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QUALITY MANUAL

OF

CONFIDENCE STEEL LIMITED

Confidence Steel Limited

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TABLE OF CONTENTS

Chapter Title Page

Quality Policy & Objectives 4-5

Cahpter-1 Quality Management System

Endorsement of the QMS 6-6

List of Abbreviations 7-7

Distribution 8-8

Quality Management System 9-12

Management Responsibility 13-18

Resources Management 19-22

Product Realization 23-29

Measurement, Analysis & Improvement 30-32

Chapter-2 Raw Material

Structural Steel ( Angle Sections & Plates) 33-37

Zinc 38-38

Chapter-3 Fabrication & Galvanization

Fabrication 40-44

Galvanization 45-48

Final Acceptance and Testing of Fabricated and Galvanized product 49-50

Final Acceptance and Testing of Bolt, Nut & Washer. 51-72

Cahpter-4 Delivery

Packaging Requirement 74-79

Loading Requirement 80-81

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CAHPTER-1 QUALITY

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CONFIDENCE STEEL LTD Document No.: QM-01

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QUALITY POLICY & OBJECTIVES Effective Date: 01 Apr, 07

Page No.:

QUALITY POLICY OF CONFIDENCE STEEL LTD

Confidence Steel Limited is committed to build and sustain itself as an organization where quality shall be the hallmark of every activity. Confidence Steel Limited will continuously strive to upgrade the work skill, manufacturing facilities and systems to achieve consistent product quality, global competitiveness and customer satisfaction.

It is the policy of CONFIDENCE STEEL LTD to—

1. a. Establish Quality Management Systems within CSL to identify and control processes to assure the quality of products.

b. Implement within CSL a Quality Management System in accordance with the

International Organization for Standardization's ISO 9001: 2008 Quality Management System Standards.

c. Obtain and maintain third-party certification to the ISO 9001 standard for all key

processes at.

2. Increase customer satisfaction by,

a. Decreasing the customer complains b. Increasing the volume of product delivery on time

3. Increase on-the-job training of the total work force

4. Increase the sales growth of the organization

This policy will be reviewed at least once in a year for its continuing suitability.

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QUALITY POLICY & OBJECTIVES Effective Date: 01 Apr, 07

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QUALITY OBJECTIVES OF CONFIDENCE STEEL LTD Confidence Steel Ltd. has taken up following quality objectives for the next three years time period: 1. It will implement Quality Management System in accordance with ISO 9001:2000 standard

and obtain third-party certification by June 2007 and maintain the same.

2. Present market share will be improved continuously by increasing the sales value .

3. It will adopt appropriate system to improve production volume

4. It will adopt appropriate system to minimize wastage by at least 0.5% per year

5. It will target for minimum break-down

.

6. It will train 15% of its people every year to improve skill.


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ENDORSEMENT OF THE QMS Effective Date: 01 Apr, 07

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CONFIDENCE STEEL LTD (CSL) has established a Quality Management System incorporating the

requirements of ISO 9001: 2008. This Quality Manual (QM) is an overview of the Quality Management System

(QMS) of CSL. Details of inside view of the quality system and commitment, which (CSL) have been pursuing,

are shown in this manual. The quality manual (QM) is the sole property of CSL. Updating of the manual is done

as per the Document and Data Control procedure of the Quality Management System. Customer who has been

provided with controlled copies of this manual will be informed whenever an amendment in the Quality Manual

is made.

Distribution of the CONTROLLED copies of this manual is limited within the List of Controlled Copy Holders

of the Quality Manual. CONTROLLED/UNCONTROLLED copy of the manual can be made available to the

Customers and any distinguished personality with the written permission of the Managing Director.

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TABLE OF CONTENTS, LIST OF ABBREVIATIONS, & DISTRIBUTION

Effective Date: 01 Apr, 07

Page No.: 2 of 3

LIST OF ABBREVIATIONS

Dir : Director

IC : Incharge

MD : Managing Director

CSL : Confidence Steel Ltd

MR : Management Representative

PO : Purchase Order

QF : Quality Forms

QM : Quality Manual

QMS : Quality Management System

QP : Quality Policy

QPr : Procedures

QWI : Work Instruction


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TABLE OF CONTENTS, LIST OF ABBREVIATIONS, & DISTRIBUTION


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LIST OF DISTRIBUTION

Followings are the controlled copyholders:

1st Copy Managing Director

2nd Copy CEO

3rd Copy Head of Operation

4th Copy Marketing

5th Copy Procurement

6th Copy Production

7th Copy Quality

8th Copy Maintenance

9th Copy Fabrication In-charge

10th Copy Customer Services In-charge

11th Copy Galvanizing In-charge

12th Copy Delivery In-charge

13th Copy Store In-charge

14th Copy Management Representative (MR)

15th Copy Reserved for Auditors

NB: Whenever any revision takes place in this Quality Manual, a record of revision is maintained under Last Change Record. This is done as per Procedure Document and Data Control No. QP-DCL-1

and as per Form No. QF-DCL-06. Please refer to the above for future reference.

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1. Introduction

CONFIDENCE STEEL LTD (CSL) is one of the most modern steel fabrication company in our country

established on 30th July in 2005 , started to function and have grown and diversified into a multifaceted

Steel Engineering organization. It is equipped to manufacture Galvanized Telescopic Poles, Machineries,

Gear-Box for water pumps, Screws & Fasteneres, Telecommunication & Transmission Towers, Portable

Steel Bridges, Pole Fittings & Hardware etc. It has its registered office address as follows:

Noor Tower (10th Floor), 110, Bir uttam C.R Dutta Road (Sonargaon Road)

Dhaka-1205, Bangladesh

Telephone no. 88-02-9666395,9666396

Fax No. 88-02-9673864

E-mail:[email protected] Factory Address:

Nayapur, Barabo, Sonargaon,

Narayanganj,Bangladesh

Telephone no. 7617704

Fax No.-88-02-7817704

2. Scope

This document outlines the Quality System that is followed by the personnel of the Confidence Steel

Ltd throughout its all functions. This Quality System is designed to comply with the requirements of

ISO: 9001:2008.

The Quality Manual includes the quality policy and the quality objectives of Confidence Steel Ltd and

describes the organizational structure, identifies management responsibilities, and references the

processes and procedures and supporting Quality System documents and records.

Quality Manual has been organized so that the section titles correspond to those of the clauses/elements

of ISO: 9001:2008. Where appropriate, procedures are referenced that provide more detailed

information.

The CSL Quality Manual provides general policies & procedures for the purchasing, design,

manufacturing, testing, storage and selling of CSL products including its compliance to ISO9001:2000.

The scope of the activity of the company covers the following activities:

Manufacturing & supply of Telecom Towers, Transmission Towers, Steel Pole, Portable Steel Bridge,

Water Distribution Steel Pipe, Hardware, screws & fasteners etc for international & local market.

3 Application: All the clauses of ISO9001:2008 except Design & development (7.3), Validation of

processes for production and service provision (7.5.2) and customer property (7.5.4).

4. Normative references: ISO9001:2008 Quality system- Model for quality assurance in Production &

Marketing.

Manufacturing standards are: BS8110 & BS829

5. Quality Management System of Confidence Steel Ltd

Confidence Steel Ltd is responsible to manufacture Telecom Towers, Transmission Towers, Steel Pole, Portable Steel Bridge, Water Distribution Steel Pipe, Hardware complying with the

requirements stipulated by customer and delivers the same in accordance to the agreed schedule.

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Accordingly, Confidence Steel Ltd has planned, mobilized human and material resources and established

the sequence of processes to realize the product. It also established and maintains a Quality Management

System and continually improves its effectiveness in accordance with the requirements of ISO-9001: 2008

standard. The Quality Manual includes the details of QMS, references to documented procedures and a

description of the interactions between the following processes.

a. Commercial: dealing with purchase and procurement

b. Marketing dealing with sales, shipping and transportation

c. Stores: dealing with storage, handling and safekeeping of materials and products

d. Product Development

e. Production process involves the following,

f. Human Resources Management

g. Maintenance Management.

These are included in the QMS. The Quality Manual of Confidence Steel Ltd is a direct collection of

QMS documents with references to documented procedures.

A mapping of the quality management system involving the major processes has been given in the next

page.

a.) Fabrication, Trial assembly

b.) Testing for different stages on

different criteria

c.) Galvanizing

d.) Final Inspection

e.) Storage & Dispatch

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QUALITY MANAGEMENT SYSTEM MAPPING

CUSTOMERS R EQU I R EME N T

S

CUSTOMERS

SAT ISFACT IONS

Continual improvement of The Quality Management System

Product realisation Purchasing, Product Development, Production, Preservation of Product, Identification and Traceability, Inspection & Test Status, Maintenance

Resource management

Provisions for Manpower, Equipment and Working Space, Training, Control of Safe and Suitable Working Conditions

Measuring, analysis & improvement

Internal Audit, Inspection & Testing, Control of Non-Conforming Product, Statistical Technique Corrective Action, Preventive Action,

Management responsibility

Quality Policy, Quality Objectives, Quality Planning, Customer Focus, Organogram, Job Description, MR deployment, Management Review

Product Input

Process materials, component parts, packing materials etc.

Fabrication &

hardware items

Value-adding activities

Information Flow


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The QMS is reviewed from time to time to ensure suitability and continual improvement by the

Management Representative (MR) and Review Committee.

Accordingly, corrective and preventive actions are adopted to improve the system. Customer is

informed whenever any modification in the QMS takes place.

All documents of Confidence Steel Ltd are controlled in accordance with the Procedure for Document

Control (QP-DCL-1).

CSL established documented procedure for the identification, storage, protection, retrieval, retention

time and disposition of quality records.

6. Quality Manual

This Quality Manual applies to whole of Confidence Steel Ltd and includes all functions that affect

quality of product. This manual specifies the Quality Management System of CSL and defines the

interactions between the processes. It defines the scope of QMS including details of and justification

for any exclusions.

7. Control of Documents

Confidence Steel Ltd has established procedure to control Quality documents (QP-DCL-1). Documents

defined as quality records will be controlled according to procedure for Control of Quality Records.

Procedure no. QP-DCL-1 gives details of the Control of Quality Documents.

8.Control of Quality Records

A Master List of Quality Records, which contains Document no, retention period, responsibility and

document name is maintained by CSL.

CSL allows customers to refer to the Quality Records if they require it during the retention period.

Procedure no. QP-DCL-2 gives details of the Control of Quality Records.

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1. Management Commitment

It is the policy of Confidence Steel Ltd (CSL) to meticulously implement the QMS. The QMS will be

developed and continually improved. Following measures are taken to improve the effectiveness of the

QMS.

The organisation now produces Telecom Towers, Transmission Towers, Steel Pole, Portable Steel Bridge, Water Distribution Steel Pipe, Hardware etc as given in para 1. Introduction (QM-

04) of the manual, complying with the requirements stipulated by customer and delivers the same in

accordance to the agreed schedule The QM demonstrates the commitment of CSL in developing and implementing QMS, meeting all the

customer needs, the statuary & regulatory requirements where applicable, establishing and

implementing quality policy and quality objective, conducting regular management review meeting &

providing required resources.

2. Customer Focus:

Top priority is given to customer requirement and customer satisfaction. All the requirements of the customer

regarding product sale and after sales service (where applicable) is documented and implemented.

