CHECKLIST FOR “HOT ROLLED PRODUCTS OF ......CHECKLIST FOR “HOT ROLLED PRODUCTS OF STRUCTURAL STEELS_EN 10025-1” (M/120) CPR_CHECK LIST_HOT ROLLED STRUCTURAL STEELS_01/2018 Pag

CHECKLIST FOR “HOT ROLLED PRODUCTS OF STRUCTURAL STEELS_EN 10025-1” (M/120)

CPR_CHECK LIST_HOT ROLLED STRUCTURAL STEELS_01/2018 Pag. 1 di 21

File N°

Organisation

Registered office address

Address of production site(s)

Applicable standard for the specific requirements:

EN 10025-2: Non-alloy structural steels

EN 10025-3: Normalized/normalized rolled weldable fine grain structural steels

EN 10025-4: Thermomechanical rolled weldable fine grain structural steels

EN 10025-5: Structural steels with improved atmospheric corrosion resistance

EN 10025-6: Flat products of high yield strength structural steels in the quenched and tempered

Type of product’s description 1 Steel grades Maximum thickness (mm)

Technical documentation review report (Mod. CPR_REDT) (when applicable)

Performed by:

On:

Type of audit Preliminary Assessment Surveillance

Supplementary Extension Certificate transfer

1 Describe the type of product, i.e.: sheared edge strip/as rolled edged plates, from coils/sheared edge plates, from coils/hot rolled steel plates from slabs, etc.



N° CHECKED REFERENCES

1 GENERAL

The intended use of the product shall be defined

The manufacturer shall have the product technical standard (harmonised and supporting standards)

The technical standards referred to in the FPC system documentation shall be available

Is there more than one production site?

If yes, is the same FPC system implemented?

The FPC system shall be implemented for at least three months

Does the manufacturer implement a quality management system in compliance with the ISO 9001 Standard which includes the production process of the hot rolled products of structural steels subject to the EN 10025-1 Standard?

− If yes, is this affirmation supported by a valid QMS ISO 9001 certificate issued by an accredited body?

− Is factory production control for the products to be certified an integral part of the quality management system?

Observations/Notes:

2 EVALUATION OF CONFORMITY

The compliance of a steel product with the requirements of the EN 10025-1 standard and with the stated values (including classes) shall be demonstrated by:

− Initial type testing (ITT)

− Factory production control (FPC) by the manufacturer

Observations/Notes:




3 INITIAL TYPE TESTS (ITT) 3.1 GENERAL

The initial type testing program comprises:

− intensive routine testing (see the following points)

(required for all products)

− supplementary testing (see the following points) (additionally required for steel products delivered: a) in the thermomechanically rolled condition with a specified

minimum yield strength ≥460 MPa for the smallest thickness range

b) in the quenched and tempered condition with a specified minimum yield strength ≥460 MPa for the smallest thickness range;

c) in the normalized condition with a specified minimum yield strength ≥420 MPa for the smallest thickness range)

An initial type testing program shall be carried out under the sole responsibility of the manufacturer of the products before they are first placed on the market

Such a program shall be carried out in each case for the steel grades with the highest requirements for tensile and impact properties which a manufacturer places on the market in accordance with EN 10025-2 to EN 10025-6

Initial type testing shall be performed on first use of harmonized standard for hot rolled products of structural steels being put onto the market

Tests previously performed in accordance with the provisions of the EN 10025-1 standard (same product, same characteristic(s), test method, sampling procedure, system of attestation of conformity, etc.) may be taken into account

In addition, initial type testing shall be performed at the beginning of a new method of production (where this may affect the stated properties)

The assessment of the following characteristics is required:

Tolerances on dimensions and shape

Elongation

Tensile strength

Yield strength

Impact strength

Weldability (chemical composition)

Durability (chemical composition)

Observations/Notes:




3.2 INTENSIVE ROUTINE TESTING

lntensive routine testing shall be specific inspection and testing in accordance with 8.4 of EN 10025-1:2004 carried out on the first five casts produced

However, for tensile and impact testing, at least 6 products from each of the five casts shall be tested and where this is not possible test pieces shall be taken from opposite ends of the products being tested

Observations/Notes:

3.3 SUPPLEMENTARY TESTING

3.3.1 GENERAL

A supplementary testing of the product shall be carried out on the thickest range and highest grade and quality being placed on the market by the manufacturer and taken from any one of the 5 casts used in the intensive routine testing

Observations/Notes:

3.3.2 CHEMICAL COMPOSITION

A chemical content analysis shall be carried out on the product in accordance with 10.1 of EN 10025-1

