LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)

FITTINGS - DUCTILE IRON Document : W- P-QCP-011

(FOR POTABLE WATER PIPELINE WORKS) Page 1/16 Date
Rev. 1
Document References :
ISO 9001 : 2000 - Quality management systems - Requirements
EN 545 : 2006/ 2010 - Ductile iron pipes, fittings, accessories and their joints for water pipelines - Requirements and tests methodsISO 2531
: 1998/ 2009 - Ductile iron pipes, fittings and accessories and their joints for water or gas applications
ISO 2859 : Part 1 : 1999 - Sampling procedures for inspection by attributes.
ISO 4179 : 2005 - Ductile iron pipes & fittings for pressure and non pressure pipelines centrifugal cement mortar lining. ISO 4633 :
2002 - Rubber seals Joint rings for water supply, drainage and sewerage pipelines Specification for materialsISO 6506 : Part1 : 2005 -
Method for the Brinell hardness test for metallic materials
ISO 7005 : Part 2 : 1988 - Metallic flanges - Cast iron flanges
ISO 8179 : Part 1 : 2004 - Ductile iron pipes- external zinc-based coating : Metallic Zinc with finishing layer (Also applicable to fittings)ISO
8179 : Part 2 : 1995 - Ductile iron pipes- external zinc coating : Zinc Rich Paint with finishing layer (Also applicable to fittings) ISO 8501
: Part 1 : 1988 - Preparation of steel substrates before application of paints and related products
EN 1092 : Part 2 : 1997 - Flanges and their joints : Cast iron flanges
EN 10204 : 2004 - Metallic products Types of inspection documents
EN 15189 : 2007 - Ductile iron pipes, fittings and accessories, External polyurethane coating for pipesADW EA
Standard Specification for Water Works

This document addresses the minimum Quality Assurance and Quality Control requirement during the manufacturing of pipes in the plants for the Contract.

The contents of the Contract Documents including Technical Data Sheet (TDS) shall be read in conjuction with this SQCP.
Abbreviations:
R = 100 % Review of documents, T = Test (Controls including Visual, Dimensional, Destructive or Non Destructive Test), W = Witness point, H = Hold point
Man = Pipe Manufacturer and/or Supplier, TPIA = Third Party Inspection Agency, ADWEA = Abu Dhabi Water & Electricity Authority / Affiliated companies, ADWEA/Consultant = Consultant Company
delegated by ADW EA for the specific project, Client/Owner: ADW EA, Cont.: Contractor.
Manufacturer inspection frequency : The actual inspection frequency shall be as stated in this document, but in any case not less than what is specified in the contract documents.
Witnessing/reviewing by TPIA : All quantified measurement checks/tests carried out shall be recorded on the applicable Quality control sheets for witnessing/reviewing by the TPIA in
line with this SQCP requirements.

IMPORTANT
NO CHANGES, WAIVER OR CONCESSIONS SHALL BE MADE IN THIS SQCP AND ITS REQUIREMENTS BY ANY INDIVIDUAL OR PARTY UNLESS EXPLICIT PERMISSION IS GIVEN IN WRITING BY ADWEA.
Prepared by Reviewed by Approved
LIAONING EVER METAL
FORMING TECH. CO LTD.
 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
NOTES:
a) ADW EA may modify this SQCP document should non-compliance with a specific Contract be noticed at any time, or should there be a change in TPIA role.
b) Any modification for non-compliance if required, shall be as per the contract documents inclusive of the specifications, knowing that in case of conflict between the QCP
and the Contract, The Contract shall prevail.
c) SQCP activity No. 14 Factory Release Certificate ( FRC ) covers the final checking stage prior to dispatch from the manufacturing siteand is a
point for each CONTRACTOR/TPIA and ADW EA/ TPIA.
A Common FRC shall be initiated by the Manufacturer and shall be issued for each batch of the product. The FRC shall be signed by CONTRACTOR/TPIA and ADW EA/ TPIA
Any deviation to this shall render release of materials as void. The FRC shall be signed and issued only when
the items are loaded on the vehicle at the manufacturing plant ready to be transported to the exit port. At the release for shipment stage and, following the transportation ofpipes from the
factory to ship / vessel loading point, Acceptance Certificate ( AC ) is required and shall be issued as per contract requirements. The activity of loading pipes and storage within the Ship
/ Vessel shall form for CONTRACTOR/ point for ADW EA/TPIA. ADW EA/TPIA may elect to witness any or all of the activities including the
transportation and handling between factory and vessel.