3. Quality Policy

The Quality Policy of Confidence Steel Ltd has been established (Ref: QM-01, page 1 of 2). Quality

Policy (QP) embraces all functions of CSL. QP reflects the commitment of CSL in meeting the

requirements of the customer. The Quality Objectives consistent to QP has been defined (Ref: QP-01).

The QMS includes commitment to review the policies and objectives for continuing suitability and

improvement. CSL ensures that Quality Policies are understood at all levels through briefing sessions,

training and on job performance. This policy should be reviewed at least once in a year for its

continuing suitability.

4. Planning

a. Quality Objectives

Ref: QM-01 (page 2 of 2)

b. Quality Planning

Confidence Steel Ltd (CSL) has identified the resources needed to achieve the Quality Objectives.

Accordingly planning has been established. Output of planning is documented.

Interlink of responsibilities between different functions in relation to different activities of Quality

Management System has been shown in the next page.

To explain the requirements of quality and how it is met with the Quality System, quality planning is

made. The planning process takes care of the various activities that are essential to meet the specified

requirements for products manufactured by CSL and to ensure customer satisfaction. The quality-

planning format is available in the following pages:


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Quality Planning Format

Activity Procedure

Reference

Responsibility Reference Document Quality Records

Document Control QP-DCL-1 Management

Representative

List of Procedures/ Work

Instructions/

Formats/Tags/Register/

Specifications

Control of Quality

Records

QP-DCL-2 Do All Quality Records as

per List: QF-DCL-03

Management

Review

QP-MNG-1 Do Internal Audit Summary,

Customer Complaints

Summary, Corrective and

Preventive Action Summary

Records in minutes of

meeting of Management

Review

Training Administration

Incharge

Appraisals, Evaluation

Reports

Training Records QF-

HRD-06

Suitable and Safe

Working Conditions

All Incharges Check Lists, Fire Drill

Records

Fire Drill Records,

Record of working

condition QF-HRD-01

Contract Review Technical

Incharge,

Director (Sales),

MD

Limits of Authority, Price

Approval, Product

Brochures, Stock Reports

Contract Review and

Amendment Records.

Invoices.

QF-CUS-01

Procurement QP-PRO-1 Procurement

Incharge

Specifications of Raw

Material, Limits of

Authority, Purchase Manual

Vendor Approval

Records, Purchase

Orders QF-PRO-01,02,

03,07,05,06,07

Process Control QP-PRN-1 Production &

Technical

Manager

Budget, Production Plan,

Stock Report of Raw

Materials.

Record Register for

production, Batch No

Register.

Maintenance Incharges of

Maintenance

Annual Maintenance Plans,

Monthly Preventive

Maintenance Plan, Machine

History Card

Break Down Record,

Annual Maint. Plan,

Machine History Card

QF-MNT-01,02,03,07

Product

Identification and

Traceability

QP-PRN-2 All Incharges Raw Materials /Finished

product Identification

Cards/Papers.

Tag Numbers, Urgent

Permission Tags,

Documents,

Inspection and

Testing

QP–QIN-1 do Raw Material Specification,

Standards for Testing and

Inspection.

Receiving Inspection

Report, Final Inspection

Report, In-Process

Inspection Reports.

Control of

Nonconforming

Products

QP–QIN-2 Production &

Technical

Manager

Inspection and Testing

Procedure, Raw Material

and Product Specification

Monthly Analysis of

Product Non-conformity

QF-QIN-07

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Quality Planning Format (Cont’d)

Activity Procedure

Reference

Responsibility Reference

Document

Quality Records

Inspection & Test

Status

All Incharges Manual and Procedure

Formats & Tags

Preservation of

Products

QP-PRN-3 Incharges of

Store and Sales

Material Receipt

Memo, Material

Transfer or Issue

advices, Store Manual

Stock Ledger, Bin

Cards, Dispatch

advices, Material

Receiving Notes.

Control of

Inspection,

Measuring and Test

Equipment

Fabrication In

charge

Manual and Procedure Calibration Records

QF-QIN –08

Internal Quality

Audits QP–IQA-1 MR Nonconformity Reports Audit Analysis

FM/AUD/555

Corrective Actions QP–CAC-1 All Functional

Heads of the

Quality System

Monthly Analysis of

Nonconforming

Products, Internal Audit

Reports Summary,

Customer Complaints,

Statistical Analysis

Reports.

Preventive Actions QP–PAC-1 -do- Monthly Analysis of

Nonconforming

Products, Internal Audit

Reports Summary,

Customer Complaints,

Statistical Analysis

Reports.


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5. Responsibility, Authority and Communication

Top management of the company ensures that responsibility and authority has been given to particular personals

in the organization. Job description of employees is maintained and organogram shows the inter-relationship

and authority to perform a job.

Please see the job descriptions & organogram.

Responsibility Matrix

Clause

No. Title of requirement MD DIR

(Prdn)

Incharges

MR Prdn Contr.

Tech. Admn. Sales Servc

Procr Store

4 Quality Management

System ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

4.2.3 Procedure for

Document Control ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

4.2.4 Procedure for Control

of Quality Records ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

5.6 Management Review

Procedure ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

6.2.2 Provision of Training ■ ■ ■ ■ ■ ■

6.4 Assessment of Suitable

and Safe Working

Environment □ ■ ■ ■ ■ ■ ■ ■

7.2.2 Contract Review ■ ■ ■ ■

7.3 Design Control NOT APPLICABLE 7.4 Purchasing Process ■ ■ ■ ■ □ ■ ■

7.5.1 Process Control ■ ■ ■ □ ■ ■

Maintenance Process ■ ■ ■ ■

7.5.3 Identification and

Traceability Process ■ ■ ■ □ ■ ■ ■

7.5.4 Customer Supplied

Product □ ■ ■ ■ □ ■ ■

7.5.5 Handling, Storage,

Packaging, Preservation

and Delivery

□ ■ ■ ■ ■ ■

7.6 Control of Inspection,

Measuring and Test

Equipment

■ ■ ■ ■ ■

8.2.2 Internal Audits Process □ □ ■ ■ ■ ■ ■ ■ ■ ■ ■

8.2.3 Inspection and Testing ■ ■ ■ ■ □ ■

8.2.3

8.2.4

Inspection and Test

Status ■ ■ ■ ■ □ ■ ■

8.3 Control of

Nonconforming Product ■ ■ ■ □ ■ ■

8.4 Corrective Action □ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

Preventive Action ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

8.5 Statistical Technique ■ ■ ■ ■ ■

Definitions: Prdn: Production Contr: Contracting Tech.: Technical

Admin: Administration Servc: Servicing MR: Management Representative

Procr: Procurement

■: Direct Responsibility □: Indirect Responsibility

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a. Management Representative

Mr. Shahidul Islam, Manager (Production & Technical) is the Management Representative of

Confidence Steel Ltd He will do the work of Management Representative in addition to his present

responsibility. MR will be specifically responsible for the following.

1. Reporting to the Director & Managing Director on the performance of the QMS.

2. Needs of improvement in QMS.

3. Promoting awareness about customer requirements throughout the organisation.

4. Where relevant communication with external parties on matters related to QMS.

b. Internal Communication

It is a policy of Confidence Steel Ltd to ensure communication between various levels and functions

regarding the process of QMS and their effectiveness through teams, committees and meetings,

telephone, & PABX services, Notice board, Office Memo/Register.


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6. Management Review

a. Introduction

Confidence Steel Limited evaluates the need for change in QMS including Quality Policy and

Objectives. The review ensures continuing suitability, adequacy and effectiveness of QMS. Confidence Steel Ltd established documented procedures for management review.

Procedure no. QP-MNG-1 gives details of the Management Review.

b. Review Input

Input of management review includes at least the following

1. Matters arising

2. Product Nonconformities

3. Internal Audit Results

4. Corrective and Preventive Actions

5. Customer Complaints

6. Progress Review of the Previous decisions /Action plans

7. Quality Objective points

8. Any other business

c. Review Output

Output from management review includes actions related to

1. improvement of the QMS and its processes

2. improvement of product related to customer requirements

3. resource needs

Results of management reviews are recorded in the Minutes of Management Review Committee

Meeting.

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1. Provision of Resources

Confidence Steel Ltd has identified human, physical resources and environmental conditions to

establish and maintain QMS and improve its effectiveness and to enhance customer satisfaction.

CSL identifies the various requirements of resources and provides them for carrying out the activities

efficiently. All functional heads in consultation with Directors and MD review the requirements and

when identified provides necessary resources depending on needs. These resources include all types of

management, implementation and Internal Quality Audits. It has trained manpower in all its

departments. CSL has trained Internal Quality Auditors to check the Quality Management System as per

ISO 9001: 2000. MR maintains a list of Trained Internal Quality Auditor.

Trained personnel are provided whenever needed and training requirements are taken care depending on

needs. Functional Heads and selected Management Staff have been trained on awareness and

documentation of Quality System to ISO 9001: 2000 to implement and verify their work as desired by

the Quality System.

Adequate plant, machinery and instruments are available to manufacture the products as per required

specifications. Care is taken to assess the needs of the facility and technology from time to time to cope

with the changing needs of the customers and accordingly plans are made to include those.

Functional heads review the requirements and when identified provides necessary resources depending

on needs. These resources include all types of management, implementation and Internal Quality

Audits.

Confidence Steel Ltd also has the system of imparting on-the job training to improve the skill level of

the people. Employees in CSL are skilled enough to carry out the work and verify quality as per

procedure.

2. Human Resources

The manpower strength of CSL is as shown below:

Sl.

No. Department Officer Staff

Technician

Total Skilled

Semi-

skilled

Un-

skilled

1 Production 30 - 100 200 200 500

2 Customer

Services 5 - - - - 5

3 Marketing 5 - - - - 5

4 Technical 3 - - - - 3

5 Finance &

Accounts 5 - - - - 5

6 Administration 5 10 - - - 15

7 Purchase 2 - - - - 2

8 Store 2 4 - - - 6

Total 57 14 100 200 200 533

Confidence Steel Ltd develops its Human Resources through training.


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CSL makes yearly assessment of all its employees. To improve the skill for covering shortcomings,

transfer to the new jobs and developing skill of prospective future leaders, training needs are identified

by the superiors. Depending on needs `peoples are selected for imparting training. In case when a

program is declared by any training institute and nomination is requested, the organization selects

people on the conditions given by training institute with due consideration to Need Assessment. On-

the-job trainings are organized as and when necessary for the production and quality control people.

Training on Quality System implementation is organized and conducted whenever there is amendment,

updating or necessity to clear the confusion.

Personnel responsible for testing are posted depending on training records and experience. For all the

jobs, there are set qualification criteria for the employment.

Trained personnel are provided whenever needed and training requirements are taken care depending on

needs. Functional Heads and selected Management Staff have been trained on awareness and

documentation of Quality System to ISO 9001: 2008 to implement and verify their work as desired by

the Quality System.

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CSL also have the system of imparting on-the job training to improve the skill level of the people.

