetings shall discuss any Corrective Actions issued as a result
of audits conducted either internally or by client representatives.
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Quality Manual
April, 2000 Revision

4.2 Quality System

Implementation of the Quality Assurance Programme shall be carried out by

following the requirements of the applicable codes, standards, procedures and
specifications referenced in Section 2 of this Quality Manual.
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Quality Manual
April, 2000 Revision

4.3 Contract Review

Following award of contract and prior to signing the Contract Documents, it is

the responsibility of the Directors of Pilbara Insulation to ensure contract
documentation is reviewed to detect and resolve differences from the Tender
documentation.

The review shall ensure that:-

• documents are identical with agreed Tender documents

• agreed minutes of tender meetings have been incorporated or that relevant
portions of the minutes have been extracted and included in the
appropriate sections of the contract documents
• copies of all relevant correspondence have been included or appended as
part of the contract
• that drawings and specifications forming part of the contract are identical
to those which were part of the tender documentation, including any
amendments
• that the duration of the contract and completion dates are as agreed per the
tender
• that Pilbara Insulation have sufficient resources and are capable of
fulfilling the contract requirements.
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Quality Manual
April, 2000 Revision

4.4 Document Control

The Quality Manager shall be responsible for implementing and maintaining a

system for the control of quality related documentation. This system shall
include the following:-

1. Quality Manual, which shall be uniquely numbered

A register shall be maintained showing the distribution of each

numbered Quality Manual, and any revisions or alterations. Each
recipient of the Quality Manual shall sign as having received it.
Approved alterations or amendments shall be formally transmitted to
the recipient of a controlled copy of the Quality Plan.

2. Drawings and Specifications

A register shall be maintained showing the status of each contract

document drawing and specification including the date received, the
revision number, acceptance and distribution.
Copies of drawings and specifications shall only be issued to Pilbara
Insulation personnel by the Quality Manager and shall be marked as
“controlled” documents.

3. Technical Queries, which shall be uniquely numbered

All Technical Queries raised shall be reviewed by the Quality Manager

prior to transmittal to the client.
A register shall be maintained showing the disposition and status of all
Technical queries.

4. Quality Control status sheets

All inspection status sheets or other approved inspection

documentation shall be maintained in an orderly manner and be easily
retrieved. Where required, such documentation shall form part of a
final handover package.
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Quality Manual
April, 2000 Revision

4.5 Purchasing

All purchase orders (PO’s) shall be raised by a person approved by the

company as the Purchasing Officer. PO’s shall be reviewed and endorsed by
the Quality Manager prior to the approval of the Company Director to ensure
that all materials requested will meet the requirements of the project
specifications, where applicable, and that appropriate quality and certification
will be supplied.

Only suppliers who have been approved by the Project Manager shall be used.
Suppliers’ ability to meet project quality requirements and those of this
Quality Manual shall be determined by assessment by the Quality Manager.

PO’s shall be uniquely and sequentially numbered so as to ensure full

traceability. The Purchasing Officer shall be responsible for ensuring a proper
record system is implemented and maintained.
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Quality Manual
April, 2000 Revision

4.6 Purchaser Supplied Products

Purchased goods shall be verified for quantity, identification, condition and

certification against accompanying documentation. Where goods are found to
be defective or damaged, the Purchasing Officer shall inform the Quality
Manager who shall determine their suitability for use or otherwise.

Where materials are supplied by the client, such materials shall be inspected
by the Quality Manager prior to their use to determine their condition. Any
discrepancies with the specifications, codes or standards shall immediately be
advised to the client in writing. Use of such goods shall only be undertaken
following written confirmation and instructions from the client.
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Quality Manual
April, 2000 Revision

4.7 Product Identification and Traceability

Reference numbers and batch numbers given on supplied goods and

manufacturer’s certification shall be the basis of material identification and
traceability. Batch numbers shall be recorded on all Quality Control process
sheets.
 Pilbara Insulation
Quality Manual
April, 2000 Revision

4.8 Process Control

Application of materials or construction activities shall be controlled and

identified against each of the referenced specifications listed in Section 2 of
this Quality Manual. Prior to application of any material, confirmation in
writing by way of the client’s signature on an Inspection Process Sheet shall
be obtained.

An example of an Inspection Process Sheet is attached in Appendix 2.

