quality assurance (qa) manual

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QUALITY ASSURANCE (QA) MANUAL

Prepared by: Mike Fleming PgD MA SIIRSM

Version: 01 Revision date: September 2020


CONTENTS

page

QUALITY POLICY STATEMENT

SECTION 1

1. Responsibilities 1

Table 1: Responsibility matrix 1

SECTION 2

1. Quality assurance objectives 3

2. Material sampling and testing 3

a) Independent assurance 3

b) Third party certification 3

Table 2: Assuring fitness for purpose (example – door sets and assemblies) 4

c) Documentation 4

3. Construction Product Regulations (CPR) and Declaration of Performance (DoP) 5

Appendix 1 – Declaration of Performance (DoP) Template

Appendix 2 – Sample specification document

Appendix 3 – Amendments procedure


QUALITY POLICY STATEMENT

At DAM Group we are committed to providing our customers with products and services of the highest possible quality and standard. In order to achieve this, we continually improve quality assurance processes for our wide range of products, in order to exceed customer expectations and meet their requirements.

Our Commitment:

• Fully identify and conform to the needs of our customers, improving customer satisfaction;

• Monitor and review our service provision and processes, identify potential errors and implement the necessary actions in order to eliminate them;

• Provide staff training, promoting a ‘do it right first time’ attitude towards quality control and service delivery;

• Forge partnerships with our approved manufacturers. We also ensure that manufacturers and suppliers used in the delivery of our services comply with our quality philosophy;

• Achieve and maintain a standard of excellence in the operation of our business; • Maintain our reputation for honesty and integrity and ensure that this is reflected

throughout the organisation; • Provide the resources and equipment required to ensure that we operate in

accordance with our documented management systems and processes; • Ensure that our quality management system provides a framework for the

management and control of our activities for quality, environment and health & safety; and

• Continually monitor and review our quality assurance processes to ensure that they remain relevant, compliant and effective to the changing needs of our customers.

The effectiveness of our quality system and processes are monitored through audits, management reviews and customer satisfaction surveys to ensure the quality of our products and service delivery remain consistent.

M Fleming Mike Fleming PgD MA SIIRSM Operations Director DAM Group UK 01 August 2019


SECTION 1

Quality assurance plays a vital role in DAM Group’s management process by ensuring all product/s supplied meet certain thresholds of acceptability. To reflect the importance of these essential requirements, DAM Group’s Operations Director is responsible for planning, directing and coordinating quality assurance processes and formulating quality control policies.

1. Responsibilities

The implementation of DAM Group quality assurance processes is the responsibility of all employees. This responsibility extends to approved manufacturers/suppliers working for or importing products on behalf of DAM Group.

Regulation (EU) No. 305/2011 (Construction Products Regulation or CPR) distinguish two phases during the distribution, making available and placing construction products onto the market and associates for each phase different responsibilities to the those involved in the process (making available on the market means any supply for distribution or use on the EU market in the course of commercial activity be it for payment or free of charge). The first time a product is made available is therefore defined as placing it on the market. Only manufacturers or importers can place products on the market, whereas distributors, importers and manufacturers can make them available thereafter.

An importer or distributor may be considered to act as a manufacturer and is thus subject to all obligations for manufacturers in cases where he places a product on the market under his name or trademark or modifies a construction product already placed on the market. Even though not expressively stated in the CPR, the Declaration of Performance (DoP) and all accompanying documents are considered legal documents and shall not be altered but supplied as they have been provided by the manufacturer.

Table 1: Responsibility matrix

Manufacturer DAM Group HK (Importer)

Definition Manufacturer under the name of the construction product/s (in some cases this may be DAM Group)

Importer places the construction product/s from another country onto the European Union market.

Responsibility • Produce and supply technical, instructional and safety documentation for all product/s manufactured;

• Ensure constancy and consistency of the product/s production;

• Complete the Declaration of Performance (DoP) if covered by a European harmonised standard or for which a European Technical Assessment has been issued;

• Label the product/s according to DAM Group UK requirements;

• Withdraw/recall products as directed/required; and

• Provide all documentation to the relevant authorities.