Employees in the Confidence Steel Limited are skilled enough to carry out the work and verify quality

as per procedure.

a. Confidence Steel Limited maintains records of education, experience, training and qualification

of its human resources .

b. CSL identified the competence necessary for its personnel for performing work affecting quality .

c. CSL has trained Internal Quality Auditor to check the Quality Management System. Trained

personnel are provided whenever needed and training requirements are taken care depending on

needs.

d. CSL provides training to satisfy the competence needs. e. It has trained manpower in all its departments. Functional Heads and selected Management Staff

have been trained on awareness and documentation of Quality System to ISO 9001: 2000 to

implement and verify their work as desired by the Quality System.

f. CSL evaluates the effectiveness of these actions

g. CSL ensures that the members are aware of the relevance and importance of their activities and

their relationship to QP and objectives.

These activities are performed accordingly and records are maintained.

3. Infrastructure/ Facilities

Confidence Steel Ltd has identified and established required facilities to achieve conformity of the

product. Adequate plant, machinery and instruments are available to manufacture the products as per

required specification. Care is taken to assess the needs of the facility and technology from time to time

to cope with the changing need of the customer and accordingly plans are made to include those.

These are

a. Work Space and associated facilities b. Equipment and Machinery (Appendix-C)

4. Work Environment

a. Confidence Steel Ltd has established physical factors and work environment needed to achieve

product conformity. These include

I. Physical factors

1. Heat Excluding areas where necessary to maintain a temperature of 25±50C

is required, e.g. testing laboratory, work areas are kept within a

temperature range of 30±50C.

2. Light level 300~500 lumen (where actual work is performed)

3. Cleanliness Total cleanliness in work area

4. Air flow Well ventilation are provided at the work area.


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5. Hygiene: Cleanliness is maintained through out the work area as it is the prime object

for a Good hygiene practice, first-aid boxes are available at appropriate

locations of work areas, safe drinking water is supplied, good number of

clean toilets are made available at appropriate locations.

II. Human factors

6. Posture Where applicable, the gap between sitting tool and work table/standing

position are set for checking fatigue ness. Working and sitting arrangements

are provided where required.

7. Safety All working places have safe walking passage, all moving parts are covered

with safety covers, all protruding edges etc. are marked for safety first. All

the gates are kept clean for emergency exits. Regular fire drills are

maintained. Sufficient number of fire extinguishers is available inside the

building in addition water hydrant. Safe drinking water is available in all

sections. First aid boxes are supplied in all sections.

a. These are monitored and recorded once every month .

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PRODUCT REALIZATION Effective Date: 01 Apr, 07

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7.1 Planning of Realization Process

Confidence Steel Limited has a three-tier Quality System with Quality Policy and Objective at the tip.

Quality Manual, which is the highest level or Apex Manual, is at the Tier –1. Quality Assurance Procedures

are at the Tier-2. Tier-3 contains Work Instructions, Formats, Charts, drawings, and reference

manuals/documents.

The documentation is used to ensure that:

- the product conforms to specified requirements

- customer satisfaction is achieved as per Quality Policy

- all the works at all the areas are done to achieve Quality Objectives

Quality Policy and Objectives

TIER 1: Quality Manual

TIER 2: Quality Assurance Procedures

TIER 3: Work Instructions, Formats

Charts, Drawings, Reference

Manuals

Please see the quality plans (describing process flow, records & responsibilities)of different products.

2. Quality System Procedures

The Quality System described is supported by Quality Procedures and Work Instructions.

These Procedures and Work Instructions are applicable to the various departments. Procedures are

supported by Work Instructions, which give detailed work steps for implementing the procedural

requirements. Formats, Charts, Registers, and Drawings again support procedures and Work Instructions in

use.

MR maintains a list of Document, Procedures, Work Instructions and Forms.

Realization of Product in Confidence Steel Limited starts from Sales section. After realization of the

product, it is kept in the custody of section concerned or sent to the store. At all the stages required checking

and testing is ensured including final testing. Necessary checking is done before final release of the product.

Confidence Steel Limited has established procedure for the above activities where required. The works are

performed in the appropriate equipment with due care of the safe and suitable working environment.


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During all the process using, maintaining and controlling of parameters are ensured to get expected quality.

Some of the important steps are given approval by the authority. For all the steps of production, acceptable

quality standards/specimens are made available near the workstations and employees with appropriate

knowledge are used to perform the operation.

Equipment are suitably maintained to ensure the process capability.

Refer Procedure no.: QP-PRN-1 may be referred for details on Process Control.

Receiving Inspection and Testing

All type of raw materials and all the procured materials undergo receiving inspection for quality as well as

quantity (QF-QIN-01. Materials are issued only when receiving inspection passes it. Any material rejected

or kept pending during receiving inspection is stored in a segregated area for further actions on this.

In the case of urgency if any material is needed to be issued before completion of the receiving inspection, it

is marked by appropriate means to track it for immediate call. The marking is withdrawn when evidence of

conformity for all the checks arrives. Record of the urgent permission and clearings are maintained as per

procedure for Control of Quality Records.

In-process Inspection and Testing

In process inspection and testing of the work or product is done as per the established procedure. Works or

products are not allowed to pass the steps until specified inspection/testing is not completed. Unacceptable

works/products are either corrected or scrapped as per the procedure.

Final Inspection and testing

Confidence Steel Limited has established quality plan to check the products at the final stages. No product

is allowed to enter the finished goods area or store until final inspection is done. Products, which cannot

pass the final inspection, are corrected to make it suitable for re-inspection and decision is taken as per

procedure.

Records of inspections and testing are maintained for all the steps. Authorities responsible for inspection

and testing are identifiable from the inspection notes at all stages.

CSL uses required material handling equipment where it is applicable. Other than trolley, manual handling

is also used where appropriate.

Storing of products are done with due care to protect them from damage or deterioration.

Packing and packaging of the product is done as per established procedures of the factory and as per

instruction of the customers.

Where required, the product is installed/commissioned at the premise of Factory.

Confidence Steel Limited also ensures preservation of the raw materials or items as per necessity.

Care is taken to deliver the product to the customer premises to ensure that product is not damaged during

transit.

CSL follows procedure no. QP–QIN-1 for Inspection and Testing.

Quality Manual

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Page No.: 3 Of 7

7.2 Customer Related Processes

7.2.1: Determination requirements related to the products

Confidence Steel Limited has identified customer requirement described in QM-05 . Besides CSL reviews

identified customer requirements together with additional requirements determined by CSL. Requirements

of Customer are documented in their PO sheet. Reviews are conducted to have a thorough understanding of

customer requirement.

The company communicates with different institutions and wholesalers to get requirement from them

through physical contact or advised by tender calls or query. The customer gives their choice and a price

quotation is offered accordingly. If the customer is convinced a written work (sometimes verbal over

phone) order is placed. The company itself determines the statutory and regulatory requirements.

In case of screws, fasteners & other hardware items the company manufactures as per its own standard. Any

modification request is received from the market by the marketing personnel AGM plant implements the

same and again comment from customer is collected.

7.2.2: Review of requirements related to the product:

The company discusses all the customer requirements in detail in meeting or phone, faxes, e-mails prior to the

execution of any contract. The review discusses the company's ability to supply the product in accordance with

the customer requirement. The review is held between the customer's representative, dealers and organizations

nominated person like Director, Marketing Manager and AGM (Factory), Production & Technical Manager.

The review of requirements is as follows:

Necessary details about the product like complete technical data and commercial information shall be

provided and or briefed by Marketing Manager. The shall be recorded in the order sheet prior to

submission of offer as and where required, duly approved by the Managing Director keeping in view

the plant capacity, stock at hand and availability of resources.

The delivery schedule shall be assessed keeping in view the plant capacity, stock at hand and

availability of resources to confirm delivery schedules.

It shall be ensured by Marketing Manager that the purchase order and / or related documents

forwarded by the customer on receipt of quotation if any, or the noted down specifications in the order

form contains complete technical and commercial data covering delivery schedule, packing and

forwarding details, mode of transport and other conditions as and where applicable.

Sometimes buyers are called for pre-delivery inspection. The products which satisfy the buyer

requirements are taken to delivery yard.

Please see the work order sheets.

7.2.3:Customer communication

The company has latest communication facility to support its operational network. The entire product related

information e.g. enquiries are received on phone, fax, e-mails. Customer complaints are received in a

documented way and the records of customer complaints/suggestion are maintained by marketing personnel.

Amendment in any agreement is communicated to the company who re-approves the amendment. Delivery

order is collected from the dealers or customers.

Please see Customer Feedback Form.

7.3: Design and Development

CSL has no design and development activity. Products are realized as per specification/ drawing/sample of

customers. Hence all functions involving design & development of the product (clause 7.3) is outside the

scope of the QMS.


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7.4 Purchasing

Confidence Steel Limited has a documented Procurement Procedure to ensure that purchased products

conform to the specified requirements.

Purchasing control

CSL maintains approved suppliers list for its major purchases on Raw Materials/components etc. CSL

selects supplier on the basis of their ability to supply identified through evaluation. The criteria of

evaluation explained in the procurement procedure. Results of evaluation and follow up are recorded.

Suppliers are evaluated depending on:

– Past performance

– Reputation in national and international market

– Result of the assessment format as used by CSL

– Certification by third party on international Quality Standards

Standard Hardware, stationary and some urgent items are managed by emergency purchases as per

instruction of Director (Service, Sales & Procurement).

Procurement department maintains List of approved suppliers for local and imported items. The authorized

persons update the lists. Suppliers for purchasing of imported items are selected by Incharge Procurement

with consultation of Director (Service, Sales &Procurement) as outlined in procedure. The authorized

persons update the lists.

Purchasing Information

Purchase orders are issued mentioning specifications and other necessary information as per procurement

procedure.

Materials to be procured depend on the order placed by Customer and the concerned department engaged

with realization of the product prepares the materials requisition accordingly. Materials Requisition

Document contains information describing the product to be purchased including requirements for approval

and QMS requirement.

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Verification of Purchased Product

The authorized person of the concerned department verifies products and items purchased at the receiving

point for conformance with the specified requirements.

Records of Suppliers evaluation are maintained as quality record. Records of Suppliers performance are

maintained for important Raw Materials for future decision in relation to the continuation of the suppliers.

All purchases are done as per Quality Procedure no. QP-PRO-1

7.5: Production and Service Provision

Process Control in Confidence Steel Limited starts from sales/service department. After receiving enquiry

from the customer by Sales department, it is sent to Technical department. It is the reviewed and final offer

is sent by Sales department. After receiving the job order by Sales department it is sent to Technical

department who then gives a job no. and the concerned departments are informed who proceeds for

production as per procedure for process control. A quality plan is made by the Technical department, which

is then forwarded to concerned departments for realizing the products. At all the stages required checking at

appropriate stages and planned testing is ensured including final testing to meet the customers’

requirements.

CSL has established procedure for all the above activities. The works are performed in the appropriate

equipment with due care of the safe and suitable working environment.

During all the processes using, maintaining and controlling of parameters are ensured to get expected

quality. Some of the important steps are given approval by the authority after setting of the parameters. For

all the steps of production, acceptable quality standards/specimens are made available near the workstations

and employees with appropriate knowledge are used to perform the operations.

Equipment are suitably maintained to ensure the process capability.

Procedure no.: QPr-PRN-1 may be referred for details on Process Control.

a. Control of Production and Service Provision

Confidence Steel Limited controls production according to procedure QP-PRN-1 under stated controlled

conditions.

Confidence Steel Limited provides the service of installation/commissioning as required by the customers.

b. Validation of process for production and service provision

Process Control in Confidence Steel Limited starts from sales department with the receipt of PO sheet. PO

sheet is analyzed to plan different stages of operation. At all the stages required checking and testing is

ensured including final checking.