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Quality Manual
April, 2000 Revision

4.9 Inspection and Testing

Provision is made on the Inspection and Test Plans (ITP’s for both Pilbara
Insulation and clients “witness”, “review” or “hold” inspections. (Refer
Appendix 5) The Quality Manager shall liase with the client’s representative
to ensure work does not proceed beyond a client’s inspection point.
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Quality Manual
April, 2000 Revision

4.10 Inspection, Measuring and Test Equipment

Inspection, Measuring and Test Equipment shall comprise as a minimum the

following:-

• thermometer
• whirling hygrometer or equivalent
• DFT paint thickness gauge
• durometer
• vernier calipers

An equipment list shall be maintained by the Quality Manager. This list shall
show the item identification, date of calibration, next calibration date due and,
in the case of items calibrated by a third party authority, a copy of any
certification.

Where calibration of equipment can be carried out in-house, such calibration

methods shall be in accordance with the manufacturer’s instructions or by
approved written procedures.
 Pilbara Insulation
Quality Manual
April, 2000 Revision

4.11 Inspection and Test Status

The Quality Manager shall be responsible for ensuring that Inspection and
Test Status is maintained by means of an appropriate, approved Inspection
Process Sheet. An example is attached in Appendix 2.
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Quality Manual
April, 2000 Revision

4.12 Control of Non-Conforming Materials

Non-conforming materials are classified into:-

• material receipt non-conformances
• construction or application non-conformances

4.12.1

Where materials inspected on receipt are found to be defective or non-

conforming, the details of their purchase order, batch number and date
of receipt shall be recorded on a Materials Received Report. Such
non-conforming materials shall be immediately place into a quarantine
area and shall not be used. The Quality Manager shall decide on the
disposition of the material. A Non-Conformance Report shall be
raised and details of corrective action noted.

A register of all non-conformance reports shall be maintained and each

report shall bear a unique number.

4.12.2

Any non-conformance as a result of construction or application

methods shall immediately be notified to the quality Manager, who
shall, following inspection of the non-conformance, raise a non-
conformance report with the details of any corrective action as detailed
in 4.12.1 above. No further work shall continue using the same work
method as caused the non-conformance.
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Quality Manual
April, 2000 Revision

4.13 Corrective Action

Corrective Action shall be implemented as a result of non-conformance as

detailed in section 4.12 of this Quality Manual or as a result of internal or
external audits.

A register shall be maintained detailing the corrective action disposition. No

corrective action shall be deemed to have been completed until the Corrective
Action Request has been signed off. It is the responsibility of the Quality
Manager to properly implement and maintain the Corrective Action Request
register.

Corrective Action Requests shall be the subject of periodic review as detailed

in 4.1.3 of this Quality Manual.

An example is attached in Appendix 3

 Pilbara Insulation
Quality Manual
April, 2000 Revision

4.14 Handling Storage and Preservation

All Materials and equipment shall be handled, stored and maintained to meet
the requirements of the manufacturer and client specifications, codes and
standards.

4.14.1

Any damaged materials noted shall be reported immediately to the

Quality Manager.

4.14.2

All materials and equipment shall be identified, stored and segregated

to prevent damage, loss, deterioration, degradation and inadvertent
substitution.

4.14.3

The Quality Manager or his delegate shall carry out frequent random
inspections of materials and equipment in storage and record their
condition.
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Quality Manual
April, 2000 Revision

4.15 Quality Records

All quality records shall be compiled, stored and filed in an orderly and easily
retrievable manner.

Inspection Process sheets, which may form part of a final handover package to
the client, shall be signed as accepted by the client and endorsed by the
Quality Manager.
 Pilbara Insulation
Quality Manual
April, 2000 Revision

4.16 Quality Audits

Quality Audits shall be carried out on a regular basis. These shall be

classified:-
• internal audits
• vendor audits

4.16.1

Internal Audits shall be conducted by a senior member of Pilbara

Insulation or their nominated auditor who shall be independent of all
construction or application activities of the contract.

Audits shall be conducted on the Pilbara Insulation Quality System to

ensure compliance with the applicable specifications, codes and
standards.

4.16.2

Vendor Audits shall be conducted by the Quality Manager on suppliers

and sub-contractors to ensure that the requirements of this Quality
Manual are adhered to and that they comply with the applicable
procedures, specifications, codes and standards which form part of the
contract.

