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INSPECTION AND TEST PLANTECHNICAL BULLETIN FOR BINA.THERM, CONTRACTORS AND CLIENTS

QUALITY MANAGEMENT SYSTEMPROJECT QUALITY CONTROL

INSPECTION AND TEST PLAN (ITP) for BAUCLAD & BAUTRIM External Prefabricated Cladding and Decoration SystemsThis document is detailing a systematic approach to testing the installation of BAUCLAD & BAUTRIMfaçade system and products (including additional materials) such as a visual inspection, dimension inspection, adhesion/bonding inspection, function test, factory acceptance test and participation of all parties.The target of the document is to guarantee the product quality and ensure the product function achieved the designed requirements.

Special edition of preliminary PQP for the Customer/General contractor.

Rev

Date Comments Prepared by

Reviewed by

Approved by

CONTRACTOR LOGO

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00 Initial issue Contractor Contractor General Contractor

Customer

Contents:

1. Construction Site Details1.1Purpose and scope1.2Document Glossary1.3Roles and Responsibilities1.4Inspection and Test Plan Input Data

1.4.1. ITP’s overview1.4.2. Work methodology1.4.3. Characteristics of product quality/correct installation details against

acceptance criteria 1.4.4. Stage / frequency1.4.5. Records1.4.6. Specification / standard1.4.7. Acceptance criteria1.4.8. Inspection / test procedures1.4.9. Hold / Witness points1.4.10. Checklists

2. Personnel / Workers training3. Identification and traceability4. Amendments to the ITP and additional information

Document appendixes: Appendix 1: Inspection and Test Plans Appendix 2: Checklists Appendix 3: Storage and protection checklist: Appendix 4: Incoming inspection checklist: Appendix 5: Pre-handover activities

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1. Construction Site Details:

Client: _________________________________________________________

General Contractor: _____________________________________________Project name and site address: ________________________ __________Site manager: __________________________________________________Emergency numbers: ___________________________________________

1.1 Purpose and scope

The purpose of the present document “Inspection and Test Plan” is to put together a single document that records all inspection and testing requirements relevant to installation of the BAUGRUP Decorative Thermal Insulating Wall Systems. Inspection and Test Plan identifies the components of the system and work activities to be inspected or tested, by whom and at what stage or frequency, as well as Hold and Witness Points, references to relevant standards, acceptance criteria and the records to be maintained. The attached in the Annexes Inspection and Test Plans, being properly implemented, help ensure that, and verify whether, work has been undertaken to the required standard and requirements, and that records are kept.

1.2 Document Glossary

Hold Point - A ‘hold’ point defines a point beyond which work may not proceed without the authorisation of a designated service provider, the General Contractor’s or Customer’s representative/authorised person or a regulatory authority representative,.

Witness Point - A ‘witness’ point provides a party such as the Contractor’s service provider, customer, general contractor, and a regulatory authority with the opportunity to witness the inspection or test or aspect of the work, at their discretion.

Surveillance - Intermittent monitoring of any stage of the work in progress (whether by the Contractor, by General Contractor’s representative or customer).

Self-inspection- Where the service provider performing the work verifies the quality progressively - often with the aid of checklists.

Work area - A discrete section of the whole contracted works on the construction project, defined specifically by location in a map as an annex to the Main Agreement, where any installation works would be completed before it moves onto another area. Also delimited areas will be referred to in the Agreement as lots.

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1.3 Roles and Responsibilities

Contractor

The foreman of Contractor will document and maintain the Inspection and Test Plans and thus will be the ITP Inspector. The Inspector (the Contractor foreman) is technically instructed and has a good technical and practical knowledge of, and experience in, the activities involved to install the BAUGRUP Facade System. The use, understanding and acceptance of ITPs by the foreman and other personnel is greatly enhanced since he was involved in the document preparation.The Contractor is responsible for ensuring that all the required Inspection and Test Plans are prepared, including those covering work or processes to be carried out by its service providers. While it is preferable that its service providers prepare the ITPs for their own work, in the final analysis some may require the service provider’s involvement.The senior responsibles of the Contractor will be made responsible for approving Inspection and Test Plans, and any subsequent amendments, prior to their submission or submission of compliance/conformity certification to the customer.

The General Contractor

The General Contractor must appoint and ensure a person who will be available anytime the review or consent from the Contractor Inspector will be requested or intrepelated. The Inspector must sign in due time the necessary documents and agree upon/report the modifications/altertion of the system according to real site situations.

The Client

The Client may also appoint and ensure a person who to review or consent the ITP’s Checklists from the Contractor’s Inspector

1.4 Inspection and Test Plan input data

1.4.1 ITP’s overview

Because 100% inspection and testing in most cases is neither practical nor desirable, the ITP’s indicate the activities/products to be inspected and tested, as separate activities, and carry out preliminary tests to assist in obtaining an early indication of conformity

The following points describe what needs and control points have been included and considered for each component of the Inspection and Test Plans. They explain the components, possible fails and defects, and the relevant checkpoints have been selected for verification.

The “what to test”, “how to test” and “when to test” is governed by:- What the work is and how complex it is- Accessibility for inspections and sampling- Consequences of failure, including as follows:- Cost of remedial work

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- Effect on construction program- Accessibility for rectification- Disruption to use of building or structure- Consequential damage to other elements- Threat to safety of workers and public- Availability of resources

The type, timing and frequency (the what, when and how often) of inspections and tests are best determined in conjunction with the consideration of the characteristics to be verified.

1.4.2 Work methodology

General sequence of work and method of erection of the BAUCLAD Wall system:

• Each bundle will be delivered in conforming transport package and lifted to the necessary elevation and stored accordingly to ensure safety. • The claddings and corniches will be fixed to the walls in sequence and placed in accordance with working drawings.• The corniches will be mechanically anchored and the claddings will be doweled.• The proper joinery will be ensured before progress to next element.• The Quality inspector will verify the quality of the installation, the strength of the joinery, the mechanical fixing order and sequence.

1.4.3 Characteristics of product quality / Correct installation details against acceptance criteria

The characteristics of a work item can be defined as “a distinguishable property of an item, material or process”. Examples of characteristics are colour, texture, size, strength, flatness, alignment, capacity and the like.

The characteristics to be verified will be tested regarding the Correct Installation Manner, Conforming product Characteristics and Classification of BAUCLAD & BAUTRIM system defects. This will determine the stage at which the inspection or test must take place if the potential for subsequent nonconformities is to be avoided.

Some characteristics can only be considered after one particular operation and before another, but prior to application of final touch-up works, priming and painting.

Correct Installation Manner:

Substrate requirements

Substrate must be levelled (not to have protruding parts like reinforced concrete over the plane of the wall surface), must be rendered (covered with rough external plastering) and dusted off and clean of debris.

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Adhesion of BAUCLAD system

BAUCLAD prefabricated wall decorative claddings

Full surface adhesion with flex cement

Perimeter and beads: adhesion with flex cement

Adhesion with polyurethane foam

BAUTRIM prefabricated decoration corniches

Full surface adhesion with flex cement Adhesion with Polyurethane foam

Jointing of BAUCLAD systemBAUCLAD prefabricated wall decorative claddings

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Connection to Fire transom and construction

BAUTRIM prefabricated decoration corniches – Flexible / Movement joint

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Mechanical fixing of BAUCLAD

Mechanical Fixing of BAUTRIM Decoration Profiles

Installation of Window Decoration

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Construction of a Flexible Joint A flexible joint is used in the application of the Big Decoration Profiles (Corniches).This joint is also used at the formation of movement joints in the wall surface, where necessary and indicated by General Contractor, as per Project Specified lines.

Note: Due to big size and considerable weught of corniches it is strongly recommended to form the joint between corniches by the method of a movement joint. The joint may be placed at each connection of the corniches (once in 2 meters) or after each 2 corniches (once in 4 meters).

The Hourglass proportion A to A/2 must be always respected.

Conforming Product Characteristics:BAUCLAD prefabricated wall decorative claddings: Plain, respected planarity (+/- 2% tolerance acceped), uniformly covered with BAUCOAT Acrylic Coating.According to producer’s Technical documentation.

BAUTRIM prefabricated decoration cornichesPlain, respected planarity (+/- 2% tolerance acceped), uniformly covered with BAUCOAT Acrylic Coating.

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According to producer’s Technical documentation.

Installation materials: Flex cement based adhesive – according to producer’s Technical DatasheetPolyurethane Foam – according to producer’s Technical DatasheetModified Silane Polymer – according to producer’s Technical Datasheet

Accessories for installation: Helix Dowels – according to producer’s Technical DatasheetPrepainted Rebars – according to producer’s Technical Datasheet

Tools used for installation:Hammer drill, Hand saw, Circular cutting machine, Hammer – according to producer’s documents.

Classification of general wall system defects:Defects in the direct adhered wall system BAUCLAD & BAUTRIM can be generally classified as:

Aesthetic defects:

- Lost vertical/horizontal level during installation- Lost planarity- Staining- EfflorescenceNote: The BAUCLAD & BAUTRIM wall system components allow to correct minor surface irregularities. However the products are dependent on substrate quality, evenness, leveling and rigidity. Before determining whether the aesthetic defects come from improper installation, or product/component defects, the surface and integrity of the substrate must be evaluated.

Functional defects:

- Cracking - Delamination and bond failure- Movement joint failureThe location of the defect is also critical in evaluation and recommendation of corrective action. Note: The BAUCLAD & BAUTRIM wall system components bear thermal differences, humidity differences and some mechanical movement of the substrate. However the products are dependent on substrate quality, and rigidity. Before determining whether the functional defects come from improper installation, or product/component defects, the strength and integrity of the substrate must be evaluated and other factors that might have affected the BAUCLAD & BAUTRIM system must be considered.

The BAUCLAD & BAUTRIM system generally consists of five distinct layers:Location of defects:

- Substrate and back-up wall construction layer (offered by General Contractor)

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- Rendering / rough external wall plastering (offered by General Contractor or can be agreed for subcontracting with BAUCLAD & BAUTRIM on the necessary surfaces under specifically determined areas)- Adhesive layer - Outer cladding/decoration prefabricated material layer - Joint forming materials and touch-up mortar- Final paint treatment (including primer)

1.4.4 Stage/frequency

The inspection/test stage/frequency will be determined by each installation lot, according to the requirements of the contract documents or by the type of inspection and/or test and the characteristics under consideration, as outlined in the ITP and ITP Checklists.

Generally, the stage of verification is a predefined assembled lot (portion of façade) assigned and specified exactly as lot in the Contract drawings.

The Frequency of testing is once for each installed lot.

Thereafter, frequencies may be increased and processes reviewed for ‘problem’ work activities and decreased where consistent conformity was evidenced.

1.4.5 Records

Records provide the documented evidence necessary to verify that the BAUCLAD & BAUTRIMproduct/service is used in accordance with the contract requirements.The records will be in various forms, but mainly ITP checklists. Additionaly where necessary the General Contractor or Client may request test certificates, certificates of compliance/conformity, written approvals.

1.4.6 Specification/standard

The standards against which conformity is measured against the contract technical specification.

Other standards may include:- Contract documents/specification generally- Contract drawings / Project design- Approved workshop drawings and/or calculations- Approved technical details/procedures- Approved samples - Approved Mock-up- Manufacturers’ recommendations, Assembly Instructions and Technical Data

Sheets- Regulatory requirements- International Standards

1.4.7 Acceptance criteria

Respecting the manufacturer’s Manufacturers’ recommendations, Assembly Instructions and Technical Data Sheets is the main acceptance criteria which is taken

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as a benchmark for evaluating the application quality and conformity.

Acceptance criteria can be defined additionally in the contract documents (either directly or by reference to international/local standards), but these criterias must mot come in contradiction with the Manufacturers’ recommendations, Assembly Instructions and Technical Data Sheets. Thus in these cases the acceptance criteria with the customer (where they are not specified or clear) must be specified in the main Agreement to agree the yardsticks (such as test panels/sections or previous work) against which a product/service is to be declared conforming or nonconforming.

1.6.8 Inspection/test procedures

For many inspections/tests, the methods employed will be specified or self evident and determined by the characteristics being examined.

A typical test procedure using statistical techniques might, for example, cover:- reference to work areas/lots or batches- frequency of sampling- method of taking samples- method of conducting a test (including conditions)- qualifications of test personnel and equipment calibration/condition/specification- method of documenting resultsIn some cases it may be possible to satisfy the requirements simply by referencing the requirements of Australian Standards and the like.

1.4.9 Hold and Witness Points

The Contractor identifies the Hold and Witness Points with the people responsible for the inspection /test /endorsement and other requirements that are required for its service providers and employees doing the work. Contractor will do this to the extent that is necessary to be confident that the work is being carried out to the standards required.

The General Contractor and Customer retain the option to inspect the work at any stage and may identify Hold and Witness Points requiring the customer’s attendance.

The word “Surveillance” will be indicated in the ITP against all selected inspection or test points that are not otherwise covered by Hold or Witness Points.

1.4.10 Checklists

Checklists will be completed with each inspection and test - where they will, in effect, summarise the procedures that have, and should have, taken place up to the particular point in the work process. They will be used to confirm all the matters have been attended to. They will also remind to the Inspector and participating parties of all the matters that should be checked.

The checklists will refer exactly to the installed lot (predefined facad area).

The fact that checklists exist, are used and are stored and content have been verified, will give the General Contractor and Customer confidence that the person doing the work at the Contractor’s Company is aware of all the important steps, attributes and

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matters to be addressed, and the standards that should be complied with, and that conformity is being verified.

2. Personnel / workers training

The Inspector – Is the Contractor’s foreman instructed as a QA/QC Engineer. The Inspector is trained to maintain and register of all Inspection and Test Plan (ITP) including Checklists. The Inspector will be responsible and the appointed person to be in control of quality control of the installation works. The person will be appointed in the main Agreement documents. The Contractor’s senior of the Inspector shall maintain, keep and archive the approved Inspection and Test Plans, Checklists and related papers. Other site operations / 3rd parties: The responsibles from the General Contractor and Client will be introduced into the application of the System and system components, including tolerances and acceptability of installed product for a correct evaluation/inspection/evaluating test results of the BAUCLAD & BAUTRIMproducts / wall system.Installers: The installers of the BAUCLAD & BAUTRIMWall Systems are instructed for the correct application and verification of installation conformity during installation. The installers are offered the contract drawings, installation patterns and drawings, assembly instructions and are introduced in the contents of the ITP, verification of Control points and Critical Control Points and the ITP’s Checklists.Helpers: Helpers are instructed into main helping operations, labor safety and correct handling of materials. Inspection and testing plans hereinbelow do not include them as relevant parties to participate in evaluation and verification processes.

3. Identification and traceability

The Inspector – Is the Contractor’s foreman instructed as a QA/QC Engineer. The Inspector is trained to maintain and register of all Inspection and Test Plan (ITP) including Checklists. The Inspector will be responsible and

4. Amendments to the ITP and additional information

Amendments to the IPT: Should any part of this ITP require amendment or alteration, this will be notified for agreement by all relevant parties prior to it being enforced.Communicate ITP: Communicated to all relevant parties and signed by all personnel.

End of document.Proceed to document appendixes.

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Document appendixes

Appendix 1Inspection and Test Plans:Use the following forms for inspecting and testing the products and systems of BAUCLAD & BAUTRIMWall Systems.

Customer:Contract Number:Contract/Project Name:

INSPECTION AND TEST PLAN for: BAUCLAD & BAUTRIMCladding and DecorationWork area: (Insert work area)

Contractor’s logo

Ref Operation or stage of work Stage/ frequency

Records Requirement/ standard/ specification

Acceptance criteria

Inspection/ test procedure

InspectionDescription Characteristic

sEmployee

Contractor

G.C./ Client

1 Proceeding to assembly (requires General Contractor’s Permit)

Approvals required obtained

Each work area

Checklist

Contractor’s written permit

Permit - H H H

2 Order of BAUCLAD & BAUTRIMprefabricated materials

To specification

Each delivery

Copy of order

Specification, as attached

Reflects spec./ safe, secure

Review H H S

3 Preliminary to installation inspection: Substrate evaluation for installation of claddings and decorations

Substrate quality

Each work area

Checklist

General requirements to rendered walls

Substrate is even, level and rendered/ plastered.

The wall blocks are holding strong

Right levels & dimensions/ clean/ safe

Visual H H S

4 Mixing of adhesive

Workability of flex glue mix

Each work area

Checklist

Producer’s instructions

Evenly mixed and viscous

Measure H W S

5 Cladding and Decoration application

Adhesion and level

Each work area

Checklist

BAUCLAD & BAUTRIMinstruction for application

At least 50% adhesion of each element

Visual H W S

6 Adhesion & glue curing

To specification

Each work area

Checklist

Producer’s instructions

Finish/ curing/ maintained

Visual X W S

7 Joint formation To specification

Each work area

Checklist

BAUCLAD & BAUTRIMinstruction for applicationShop Drawing Presented joint formation type

Correct placement and construction

Visual X W S

8 Touch-up Works To specification

Each work area

Checklist


Correct placement

Visual X W S

9 Priming and painting

Ready to paint, clean and smooth

Each work area

Checklist


Correct placement

Visual X W S

10 Pre-handover activities

All matters finalised, clean and tidy

Each work area

Checklist


Completed to spec./ clean and tidy

Final visual inspection

H H H

*W = Witness Point; H = Hold Point; H(A) = Inspection/Test by Authority; U(C) = Inspection/Test by Consultant; S = Surveillance or monitoring; X = Self inspection by performer of work.

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Appendix 2ITP Checklists:Use the following checklists for tracking verified parameters of the inspection and testing procedures of the products and systems of BAUCLAD & BAUTRIM.

The following typical checklist for Inspection and Test Plans has been designed to assist interested parties in assessing Contractor’s ITPs. The customer may specify other items that would be addressed in the service providers’ ITPs to support the control of risks, but the items must be agreed before usage and introduced into reviewed redaction of document. The Clause references are to those in the current ISO 9001 Quality management systems – Requirements.

Key to symbols to be used in check-boxes is: ü = Yes û = No O / - = Not applicable

INSPECTION AND TEST PLAN CHECKLIST for: BAUCLAD & BAUTRIM FAÇADE THERMAL INSULATION, DECORATION AND FINISHING WORKS(To be completed by Contractor’s Inspector)

Contract Number:Contract/Project Name:Contractor:Subcontractor:

Work area: Checklist Number:

Work Items/activities to be verified Reference Initialled/ OK

Comments / Explanations / References

Proceeding to assembly

Access permission obtainedAccess obtainedEquipment approved/on site -Scaffold/laddersSignage/barricadesApplication InstrumentsMaterials approved/on site -BAUCLAD & BAUTRIM prefabricated claddings/decorationPaints/ glues/ caulks Extra:

I have carried out all necessary inspections and verify that the above items/activities conform to the contract specification/documents

Name:Signature:Date:

Order of BAUCLAD & BAUTRIM prefabricated materials

BAUCLAD & BAUTRIM Claddings BAUCLAD & BAUTRIM main Corniche profiles (parts) BAUCLAD & BAUTRIM Window decoration plateBAUCLAD & BAUTRIM Window decoration profileApplication materials



Preliminary to installation inspection: Substrate evaluation for installation of claddings and decorations

Notification of power disruptionProtective measuresIsolate appropriate circuitsVerify smoothness and planarity of substrateVerify lack of uneven / protruding surface parts Free of oil/greaseFree of dirt and loose particlesWashed downRepaired spots cured

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Mixing of adhesive

Humidity/temperature appropriateProtective measuresAdhesive validity (check expiry date) Water mixing ratio respected 1 part water to 5-6 parts of glueWater impurities missing



Cladding and Decoration application

Check product integrity – generally top coat free of imperfections such as runs, patchiness, pinholes, misses etc.Delivered product conforms for installation areaThe BAUCLAD & BAUTRIM application Instructions are respectedThe project design and elevation placing are respected when assemblingDifferent work areas combine evenly between them into forming a full visual assembly



Adhesion & glue curing

Humidity/temperature appropriateAdhesive correctly prepared and suitable for use (open time – 30 mins)Adhesive applied on the back side of claddings and decorations according to application patternsGlue strength and adhesion to substrate are verified on 2 areas of the work area

Specify test result: ___________________(Breaking – EPS Layer – good adhesion. Breaking in Glue, or render layer – bad adhesion)

Drying time of the main adhesive (24 hours) is respected



Joint formation

Humidity/temperature appropriateProtective measuresSpecial adhesive Thixocoll applied in rigid joints MS-Polymer adhesive is correctly applied in flexible/movement jointsDrying time between joints (24 hours) of each component is respected



Touch-up Works

Humidity/temperature appropriateTouch-Upo mortar repaired accordinglyEach coat free of imperfections such as runs, patchiness, pinholes, misses etc.Drying time of touch-up appropriate (24h)Surface sandpapered to level



Priming and painting

Humidity/temperature appropriateProtective measuresPaint applied to manufacturer’s instructionsEach coat free of imperfections such as runs, patchiness, pinholes, misses etc.Drying time between coats appropriate



Pre-handover activities

Replace fixturesTouch up

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Remove protective measuresFinal inspection confirms conformingClean up working area

CONTRACTOR’s INSPECTOR



GENERAL CONTRACTOR APPOINTED REPRESENTATIVE

I have carried out all necessary inspections and verify that the above work for this work area has been completed and conforms to the contract specification/documents


Appendix 3:Storage and protection checklist:

INSPECTION AND TEST PLAN CHECKLIST for: STORAGE AND PROTECTION(To be completed by the person(s) directly responsible for the work)Contract Number:Contract/Project Name:Contractor:Subcontractor:


Materials/ components/ equipment

Location of storage Date Initials CommentsPass Fail

Appendix 4:Incoming inspection checklist:

INSPECTION AND TEST PLAN CHECKLIST for: INCOMING INSPECTION(To be completed by the person(s) directly responsible for the work)Contract Number:Contract/Project Name:Contractor:Subcontractor:


Materials/ components/ equipment

Purchase Order No.

Delivery Docket No.

Quantity/size verified

Inspected for Date Initial

Against PO

Against DD

Damage Technical details

Marketing

Appendix 5:Pre-handover activities:Use the following forms for pre-handover verification activities.



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