Confidence Steel Limited has established procedure for all the above activities. The works are performed

in the appropriate equipment with due care of the safe and suitable working environment.

During all the processes using, maintaining and controlling of parameters are ensured to get expected

quality.


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c. Identification and Traceability

All products at Confidence Steel Limited factory and stores are maintained in a clearly identifiable way

to ensure using of right product in manufacturing of different products. CSL uses the specific number

for specific customer like GP, Motorolla etc assigned for each PO are maintained throughout the

process of product realization as identification number for identification and traceability. The raw

materials/components and supplies are identified from receiving point to usage with printing/markings

on the package or tags attached. In process materials are marked with tags, stands with labels. The

members in tower production is identified by suitable numbering method.

Confidence Steel Limited follows procedure no. QP-PRN-2 for Product Identification and

Traceability.

All the Products of the Confidence Steel Limited either on the Factory Floor or in Stores are identifiable

with its status of quality. The products carry following tags or mark:

– Suitable for use

– Not acceptable

– Hold

– Not suitable for use

– Waiting to be inspected/sorted

Etc.,

In addition to these, storage locations with marking also declare inspection and test status. Only the

acceptable products are stored in the Raw Materials and Finished Goods Stores. Unacceptable and Hold

items are kept at designated spaces.

In the case when any product or item is used in the production pending some decision under urgent

permission, such item is marked for ready traceability. Record for such traceability is maintained. Job

number of product is maintained for traceability of finished products.

d. Customer Property

Not Applicable.

e. Preservation of Product

Confidence Steel Limited uses required material handling equipment where it is available. Other

equipment like pallet trucks and vehicles, manual handling is also used where appropriate.

Storing of products are done with due care to protect them from damage or deterioration.

Packing and packaging of the product, where required, is done as per established procedures of the

factory and following instruction given by Customer.

Confidence Steel Limited also ensures preservation of the raw materials or items as per necessity.

Care is taken to deliver the product to the customer premises to ensure that product is not damaged

during transit. Care is also taken during installation period, where required by the customer, to preserve

the quality of product. BIN CARD is used for identification & stock information.

Confidence Steel Limited maintains Procedure no. QP-PRN-3 for Preservation of product at all

stages.

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7.6: Control of Measuring, Inspection and Test equipment

Confidence Steel Limited maintains a list of all Inspection, Measuring, and Test Equipment which contains

following Information:

Id number of the instrument

Name and specification of the Instrument

Location for use

Range of use

Least count necessary for use

Calibration interval

The list includes the Instruments identified to be necessary for ensuring product quality. Instruments are

selected for use only when they are found to be suitable for performing the inspection, measurement or

testing at specified locations in terms of accuracy, measurement range and precision requirement.

All the instruments are considered to be at calibration stages at all times. Instruments carry tags/stickers

with them to indicate the status of calibration. Calibrations of the user instruments are carried out by

comparing the measurements with those of Master Instrument’s. Master instruments are calibrated at

specified intervals from the organizations, which have nationally or internationally traceable code.

Only the Trained personnel calibrate instrument in the suitable environment to ensure accuracy of the

calibration. Qualified persons carefully perform the maintenance and adjustments of the instruments.

When any instrument is found to give wrong measurements, are replaced immediately. And all the

measurements completed by the faulty instrument are called back and rechecked.


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MEASUREMENT, ANALYSIS AND IMPROVEMENT


Page No.: 1 of 3

1. Introduction

To demonstrate conformance of the product, ensure conformity of the QMS and continually improve

its effectiveness, Confidence Steel Limited utilizes statistical techniques.

2. Monitoring and Measurement

a. Customer Satisfaction

Confidence Steel Limited analyses the requirement of Customers, which is an integral part of

its system. Quality Parameters, which will satisfy Customer, are outlined in QM-05 item 2.

Requirements of Customer are reviewed after receiving a PO Sheet to deepen the understanding

about product, coordination and communication.

Confidence Steel Limited organizes briefing and training to its members to fully realize the

requirements of Customer.

CSL will monitor whether it has met the requirements of Customers. After every consignment Customer

is requested to provide a information stating the extent to which the product and

services satisfy them (Ref: QF-CUS-03). This is taken as an assessment of customer satisfaction.

b. Internal Audit

Confidence Steel Limited conduct internal audit to determine whether the QMS conforms to

the requirements of ISO-9001: 2K effectively implemented and maintained. Documented

Procedure QP–IQA-1 is followed for internal audits. Records for conducting the audit and its

results are maintained (Ref: QF-IQA-01, 03, 07, 05).

c. Monitoring and Measurement of Process

Confidence Steel Limited has established monitoring and measurement of processes at

different stages of product realization (QF-QIN-02. 03, 07, 05), where applicable, necessary to

meet the requirement of Customer. In cases where desired results are not obtained,

nonconformity of product is raised (QF-QIN-07). and corrective (QP–CAC-1) action is taken to

ensure conformity of product. This is established in CSL after going through long experience of product

realization.

d. Monitoring and Measurement of Product

Receiving Inspection and Testing Except minor materials like: cleaning waste cotton, kerosene oils, old pipes etc. Mostly row

materials, all the procured materials undergo receiving inspection for quality as well as quantity.

Materials are issued only when receiving inspection passes it. Any material rejected or kept

pending during receiving inspection is stored in a segregated area for further actions on this.

In the case of urgency if any material is needed to be issued before completion of the receiving

Inspection, it is marked by appropriate means to track it for immediate call. The marking is

withdrawn when evidence of conformity for all the checks arrives. Record of the urgent

permission and clearings are maintained as per procedure for Control of Quality Records.

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Page No.: 2 of 3

In-process Inspection and Testing In process inspection and testing of the work or product is done as per the established procedure. Works

or products are not allowed to pass the steps until specified testing is not completed. Unacceptable

works/products are either corrected or scrapped.

Final Inspection and testing Confidence Steel Limited has established quality plan to check the products at the final stages. No

product is allowed to enter the finished goods store until final inspection is done. Products that cannot

pass the final inspection are corrected to make it suitable for re-inspection and decision is taken as per

procedure.

Records of inspections and testing are maintained for all the steps. Authorities responsible for

inspection and testing are identifiable from the inspection notes at all stages.

Releasing Product

In Confidence Steel Limited all operators check the quality of the previous process. Besides, in-

process and final inspection is carried out. The operator of the end process, after being satisfied through

checking ,deliver the product to customer.

CONFIDENCE STEEL LIMITED follows procedure no. QP-QIN-1 for In-Process Inspection

and Testing.

3. Control of Nonconforming Product

Nonconforming products are segregated. A document is raised in relation to the Nonconforming case

detailing cause of nonconformance and all other details like : stage, location, batch number/identity etc.

Nonconforming product is segregated to ensure that this does not mix with the conforming products and

dispatched to the point of use or to customers.

The segregated nonconforming product along with the document is then referred to the appropriate

authority to decide whether to be reworked/accepted by concession /considered for alternative

applications or to be rejected or scrapped.

In case of reworking and repairing of the product it is re-inspected as per inspection plan for

compliance. The Nonconformity and all the decisions in relation to this are recorded and record is

maintained as per procedure for Control of Nonconforming Product (QP–QIN-2).

Procedure no. QP–QIN-2 may be referred for details on the Control of Nonconforming Product.

4. Analysis of Data

Confidence Steel Limited collects applicable data to evaluate the following.

a. Report of all tests done by Customer to ascertain the extent of customer satisfaction,

b. A conformity report from Customer on completion of an assignment to ascertain the

conformity to product requirement,

c. Data reflecting characteristics and trend of processes,

d. Data reflecting characteristics of product including opportunities for preventive action,

e. Data on suppliers, etc.


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Confidence Steel Limited analyses these data to determine the suitability and effectiveness of the QMS and

to identify where improvements can be made. Statistical techniques, where appropriate, are applied to

decide and implement preventive measures.

Procedures no. QP–IQA-1, QP–QIN-1, 2, may be referred for Analysis of data.

5. Improvement

5.1 Continual Improvement

Confidence Steel Limited will evaluate quality objectives and quality management system planning

as an effort to align the management approach to continual improvement as an inherent element in the

QMS.

5.1.a

Improvement is a continuous process and with the view of that target CSL developed Q.C team

comprising of some dedicated members responsible for different job. The main task of these team is to

think about up gradation and quality improvement of job. Any renovative/new idea regarding quality

control or product improvement is always rewarded by the management.

5.2 Corrective Action

Confidence Steel Limited established and maintains standard procedures for corrective and

preventive action for any non-conformity encountered at any stage. The procedure for corrective action

includes:

– Effective handling of customer complains,

– Report of product non-conformities,

– Analyze data and process,

– Investigate causes

– Implement solutions

– Verify if correction is effective and

– Document necessary changes in procedures and quality manual

Depending on the information gathered, detailed analysis is made in relation to above cases to find out

the actual causes. The information gathered from investigations, results of analysis and subsequent

decisions are maintained as quality records.

Procedure no. QP–CAC-1 is referred on the details of the activities in relation to Corrective

Action.

5.3 Preventive Action

Preventive steps are initiated against all the nonconformity and customer complains after proper

investigation, study and analysis. The preventive steps are taken to remove potential cause for the faults

from which the nonconformance and customer dissatisfaction developed. After implementing the

preventing steps it is studied to find out whether the preventive actions are effective or not.

Product Nonconformity, Customer Complaints, Audit Results, their analysis, Corrective and preventive

Actions are referred for Management Review.

Preventive actions are also taken to improve operations and various works of the organizations. Any

such preventive actions are also referred to Management Review.

Procedure no. QP–PAC-1 is referred on the details of the activities in relation to Preventive

Action.

Quality Management

System


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Page No.: 3 of 3

Quality Manual

of 81

CHAPTER-2 RAW MATERIAL


of 81

SR.

NO.

COMPONENT

/OPERATION

AND

DESCRIPTION

OF TEST

SAMPLING

PLAN WITH

BASIS

REFERANCE

DOCUMENT&

ACCEPTANCE NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

1.0

1.1

1.1.1

RAW

MATERIALS

PROCUREMEN

T

STRUCTURAL

STEEL (ANGLE

SECTIONS &

PLATES)

PHYSICAL

PROPERTIES

A) TEST FOR

ULTIMATE

TENSILE

STRENGTH

B) TEST FOR

YIELD STRESS

One sample for

20MT/Lot or

part thereof

One sample for

20MT/Lot or

part thereof

a) Mild Steel

BS EN 10025 -2:2004

(Gr. S-275 JR I JO)

or equivalent

410 – 560 N/mm2

b) High Tensile Steel

BS EN 10025 -2:2004

(Gr. S-355 JR IJO)

470 - 630 N I mm2

or equivalent

a) Mild Steel

BS EN 10025 -2:2004(Gr.

S-275 JR IJO)or equivalent

-275 N I mm2

(min.)(upto 16 mm thick)

-265 N I mm2

(min.)(above 16 mm thick)

CONFIDENC

E

STEEL

LTD/TPL

CONFIDENC

E

STEEL

LTD/TPL

Raw materials to be

procured from reputed

vendors from

China/India/Turkey/Ukr

aine

CWP (Customer

Witness Point)

Verification of

manufacturer's

Test

Certificates &

CONFIDENCE

Record, duly correlated

at the time of

Final Inspection.