4.16.3

Following all audits, an Audit Report will be created. (Refer Appendix

4) Audit Reports and resultant corrective action requests shall be held
in file by the Quality Manager as detailed in 4.15 of this Quality
Manual.
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Quality Manual
April, 2000 Revision

4.17 Training

Pilbara Insulation is committed to increasing the efficiency and

competitiveness of their work by ensuring that all employees:-

• are thoroughly trained in existing work methods and quality related

procedures, and
• have the opportunity of further increasing their skills and knowledge of
new products available.

On-going training is established both by on-the-job and workshop methods.

The Quality Manager shall implement training for personnel involved in
application tasks.

All employees shall undergo induction before commencing work. The

emphasis shall be on SAFETY and QUALITY.
 Pilbara Insulation
Quality Manual
April, 2000 Revision

appendix 1
 Pilbara Insulation
Quality Manual
April, 2000 Revision

appendix 2

INSPECTION PROCESS SHEET

X PRODUCT/ SYSTEM APPLICATION CHECKLIST

Date: Product &Batch nos:

Structure ID:

Location:

Leading Hand:

Report by:

ACTIVITY PI client owner COMMENTS

Substrate inpected, ready for blast & prime,
weld studs,bend test

Blast cleaning, profile, soluble salts, dust,

grease

Primer coat, adhesion, DFT,

holidays,contamination

PFP mixing

PFP first coat, DFT,mesh placement,

contamination

PFP second coat, DFT, contamination

PFP curing, adhesion

Top coat application,coverage,contamination

Clean up

THE ITEMS ABOVE HAVE BEEN INSPECTED AND ACCEPTED AS CONFORMING TO SPECIFICATIONS.

Pilbara Isulation client owner

Sign: Sign: Sign:

Name: Name: Name:

Date: Date: Date:

 Pilbara Insulation
Quality Manual
April, 2000 Revision

appendix 2
AMBIENT CONDITIONS
DAILY REPORT

Date Time WetBulb Drybulb Dew pt. Steeltemp R/H% Comments Checked by
 Pilbara Insulation
Quality Manual
April, 2000 Revision

appendix 2
DFT CHECKS PROCESS SHEET

Checked by: Pilbara Insulation

client
owner

DFT
Date Location Structure ID Product
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Quality Manual
April, 2000 Revision

appendix 3
MATERIALS RECEIVED REPORT

DELIVERY DATE: SPECIFICATION:

REPORT BY:

PRODUCT: MANUFACTURER:

BATCH NOS: TEST CERTIFICATES:

QUANTITY: DELIVERY ADVICE:

PACKAGING DETAILS: DOCKET NOS:

DELIVERY ACCEPTED: REJECTED:

HAVE REJECTED MATERIALS

BEEN SEGREGATED?

CORRECTIVE ACTION IF
REQUIRED:

SIGNED: DATE:
 Pilbara Insulation
Quality Manual
April, 2000 Revision

appendix 4

AUDIT REPORT internal/ vendor (delete one)

DATE:

AUDITOR:

PROJECT:

GENERAL COMMENTS attach separate sheets as required

NON-CONFORMANCE

CORRECTIVE ACTION REQUEST

 Pilbara Insulation
Quality Manual
April, 2000 Revision

appendix 5

INSPECTION AND TEST PLAN

APPLICATION OF Product X FIREPROOFING SYSTEM TO STRUCTURAL STEEL

ELEMENTS

INSPECTION
KEY: x1 100% inspection x2 random inspection x3 review
H hold/witness D document

ACTIVITY PROCEDURE P client owner COMMENTS

I
1.0 Materials handling
1.1 Inspect materials P.I.. Materials Received Report x1 Record batch nos., quantities,
P.I.. CPS 4.0 delivery advice,test
certs.,packaging detailsand any
nonconformance

2.0 Daily ambient conditions P.I.. CPS 5. 1 x1 Record throughout production

Check and calibrate all testing
equipment

3.0 Preparation
3.1 Substrate inspection P.I.. CPS 5. 2 x1 Remove foreign matter, treat
defects
3.2 Stud welding P.I.. CPS 5. 3 x1 Check centres, all studs must
pass bend test
3.3 Blast cleaning P.I.. CPS 5.4 x1 Class 2 1/2, 30-85 microns,
AS 1627 part 4 check for surface contamination
Class 2.5 Blast

3.4 Surface Profile Testing P.I.. CPS 5.5N/A x1 Retain testex samples and record

3.5 Masking P.I.. CPS 5.6 x1 Check masking for tight fit and
complete cover. No
environmental contamination
3.6 Primer application P.I.. CPS 5.7 x1 Take frequent wet film readings
and check for excess build,
holidays, contamination. Record.

