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INSPECTION AND TEST PLAN

TECHNICAL BULLETIN FOR BINA.THERM, CONTRACTORS AND CLIENTS

CONTRACTOR LOGO

QUALITY MANAGEMENT SYSTEM


PROJECT QUALITY CONTROL

INSPECTION AND TEST PLAN


(ITP)
for BAUCLAD & BAUTRIM External Prefabricated
Cladding and Decoration Systems
This 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.

Re Date Comments Prepared Reviewed Approved by


v by by

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INSPECTION AND TEST PLAN
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00 Initial issue Contractor Contractor General Customer


Contractor

Contents:

1. Construction Site Details


1.1Purpose and scope
1.2Document Glossary
1.3Roles and Responsibilities
1.4Inspection and Test Plan Input Data
1.4.1. ITP’s overview
1.4.2. Work methodology
1.4.3. Characteristics of product quality/correct installation details against
acceptance criteria
1.4.4. Stage / frequency
1.4.5. Records
1.4.6. Specification / standard
1.4.7. Acceptance criteria
1.4.8. Inspection / test procedures
1.4.9. Hold / Witness points
1.4.10. Checklists
2. Personnel / Workers training
3. Identification and traceability
4. 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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INSPECTION AND TEST PLAN
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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 Perimeter and beads: Adhesion with


flex cement adhesion with flex cement polyurethane foam

BAUTRIM prefabricated decoration corniches

Full surface adhesion with flex cement Adhesion with Polyurethane foam

Jointing of BAUCLAD system


BAUCLAD 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 corniches


Plain, 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 Datasheet
Polyurethane Foam – according to producer’s Technical Datasheet
Modified Silane Polymer – according to producer’s Technical Datasheet

Accessories for installation:


Helix Dowels – according to producer’s Technical Datasheet
Prepainted 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
- Efflorescence

Note: 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 failure

The 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
as a benchmark for evaluating the application quality and conformity.

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

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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 1
Inspection and Test Plans:
Use the following forms for inspecting and testing the products and systems of BAUCLAD &
BAUTRIMWall Systems.
Customer: INSPECTION AND TEST PLAN for: BAUCLAD &
Contract Number: BAUTRIMCladding and Decoration Contractor’s logo
Contract/Project Name: Work area: (Insert work area)
Ref Operation or stage of work Stage/ Records Requirement Acceptanc Inspection Inspection
Description Characteristic frequen / standard/ e criteria / test Employe Contracto G.C./
s cy specification procedure e r Client
1 Proceeding to Approvals Each Checkli Contractor’s Permit - H H H
assembly required work st written
(requires obtained area permit
General
Contractor’s
Permit)
2 Order of To Each Copy of Specification Reflects Review H H S
BAUCLAD & specification delivery order , as attached spec./
BAUTRIMprefab safe,
ricated secure
materials
3 Preliminary to Substrate Each Checkli General Substrate Visual H H S
installation quality work st requirement is even,
inspection: area s to level and
Substrate rendered rendered/
evaluation for walls plastered.
installation of
claddings and The wall
decorations blocks are
holding
strong

Right
levels &
dimension
s/ clean/
safe
4 Mixing of Workability of Each Checkli Producer’s Evenly Measure H W S
adhesive flex glue mix work st instructions mixed and
area viscous
5 Cladding and Adhesion and Each Checkli BAUCLAD & At least Visual H W S
Decoration level work st BAUTRIMinst 50%
application area ruction for adhesion
application of each
element
6 Adhesion & glue To Each Checkli Producer’s Finish/ Visual X W S
curing specification work st instructions curing/
area maintaine
d
7 Joint formation To Each Checkli BAUCLAD & Correct Visual X W S
specification work st BAUTRIMinst placement
area ruction for and
application constructi
Shop on
Drawing
Presented
joint
formation
type
8 Touch-up Works To Each Checkli Specification Correct Visual X W S
specification work st , as attached placement
area
9 Priming and Ready to Each Checkli Specification Correct Visual X W S
painting paint, clean work st , as attached placement
and smooth area
10 Pre-handover All matters Each Checkli Specification Complete Final H H H
activities finalised, work st , as attached d to spec./ visual
clean and tidy area clean and inspection
tidy
*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 2
ITP 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: Work area: Checklist Number:


Contract/Project Name:
Contractor:
Subcontractor:
Work Items/activities to be verified Reference Initialled Comments / Explanations /
/ OK References
Proceeding to Access permission obtained
assembly Access obtained
Equipment approved/on site -
Scaffold/ladders
Signage/barricades
Application Instruments
Materials approved/on site -
BAUCLAD & BAUTRIM prefabricated
claddings/decoration
Paints/ glues/ caulks
Extra:
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Order of BAUCLAD & BAUTRIM Claddings
BAUCLAD & BAUCLAD & BAUTRIM main Corniche
BAUTRIM profiles (parts)
prefabricated
materials BAUCLAD & BAUTRIM Window
decoration plate
BAUCLAD & BAUTRIM Window
decoration profile
Application materials
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Preliminary to Notification of power disruption
installation Protective measures
inspection:
Isolate appropriate circuits
Substrate
evaluation for Verify smoothness and planarity of
installation of substrate
claddings and Verify lack of uneven / protruding
decorations surface parts
Free of oil/grease
Free of dirt and loose particles
Washed down
Repaired spots cured

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I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Mixing of Humidity/temperature appropriate
adhesive Protective measures
Adhesive validity (check expiry date)
Water mixing ratio respected 1 part water to 5-6 parts of glue
Water impurities missing
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Cladding and Check product integrity – generally top
Decoration coat free of imperfections such as runs,
application patchiness, pinholes, misses etc.
Delivered product conforms for
installation area
The BAUCLAD & BAUTRIM application
Instructions are respected
The project design and elevation
placing are respected when assembling
Different work areas combine evenly
between them into forming a full visual
assembly
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Adhesion & Humidity/temperature appropriate
glue curing Adhesive correctly prepared and
suitable for use (open time – 30 mins)
Adhesive applied on the back side of
claddings and decorations according to
application patterns
Glue strength and adhesion to Specify test result:
substrate are verified on 2 areas of the ___________________
work area (Breaking – EPS Layer – good
adhesion. Breaking in Glue, or
render layer – bad adhesion)
Drying time of the main adhesive (24
hours) is respected
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Joint Humidity/temperature appropriate
formation Protective measures
Special adhesive Thixocoll applied in
rigid joints
MS-Polymer adhesive is correctly
applied in flexible/movement joints
Drying time between joints (24 hours)
of each component is respected
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Touch-up Humidity/temperature appropriate
Works Touch-Upo mortar repaired accordingly
Each coat free of imperfections such as
runs, patchiness, pinholes, misses etc.
Drying time of touch-up appropriate
(24h)
Surface sandpapered to level
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Priming and Humidity/temperature appropriate
painting Protective measures
Paint applied to manufacturer’s
instructions
Each coat free of imperfections such as
runs, patchiness, pinholes, misses etc.
Drying time between coats appropriate
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:
Pre-handover Replace fixtures
activities Touch up

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Remove protective measures


Final inspection confirms conforming
Clean up working area
CONTRACTOR’s INSPECTOR Name:
Signature:
I have carried out all necessary inspections and verify that the above Date:
items/activities conform to the contract specification/documents
GENERAL CONTRACTOR APPOINTED REPRESENTATIVE Name:
Signature:
I have carried out all necessary inspections and verify that the above work for this Date:
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: Work area: Checklist Number:
Contract/Project Name:
Contractor:
Subcontractor:
Materials/ Location of storage Date Initials Comments
components/ Pass Fail
equipment

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: Work area: Checklist Number:
Contract/Project Name:
Contractor:
Subcontractor:
Materials/ Purchase Delivery Quantity/size Inspected for Date Initial
components/ Order Docket verified
equipment No. No. Against Against Damage Technica Marketin
PO DD l details g

Appendix 5:
Pre-handover activities:
Use the following forms for pre-handover verification activities.
I have carried out all necessary inspections and verify that the above Name:
items/activities conform to the contract specification/documents Signature:
Date:

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