Verification of

manufacturer's

Test

Certificates &

CONFIDENCE

Records, duly correlated

at the time of

Final Inspection.

C)PERCENTAG

E

ELONGATION

TEST

One sample for

20MT/Lot or

part thereof

b) High Tensile Steel BS

EN 10025-2:2004

(Gr. S-355 JR IJO

-355 N I mm2

(min.)(upto 16 mm thick)

-345 N Imm2(min.)

(Above 16 mm thick) or

equivalent.

a) BS EN 10025 -2:2004

(Gr. S-275 JR IJO

or equivalent

23 % min.

for 3< t < 40 mm

b) BS EN 10025 -2:2004

(Gr.- S355 JR/JO

CONFIDENC

E

STEEL

LTD/TPL

Verification of

manufacture’s Test

Certificates &

CONFIDENCE


at the time of

Final Inspection.

Quality Manual

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D) IMPACT

TEST (CHARPY

‘V’ Notch)

One sample for

20MT/Lot or

part thereof

for 3< t < 40 mm

Of equivalent

22 % min.

BS EN 10025-2:2004

(Gr.S355 JR/JO) or

equivalent

Minimum Energy for

S275JR/S355JR=27Joules at

200C for Thickness 6mm &

above

And

Minimum Energy for

S275JO/S355JO=27Joules at

00C for Thickness 6mm &

above

CONFIDENC

E

STEEL

LTD/TPL

Verification of

manufacturer's

Test

Certificates &

CONFIDENCE


at the time of

Final Inspection.

1.1.2

1.1.3

1.1.4

CHEMICAL

COMPOSITION

VISUAL

CHECKS FOR

SURFACE

FINISH

DIMENSIONAL

CHECKS

One sample for

20MT/Lot or

part thereof

One sample for

20MT/Lot or

part thereof

One sample for

20MT/Lot or

part thereof

BS EN 10025-2 : 2004

(Gr. S-355 JR / JO) OR

(Gr. S-275 JR / JO)

Table-4 (Annexure-V)

Material to be free

from the lot surface defects

like

Laminations. rough I

jagged and imperfect

edges, cracks, rounded

apex. deep roll marks,

pipy and any harmful

defects (Removal of

minor surface defects

as per BS EN 10025-2:2004

clause 7.5.2/7.5.3 acceptable)

BS EN 10163 P-1 & P-3

BS EN 10056-2:1993

CSL/ TPL

CONFIDENC

E

STEEL LTD

CONFIDENC

E

STEEL LTD

Verification of

manufacturer's

Test

Certificates &

CONFIDENCE

Records, duly

correlated

at the time of

Final Inspection.

Record Review at

the time of Final

Inspection, duly

correlated

at the time of

Final Inspection.

Record Review at

the time of Final

Inspection, duly

correlated

at the time of

Final Inspection.


of 81

SR.

NO.

COMPONE

NT

/OPERATIO

N AND

DESCRIPTI

ON OF

TEST

SAMPLIN

G PLAN

WITH

BASIS

REFERANCE

DOCUMENT &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT

OF

RECORD

REMARKS

1.1.4

(A)

1.1.4

(B)

TOLERANC

ES FOR

LEG

LENGTH

OF ANGLES

(a) EQUAL

ANGLES

1) Upto 50

mm Leg

Length

2) Over 50 to

100 mm

3) Over 100

to 150 mm

4) Over 150

to 200 mm

5) Over 200

mm

(b)

UNEQUAL

ANGLES

TOLERANC

ES FOR

THICKNES

S

(a) Section

Thickness

1)t ≤ 5mm

2)

5<t≤10mm

3)10<t≤15m

m

4) 15 ≤t mm

One sample

for

20MT/Lot

or part

thereof

One sample

for

20MT/Lot

or part

thereof

One sample

for

20MT/Lot

or part

thereof

BS EN 10056-2:1993

± 1.0 mm

± 2.0 mm

± 3.0 mm

± 4.0 mm

+6mm, -4mm

For unequal angles

take the longer leg

length as the reference

as per BS EN 10056-

2:1993

BS EN 10056-2:1993

± 0.5 mm

± 0.75 mm

±1.0 mm

±1.2 mm

CONFIDE

NCE

STEEL

LTD

CONFIDE

NCE

STEEL

LTD

CONFIDE

NCE

STEEL

LTD

Record Review at

the time of Final

Inspection, duly correlated

at the time of

Final Inspection.

Record Review at

the time of Final


at the time of

Final Inspection.

Record Review at

the time of Final


at the time of

Final Inspection.

Quality Manual

of 81

SR.

NO.

COMPONE

NT

/OPERATIO

N AND

DESCRIPTI

ON OF

TEST

SAMPLIN

G PLAN

WITH

BASIS

REFERANCE

DOCUMENT &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT

OF

RECORD

REMARKS

1.1.4

(C)

1.1.4

(D)

1.1.4

(E)

1.1.4

(F)

1.1.4

(G)

OUT OF

SQUARENE

SS

1) Upto100

mm Leg

Length

2) Over 100

to 150 mm

3) Over 150

to 200 mm

4) Over

200mm

CAMBER

for full bar

length (For

Leg Length)

1) Up to 150

mm

2) Over 150

to 200 mm

3) Over 200

mm WEIGHT

TOLERANCE

FOR ANGLE

SECTIONS

1) Over 4 mm

Thickness

2) for t≤ 4 mm

WEIGHT

TOLERANCE

FOR PLATES

THICKNESS

TOLERANCE

FOR PLATES

1) ≥ 3 < 5

2) ≥ 5 < 8

3) ≥ 8 < 15

4) ≥ 15 < 25

5) ≥ 25 < 40

One sample

for

20MT/Lot

or part

thereof

One sample

for

20MT/Lot

or part

thereof

One sample

for

20MT/Lot

or part

thereof

BS EN 10056-2:1993

Table 1 Deviation in

mm (max.)

± 1.0 mm

± 1.5 mm

± 2.0 mm

± 3.0 mm

BS EN 10056-2:1993

0.4% of length

0.2% of length

0.1% of length

BS EN 10056-2:1993

±4%

±6%

BS EN 10029:1991

(Maxm Thickness

difference shall be as per

Table-1)

±0.6mm

±0.75mm

±0.85mm

±0.95mm

±1.1mm

CONFIDE

NCE

STEEL

LTD

CONFIDE

NCE

STEEL

LTD

CONFIDE

NCE

STEEL

LTD

CONFIDE

NCE

STEEL

LTD

CONFIDE

NCE

STEEL

LTD

Record Review at

the time of Final


at the time of

Final Inspection.

Record Review at

the time of Final


at the time of

Final Inspection.

Record Review at

the time of Final


at the time of

Final Inspection.

Record Review at

the time of Final


at the time of

Final Inspection.


of 81

SR.

NO.

COMPONE

NT

/OPERATIO

N AND

DESCRIPTI

ON OF

TEST

SAMPLIN

G PLAN

WITH

BASIS

REFERANCE

DOCUMENT &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT

OF

RECORD

REMARKS

1.2

1.2.1

ZINC

CHEMICAL

COMPOSIT

ON

One sample

for

50 MT or

part thereof

One sample

from

Galvanizing

bath once in

a month.

ISO 752:1981 (E)

a) Gr.Zn 99.99%

b) Gr. Zn 99.95%

The molten metal in

the

Galvanizing bath shall

not contain less than

98.5% by mass of

Zinc.

CSL/ Third

party

Independen

t Certified

lab

To be procured from

Abroad (Imported from

Korea/Japan/Australia/Indi

a/ Iran)

Verification of

manufacturer's

Test

Certificates &CSL

Third party Records.

Quality Manual

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CHAPTER-3 FABRICATION & GALVANIZATION


of 81

A) FABRICATION

SR.

NO.

COMPONENT

OPERATIONAND

DESCRIPTION

OFTEST

WITH

BASIS

SAMPLING

PLAN

REFERANCE

DOC. &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

2.0

2.1

2.2

2.2.1

2.3

IN PROCESS

INSPECTION

FABRICATION

OF

TOWERPARTS

STRAIGHTENING

CUTTING

(CROPPING

Length)

a) up to 16 mm

thick angle/Plate

b) above 16 mm

thick angle/Plate

STAMPING

Within 600mm of

the end but clear of

holes

One sample

for

20MT/Lot

or part

thereof

One sample

for

20MT/Lot

or part

thereof

One sample

for

20MT/Lot

or part

thereof

Approved Drag.,

Shop Sketches

BSEN 10056-2 :

1993

Cutting Length

Tolerances

± 2.0 mm

Shearing cutting

Hack-saw cutting

(The cut surface to

be clear square and

free from distortion)

Letter size as per

CSL specification.

(Letter height-

12mm) Visually

Legible

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Quality Manual

of 81

SR.

NO.

COMPONENT

OPERATIONAND

DESCRIPTION

OFTEST

WITH

BASIS

SAMPLING

PLAN

REFERANCE DOC.

& ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

2.4 PUNCHING I

DRILLING

Punching of full

sized holes will be

permitted up to and

including the

thickness and

Material quality

specified.

A) i) Hole

Diameter

ii) Taper on

punched hole

B) Hole to Hole

Dimension

(Punching/

drilling)

C) Edge Security

For 13.5 mm dia.

hole

For 17.5 mm dia.

hole

For 21.5 mm dia.

hole

For 25.5 mm dia.

hole

D) Back Mark

One sample

for

20MT/Lot or

part thereof

Quality- Thickness

275 JR- 16mm

355 JO 20mm

(No hole to be

punched

where the thickness

of

the material exceeds

the finished dia. of

the hole)

+ 0.5 mm, - 0.0 mm

+ 1.00 mm (on die

side)

Dimensional

Tolerances

± 2.0 mm for long

distance holes

± 1.0 mm for

consecutive

Holes

Sheared 20 mm Min.

Rolled 16 mm Min

Sheared 23 mm Min.

Rolled 20 mm Min.

Sheared 28 mm Min.

Rolled 25 mm Min.

Sheared 35 mm Min.

Rolled 35 mm Min.

± 1.0 mm

CONFIDENC

E STEEL

LTD.

Record review

at the time of

Final

Inspection.


of 81

SR.

NO.

COMPONENT

OPERATIONAND

DESCRIPTION

OFTEST

WITH BASIS

SAMPLING

PLAN

REFERANCE

DOC. &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

2.5

2.6

2.7

NOTCHING

( Flange Cut I

Corner Cut/ Bevel

Cut)

HEEL GRINDING

BENDING

i)HT sections

(Angles/Plates)

ii) MS Sections

(Angles)

iii) MS Plates

iv) Temperature

Range for Hot

Bending

One sample for

20MT/Lot or

part thereof

One sample for

20MT/Lot or

part thereof

100 %

PROCESS

Cold

Cold

Hot

Hot

PROCESS

Cold

Hot

+ 5 mm on

specified

Length of cut.

a) Operation by

shearing

up to 12 mm or

less thick

b) by gas cutting

for

material 12 mm

or larger thick

For Notching by

gas cutting,

cut edges to be

cut oversize&

ground smooth

to remove

notches

Approved drags.

I Shop Sketches

>8 mm gas

cutting to be

adopted

followed by

grinding/

machine cutting.

