List of Mistake/Defect that

may happen during

Fabrication
 Contents
1. Material Procurement 3. Welding 5. Finish 6.Packing and Shipment
• Bending • Miss welding • Wrong specification (Wron • Mishandling
g Finish)
• Dent • Welding defect • Possible Prevention M
• Wrong Non Painting locati ethod Suggestion duri
• Scratched Surface • List of Acceptable Welding on ng packing and shipm
ent
• Sample of Acceptable • Checklist Sample for Weldi • Leftover Painting Bead and
Visual Appearance ng Bubble • Example of Acceptabl
e Packing
• Checklist Sample of Ma • Painting Peeled off
terial Procurement • Sample Preshipment
4. Test Assembly • Dirty HDG Checksheet
• Sample Defect that may b • Sample of Acceptable Pain
2. Machining e found during Test Assem ting Visual
bly 7. Quality Commitment
• Wrong Shape • Checklist Sample for Finish
• Possible Prevention Metho Agreement
• Sample of Acceptable S d Suggestion during Fit Up
hape and Test Assembly Agreement Letter
• Wrong Machining Loca • Required Test Assembly
tion
• Checklist Sample for Test A
• Checklist Sample for M ssembly
achining
 Material Procurement - Bending
Possible cause:
- bad material properties: even same carbon steel material steel member
may bend during machining or welding due to heat.
- no bend inspection during material incoming inspection

Possible prevention method suggestion:

- perform full checking during material incoming inspection
- perform bending check for each steel member after machining or welding
 C Channel that are bending to Left
that found during inspection
Bending

Long Beam is bended to left Long Beam is bended to Right

which can be seen clearly
during test assembly
 Material Procurement - Dent
Explanation: dent or cut on the surface or other part of the material

Possible Cause: outer or inner material peel off during rolling, which
cause visual appearance defect

Possible prevention suggestion:

- perform full visual check
- return material for any dent defect detection
Dent

Dent on L Angle due to miss Dent on Plate due to wrong

on material inspection fabrication method
 Material Procurement - Scratched Surface
Possible Cause
- Scratch found during material inspection
- bad handling (material is directly put on the floor
without any soft layer, material hitting each other)

Possible prevention suggestion:

- perform full visual check
- return material for any detection
- in case no defect detected, all of the materials are to
be handled properly during machining /welding /finish
to avoid scratch after fabrication.

Multiple deep scratches on inside part of C Channel

due to mishandling during machining (item was put
roughly mixed with other sharp item)
Material Procurement –
Sample of Acceptable Visual Appearance

Sample of Clean visual steel member – no dent, and scratch Repaired Parts – no Bend
during thread inspection
Checklist Sample for Material Procurement
Material Bend Dent Scratch
H Beam

C Channel

Plate

Pipe
Machining - Wrong Shape
Possible Cause:
Wrong Drilling method on
- Unclear instruction (tolerance, drawing the hole, which make the
specification, instruction) hole become irregularly
oblong.
- Wrong interpretation on drawing

Possible Prevention Method Suggestion:

- state on inspection method, the correct Wrong shape on
shape and size tolerance corner part, caused
by no clear
(Include Chamfering and Rounding) instruction in
- For hole always check with related bolt drawing and worker
size, if bolt can be inserted normally didn’t pay attention
or check drawing
without too many horizontal movement. clearly.
Machining - Sample of Acceptable Shape

Sample of correct bolt shape.

We can see that bolt will be easily fit without any irregular movement.
Machining - Wrong Machining Location
Explanation: wrong cutting, drilling or fit up spot.

Possible cause: unclear instruction in drawing or drawing is difficult to be read.

Possible Prevention Method Suggestion:

- Fabricator always convert drawing from end user to their own fabrication
drawing that usually used by people on site.
Make sure on the drawing, all of the needed information is written clearly, for
example: not only overall dimension, but detail dimension (straight length or
slanted length, especially on complex shape such as circle or 5 corner shape)
- Full scale test assembly to make sure every connection is on the right spot.
Wrong Machining Location

Wrong Hole location

(hole should be on
bottom)
Possible Cause:
No test assembly
performed and also
misread drawing due
to drawing is difficult
to be read

This should be the correct hole location

Checklist Sample for Machining
Part Size Shape
 Welding - Miss welding Miss welding on corner
inner part of frame

Explanation:
Welder forgot to weld on one other side and no one
found this mistake until item arrived in end user.