The content of the following elements shall be determined and recorded:

‒ Carbon ‒ Silicon ‒ Manganese ‒ Phosphorus ‒ Sulphur ‒ Copper ‒ Chromium ‒ Molybdenum ‒ Nickel ‒ Aluminium, ‒ Niobium ‒ Titanium ‒ Vanadium ‒ Nitrogen ‒ Any other element intentionally added

Observations/Notes:




3.3.3 TENSILE TESTS

Tensile tests shall be carried out in accordance with 10.2.1 of EN 10025-1 (the test method for which is the normative reference to EN 10002-1)

Observations/Notes:

3.3.4 IMPACT TESTS

Impact tests shall be carried out in accordance with 10.2.2 of EN 10025-1 (the test method for which is the normative reference to EN 10045-1)

The results shall be recorded and presented in the form of transition curves showing the impact energy in Joules of one set of 3 test pieces at test temperatures of +20 °C, 0 °C, -20 °C, -40 °C and at two additional test temperatures to show the ductile to brittle transition behaviour

Where longitudinal and transverse impact tests are specified in EN 10025-2 to EN 10025-6, two transition curves shall be established, one for each orientation

Where impact energy values are specified at more than one test temperatures, the transition curve(s) shall include all the temperatures specified in EN 10025-2 to EN 10025-6

Individual values shall be plotted on a graph

Individual and average values shall be recorded

Impact energy values measured at test temperatures other than those specified in EN 10025-2 to EN 10025-6 shall be for information only.

Observations/Notes:

3.3.5 WELDABILITY

Where appropriate and as an indication of weldability the carbon equivalent value (CEV) shall be calculated in accordance with 7.2.3 of EN 10025-1 and recorded

The controlled thermal severity (CTS) tests, the Tekken tests or implant tests shall be carried out in accordance with EN ISO 17642 Parts 1 to 3 in order to determine the susceptibility of the steel product to hydrogen cracking in the heat affected zone of the weld




The results of the test shall be a crack/no crack criterion

Observations/Notes:

3.4 DOCUMENTATION

The results of the initial type testing program shall be recorded

The records shall be maintained and be made available for inspection for a period of at least 10 years after the date when the last product to which the test program refers to was delivered

Observations/Notes:

4 TESTING OF SAMPLES TAKEN AT THE FACTORY BY THE MANUFACTURER

The testing of samples taken at the factory by the manufacturer shall be in accordance with a prescribed plan as specified in EN 10025-1 and in accordance with the requirements of Clauses 8, 9 and 10 of EN 10025-1 (for the test frequency see the below tables)

The products shall be delivered either with specific or non-specific inspection and testing as specified in EN 10025-2 to EN 10025-6 to confirm compliance with the order and the EN 10025-1 standard

Observations/Notes:



EN 10025-2:

FREQUENCY OF TESTING

SAMPLING

TEST UNITS

VERIFICATION OF CHEMICAL COMPOSITION

TEST TO BE CARRIED OUT FOR SPECIFIC INSPECTION



EN 10025-3:


SAMPLING

TEST UNITS





EN 10025-4:


SAMPLING

TEST UNITS





EN 10025-5:


SAMPLING

TEST UNITS





EN 10025-6:


SAMPLING

TEST UNITS






4 TESTING OF SAMPLES TAKEN AT THE FACTORY BY THE MANUFACTURER

The reporting of such testing as carried out by the manufacturer shall be in an inspection document in accordance with EN 10204 and of a type of document as set out in the following Table B

The following essential product characteristics shall be declared in the Declaration of Performance (DoP) and in marking (see Annex ZA of the harmonised product standard)

Tolerances on dimensions and shape

Elongation

Tensile strength

Yield strength

Impact strength

Weldability (chemical composition)

Durability (chemical composition)

Observations/Notes:

TABLE B – TYPE OF INSPECTION DOCUMENT

Requirement Inspection document

Specified minimum yield strength for the thinnest thickness range ≤355 MPa a) and a specified impact energy tested at a temperature of 0 °C or 20 °C 2.2

Specified minimum yield strength for the thinnest thickness range ≤355 MPa a) and a specified impact energy tested at a temperature less than 0 °C 3.1 b) o 3.2 c)

Specified minimum yield strength for the thinnest thickness range >355 MPa a) 3.1 b) or 3.2 c)

a) 1 MPa = 1 N/mm2

b) Inspection document type 3.1 replaces in EN 10204:2004 type 3.1.B of EN 10204:1991 c) Inspection document type 3.2 replaces in EN 10204:2004 type 3.1.C of EN 10204:1991


5 FACTORY PRODUCTION CONTROL (FPC)

The manufacturer shall establish, document and maintain an FPC system to ensure that the products placed on the market conform with the stated performance characteristics

The FPC system shall consist of procedures, regular inspections and tests and/or assessments and the use of the results to control raw and other incoming materials or components, equipment, the production process and the product




NOTE: An FPC system conforming with the requirements of EN ISO 9001, and made specific to the requirements of the EN 10025-1 standard, shall be considered to satisfy the above requirements

NOTE: A quality system in accordance with EN ISO 9001 does not necessarily have to be certified to satisfy the FPC requirements of the EN 10025-1 standard

The FPC system shall contain at least the following elements:

a) control of the raw materials

b) control of the component construction process

c) management of maintaining equipment efficiency

d) control of finished products

e) control of the identification of finished products

f) management of non conformities

g) management of market complaints

h) management of the documentation recording the FPC data

For each one of the controls specified in the FPC system, shall be indicated the following indicated:

a) reference to the applicable operational documents

b) reference to the test and control equipment to be used

c) reference to control frequency

d) reference to acceptance criteria of the controls carried out

e) reference to action taken in the case of non conformity of the results of the controls in relation to expected results

The results of the controls, tests and evaluations indicated in the manufacturer’s FPC system shall be recorded

These records shall be legible, clearly identified and traceable

The action to be taken when the values or criteria of the control are not met shall be recorded and kept for the period specified in the manufacturer’s procedures for factory production control (FPC)

Observations/Notes:




6 ORGANISATION AND PERSONNEL

The responsibility, authority and the relationship between personnel that manages, performs or verifies work affecting product conformity, shall be defined

This applies in particular to personnel that needs to initiate actions preventing product non-conformities from occurring, actions in case of non-conformities and to identify and register product conformity problems

The manufacturer shall define the person responsible for the FPC system (who ensures compliance of the products with the requirements established by the reference standards)

The person responsible for the FPC system shall appear in an organisation chart

This person must have the responsibility and authority to:

− decide the action to be taken to ensure compliance of the products with the requirements of the reference standards

− decide the action to be taken in the case of non conformity of the products with the requirements of the reference standards

The FPC system shall describe the measures to ensure that the personnel involved in activities which influence product conformity have adequate qualification and training for the range of hollow sections to be manufactured

Is there an organisation chart?

Is there a job description document?

The necessary competences shall been defined for each functional role in terms of education, training, skills and experience

Observations/Notes:

7 EQUIPMENT

TESTING

All weighing, measuring and testing equipment shall be calibrated and regularly inspected according to documented procedures, frequencies and criteria

MANUFACTURING

The procedures to maintain the efficiency of the plants and equipment used to manufacture the hollow sections shall be defined and implemented




All equipment used in the manufacturing process shall be regularly inspected and maintained to ensure use, wear or failure does not cause inconsistency in the manufacturing process

Inspections and maintenance shall be carried out and recorded in accordance with the manufacturer’s written procedures

The records shall be retained for the period defined in the manufacturer's FPC procedures

Observations/Notes:

8 RAW MATERIALS

Procedures for the acceptance of raw materials shall be defined and implemented

The specifications of all incoming raw materials shall be documented

The inspections to ensure compliance of the raw materials shall be documented

The documents which record the checks made for acceptance of raw materials shall be available

Observations/Notes:

9 PRODUCT TESTING AND EVALUATION

The manufacturer shall establish procedures to ensure that the stated values of all of the characteristics are maintained

The characteristics, and the means of control, are:

− tensile test in accordance with EN 10002-1

− impact test in accordance with EN 10045-1

− chemical analysis in accordance with the standards listed in CR 10261

Observations/Notes:




10 NON-CONFORMING PRODUCTS

The manufacturer shall have written procedures which specify how non-conforming products shall be dealt with

Non conformities shall be recorded and kept when they occur

The causes of the non conformities shall be sought

Procedures for non-conforming products, which ensure the following, shall be defined:

a) identification

b) the documentation

c) the evaluation

d) segregation (where applicable)

e) treatment

f) communication to the functions concerned

The necessary corrective action to eliminate the cause of the non conformities shall be defined

Checks shall be made to ensure that corrective action:

a) is implemented

b) is effective

The system shall include appropriate measures to prevent the recurrence of system non conformities (preventive action)

A documented system used to deal with complaints about products shall be available

Observations/Notes:

11 WORKING/SERVICE SUBCONTRACTING

Are there manufacturing and/or services processes subcontracted?

If yes, procedures to control subcontracted work/service shall be defined

Observations/Notes:




12 HANDLING AND STORAGE

Procedures for the handling, storage, packaging and dispatch of the products shall be defined and implemented

The handling equipment and method shall be such as to avoid damage to the products

The storage areas shall be adequate in terms of space and protection against external agents, where necessary

The packaging machinery and method shall be such as to avoid damage to the products

The manufacturer shall define methods for delivery of the product declaration of performance (DoP) and for the application of the CE marking

Observations/Notes:



ADDITIONAL CHECKLIST FOR SURVEILLANCE AUDITS N° CHECKED REFERENCES

S MAINTENANCE OF THE FACTORY PRODUCTION CONTROL SYSTEM

S.1 SCOPE OF THE FPC SYSTEM

Has the manufacturer implemented and continued to implement the FPC system whose scope covers all the products contained in the enclosure to the RINA certificate?

Is the certificate issued by the Notified Body valid?

Have substantial changes been made to the FPC documentation?

Have important organisational/managerial changes been made which have affected the FPC system?

Have significant changes been made to the company’s logistics?

Does the scope of the FPC system cover new production sites/offices?

Does the scope of the FPC system cover new products and/or new standards?

If yes, has the pertinent type testing been carried out (TT)?

Are there new production lines or have important changes been made to the existing ones?

Is there important new equipment?

Has the production process undergone substantial changes compared to the previous audit carried out on the FPC system?

If yes, in compliance with the rules of the Notified Body, has:

− the manufacturer informed the Notified Body of these changes?

− the manufacturer consequently updated the FPC documentation?

− the manufacturer obtained approval from the Notified Body to implement the changes, where necessary?

− the manufacturer implemented the changes according to what has been approved by the Notified Body, where necessary?

Observations/Notes:




S.2 PREVIOUS AUDIT FINDINGS/OBSERVATIONS

Have the corrective actions, established in relation to the findings issued during the previous audit, been implemented?

Have the type B findings, identified during the previous audit, been successfully resolved?

Has the manufacturer taken note of the observations made during the previous audit?

Observations/Notes:

S.3 RECORDS

Has the manufacturer provided a copy of the Declaration of Performance (DoP) of the product made available on the market?

Are the products placed on the market duly CE marked in compliance with what is established in the ZA Annexes of the respective product standards?

Does the CE marking information contain the examples given in the ZA Annexes of the respective product standards?

Is the CE marking information affixed to the product label or packaging or accompanying commercial documentation?

Does the commercial documentation contain a reference to the CE marking information and/or vice versa?

Observations/Notes:



ASSESSMENT OF THE LABORATORY/LABORATORIES (fill in the form below relevant to the audit/assessment review of the laboratory/laboratories in charge of testing)

Name of Laboratory:

Address: Address:

Tel: Tel: Tel:

Certificates / notification/ authorisation obtained by the laboratory:

Since:

Since:

Since:

Since:

1 – TESTS PERFORMED

Requirement/Characteristic Test method Instrument identification CHECKED

Observations/Notes:

2 – LABORATORY REQUIREMENTS CHECKED References/Notes:

Does the laboratory have the professional competency and necessary experience to provide the service?

Has the Management of the laboratory implemented adequate training and qualification of its personnel in accordance with national or international standards?

Is the list of qualified personnel up to date?

Is the age, education, training courses, qualifications and work experience of the personnel recorded (curricula vitae)?



2 – LABORATORY REQUIREMENTS CHECKED References/Notes:

Does the laboratory have the equipment and resources needed to provide the service?

Does the laboratory have up-to-date instruction manuals for its equipment, provided by the manufacturer of the equipment?

Do the lists of equipment and instruments include maintenance and calibration instructions?

Is there objective evidence of the state of maintenance and calibration of the equipment and instruments?

Are process documents available relevant to the services provided?

Does the laboratory check that all the services have been provided according to the applicable procedures?

Do the test reports contain all the information as required by the applicable standards?

Are the reports signed by technical personnel who have the necessary qualification?

Other…..

Documents

CHECKLIST FOR “HOT ROLLED PRODUCTS OF ......CHECKLIST FOR “HOT ROLLED PRODUCTS OF STRUCTURAL STEELS_EN 10025-1” (M/120) CPR_CHECK LIST_HOT ROLLED STRUCTURAL STEELS_01/2018 Pag