Tolerance on

heel cutting. -0,

+10 on length &

-0, +2 on depth.

All Sections &

plates

to be hot bent.

SECTION

upto75 x6

upto100x8

above 75 x 6

above 100 x 8

SECTION

up to 10 mm

thick

Above 10 mm

thick

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

ANGLE

up to 100

up to 50

above100

above 50

ANGLE

up to 150

above 150

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Quality Manual

of 81

850 - 1000°C


of 81

2.8

3.0

FINAL

INSPECTION OF

FABRICATED

PARTS

PROTO MODEL

ASSEMBLY

To be assembled

and

checked for

(dimensions, angle

size, by this, to

verify

interchangeability

Of members etc.

One sample for

20MT/Lot or

part thereof

One structure of

each type of all

tower/extensions

All parameters

from

pt 2.1 to 2.7

above are

checked and

records

maintained

before

releasing the

materials

for galvanizing

Approved

structure

Assembly

drawings

a) Determine if

error

fabrication or

work ·

shop drawing

b) List all

conforming

Items

c) Present

information to

Design for

action,

Assembly,

work-shop

Drawing

revision etc.

CONFIDENCE

STEEL LTD

CONFIDENCE

STEEL LTD

Record review

at the time of

Final

Inspection.

CWP(Customer

Witness Point)

CWP(Customer

Witness Point)

CHP(Customer

Hold Point)

Quality Manual

of 81

B) GALVANIZATION

SR.

NO.

COMPONENT

OPERATIONAND

DESCRIPTION

OFTEST

WITH

BASIS

SAMPLING

PLAN

REFERANCE

DOC. &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

4.0

4.1

GALVANIZING

PROCESS

CONTROL

A) DEGREASING

Alkali based

Degreasing

to be followed by

rinsing of water

B) PICKLING

( HCl Acid)

i)Specific Gravity

ii)Acid Content

iii) Iron Content

iv) Inhibitor to be

added to prevent over

pickling

C) RINSING

(in continuous tap

water)

D) PRE FLUXING

In Zinc Chloride and

Ammonium Chloride

Soln.

i) Temp

ii)Specific Gravity

iii) pH Value

iv) Iron Content

One sample

daily

One sample

daily

One sample

daily

One sample

daily

One sample

daily

One sample

daily

BSEN ISO

1461:2009

a) Sp. Gravity

1.01 ~ 1.03 b) PH 10 ~ 12

1.07 to 1.26

180 gm/ Lit to

60gm/ Lit

120 gm/Lit

(Maxm)

PH value 4 to 7

Vendor Norms

Room to 80oC

1.08 ~ 1.16

4 to 5.5 pH

Maximum 5

gm/Ltr

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Rinsing with

water

Record review

at the time of

Final

Inspection.


of 81

4.2

DIPPING

(GALVANIZATION)

A) Zinc bath

temperature is

continuously recorded

and auto controllers

are set so as to

receive the desired

Temp. range

B) Immersion time

and withdrawal Time

C) Quenching in

Running

Water

D) Dichromating

Hourly

checks

Once daily

BSEN ISO

1461:2009

Range:

i) At Idle -

4350C to 4400C

ji) At working -

4500C to 4600C

Articles to be

immersed

till reaction takes

place which is

indicated by

Stoppage of

bubbling.

Withdrawal to be

Controlled so that

Zinc drains

freely.

(BS EN ISO

1461:2009

Prepare the

solution by

adding 1%

Sodium

Dichromate and

0.5%

Sulphuric Acid in

Water.

Keep strength of

the

solution in

between

1% to 0.2% at

temperature less

than 65oC

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

Record review

at the time of

Final

Inspection.

4.3

4.3.1

GALVANIZING

CHECKING

VISUAL

CHECKING

100 %

BSEN ISO

1461:2009

Surface to be free

from defects like

Bare/ Black spots

CONFIDENCE

STEEL LTD.

Record review

at the time

of Final

Inspection

Quality Manual

of 81

4.3.2

GALVANIZING

TESTING

A) Thickness of Zinc

Coating (For Member

Thickness)

T > 6mm

6mm≥ T >3mm

B) Weight of Zinc

Coating

T > 6mm

6mm≥ T >3mm

C) Uniformity of

Zinc Coating

Immersion of test

specimen in the

Copper Sulphate

solution

(Sp. Gr. 1.186) at a

temperature of 160 to

200

D) ADHESION

TEST

(Pivoted Hammer

Test I

Knife Test)

8

sample/shift

3

sample/shift

3

sample/shift

3

sample/shift

(except when

small & suitable

for patching)

heavy ash/ flux

inclusions/

lumps/ pimples/

Drips & Runs

etc.

BS EN ISO

1461:2009

Mean coating

thickness (µm)

min.

85

70

Mean coating

mass (g/m²) min.

610

505

BS EN ISO

1461:2009

Material to

withstand

4 dips of one

minute

each without

showing

Signs of Copper

deposits.

BS EN ISO

1461:2009

No removal of

lifting

of coating in

areas

between hammer

impressions I

coating

should not peel

off.

CONFIDENCE

STEEL LTD.

Record review

at the time of

Final

Inspection.


of 81

SR.

NO.

COMPONENT

OPERATIONAND

DESCRIPTION

OFTEST

WITH

BASIS

SAMPLING

PLAN

REFERANCE

DOC. &

ACCEPTANCE

NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

5.0

PACKING,

STORING,

BUNDLING,

HANDLING

100%

Bundling to

be carried

out as per

customer’s

requirement

(BS 1133

Section 1 to 3-

1989)

Bundle. Weight

as per

Customer's

requirement.

Packing List to

be

submitted along

with

Dispatch

documents.

CONFIDENCE

STEEL LTD.

Plates and

small

parts to be

packed

Into boxes.

All sections to

be

securely

bundled.

Stacking to

have

Proper

ventilation and

kept inclined.

Damage to

Galvanization

coating to be

avoided while

handling.

CONFIDENCE

STEEL LTD to

ensure

Sequential

supplies.

Quality Manual

of 81

C) FINAL ACCEPTANCE AND TESTING OF FABRICATED AND GALVANIZED PRODUCT

(CUSTOMER WITNESS POINT)

SR.

NO.

COMPONENT

OPERATIONAND

DESCRIPTION

OFTEST

WITH

BASIS

SAMPLING

PLAN

ACCEPTANCE

DOC. &

REFERANCE

NORM

TESTING

AGENCY /

FORMAT OF

RECORD

REMARKS

6.0

6.1

6.2

6.3

FINAL

INSPECTION

AND TESTING

(Inspection

Engineer to

Check I ensure

compliance

to notes I General

Requirement given

in this

Plan)

PHYSICAL

PROPERTIES

i) UTS TEST

II) YIELD

STRESS TEST

III)

PERCENTAGE

ELONGATION

TEST

IV) IMPACT

TEST

CHEMICAL

COMPOSITION

VISUAL

INSPECTION

For Fabrication and

Galvanization

One sample

for

50MT/Lot or

part thereof

One sample

for

50MT/Lot or

part thereof

One sample

for

50MT/Lot or

part thereof

Please Refer

Clauses

No. 1.1.1(A),

1.1.1(B),

1.1.1(C)

Please Refer

1.1.1(D)

BS EN

10025:2004

Table-

4(Annexure-V)

BS EN

10025:2004

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

CONFIDENCE

STEEL LTD.

Customer Witness

Point

Customer Witness

Point

Customer Witness

Point

Customer Witness

Point


of 81

6.4

GALVANIZING

TESTS

i) Thickness of

Zinc coating

ii) Weight of Zinc

coating

iii) Uniformity of

Zinc coating

iv) Adhesion of Zn

coating

One sample

for

50MT/Lot or

part thereof

BSEN ISO

1461:2009

CONFIDENCE

STEEL LTD.

Customer Witness

Point

Quality Manual

of 81

D) FINAL ACCEPTANCE AND TESTING OF BOLT,NUT & WASHER

SRL

NO.

COMPONENT/OPERATIO

N AND DESCRIPTION OF

LIST

SAMPLING PLAN WITH BASIS REFERANCE DOC. &

ACCEPTANCE

NORM

TESTING AGENCY REMARKS

1.0

2.0

2.1

2.2

2.3

2.4

MATERIALS

Batch Certificates for Bolts

& Nuts , Spring Washers,

Step Bolts from approved

Sub contractors to be

supplied.

M12 Bolts (4.6

Grade) VISUAL

DIMENSIONAL

a) Bolt Length

b) Body Diameter (Ds)

c) Width across flats (s)

d) Width across corners ( . e)

e) Height of Head (k)

f) Pitch (p)

g) Thread Length (b)

PHYSICAL PROPERTIES

a) Tensile strength under

wedge (Minimum

ultimate tensile load)

b)Proof load

Test c)Hardness

Test

Vickers Hardness

OR Brinnel Hardness

OR Rockwell Hardness

GALVANIZING TEST

a) Zinc Coating Thickness

b) Uniformity of Zinc Coating

c) Adhesion of Zinc Coating

P=4; n<500

P=4+1.5n/1000;

n>500,maximum 50 pieces

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:2009 ( . E)

ISO 6157-1

Bolts shall be cleanly finished ,

sound and free from surface

defects

DIN 7990

as specified

11.3-12.7 mm

17.57/18 mm

19.85 mm min.

7.55- 8.45 mm

1.75 mm

17.75/23 mm

24.75/30 mm (For Anti-theft

Bolt)

ISO 898-1:2009 ( . E)

33700 N (3438

kg) (Table 4)

19000N (1938

kg) (Table 5)

120 HV to 220 HV

114 HB to 209 HB

67 HRB to 95 HRB

BSEN ISO 1461: 2009, Table 4

50 microns min. I.e. 360

g/m² Should withstand 6 dips

of 1

minute duration in Copper

Sulphate

The coating shall be

sufficiently adherent to

withstand normal handling

condition without peeling.

CSL/Supplier T.C./

CSL/Supplier T.C./ Third

Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.

To be procured from

reputed vendor of

China/India.

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)


of 81

3.0

3.1

3.2

3.3

3.4

12 mm NUTS (Grade 4)

VISUAL

DIMENSIONAL

a) Height of Nut (m)

b) Width across flats (s)

c) Width across corners ( . e)

d) Diameter of Bearing Face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 6157-2, Nuts

shall be cleanly finished , sound

and free from surface defects

ISO 4034

10.4/12.20 mm

17.57/18 mm

19.85 mm min.

16.47 mm min.

1.75 mm

ISO 898- Part II:2012 ( . E)

. -

. -

BSEN ISO 1461: 2009,Refer Point

no. 2.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.

Third Party Certified

Lab

CSL/Supplier T.C.

CWP (Customer witness

point)


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION

AND DESCRIPTION OF LIST


ACCEPTANCE NORM


4.0

4.1

4.2

4.3

4.4

SPRING WASHER (M12)

VISUAL

DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)

a) Section width (b)

b) Section Thickness (s)

PHYSICAL PROPERTIES

a)Hardness

b) Twist Test

c) Permanent Set Test

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127

Surface shall be free from cracks

, burrs pits and loose scale.

The flat face shall be free from

knurling, scratches, die marks

etc.

DIN 127

Table 1

12.2 to 12.7 mm max.

21.1 mm (max.)

3.8/4.2

2.35/2.65 mm

BS 4464

440 / 550 HV or

45/52 HRC

Washer should not be cracked or

broken after twisting through

90°.

Washer shall be completely

closed between hardened and

ground plates . After releasing,

free height of the washer should

not be less than 1.66 times

sectional thickness.


no. 2.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C./Third

Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


5.0

5.1 5.2

5.3

PACK WASHER (For M12

Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;

n>500,maximum 50 pieces P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


Free from cracks, bun pits, no

sharp edges and other defects.

As per approved drawing

13.5 mm to 13.93 mm

22.7 to 24 mm

As per Specification

5 mm thick

6 mm thick

8 mm thick


no. 2.4

CSL

CSL

CSL


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATIO

N AND DESCRIPTION OF

LIST

SAMPLING PLAN WITH BASIS REFERANCE DOC.

& ACCEPTANCE

NORM


6.0

6.1

6.2

6.3

6.4

M16 Bolts (5.6

Grade) VISUAL

DIMENSIONAL

a) Bolt Length



d) Width across corners (.e)


f) Pitch (p)


PHYSICAL PROPERTIES


wedge (Minimum

ultimate tensile load)

b)Proof load

Test c)Hardness

Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST




P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:2009 ( . E)

ISO 6157-1,

Bolts shall be cleanly finished

, sound and free from surface

defects

DIN 7990

as specified

15.3-16.7 mm

23.16/24 mm

26.17 mm min.

9.25- 10.75 mm

2 mm

21/27 mm 28/34 mm (For Anti-theft

Bolt) ISO 898-1:2009 (.E)

78500 N (8010

kg) (Table 4)

44000N (4490

kg) (Table 5)

155 HV to 220 HV

147 HB to 209 HB

79 HRB to 95 HRB

BSEN ISO 1461: 2009,Table 4

50 microns min. I.e. 360

g/m² Should withstand 6

dips of 1


Sulphate





CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


7.0

7.1

7.2

7.3

7.4


VISUAL

DIMENSIONAL




d) Diameter of bearing face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,

Nuts shall be cleanly finished ,


defects.

ISO 4034

14.1/15.90 mm

23.16/24 mm

26.17 mm min.

22 mm min.

2 mm

ISO 898- Part II

130-302 HV

95800N (9775 Kg)


no. 6.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


8.0

8.1

8.2

8.3

8.4

M16 Bolts (8.8 Grade)

VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)

g) Thread Length (lg)

PHYSICAL PROPERTIES


wedge (Minimum ultimate

tensile load)

b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:2009 ( . E)

ISO 6157-1,



defects

DIN 7990

as specified

15.3-16.7 mm

23.16/24 mm

26.17 mm min.

9.25- 10.75 mm

2 mm

21/27 mm

28/34 mm (For Anti-theft Bolt)

ISO 898-1:2009 (.E)

125000 N (12755 kg)

(Table 4)

91000N (9285 kg)

(Table 5)

255 HV to 355 HV

242 HBW to 318 HBW

23 HRC to 34 HRC

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)

BSEN ISO 1461:2009 ( Table 4)

BS 729

50 microns min. I.e. 360 g/m²

Should withstand 6 dips of 1


Sulphate The coating shall be sufficiently

adherent to withstand normal

handling condition without

peelin


(Mean)




of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


9.0

9.1

9.2

9.3

9.4


VISUAL

DIMENSIONAL




d) Diameter of bearing face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

a)Hardness

b)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034,



defects

ISO 4034

14.1/15.90 mm

23.16/24 mm

26.17 mm min.

22 mm min.

2 mm

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)

ISO 898- Part II:2012

Maximum 30 HRC

138200N (14102 Kg)

BSEN ISO 1461,BS 729 Refer

Point no. 2.4

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


10.0

10.1 10.2

10.3

10.4

SPRING WASHER (M16)

VISUAL DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)



PHYSICAL PROPERTIES

a)Hardness

b) Twist Test


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127


, burrs pits and loose scale.



etc.

DIN 127

Table 1

16.2 to 17 mm

27.4 mm (max.)

4.8-5.2 mm

3.3-3.7 mm

BS- 4464

440 / 550 HV or

45/52 HRC



90◦






sectional thickness.

BSEN ISO 1461: 2009, Refer Point

no. 6.4

CSL/Supplier T.C./

CSL/Supplier T.C.


Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


11.0

11.1 11.2

11.3


Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;





17.50 to 17.93 mm 28.7 to 30 mm

As per specification

5 mm thick

6 mm thick

8 mm thick

10 mm thick


no. 6.4

CSL

CSL

CSL


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


12.0

12.1

12.2

12.3

12.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES



tensile load)

b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST




P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 ( . E)

ISO 6157-1,



defects

DIN 7990

as specified

19.16/20.84 mm

29.16/30 mm

32.95 mm min.

11.6/13.4 mm

2.5 mm

23.5/31 mm

32.5/40 mm (For Anti-theft Bolt) ISO 898-1:1999 (.E)

122000 N (12448 kg)

(Table 4)

68600N (7000 kg)

(Table 5)

155 HV to 220 HV

147 HB to 209 HB

79 HRB to 95 HRB








peeling.

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


13.0

13.1

13.2

13.3

13.4


VISUAL

DIMENSIONAL




d) Diameter of Bearing face

(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,



defects

ISO 4034

16.90/19 mm

29.16/30 mm

32.95 mm min.

27.7 mm min.

2.5 mm


146/302 HV

154400N (15755 Kg)

BSEN ISO 1461: 2009,

Refer Point no. 10.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


14.0

14.1

14.2

14.3

14.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES



tensile load)

b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 ( . E)

ISO 6157-1,



defects

DIN 7990

as specified

19.16/20.84 mm

29.16/30 mm

32.95 mm min.

12.1/13.9 mm

2.5 mm

23.5/31 mm

32.5/40 mm (For Anti-theft Bolt)

ISO 898-1:1999 (.E)

203000 N (20714 kg)

(Table 4)

147000 N (15000 kg)

(Table 5)

255 HV to 355 HV

242 HBW to 318 HBW

23 HRC to 34 HRC

CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab CSL/Supplier T.C.


point)


point)


point)


point)


point)


BS 729




Sulphate

The coating shall be sufficiently



peeling.


(Mean)




of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


15.0

15.1

15.2

15.3

15.4


VISUAL

DIMENSIONAL





(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,



defects

ISO 4034

16.90/19 mm

29.16/30 mm

32.95 mm min.

27.7 mm min.

2.5 mm


233/353 HV

225400N (23000 Kg)

BSEN ISO 1461: 2009, Refer

Point no. 10.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


16.0

16.1 16.2

16.3

16.4

SPRING WASHER (M20)

VISUAL DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)



PHYSICAL PROPERTIES

a)Hardness

b) Twist Test


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127


, burrs, pits and loose scale.



etc.

DIN 127

Table 1

20.2/21.2 mm

33.6 mm max.

5.8/6.2 mm

3.8/4.2 mm

BS 4464

440 / 550 HV or

45/52 HRC



90◦






sectional thickness


no. 10.4

CSL/Supplier T.C./

CSL/Supplier T.C.


Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


17.0

17.1 17.2

17.3


Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;





22 mm (+0.5 mm) 37 mm (± 0.5 mm)


5 mm thick

6 mm thick

8 mm thick

10 mm thick


no. 10.4

CSL

CSL

CSL/Supplier T.C.


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION

AND DESCRIPTION OF

LIST


ACCEPTANCE

NORM


18.0

18.1

18.2

18.3

18.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES



tensile load)

b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST




P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 ( . E)

ISO 6157-1,



defects

DIN 7990

as specified

23.16/24.84 mm

35/36 mm

39.55 mm min.

14.1-15.9 mm

3 mm

26/36 mm

35/45 mm (For Anti-theft

Bolt) ISO 898-1:1999 (.E)

176000 N (17960

kg) (Table 4)

98800N (10082

kg) (Table 5)

155 HV to 220 HV

147 HB to 209 HB

79 HRB to 95 HRB





Sulphate





CSL/Supplier T.C./


Party Certified Lab


Party Certified Lab

CSL/Supplier T.C.

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)

CWP (Customer

witness point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


19.0

19.1

19.2

19.3

19.4


VISUAL

DIMENSIONAL





(Dw)

e) Pitch

PHYSICAL PROPERTIES

b)Hardness

c)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,



defects

ISO 4034

20.2/22.3 mm

35/36 mm

39.55 mm min.

33 mm min.

3 mm


146 HV to 302 HV

222400N (22693 Kg)


no. 14.4

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


20.0

20.1

20.2

20.3

20.4


VISUAL

DIMENSIONAL

a) Bolt Length





f) Pitch (p)


PHYSICAL PROPERTIES



tensile load)

b)Proof load Test

c)Hardness Test

Vickers Hardness

OR Brinnel Hardness


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 898-1:1999 ( . E)

ISO 6157-1,



defects

DIN 7990

as specified

23.16/24.84 mm

35/36 mm

39.55 mm min.

14.1-15.9 mm

3 mm

26/36 mm 35/45 mm (For Anti-theft Bolt)

ISO 898-1:1999 (.E)

293000 N (29897 kg)

(Table 4)

212000N (21632 kg)

(Table 5)

255 HV to 335 HV

242 HB to 318 HB

23 HRC to 34 HRC

CSL/Supplier T.C./


Party Certified Lab CSL/Supplier T.C./ Third

Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


BS 729







peelin


(Mean)




of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


21.0

21.1

21.2

21.3

21.4


VISUAL

DIMENSIONAL





(Dw)

e) Pitch

PHYSICAL PROPERTIES

a)Hardness

b)Proof Load

GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;

P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


ISO 4034

ISO 6157-2,



defects

ISO 4034

20.2/22.3 mm

35/36 mm

39.55 mm min.

33 mm min.

3 mm

CSL/Supplier T.C./

CSL/Supplier T.C.

CSL/Supplier T.C.


Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


Maximum 36 HRC

324800N (33142 Kg)

BSEN ISO 1461: 2009, Refer

Point no. 18.4

Quality Manual

of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


22.0

22.1 22.2

22.3

22.4

SPRING WASHER (M24)

VISUAL DIMENSIONAL

a) Inside Dia (D1)

a) Outside Dia (D2)



PHYSICAL PROPERTIES

a)Hardness

b) Twist Test


GALVANIZING TEST

P=4; n<500

P=4+1.5n/1000;


P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 127


, burrs, pits and loose scale.



etc.

DIN 127

Table 1

24.5/25.5 mm

40 mm max.

6.75/7.25 mm

4.8/5 mm

BS 4464

440 / 550 HV or

45/52 HRC



90◦






sectional thickness


no. 14.4

CSL/Supplier T.C./

CSL/Supplier T.C.


Party Certified Lab

CSL/Supplier T.C.


point)


point)


point)


point)


point)


of 81

SRL

NO.

COMPONENT/OPERATION



ACCEPTANCE NORM


23.0

23.1 23.2

23.3

24.0

24.1

24.2

24.3

25


Bolts)

VISUAL

DIMENSIONAL

a) Inside Diameter

a) Outside Diameter

a) Thickness

GALVANIZING TEST

STEP BOLT

(As Per Approved Drawing)

DIMENSIONAL

PHYSICAL PROPERTIES

(Cantilever Test)

GALVANIZING

D-SHACKLES & FLAT LINKS

P=4; n<500

P=4+1.5n/1000;


P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


P=4; n<500

P=4+1.5n/1000;


DIN 126A




26 mm (+0.5 mm) 40 mm (± 0.5 mm)


5 mm thick

6 mm thick

8 mm thick

10 mm thick


no. 14.4

Customers Drawing

Refer Point no. 2.4

Customers Drawing

CSL

CSL

CSL

CSL/Supplier T.C./


Lab

CSL/ Supplier T.C.


Lab


point)


point)


point)


point)


point)


point)

Quality Manual

of 81

CAHPTER-4 DELIVERY


of 81

A) Packaging Requirement

1. Tower Overview

As shown in the following figure, a Telecommunication consists functionally of tower body,

aircraft warning light, lightning protection grounding system, and accessories:

Figure 1

2. Technical Specifications of the Tower Body

2.1 All materials must be packed according to each tower. Only the materials of the some tower

can be packed together.

2.2 The packages (packing rules and packing box specifications) of the same supplier and the same

product (or product set) must be strictly kept consistent. Ensure that the package with the same

box No. can be interchanged.

2.3 All products must be separately packed. Then, they should be collectively packed in wooden

cases according to the site configuration and actual conditions.

2.4 Inside each packing box, there must be a packing list of the box. In addition, items on the

packing list and real objects in the box must be in one-to-one mapping.

2.5 A mark label that is used for goods separation must be attached to each packing box. In

addition, the words on the label should be eye-catching.

2.6 The package of a packing box should facilitate secondary suite and goods separation.

2.7 As long as a single package does not exceed its weight limit, each tower should have as few

packages as possible.

2.8 tower poles should be bundled. Fragile, or small and irregular accessories should be packed in

wooden cases.

3. Tower Body Packing

3.1 Tower materials should be bundled as follows: big ones wrap small ones; the upper and lower

layers are bigger angle steel while the middle layer is smaller angle steel. Foe a single-base

tower, multiple packages should be bundled.

Quality Manual

of 81

3.2 It is recommended to use steel strips to bundle tower and the thickness of steel strip must

ensure the wraps of the tower bundles to be firmer (steel strip: width is bigger than 3mm, and

the thickness is thicker than 0.8mm)

3.3 there shall have underlay for protecting galvanization from damage.

3.4 Starting to pack at a distance about 0.5 meter from the package tip (as the figure 1); Bundling

one point by using two strips with a distance about 10 centimeters on underlay, at intervals of 2

meters ( as the figure 1);

Figure 1 Strip rule

Package length Point number Strips number

3.0M 2 4

>3.0M ; 5.0M 3 6

>5.0M 4 8

3.7 Tower materials with an equal or a similar length should be bundled together. In addition,

ensure that a whole bundle of tower materials should be strong enough lest they should deform

when handled.

3.8 Tower materials should be packed in the order in which a tower is erected. The same bundle of

tower parts should be packed together according to adjacent segments of the tower.

3.9 The maximum weight of a single bundle should not exceed 1,000KG. Tower boots (tower

feet), climbing ladders, fences for climbing ladders, and fusser plates should be bundled as

shown in the following figures. The pole parts unable to be well poled up, such as working

platforms and half spaces should be separately packed and fastened.

Figure 2 Bundling of tower foots Figure 3 bundling of climbing ladders


of 81

Note: Every two tower foots should be bundled together. The tower foot accessories of the

same tower should be bundled and fastened.

Climbing ladders should be bundled together by the site. Longitudinal fence connection straps

should be bundled together with climbing ladders. Angle steel should be buckled inside.

Figure 4 Bundling of fences for climbing ladders Figure 5 bundling of gusset plates

Note: As shown in Figure, fences must be bundled as a plane. They should not be disordered or

loose.

Gusset plates should not be bunched by iron wire and loosely packed. They must be bunched

and then fastened. It is recommended to bundle them with screw rods or iron wires.

4. Embedded Parts

4.1 Anchor bolts should be packed by the single-base tower. All the anchor bolts of a tower should

be packed as one piece. It is recommended that they should be backed with angle steel + screw

rod framework or steel die sleeve, as shown in Figure 6 and Figure 7.

Figure 6 bundling of anchor bolts (steel die sleeve)

Figure 7 bundling of anchor bolts (steel die sleeve)

4.2 Anchor bolt washers should be packed together with tower body instead of with anchor bolts.

Quality Manual

of 81

4.3. Orientation templates should be packed by the single-base tower. All the orientation template

angle steel of a tower should be packed as one piece.

44. Orientation templates (including those at both ends of anchor bolts) should be packed as one

piece ( the connecting bolts on orientation templates are first packed in a firm sack and then

clamped in between orientation templates or firmly bound onto orientation templates). Cable

racks should meet load-bearing requirements.

5. Accessories

5.1 According to the shape of their components, antenna supports and microwave supports should

be packed as two pieces (or fewer) by the single-base tower. As shown in Figure 9, the bolts of

antenna supports and microwave supports should be packed together with those of tower body.

Figure 9 bundling of antenna supports

5.2 According to the shape of their components, horizontal cable racks and support posts should be

packed as one to two pieces by the single-base tower. The mounting bolts of accessories should

be packed together with the bolts of tower body.

5.3 Aircraft warning light supports should be packed by the single-base tower. Their mounting

bolts should be packed together with the bolts of tower body.

5.4 Small parts, such as fasteners, copper grounding clips, and wiring terminals, should be

separately packed in a sack and then put into an iron drum. Or they may be first packed in a sack

and then put into a braided bag, finally put into a wooden case.

5.5 The mounting bolts of horizontal cable racks, support posts, bogies, antenna supports, and

aircraft warning lights should be packed together with those of tower body.

5.6 If there are other custom-made accessories or some accessories that are not mentioned above,

suppliers should provide a packing plan, which must be confirmed by Huawei.

5.7 The above tower parts to be bundled must be firmly bound. Bundling tapes should be enwound

with buffer (pearl cotton or strip of cloth) lest the surfaces of the parts should be damaged. It is

recommended that they should be bundled with steel strips.

6. Requirements for the packing list 6.1 Tower suppliers should make a detailed description of ex-factory towers, part numbers, and

packing rules so that procurement personnel can inspect goods and warehouse management

personnel can conduct secondary goods separation.

6.2 For delivered towers, tower suppliers must provide a detailed packing list, including but not

limited to tower No., part No., quantity, and weight. Cases must indicate their volumes for the

sake of goods search and goods separation. The packing list should be prepared and provided by

suppliers and must be confirmed by Huawei.


of 81

6.3 A container list should keep a detailed record of tower parts in each container, including but not

limited to packing list No., contract No., tower type, quantity of towers, name of tower part,

quantity of tower packages, package No., gross weight, net weight, dimensions, and volume.

6.4 In small part (fasteners, copper grounding clips, and wiring terminals) packages, there must be a

descriptive label in each sack, which indicates names, models, quantity, and weight of these

small parts. On each braided bag, there should be a piece of plasticized label paper, which

indicates model, quantity, and weight. Inside and outside an iron drum or a wooden case, there

must be a packing list respectively. The materials inside the case must be kept consistent with

the packing list. The packing list includes, but is not limited to product name, specification,

model, quantity, and weight. The packing list is first put into a plastic bag and then into the

uppermost layer of the packing box so that it can be seen upon unpacking. Outside the wooden

case, the packing list must be strikingly pasted onto one side of the case.

Figure 10 Packing in a wooden case

6.5 For each tower, there should be a detailed tower part packing list, including but not limited to

tower part name, quantity of packages, and package No., together with the No., specification,

length, quantity, and remarks of various parts in each package.

7. Requirements for Packing Identification

7.1 Color marks: In the same container, all bundles of the same tower should be marked in the

same eye-catching color on both side of the bundle other than the strips. Thus, all packages of

the same tower inside the container can are separated in turn by using eye-catching color

marks.

7.2 Steel impression marks of tower parts: If any bundle comes loose, you must first restore the

bundle according to the tower packing list (attached to the container) and container list,

together with the steel impression marks on the parts. Then, you should in turn separate all the

bundles of the same tower.

7.3 All bundles of the same tower with the same bold color marking must have the same packing

identification numbers on the bold color markings.

7.4 For zinc-coated tower parts, you should write down a package No. on the eye-catching position

of each package (including small packages inside big packages) with non-fading paint. Ensure

that your handwriting is neat and legible.

7.5 For non-galvanized tower parts, you should write down a package No. on them with non-fading

paint In addition, you need to print the package No. on plasticized paper labels and attach the

labels to the parts.

7.6 In the case of packing with a wooden case, you should attach a label to each separate part

according to the packing lit. The label includes part No. and part description. The label should

be in English and its size can be adjusted as require. For the label template, you may refer to

Figure 21.

Quality Manual

of 81

PART NO. 38

PART DESCRIPTION ST5. 5*20

Tapping screw by drill

Figure 21 Label template

7.7 A cargo label should be respectively attached to both the inner and outer packing boxes. Thus,

we can know about what is inside according to the label.

7.8 An apparent identifier must be pasted on each uppermost layer packing. It includes storage and

transportation sign, size and weight of the packing box, material information sigs, mark label,

and environmental protection sign.

8. Requirements for Packing Material

8.1 A wooden case must be strong enough so that it will not deform or break even in a complex

circulation environment.

8.2 The wooden case must be waterproof, moisture-proof, rustproof, and shake-proof. It must

provide buffers.

8.3 The wooden case should be made of real wood board or plywood. Teal wood must be

fumigated. Plywood should be thick enough in its load-bearing direction. The wooden case

must be firm enough and enclosure-type. In addition, the wooden case should have iron sheet

wrapping and there should be no mould on the surface of the board.

8.4 The water ration of plywood should be less than or equal to 18% the water ratio of real wood

should be less than or equal to 20%

8.5 The plate thickness of the wooden cade should be no less than 9 mm.

8.6 The wooden cade may be a framework wooden cade or an assembled wooden case. The latter

is recommended because its cover is simply connected with the cade body, which facilitates

unpacking and packing.


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B) Loading Requirement

1 Loading principle

The tower is loaded by tower wise, according to the container list.

2 Loading manners

For making full use of the container, we shall properly choose the following loading manners:

1) Loading some complete sets of towers in one container;

2) Loading some complete sets of towers and a half set of tower in one container.

For example:

If the container can contain more than one tower but cannot contain two towers, we can load

one tower and part of another towers in one container;

3 Loading Requirement

3.1 If the container contains more than one complete tower, the tower in this container shall be

easily distinguished by using the different colors painting on the tip of the package or on the

first steel strip, and remarked in the container list (referring to the figure 12

Figure 32 Container loading rule 1

3.2 If the container contains some complete sets of towers and a half set of tower in one container,

it is not to do referring to the point 1), but also to make sure all the packages of the tower that

divides to load in two containers pained with the same color (referring to figure 13), and

remarked as” the other parts of the tower is in ** container” in the container list;

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Figure 43 container loading rule 2

3.3 It is not permitted to put one tower into three containers.

3.4 The different type towers can be put into one container to make full use of the container

(referring to the following picture);

3.5 Putting the light, small and brittle packages above; putting the heavy, big and stiff packages

under;

3.6 The wood blocks shall be put under the tower packages at each floor to make sure the package

easily download;

3.7 Assigning one person to instruct the loading and record the loaded packages in the container

list.

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