Possible prevention method suggestion:

- Clear instruction on drawing (not only symbol, but Miss welding on corner
written, for example “welding on both sides” or other) inner part of frame
- Always give enough time to do welding and inspection
- double check on each location after welding
- By performing NDT test after welding, it will also help
to double check if there is any miss welding or not
 Welding - Welding Defect
Type of Welding Defect:
Undercut
Spatter
Pit
Untidy welding bead
Overlap
Possible cause:
- Untrained welder
- Insufficient welding time
- Wrong welding method and material
Possible prevention method suggestion:
- Periodic welder training (certified welder
will be preferred)
- Thorough inspection after welding
- Always plan for sufficient welding time
- Follow for welding method and material
as per specification or establish company
standard welding procedure (WPS/PQR)
- Detailed welding instruction in drawing
(always confirm before starting fabrication
to avoid any misunderstanding)
Welding Defect
Pit

Messy
Weld bead

undercut

Spatter
Welding - Sample of Acceptable Welding

Tidy welding line, no spatter, pit Tidy welding line, no spatter, pit
*photo is before painting *photo is after painting and different from left
 Checklist Sample for Welding

Part Miss Bead Over Undercut Overlap Pit

Welding Appearance Height
Sample Defect that may be found
during Test Assembly
Wrong position of toe plate
attachment (left toe plate was
welded on inner part, while right
was on outer part)
Correct Handrail Support position
Insufficient length chain due to not
Wrong Handrail Support position,
performing test assembly and no
due to carelessness of the fitter
additional detail length in drawing
didn’t read the drawing properly.
(only distance of the post and
Or drawing is difficult to be read
handrail were written)
Sample Defect that may be found during Test Assembly

Wrong size (height) due to fitter didn’t
properly check during fit up.
Wrong size in which the distance between 2 spaces were flipped, which
is not acceptable
(The L angle in the middle was welded on the wrong direction)
Possible cause is because of misreading of the drawing in additional of
short checking time.
Sample Defect that may be
found during Test Assembly

Rusted bolt, nut, washer and also saddle clip due to insufficient
anti rust lubrication

Other possible defect happened related with accessories:

Temporary fixer plate that forgot to be taken after
test assembly
- wrong quantity
- bolt type/shape is not unified
i. Same size but slight different head
ii. Same size but different actual thread
iii. Same size but different height (modified bolt)
Sample Defect that may be found during Test Assembly

Hole that are

not specified in
drawing due to
miss on
checking during
engineering.
 Sample Defect that may be found during Test Assembly - Grating

Grating with different height tolerance on each spot resulting in height difference which affect safety in the
site, also affect quality as people will feel the tremor during walking (grating keep moving up and down)
Test Assembly - Possible Prevention Method
Suggestion during Test Assembly
• Make sure to always plan enough time for assemble and disassemble to check properly
• Clear Instruction in the drawing – Make sure to always double check the drawing and
confirm before start test assembly. (ask for 3D model if needed)
• Thorough inspection step by step from machining up to test assembly.
• Always perform full test assembly for each item, never skip even only 1 item.
• For Grating, while test assembly is not needed, it is always recommended to have test
assembly and check thoroughly for each dimension (LxWxH), especially for grating with
complex shape (circle or non standard cutting), test assembly is a must to avoid wrong
assembly dimension.
• For chain and similar accessories, put detail of size of each item (not only curving but also
straight size) in drawing to avoid wrong understanding of size.
• Always perform quantity inspection for all of steel member and accessories.
 Test Assembly - Required Test Assembly

Include ladder

Complete up
to column

Assembled
dimension is
checked.
 Required Test Assembly
If possible test assembly for grating is being done altogether with frame.
If not, like this picture, assemble all of the grating in one space

Check each dimension (LxWxH), then also check assembly

dimension, specially distance on opening part

Also check for height of the grating, make sure grating is

firmly fix on floor (not moving when you step on them)

Make sure grating is placed on flat floor to avoid wrong

judgment during inspection.
Required Test Assembly

Check the length and diameter of the bolt to

Line up the bolt, nut, washer.
Especially for the bolt so we can easily
check height of the bolt and count the
quantity
prevent wrong supply.
Specify in BOM each specification(size, finish,
material) of the bolt to avoid wrong specification.
Checklist Sample for Test Assembly

Part Quantity Shape Size

Finish - Wrong specification (Wrong Finish)
Possible cause:
- No confirmation during specification clarification.
- No instruction in drawing.

Possible prevention method suggestion:

- To double check with end user and also submit color sample during clarification.
- In case there are multiple finish and panting method, always put that in each
respective drawing/item for easier identification.
- Thorough inspection (always check step per step – in case there are multiple layer
painting) and make sure to always paint more carefully on side that are difficult to be
painted as those are source of painting defect.
- Multiple inspection point/spot for painting thickness especially on area that are
difficult to be painted (inside corner part)
Wrong specification (Wrong Finish)

Finish color of toe plate is same with handrail,

while as per specification, finish color of toe
plate should be different

*please remember this as this mistake

happens most of the time due to finish color
specification is different every project.

Some projects require same color for toeplate

and handrail while some projects require
different color.
Finish - Wrong Non Painting Location
Possible Cause: Fabricator forgot to mark this part and
remove the painting properly, thus they have no time to fix
this and remove this non painted part in hurry

Possible prevention method suggestion:

- Always put additional remark of non painting area in
drawing
Due to non painted part was
- Painter to always tape those non painted part before mistakenly painted and no one
painting after sandblasting – tape can always act as realized on this, fabricator peel
the painted part in rush and
additional packing for this non painted part. result in untidy non painting part.
 Finish - Leftover Painting Bead
and Bubble Painting bead was
left due to
Possible Cause: Due to thickness is way over required from
thickness is over
specification, in addition, there is not enough drying time
after each painting and environment is too humid the specification
(painting booth environment should be dry enough or and insufficient
install dryer in painting booth during rainy or cold season, drying time
the over painted liquid left as bead or bubble during final
drying.