• Import only compliant product/s;

• Ensure all documentation is made available by the manufacturer;

• Supply all technical, instruction, and safety documentation;

• Ensure the compliant storage and transport of product/s i.e. photographic evidence of container, 50% loaded, fully loaded and sealed (with serial number);

• Where appropriate carry out sample testing of product/s as directed;

• Keep the DoP available if applicable;

• Withdraw/recall products as directed/required; and

• Provide all documentation to the relevant authorities.


DAM Group UK as sole distributor and European representative

Definition Entity other than the importer or manufacturer making the products available with a written mandate such as an exclusivity or sole distributor agreement..

Responsibility • Ensure that all documentation is available from the manufacturer and importer;

• Ensure that CE marking is applied to product/s as and if required;

• Provide all documentation to the relevant authorities as required;

• Inform DAM Group HK immediately of any defects or deficiencies including the need to withdraw/recall any product/s;

• Arrange for representative assurance testing through Exover Warringtonfire as directed by the Operations Director;

• Ensure compliant storage and transportation of product/s to the client;

• Ensure the DoP, if applicable, is published and made available as required; and

• Always cooperate with all relevant authorities.


SECTION 2

The Material Quality Assurance (QA) sampling and testing methodologies described in this manual have been developed by DAM Group UK (United Kingdom) in consultation with DAM Group HK (Hong Kong) and its manufacturers/suppliers. These methodologies include a documented regime of sampling and testing such as independent assurance, third party certification and the retention of all relevant documentation.

1. Quality assurance objectives:

a) Design and implement sampling and testing procedures to assure that materials conform to specifications and comply with requirements;

b) Provide the required documentation through test results and other pertinent records, to allow DAM Group staff to take remedial action;

c) Continuously monitor DAM Group processes against currently accepted testing standards and monitor personnel for product control competency;

d) Maintain a product testing database to allow DAM Group to evaluate new products, analyse product performance over time and to assist in product approval; and

e) Maintain the quality of testing laboratories by monitoring quality systems and accreditation;

Should questions arise as to the quality of products, DAM Group will promptly furnish information and perform additional sampling and testing when specifically requested to do so by the Operations Director of DAM Group UK. The results of all quality assurance sampling and testing will be made available to all relevant parties as requested.

2. Material sampling and testing

Sampling and testing is performed on all construction products supplied by DAM Group according to specification documents and the requirements set out at 2 a), b) and c) below. Together, these documents contain the instructions and information required to fulfil the requirements of DAM Group’s Quality Policy.

DAM Group product sampling and testing processes include the following:

a) Independent assurance – Prior to selecting an approved manufacturer, DAM Group conducts independent assurance inspections which serve to check the quality standards and accreditations, product/s being supplied, processes being used as well as any test performance data issued within the country of origin. This process involves the manufacturer developing technical documentation describing in detail the construction product/s, its method of production, test reports performed at third party laboratories and their independent classification of the results.

The first phase of independent assurance is backed up factory audits, with which the appointed notified body verifies if the quality system (i.e. ISO 9001 Quality Management) of the manufacturer at their factory can assure over time constancy in order to preserve for the serial production the declared essential characteristics of the tested specimen.

b) Third party certification – All third party laboratories and technicians involved in conducting testing on behalf of DAM Group must be registered with the


appropriate test authority in accordance with the requirements for each specific material i.e. The United Kingdom Accreditation Service (UKAS) which is the UK’s National Accreditation Body, responsible for determining, in the public interest, the technical competence and integrity of organisations such as those offering testing, calibration and certification services.

Table 2: Example – Assuring fitness for purpose

Fire Doorset, Fire

Door or Fire Door Assembly?

Fire Doorset A fire door leaf supplied pre-

hung in its frame, with hinges, glazing, fire and smoke seals,

ironmongery supplied as a complete set

Fire Door A door leaf of a design that

has been tested to have residence to fire (the main

component of the assembly)

Fire Door Assembly All the correct, compatible and third party certified elements of a fire doorset, BUT which have been collated together

from different sources

European door set product norms apply (Harmonised

European Standards – hEN’s)

Harmonised European Standard - hEN’s do not fit

products in the market

CE marking, with a notified body (NB)

NOT possible to use the

CE marking process

Fire resistance tests BS EN test norms

Classification to BS EN 13501

Test reports

(by test authorities)

Fire resistance tests BS EN test norms and/or BS

476 series

CE MARK Certificate of Constancy of Performance Declaration of Performance

(DoP)

Compliance with UK Building Regulations

Approved Document B

PRODUCT

CERTIFICATION Voluntary, independent scrutiny, with scope for

product auditing

To remove technical barriers to trade in the

European internal market. A common technical

language

Third party certification provides additional

assurance under Building Regulations (e.g. Approved

Document B)

c) Documentation – Reports and third party test certification of all products manufactured on behalf of DAM Group is reviewed by the Operations Director prior to approval. Any deficiencies found in procedures and any non-


conforming test results will be investigated with corrective action being taken by the manufacturer as directed by the DAM Group Operations Director.