4.0 PFP Application

4.1 Mixing of PFP P.I.. CPS 6.1 x1 Check for thorough mixing. Care
with measurements.
4.2 Application of PFP P.I.. CPS 6.2, 6. 4 x1 Inspect substrate for
contamination, check wft, dft and
mesh placement
4.3 Mesh placement P.I. CPS 6.3 x1 Check for 50mm overlaps, check
for alignment of carbon fibre
4.4 PFP Curing P.I. CPS 6.5 x1 Shore D 25, take sample cores if
required

5.0 Top coat

5.1 Top coat application P.I.. CPS 7.1 x1 Inspect PFP surface for
contamination. Check for
continuous coverage

6.0 Clean up P.I.. CPS 8.0 x1 Check integrity of adjacent

coatings. Check for
environmental contamination.
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Quality Manual
April, 2000 Revision

appendix 6
COATING PROCEDURE SPECIFICATION (CPS)
FOR SUPPLY AND APPLICATION OF
PRODUCT X PASSIVE FIREPROOFING COATING SYSTEM
TO STRUCTURAL STEEL/VESSEL/EQUIPMENT ON :

1.0 SCOPE
1.1 The handling and application of PRODUCT X as a fire barrier system for use
on :

2.0 APPLICATION EQUIPMENT

2.1 compressor
2.2 Conventional blasting and painting equipment for primer application
2.3 Mixer
2.4 Hand held mixer
2.5 Pumping and/or sprating equipment
2.6 Hand tools
2.7 Paper dispenser for masking
2.8 Capacitor discharge stud welder and hand tools for wire fixing
2.9 Brooms, shovels, bags, rags, etc. for clean up
2.10 QC testing equipment: Testex Guage Blast Profile
Elcometer 106 Adhesion/Cohesion
Elcometer 955F DFT readings
Vernier Caliper DFT readings
Whirling Hygrometer Relative humidity/ dew point
Magnetic Thermometer Steel temperature
Durometer Shore D Hardness
Incotest or similar Soluble salts

3.0 MATERIALS

3.1 Masking materials: Polythene sheeting

gaffer tape and masking tape
paper
hessian, tarpaulins, monarflex sheeting system
3.2 Primer system
3.3 PFP system
3.4 Metal mesh and stud system
3.5 Carbon fibre or glass mesh system
3.6 Top coat system

4.0 MATERIALS HANDLING

4.1 All batch numbers, quantities, delivery advice information, test certificate
numbers,packaging details and any nonconformance shall be recorded on Pilbara
Insulation Materials Received Report Form.
4.2 Any damaged or nonconforming material shall be stored seperately for corrective
action
4.3 All materials received shall be stored under cover with provision for maintaining the
manufacturers recomended storage temperature range.
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Quality Manual
April, 2000 Revision

4.4 All relevant dangerous goods storage requirements shall be observed.

4.5 Substrate handling instructions

5.0 PREPARATION

5.1 Ambient weather conditions shall be recorded frequently during all aspects of
blasting and coating application, including primer, PFP and top coat. This record
shall include whirling hygrometer results, relative humidity, dew point, steel
temperature and comments, if appropriate, on macro weather conditions.
5.2 Substrate inspection
5.3 Metal mesh instructions
5.4 Blasting instructions
5.5 Soluble salt testing
5.6 Masking: adjacent surfaces and work areas shall be masked or shrouded to prevent
overspray, environmental contamination or health risk to others. Where appropriate
for environmental protection or weathering temporary shelters shall be erected using
the Monarflex System.
5.7 Priming instructions
5.8 Adhesion testing
5.9 The primed surface shall be free of oil, grease, dust, soluble salts or moisture prior to
PFP application.

6.0 PFP APPLICATION

6.1 Mixing instructions

6.2 Application instructions
6.3 Fibre mesh instructions
6.4 DFT testing
6.5 Cure and hardness testing
6.6 Contamination between coats shall be avoided. The surface of the cured PFP shall be
free of any dust, grease, oil or soluble salts prior to top coat application.

7.0 TOP COAT

8.0 CLEAN UP

9.0 MANUFACTURERS PRODUCT DATA

9.1 Attached are product data sheets and material safety data sheets for: