watford, herts wd25 9ba bba approval inspection testing

BBAAPPROVAL INSPECTION TESTING CERTIFICATION

TECHNICAL APPROVALS FOR CONSTRUCTION

Bucknalls Lane, Garston Watford, Herts WD25 9BA

Telephone: Facsimile:

Website: Wl/1""'{.bbacerts.co.uk

UK Member of EOTA (European Organisation for Technical Approvals)

UK Member of the UEAtc (European Union of Agrement)

Assessment of Production

Agreed Quality Plan for

Kingspan Optim-R (Vacuum Insulation Panels - VIP)

Agrement Certificate: 16/5347 (Radmat ProTherm Quantum Inverted Roof Insulation)

NB. This AQP document contains comments and amendments (highlighted in yellow) which were made because of the inspection carried out on the 17.10.2017 by Lee Tally.

Document reference 16-5347 AQP 12.09.16 Rev 1 07.04.17

Date of issue 12.09.2016

BBA Section responsible Construction Products

BBA Project Manager Chris Hirschfield

Other products covered by 08/4590, 95/3126, 14/5133, 14/5134, 16/5299, 16/5332. BBA Certificates manufactured on this site:

Qualplan.doc (V.6.5) of 11 Job number:

BBA00011249_0001 BBA00011249/1

Product name:

Kingspan Optim-R Vacuum Insulation Panels (VIP)

To be supplied to Radmat Building Products Ltd for distribution as : Radmat ProTherm Quantum Inverted Roof Insulation

Product range: Sizes/Co/ours/Finishes/Grades, etc.

Kingspan Optim-R Vacuum Insulation Panels (VIP) A rigid board insulation panel, with a micro-porous fumed silica core containing fillers, covered in polyester fleece and vacuum wrapped in a multilayer metallised laminate film with heat sealed edges.

Standard board sizes : 300 x 300 mm, 400 x 300 mm, 600 x 400 mm, 600 x 600 mm, 1200 x 300 mm, 1200 x 400 mm, 1200 x 600 mm boards, Other sizes to suit, subject to quantities

Thicknesses - 20, 25, 30, 40, and 50mm Straight edges, butt jointed

Production location:

Produced by: Kingspan Insulation Limited

Address: Pembridge

Postcode:

Telephone:

Fax:

Leominster

Herefordshire

HR6 9LA

Contact: Christian Elliott, Samuel Pearce and Nikolay Vatahov

Quality manager- Christian Elliott

Telephone:

Email Christian .elliott@kinqspan .corn

Quality Engineer: Samuel Pearce and Nikolay Vatahov

E-mail: [email protected] and [email protected]

Is the above production site covered by ISO 9001: 2008 Registration? YES

If YES, Registration No: 388-1 QMS

Assessed by (organisation): The Loss Prevention Certification Board (LPCB)

Scope of assessment: Issue 11 Design and Manufacture of Insulation and composite insulation materials for the construction industry- Expiry 16 May 2016


BBA00011249_0002 BBA00011249/2

Note from Assessor - ISO details were found to be correct.

Purchasing data & receiving inspection and testing:

All materials are purchased to agreed specifications. For each delivery of raw materials, i.e. Fumed Silica, Silicon Carbide, Pet Fibres, PET fleece and Barrier film, a Certificate of Analysis is also provided. Materials are visually checked and processed in accordance with IMP 202 latest version. If a delivery of any material does not appear to meet the specification set out in the Raw Material Database, then a concession is raised and authorised by the Technical Process Manager.The following table is an example of the style, format and content that is required. However it can be modified for proportions, orientation (portrait or landscape*) or converted to other non table formats. * Please note that landscape orientation can be irritating to the reader (client) and therefore should be used with caution.

Incoming Supplier Property Method of test Frequency of Acceptance product measured testing limits

Fumed Silica Cabot Surface area C of A Each delivery m2/g spec

ESK-SIC SiC content C of A Each delivery Silicon Carbide (D/N (C OF A SEEN) 810988111)

Pet Fibres Goonvean Fibre length C of A Each delivery mm

PET fleece Spunweb Weight C of A Each delivery -5) (C OF A SEEN) Barrier film Hanita Water vapour C of A Each delivery

Coatings permeation (DIN (C OF ANOT 1800114400) SEEN)

Details of incoming raw materials are recorded in SAP.

Note from Assessor- Method of receiving Inspection was found not to be found to be in line with the Quality Plan requirements.

NC-01- Purchasing data & receiving and testing: 16/5347

It was witnessed that there was no C of A available for the Barrier film- D/N 1800114400 at the time of the visit.

Product identification and traceability:


BBA00011249_0003 BBA00011249/3

Every order that is placed is given a unique SAP Order Number. The Production Programmes for the OPTIM-R Line is generated in SAP, and then formulated to incorporate all the necessary orders, quoting the respective Order Numbers.

The Order Number is itself used to identify the boards together with unique serial number and bar code for each panel - post vacuum sealing. The Raw Material Goods Issue Usage Transaction Sheet SAP Based MIGO Sheet and Works Order Report can be used to identify which consignment of raw materials was used in production used against work order.

Note from Assessor - Method of Product identification and traceability were found to be in line with the Quality Plan requirements.

Product in manufacture at the time of the visit- Optim -R- 300mm x 300mm at 25mm- Production 8100262934

Method of production and process control:

Ingredients (i.e. Fumed Silica, Silicon Carbide, and Pet Fibres) are loaded from their respective storage areas, and then vacuum transferred to the mix tanks (MX600 or MX700) and conventionally mixed. Once the mix is ready is then transferred to the Day Tank MX800 and to the hopper allowing dispensing into cavity of 1200mm x 600mm or 1200mm x 1200mm mould as required using dispense nozzle and X,Y table. The above operation is computer controlled by the OPTIM-R Laydown computer software. The mix in the mould is subject to pre-pressing (Pre-press station) and pressing (Press station), then the core is ejected and introduced to the saw, where the core is cut accordingly and transferred to the Fleece wrapper. Fleece wrapped core is heated up and dried out using on-line conveyor oven. The drying time length depends on the thickness of the product. The fully dried cores are foil wrapped and partially sealed and then sent to a vacuum chamber where the final sealing is performed under negative pressure (vacuum).

All VIP panels are gas pressure tested 24h post production and subject to 7 days "Q"-block period.

Process Control:

OPTIM-R Lines has fully computerised control device which governs formulation, mix ratio, speed and output (as laid out in the SOP).

All critical machine parameters (such as: Mix ratio, mixing time, Dosing, X,Y table, Pre-press positions & timings, Press positions & timings, Foil wrapper and Vacuum chamber settings) are password protected in order to eliminate any chances human error or unauthorised interference.

Each production run has a specific works order number together with unique board number and bar code (displayed on the panel label). This work order number is used on all paperwork for full traceability. The machine operators are given a standard operating procedure to run the machine. The machine operators set the machine conditions and chemical outputs using this information and according to the relevant SSW.


BBA00011249_0004 BBA00011249/4

A computer record complete with (SAP Based Production Program viewed in QA 33) is given and every 30 minutes checks are carried out to determine dimensions and density. Values are recorded on the computerised record. The line software will highlight if control inverters are >1 % from and will fault out if >2% the norm on input. A computer print-out of material yield and line conditions can be raised.

Note from Assessor - Method of manufacture were found to be in line with the Quality Plan

requirements .

In-process inspection and testing

As per IMF 253

Results are recorded on form - SAP based PI Sheet viewed through SAP QA33 format.

Property measured Method used Frequency Acceptance limits Action upon SAP rejection Operation

Core weight Scale 30 min +/- 5 % of nominal

SAP 06 weight

Tape 30 min +/- 3 mm for <1 m SAP

Dimension of VIP measure +/- 5 mm for >1 m

06

Dimension of VIP Vernier 30 min +/- 2mm SAP 06

Thickness

Note from Assessor -

On review of the test data it was found that overall the testing has been carried out as described with a good level of compliance being achieved. Stock noted in the warehouse were checked;

1. Optim-R-1200 X 600mm X 50MM, Production batch 8100254736. Production dated 17-8-17. 2. Optim-R-1200 X 600mm X 50MM, Production batch 8100261885. Production dated 09-10-17 3. Optim-R-1200 X 600mm X 50MM, Production batch 8100255750. Production dated 22-08-17.

All QC Results seen were noted as all within all nominated specifications and where applicable

Final inspection and testing:

Acceptance limits are also specified in IMF 253 and SAP based In Line Inspection & QC Lab based Quality Plans. Results are recorded on form - SAP based PI Sheet viewed through SAP QA33 format.

Property measured Method used Frequency Acceptance limits Action upon SAP rejection Operation

Test dimension

30 min +/- 5 mm for >1m, SAP Dimension of VIP with tape

+/- 3 mm for< 1 m 09

measure

Thickness of VIP Test

30 min +/- 2mm SAP 09 dimension


BBA00011249_0005 BBA00011249/5

with Vernier Calculation

Density based on

30 min 170 to 210 kg/m3 SAP 09 dimensions and weight

Test Flatness dimension 30 min :510mm SAP 09

with Vernier Straight edge

Length & width 5mm/m Squareness table (picture 30 min SAP 09

frame) Thickness 2mm

Gas pressure test Internal

30 min <5mbar SAP 01 pressure

(QC) Thermal Lasercomp

1 Per 24 Heat flow 0.00450 W/m.K SAP 01

Conductivity meter

hours

(QC) Compression Tinius Olsen

H5 KS 1 Per Week Average <::160kPa SAP 01 Test

Tester Tensile strength Tinius Olsen 1 per year

test H5 KS (external >80kPa SAP External

Tester FIW) Final Visual

Visual Every 100% - vacuum integrity Inspection

Inspection batch VIP SAP 02


On review of the test data it was found that overall the testing has been carried out as described with a good level of compliance being achieved. Stock noted in the warehouse were checked;

1. Optim-R-1200 X 600mm X 50MM, Production batch 8100254736. Production dated 17-8-17. 2 . Optim-R-1200 X 600mm X 50MM, Production batch 8100261885. Production dated 09-10-17 3. Optim-R-1200 X 600mm X 50MM, Production batch 8100255750. Production dated 22-08-17.

All QC Results seen were noted as all within all nominated specifications and where applicable

Calibration:

Inspection and calibration of test equipment


BBA00011249_0006 BBA00011249/6

Equipment to be Inspection Inspection Registration of

inspected Aspects of inspection

method Frequency records

functioning calibration 1 .Temperature controller x x Comparing with 2 x annually Test

of the electric oven a calibrated equipment temperature control form

controller 2.Micrometers and x x External 1 x annually Certificate and

dial gauge calibration and external, internal record internal 1 x every 2 sheet

calibration check months internal on items used for thickness

3.Scales x x External 1 x annually Certificate and & load cells calibration and external, internal record

internal 1 x every 2 sheet calibration check months internal

4.Stress testing x x External 1 annually Certificate equipment calibration

5.Thermal conductivity x x External 1 x annually Certificate and test equipment calibration and externally 1 x internal record

internal weekly internal sheet calibration check on items used

for thickness 6.Environment x x External 1 annually Certificate

Chambers calibration 7. Vacuum Pressure x x Internal 1 annually Certificate

Gauge Calibration

External Every 5 years calibration

Calibration procedures are described in IMP 206

Notes from the Assessor The method of calibration was not seen to be in line with the quality plan

NC-02 Calibration -16/5347 It was witnessed that the Thermal conductivity test equipment does not get tested 1 x annually by an external company only internal. Ref. FX61

Packaging:

Boards are manually packed into cardboard boxes using EPS supporting strips. Each box bears a label showing relevant information regarding product description and traceability, including works order number.

The VIP boxes have specially designed visors allowing quick and efficient visual inspection. Every pack has

a leaflet with handling instructions.

Note from Assessor - Method of Packaging were found to be in line with the Quality Plan requirements.


BBA00011249_0007 BBA00011249/7

Labelling:

Boxes are labelled with a product identification label showing the following information:

• Thickness of product

• Product name

• Board dimensions

• No of boards per pack

• Batch No

• Production date (1l

VIP panels are labelled with board identification label showing:

• Batch No

• Dimensions of the product (Length, width and thickness)

• Unique panel number

• Bar code

• Date of manufacture

Note from Assessor - Method of Labelling were found to be in line with the Quality Plan requirements .

Use of the BBA symbol:

Not applied to this product, as the Certificate belongs to Radmat Building Products Ltd (not Kingspan).

Note from Assessor- Use of the BBA symbol were found to be in line with the Quality Plan requirements.

Training:

Training procedures are described in IMS GIMP 003 - Training and Competence


Training records for QC and production personnel was seen to be satisfactory, with training covering job roles.

Samples records seen for the following Staff;

1. Mr. Doug Glasgow - Production Operative. 2. Mr. Angel Martinez - Line Manager. 3. James Smith- Production Operative

Complaints:

Complaints procedures are described in IMP 207



BBA00011249_0008 BBA00011249/8

The complaints system in place is satisfactory.


BBA00011249_0009 BBA00011249/9

Quality policy: We undertake to have the product produced and placed on the market as described above. We will advise the BBA of any changes and receive agreement from the BBA before the changes are implemented.

Signed .............................................. . Dated ............................................. .

Title ............................................... .

End of Quality Plan

For BBA internal use only

BBA Cert(s): 16/5347 Approved by: Date:


BBA00011249_0010 BBA00011249/10

Appendix - Document Revisions

Revision No Reason for re-issue Date

BBA logo not applied to this product (as Cert belongs to Radmat and not Kingspan).

1 Front page list of Certs/products manufactured on this site 07.04.17 updated. Frequency of calibration of vacuum pressure gauge, scales and dial gauges updated.


BBA00011249_0011 BBA00011249/11

watford, herts wd25 9ba bba approval inspection testing

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