ADW EA/TPIA observation shall be attended to by Contractor/Supplier in line with the contract objectives and at no additional cost to ADW EA.

d) Manufacturer shall devise for approval by ADW EA, a system to trace defective pipes with cement mortar lining cube test failure. The quantity
in question includes production from the date of sampling to the date of successive successful sample testing.
e) The processing of inspection or test by ADW EA/TPIA in accordance with this SQCP shall take place without delaying the production rate.
For this purpose, it is agreed that production of one day, offered for release shall be inspected by ADW EA/TPIA in one day. The unique serial numberof the part shall
be given after acceptable coating and will be available for the TPIA on a daily basis to permit the release.
f) Prior to dispatching from manufacturing and prior to loading into the vessel CONTRACTOR/TPIA shall ensure that there are no pipes requiring any repairs. Repairs, if any, shall
be carried out at the manufacturing site.
g) Frequency and control items of ADW EA's TPIA may be increased or decreased depending on the results obtained. These modifications are to be agreed between ADW EA and ADW
EA/TPIA prior to implementation.
h) Non toxicity certificate to be provided for all materials in contact with potable water at 60°C max. (ADW EA circular no. 5 of year 2000).
i) Inspection / Test frequency (intervention) indicated in this SQCP under Contractor/TPIA and ADW EA/TPIA columns may be invoked, waived, changed, increased or decreased depending on
ADW individual contract requirement or, when non-conformities are found or reported.

* Deployment of ADW EA's TPIA shall be at ADW EA's discretion and Deployment of Contractor's TPIA shall be as agreed / indicated in the Contract.

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
0 PRE-INSPECTION
ADWEA / TPIA Interventions.
- List and characteristics of R R R
See Note (i) on Page 2
products of the order
- Packing and marking Acknowledgement of Order R R R See Note on Page 2 of 17
instructions Review of Documents Every Order

- Applicable standards R R R

- Quality System Validity of the certificate R R R

1 Fitting System
- Fitting DN - Visual T W (100%) W (100%)
(As per Project approved TDS)

- Fitting Identification - Visual Conformity with T Each Delivery W (100%) W (100%)

(As per Project approved TDS) purchase order

- Type of Joint - Visual T W (100%) W (100%)

(As per Project approved TDS)
- Quantity
- Type test for joint leak
tightness
- Counting on Delivery
- Review of Documents
T W (100%)
One representative
As per EN 545 type piece from each
T R
DN Grouping as in the
Table below.
Type Test is a performance test
W (100%)
which is a proof that the design
test is OK. It is done only once
and repeated only after change
R
of design. Type test results to be
reviewed by the inspector.

DN Grouping 40 - 250 300 - 600 700 - 1000 1100 - 2000

Preferred DN in Each Grouping 200 400 800 1200

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
2 POST CASTING
INSPECTION
- External appearance T
Visual Each Piece
- Internal appearance ` EN 545/ ISO 2531 T W (15%) W (15%)
Visual
- Cast iron thickness
Ultra-sonic gauge or other
approved method According to Manufacturing T R R
Once per new
Design
mould pattern and
T
any suspicious
filling ADWEA / TPIA Interventions.
See Note (i) on Page 2
- Dimensions Measuring Tape T Once per shift
W (15%)
and any W (15%)
suspicious pipe
- Spigot (DE + Ovality) Gauges T

3 DUCTILE IRON TESTS

-Chemical Analysis Analysis of cast iron before casting

(ladle or channel furnaceanalysis)
Production Tables T Manufacturing
Process Control
The chemical composition
R R is adjusted in order to satisfy the
material characteristics
and all requirements according to
EN 545 / ISO 2531

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *

- Tensile strength (Rm) Rp 0.2 > 270 Mpa T

- Yield Strength (Rp0.2) Tensile Testing Machine R (100%)

for (A > 12% for DN 40 1000)
and for (A > 10% for DN > DN T 1 per 4 Tons & R
- Min. elongation (A%) 1000) W (15%)
Rp 0.2 > 300 Mpa in other Cases T

Min Elong. A (%)

Type of
DN 40 - DN 1100
Casting
1000 - 2600
Pipes 10 7
Fittings 5 5

-Brinell Hardness (HB) Tests in accordance withEN 250 HB T W (15%) R Higher HB is allowed in heat
ISO 6506-1
effected areas of welded
components.

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
4 METALLIC ZINC OR ZINC
EN 545, Sec 4.5
RICH PAINT APPLICATION
- Zinc Material : Metallic Zinc coating (ISO 8179-1 ):
Metallic Zinc Check material type Check 99.99% purity for metallic zinc R Each Batch R R mean mass 200 g/m2
Zinc Rich Paint Certification Check pot life > 85% zinc content in dry film for zinc R Each Batch R R local min. 180 g/m2
& shelf life rich paints

- Surface Cleanliness Visual T Each Fitting Zinc Rich coating (ISO 8179 -2 ):
mean mass 150 g/m2
- Coating appearance Visual ISO 8179 - parts 1 & 2 T Each Fitting W (15%) W (15%) local min. 130 g/m2

- Mass (See remarks) Process control T Min.1 / gun / shift

5 PRESSURE TESTING For Air Test : Fittings must be

properly sealed at all ends, coated
Hydro-static Test Visual according to :EN Fittings: T Each Fitting W (15%) W (15%)
with suitable foaming agent and
Or 545 / ISO 2531 As per ISO 2531 internally pressurized to 1 Bar for 10
Air Test - No leakage, sec. OR
- No pressure drop
For Fittings < 600 mm to be fully
submerged in water during test.

For Flanged joints refer EN 545 Sect

6 CEMENT MORTAR LINING
Preparation and mortar
proportions S, C, W,
additives, W eight
Controls of process (weight)
Production tables
T Process Control
5.4 for leak test pressures.
Process to be included and
described in Material submittal.
W (15%) R Additives to be declared by the
Manufacturer.

6.1 - Cement
- Sand (grain size
distribution)
- Sand (organic impurities
& clay bearing substances)
Supplier certificate Sulphate resisting ISO T Manufacturer shall conduct tests
Granulometry 4179 § 3.2 & 7.2 T Certificates
according to ISO 9001:2000
from suppliers
requirements.
to be provided
Colorimetry and ISO 4179 § 3.2 & 7.2 T
chemical tests

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA
Remarks
Type Frequency TPIA * TPIA *
- Water Potability analysis or Supplier ISO 4179 § 3.3 T once every 3 months, or W (15%) R See attachment 2
analysis evidence that waterused is
potable water supplied by
- S, C, W process control (weight) ISO 4179 § 3.4
local waterauthority /
- S/C process control (weight) ISO 4179 § 3.4 , S/C 3.5 (by mass)ISO utility.
Manufacturer to specify W/C ratio
- W /C process control (weight) 4179 § 3.4 ,
to be used.

6.2 Surface preparation Visual Sect. 4.1 ISO 4179 T Each Piece W (15%) W (15%)
(Interior surface before Free from all foreign bodies, loose
application of lining) scale, other materials andany metal
projections likely to protrude
beyond 50% of the thickness of
the lining.

6.3 Curing
6.4 Compression strength
Visual
Test according to EN 545A
representative sample shall
be taken accordingly
As per curing tables T Process Control W (15%) W (15%)
(duration according to
temperature)
50 Mpa T 1 per Month of effective W (100%) W (100%) Frequency can be increased in
production or every
EN 545, 4.4.3.2 cases where defects are
change in the mix design
detected. Refer to item d, page 2
or the mortar materials
used.
of 15.

6.5 Laitance Visual Lining free of non adhesive laitance T Each Piece W (100%) W (100%)
(NAL).

6.6 Lining Thickness According to ISO4179 Contract technical data sheets T Sampling as per W (15%) W (15%) Average is the mean of 3 or
(approved) fabrication table more readings on one piece.
depending on DN

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
Cont. : Lining Thickness Thickness (mm)

DN Minimum Min. at
Nominal Average any
point
Dry lining method : 80 - 600 5 4.5 3.5
magnetic gauge, 200 mm fromthe 700 - 1200 6 5.5 4.5
end face. 1400 2000 9 8.0 7
2200 2600 12 10 7

6.7 Mortar Lining appearance / Visual ISO2531:1998 T Each Piece W (100%) W (100%)
adhesion / cracks inspection Cracks : Repair procedure to be
Max. crack width included and described in
DN
(mm) Material Submittals.

Cement mortar lining shall not

40-300 0.4
have a sealing coat.
350 600 0.5
700-1200 0.6
1400-2000 0.8
- Longit. Length 100% DN.
(e.g. 1200 mm for DN 1200)

- Circumf. length 50 % of
circumference
(e.g.1885 mm for DN 1200)

6.8 Radial displacement Visual T Each Piece W (100%) W (100%)

No disbondment in the factory.

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Typ Frequency TPIA * TPIA *
7 Fitting External Coating
7.1 Zinc & Finishing Layer
- Zinc : See item no. 4 Coating material manufacturers
- Coating Material Check material type R Each Batch recommendation shall be included in
(Bitumen or Synthetic Resin) Check certificate Material Submittals. This shall
Check shelf and pot life As per coating include the coating process
description.
recommendation and W(15%) W (15%)
- Coating Equipment Check condition procedures T Each Equipment

- Preparation of paints Check preparation and T Each Batch

condition.

7.1.1 Fittings External ADWEA W-P-SS-001 Sec. 8.2

- Dry Film Thickness (DFT) Myler Token / Magnetic gauge Mean average DFT 120 µm (100 T 1/shift / s pr ay gun W (15%) W (15%) Average DFT is the mean of 10
(combined : Zinc + final coating) (Zinc + Bituminous) µm DFT min. at any point) and 1 / 15 F i t t ing s or more readings on one fitting.
for > 1 0 00 mm
- Appearance Visual No coating defects T Each Piece W (15%) W (15%)

7.1.2 Fittings ends ( Internal Socket Same coating type as 7.1 ADWEA W-P-SS-001
W (15%) W (15%) Average DFT is the mean of 10
& External Spigot ) above or Non-Toxic solvent 1 / 10 Fittings
Mean average DFT 120 µm (100 T or more readings on one fitting.
free two part epoxy coating
with thickness > 300 microns. µm DFT min. at any point)

Visual
- Appearance W (15%) W15%)
No Coating defects Each Piece

Confirm that paint

- Non-toxicity used is non-toxic. Each batch of epoxy
Compliance with mat. certification material R R

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA
Remarks
Typ Frequency TPIA * TPIA *
7.2 Fusion Bonded Epoxy EN 14901 With the exception of : FBE Coating process to be
Coated Fittings - Maximum water temperature shall be considered as 60 Deg C (ADWEA Circular No. 5, Year 2000) included and described in material
- The minimum thickness at any point, the minimum mean average thickness & max. thickness are as per figuresbelow submittal.
(7.2.2)

7.2.1 Performance / Type

Test
Drop Weight as per No electrical puncture permitted. T
-Impact Resistance EN 14901 Sec 7.2.2 Non-porosity test certificate
R R
according to EN 14901 Sec 7.2.4

-Indention Resistance Indentation depth measured after 48 h< At start of

Penetrometer as perEN T R R
30% of the initial coating thickness production,
14901 Sec 7.2.3
measured. EN 14901 Sect when upon
6.3 change of epoxy
Methyl Iso-Butyl Ketone (MIBK) coat supplier or R R
-Cross Linkage T
Limits of change as defined by application
test as per EN 14901 Sect 7.1.5
coating manufacturer. process. Also
applicable to R R
T suspicious
-Heat ageing Hot air ageing of bent test plates No electrical puncture EN 14901 fittings.
resistance in air EN 14901 Sect 7.2.5.1 Sect 6.6.1

-Heat ageing
Ageing in 70 Deg C hot water
resistance in water Adhesion >5 MPa EN14901 Sect R R
EN 14901 Sect. 7.2.5.2 6.6.2 T

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
7.2.2
Routine Test
SA 2.5 as per ISO 8501-1
-Surface Preparation Visual EN 14901 ISO 8501-1 T Each Piece Checking of type, condition, expiry of
Uniform Colour appearance FBE Coating materials, equipment &
- Coating Appearance & Visual smoothness and free of visible W (15%) W (15%) preparation of coating shall be as in
Continuity defects. EN 14901 Sect. 5.3 Section 7.
T Each Piece
acc. To EN ISO Min. Single Value = 6 Mpa
- Adhesion Test
4624 (EN 14901 Sect 7.1.3) Min. Ave Value = 8 Mpa. Once / three months
acc to EN 14901 W (15%) W (15%)
Annex A
- Dry Coating thickness NDT Instrument using magnetic Min. at any point = 300 microns
or electro-magnetic principle. Avg DFT = 350 microns
T
EN 14901, 7.1.4 Max. Allowable DFT avg. = 420 1 / shift W (15%) W (15%) Average DFT is the mean of 10
microns. or more readings on one fitting.

Coating thickness on designated

- Cross Linking Methyl Iso Butyl Ketone (MIBK) No deviation against referencetest zones, ie; Bolt holes, ribs, joints,
T
test sample. 1 / shift W (15%) W 15%) edges and markings shall be >
As per EN 14901 7.1.5
150 microns.

- Non Porosity (Holidays) High Voltage detector

As per EN 14901 7.2.4 No Holidays T Each R R Except in gasket chamber.
(2.2 kV)

7.2.3
Non Toxicity
Review epoxy acceptance Certificate of compliance with T
International regulations for Each epoxy R R
Certificate for contact with
materials in contact with water, product.
flow media.
such as WRAS.

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No. Inspection Item
7.3 POLYURETHANE COATING
7.3.1 Performance type test
-Chemical Resistance
-Impact Strength Test
-Indentation Resistance
-Elongation at break
-Specific Coating Resistance
0.1 M Nacl Solution
-Coating resistance ratio.
7.3.2 Routine Tests :
-Surface Preparation
-Surface Roughness
-Appearance & Continuity
LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
Acc. To EN15189:2006 See ADWEA e-p-ss-001 Sec 8.4
Table 1.
De-ionised water immersion : T Checking of coating materials,
Less than 15% Weight increase. Type Test
Clauses 6.1 & 7.2.1.1 Table A.1 equipments and preparation of
paints shall be as in Section7.
Diluted sulphuric acid immersion
(10% dilution) ; Clauses 6.1 and Less than 10% Weight increase. T Type Test
7.2.1.2 Table A.1
Dropping weight / High Voltage 8 j/mm PU-Coated pipe barrel T R R
test clauses 6.2&7.2.2 Table A.1 5 j/mm EP-Coated Spigot end (EN Type Test
14901)
Indentation test
Less than 10% at 10 Mpa. T Type Test
Clauses 6.3 & 7.2.3, Table A.1
Tensile Test : < 10% at 10Mpa 2.5% T Type Test
Clauses 6.4&7.2.4 Table A.1
106 Ohm m2 Clauses 6.5 &
Resistivity Test : Towel methodor Type Test
7.2.5 Table A.1
Vessel Method.
Res. 100 d / Res 70 d Clauses 0.8 Type Test
6.5 & 7.2.5 Table A.1
Visual Dry and clean, free of rust, loose
material, dust, oil, grease, Sa 2.5, EN iso T 100%
8501-1
According to EN ISO 8503-1 Ra > 10 µm T Min. 1 / shift W (50%) W (50%)
Clauses 5.1 & 7.1.1 Table A.2
Visual : 5.2.1, 7.1.2 Table A.2 Uniform and Smooth T 100%
Clauses 5.2.2 & 7.1.3 Table A.2
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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
-Minimum Coating Thickness Non-Destructive : Magnetic or 1500 µm, Sec Clauses 5.2.2 & T Min 1 / Shift Requirement
electro-magnetic. 7.1.3 Table A.2 10 Kv for Wire mesh electrode or
15 Kv for conductive rubber
Appropriate measures. No defects. Clauses 5.3 & 7.14 elelctrodes. For thicker coatings, a
-Pipe ends painted Parts T 10% higher voltage can be used.
Table A.2 W (50%) W (50%)
High Voltage Test Meets non-porosity test req. T
-Repairs 100% ** Deviate for Holiday Testing. As
Visual Legible and durable. T
-Marking 10% per previous experiences, we
-Non-Porosity (Holidays) High Voltage detector No Holiday T 1 / shift would request Holiday testing
-Hardness Hardness test 70 Shore D T Min 1 / shift using 4.2 Kv, as higher voltage
-Adhesion Punch separation method. 8 Mpa at 23 Deg C T 1 / 1000 pieces would result in damaging the PU
Coating itself. Moreover as per EN
15189:2006 for PU Coating, the
tension used shall be 4.2 Kv.
7.3.3 Fittings Ends (Internal Socket & Magnetic or electro-magnetic
External Spigot) Test Mean average DFT : Non-toxic
solvent free two epoxy coating
T Each Piece
W (15%) W (15%)
This applies to the external spigot
with DFT > 300 µm Compliance end surface at a min. length of 250
with material Certification Each Product / R R mm from face of the internal
-Non-Toxicity Confirm that used material is
non-toxic. T Coating socket and surface which may
have direct contact with potable
water.

8 ACCESSORIES Conformity verification as specified in relevant documents R Each Piece W(15%) W (15%)

9 PACKAGING All according to the Manufacturer Markings Cast or Cold

- Appearance of
pallets and boxes
- Marking on fittings
(Cast-on or painted)
-Upto 600 mm : WoodenBoxes
Above 600 mm : Open Crates Visual
Visual Technical description approved by T Each piece W (100%) W (100%) Stamped on inside of socket
ADW EA. 1)- Manufacturer's name
2)- Year of production
3)- DI"xx" (xx=DN in mm)
4) PN Rating of Flanges
For fittings markings, whether caston
Visual or painted, see the remarks column on T Each Piece W (100%) W (100%)
Markings Painted on fitting
the right.
shall include :
1)- Client name
2)- Contract number
Each Piece W (100%) W (100%)
T 3)- Reference to EN 545
4)- Class of Fitting

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Manufacturer Contractor ADWEA Remarks
Type Frequency TPIA * TPIA *
10 EPDM RUBBER GASKET
- Type Conformity to the Visual R R
order According to ISO 4633 and
- Quantity Count Technical Data Sheet. T R R
- Packaging and Marking(as Visual Water temp. is 60 oC W (15%) W (15%)
required on order) Each Delivery
- Physical Properties Review and measure For Flanged joints, EPDM rubber gaskets T R R
shall be 3 mm and shall be metal
reinforced for pressure ratings of
16 bar.
- Non toxicity Confirm used material. Confirm non Compliance with material certification R R
R
toxicity of material at 60°C

11 FINAL INSPECTION by Visual Stamping According to TDS and QCP All Fittings W (100%) W (100%)
CONTRACTOR/ TPIA
(If required by ADWEA) Rubber Stamp of Inspector Logo oneach All Fittings
W (100%) W (100%)
controlled Pipe

12 Sampling and Measurement Each measurement is recorded Measurements to be taken by

report
- Pipe dimensions
- Coating thicknesses
- Cement thickness
- Spigot diameter
- Appearance of int. coating
- Appearance of ext. coating
- Result
according to Sampling and Measurements Tests :- ADWEA TPIA (if appointed)
measurement report. within 24 hrs, as a maximum,
refer to item 7 from the time of being advised.
refer to item 6.6 100%
refer to item 2 refer 100%
Visual Visual Stamping to item 6.7refer to 20%
item 7 100%
Rubber Stamp of TPIA on each 100%
controlled piece
100%

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 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)
Inspection / Test
No. Inspection Item Inspection Method Acceptance Criteria Remarks
Manufacturer Contractor ADWEA
Type Frequency TPIA * TPIA *
14 FACTORY RELEASE FRC attachments :- H Every product H H This compliance certificate
CERTIFICATE 1- Certificate of compliance Release states that the delivered
delivered by Manufacturer. (EN products have been
10204) Type 2.2 For mass manufactured and inspected in
- The Factory Release Cont. / TPIA verify and endorse production Fittings conformity with Contract and
Certificate (FRC) is initiated the FRC based onrelevant Type 3.1 and 3.2 as per QCP
and signed by the inspection records obtained ADWEA Special request.
manufacturer offering the throughout the manufacturing Refer Page 2 Note C
products for release process in accordance with this
2- Checklist of delivery(description
QCP.
and quantity).
- The FRC is then signed by
3- certificates with material
Cont. / TPIA.
characteristics and results of hydraulic
-Once signed by Cont. / TPIA, the ADW EA TPIA verifies and tests.
FRC along with all supporting endorses the FRC based on the 4- List of the individual serial number
documentation shall then be offered acceptable sampling and of each released piece > 300 mm
to ADW EA TPIA. measurements results as perItem 5- Sampling and measurement report sent
0 to 13. by ADWEA / TPIA directly to ADWEA.

Doc Title Doc. No.

Date Sep-15
QUALITY CONTROL PLAN FOR W- P-QCP-011
DUCTILE IRON FITTINGS Rev. 1
Page 15/16
 LIAONING EVER METAL QUALITY CONTROL PLAN (QCP)

Attachment 1 : Cement Mortar Lining

3.1 Cement
The cement used for the lining shall be sulphate resisting

3.2 Sand
The sand used shall have a controlled granulometric distribution from fine to coarser elements; it shall be clean and shall be composed of inert, hard, strong and stable granular particles. The granulometric curve for the
sand shall be appropriate to the lining method, the lining thickness and the surface conditions required in Clause 6 of ISO 4179. Sampling shall be carried out in accodance with national standards for the testing of
construction materials. The cleanliness of the sand shall be evaluated in terms of organic impurities and clay-bearing substance according to the methods described in ISO 4179. The test for organic impurities shall be
carried out by a colorimetric method in accordance with the standards in force in the producing country. The sand shall not produce any coloration darker than that of the reference solution. The determination of the
content of clay-bearing substances in the sand (having dimensions less than 63 microns to 93 microns depending on the country) shall be carried out in accordance with the standards in force in the producing
country; it shall not exceed 2% by mass.

3.3 Mixing water

The water used for the preparation of the mortar shall be either potable water or water free from substances deleterious either to the mortar or to the water to be transported in the pipeline. The presence of solid mineral
particles is, however, admissibl provided that these requirements are still fulfilled. Existing national hygienic requirements have to be complied with.

3.4 Mortar
The fresh mortar of the lining shall be composed of cement, sand and water complying with 3.1, 3.2 and 3.3 respectively. Additives may be
used, provided that :-
they do not prejudice the quality of the lining and that of the transported water.
they comply with the hygienic requirements of the country where the pipes are to be installed.
the lining remains in accordance with all the requirements of ISO 4179.
The mortar shall contain at least one part of cement to 3.5 parts of sand by mass (i.e. S/C 3.5 by mass in the mortar). The respective proportions of sand and water to cement (S/C and W/C) shall be selected and
controlled by the manufacturer in order to achieve compliance with this QCP. The methods of determination of the ratios S/C and W /C shall be specified by the manufacturer.

Doc Title Doc. No.

Date Sep-15
QUALITY CONTROL PLAN FOR W- P-QCP-011
DUCTILE IRON FITTINGS Rev. 1
Page 16/16