Possible prevention method suggestion:

- establish correct painting specification (correct painting Bubble on
method and thickness) painting surface
- sufficient drying time (not only follow manufacturer due to
standard but also consider environment as humid, insufficient
cool/cold area, or rainy season will affect drying time. drying time and
- in case painting time is short, always consider to use humid
dryer in painting booth environment
 Painting Peeled off Painting peeled off due to
mishandling during shipment

Possible cause: On bottom peeled paint, we

- Wrong Painting specification (thickness,
method, drying time)
- Sandblasting wrong specification
- Insufficient painting time
can see that sandblasting is
not being done properly 
sandblasting layer is not white
enough which shows it is not
SA 2.5

Possible prevention method suggestion:

- Establish company standard painting procedure
Painting peeled off
(or follow specification)
(spotting of peeled
- Always check after sandblasting to make sure
paint) due to
surface are clean and polished enough (SA 2.5
mishandling during
near white or above are always standard)
shipment
- Always consider sufficient painting time include
(Item hitting sharp
drying
object)
 Dirty HDG
Possible Cause: Due to dirty HDG bath,
some of HDG residues stuck in the item
after HDG process and stain the whole finish Dirty HDG Finish –
color. a lot of residues,
scratches in
surfaces
Possible prevention method suggestion:
- Thorough visual inspection before HDG to
make sure surface is clean and free of
impurities caused by defect during
fabrication process
- HDG subcontractor to always clean their
bath periodically
- In case if dirty HDG happened, then use
HDG spray to repair
 Finish - Sample of Acceptable Painting
Visual

Standard sandblast is at least

SA2.5 or SSPC 10 Clean Surface on either painting or HDG
Checklist Sample for Finish

Part Finish Color Thickness Visual

Packing and shipment - Mishandling

Broken pallet due to overweight which result in item moved

during shipment and hitting each other.
 Packing and Shipment - Mishandling

Mishandling of item during shipment caused item hitting each other and leave
dent, scratch and peeled off paint
 Possible Prevention Method Suggestion
during packing and shipment
• Plan for enough packing time
• Always consider max load on each pallet design. In case needed, change pallet material from wood to steel or change packing type from
pallet to box for more robust packing.
• Always consider also for max amount of item that can be placed on 1 pallet.
• Always make size of the pallet bigger than the item placed on top to avoid item hitting each other during shipment.
• Always make sure all of the pallet will be fixated in container to ensure pallet not moving during shipment
• Always attach enough soft cushion (foam sheet) in between each item to make sure item will not hitting each other during shipment.
• Always make sure to also attach soft cushion (foam sheet) on each corner especially on sharp corner to make sure those item will not break
other item in case those item hit each other during shipment
• Hard Cushion such as plywood is NOT ALLOWED.
• Always pack the pallet before shipment with plastic wrap thick enough to cover whole area and withstand anything during shipment (water,
humidity, etc)
• As shipment time is always long, if possible please input absorbent to avoid vapor that may induce corrosivity and rust for non painted part.
(non painted part is always coated with anti rust coating)
• For accessories, always coat with enough lubricant then pack separately on new packing plastic
• While logically acceptable, end user never accept packing that made from non specialized packing (for example, don’t use plastic that has
picture in the surface)
 Example of Acceptable Packing Plastic wrap for
packaging with
thickness thick
enough to cover
and protect from
Pallet strong any water
enough to hold all
of the item weight.
Take attention to
Soft cushion
thickness of the
(carton paper)
wood and quantity
in between item
of the horizontal
support wood.

Also Pallet size is Strapping that tight

bigger than the enough to keep item
item. from moving during
shipment
 Example of Acceptable Packing
Strapping that tight
enough to keep item
from moving during
Pallet strong shipment
enough to hold all
of the item weight.
Take attention to
thickness of the
wood and quantity Label/Tag with enough size.
of the horizontal Also information on detail
support wood. of the item on each pallet is
written carefully and clear
Also Pallet size is enough to avoid any
bigger than the mishandle
item.
Sample Preshipment
Checksheet
 Quality Commitment Agreement
1. During inspection, if item that are out of specification, Fabricator is going to repair and/or replace
for 100% free and make it until shipment date.

2. In case of late shipment due to any reason, Fabricator will pay penalty max 10% (Ten Percent)
from total Purchased Order Amount, in which on this case is equivalent to be USD 28,500.

3. In case for any defect found after shipment which during investigation is clearly caused by
Fabricator, Fabricator will shoulder repair cost subject to final agreement with end user.

Fabricator
CBB Engineering and Trading Co., Ltd

Director Sales Director

Mr. Nguyen Khac Van Mr. Duong Xuan Thai