All documentation, including images of container loading and intact seals, relating to assurance inspections and testing, including corrective actions, will be retained by DAM Group for inspection as required.

3. Construction Product Regulations (CPR) and Declaration of Performance (DoP)

In accordance with The Construction Products Regulations 2013, the DAM Group (in assuming a manufacturers role, see table 1 at page 3) is obliged to draw up a ‘Declaration of Performance’ (DoP) when a construction product is covered by a harmonised standard or conforms to a European Technical Assessment. Information about the product's performance in relation to the essential characteristics will be provided in the form of a DoP (Appendix 1). The CE marking will be applied to the product itself and where this is not possible to the packaging or accompanying documentation.

In order to draw up its DoP, DAM Group approved manufacturers must develop technical documentation describing in detail the construction product, its method of production, eventual test reports performed at third party laboratories (ITT – initial type test), their classification of the results (classification report) and eventual extensions (EXAP - extended application report). This first phase is followed by a factory audit, with which the appointed notified body verifies if the quality system of the manufacturer at their factory can assure over time constancy in order to preserve the declared essential characteristics of the tested specimen. A positive audit leads to the issuing by the notified body of the Certificate of Constancy of Performance with which the DAM Group is authorised to issue the DoP for the manufacturers certified construction product.


APPENDIX 1 – Declaration of Performance (DoP) Template

Construction Products Regulation 2011 Declaration of Performance (DoP)

DoP number: DAM-UK/< >

1. Unique identification code of the product:

< > 2. Type, batch or serial number or any other element allowing identification of the construction product as required under Article 11(4) of the CPR:

< > 3. Intended use or uses of the construction product, in accordance with the applicable harmonised technical specification, as foreseen by the manufacturer:

< > 4. Name, registered trade name or registered trademark and contact address of the manufacturer as required under Article 11(5)

< > 5. Where applicable, name and contact address of the authorised representative whose mandate covers the tasks specified in Article 12(2):

< > 6. System or systems of assessment and verification of constancy of performance of the construction product as set out in CPR, Annex V:

< > 7. In case of the declaration of performance concerning a construction product covered by a harmonised standard. EN 1935:2002 Notified product certification No.1121 performed the determination of the product type on the basis of type testing (including sampling); initial inspection of the manufacturing plant and of the factory production control and continuous surveillance; assessment and evaluation of factory production control; and issued the certificate of constancy of performance of the product.

< > 8. European Technical Assessment:

< >


9. Declared performance:

Essential characteristics

Performance Harmonised technical specification

The performance of the product identified in points 1 and 2 is in conformity with the declared performance in point 9.

This declaration of performance is issued under the sole responsibility of the manufacturer identified in point 4.

Signed for and on behalf of the manufacturer by:

Mr Michael Fleming PgD MA SIIRSM Operations Director DAM Group UK Date of issue:

< >


APPENDIX 2 – Sample specification document - Doors

Standard Fire Door Specification

Note: This standard specification sets out the basic functional requirements for a fire door.

*Our fire door sets are designed and built to your exact specifications and are fully tested to British (BS) and European (EN) Fire Resisting Standards as required.

Completed by: < > Signature: < >

Position: < > Date: < >

*Fire Doorset: A fire door leaf

supplied pre-hung in its frame, with hinges, glazing, fire and smoke seals and ironmongery supplied as a complete set.

Total Fire Door Assembly: All the

correct, compatible and third party certified elements of a fire doorset, BUT which have been collated together from different sources.

Total Fire Door: A door leaf of a design

that has been tested to have residence to fire (the main component of the assembly)

Total

Element Minimum requirements Customer specific requirements

To be defined by the customer and must meet the requirements of Building Regulations

Door type and fire resistance

Doors must be suitably fire protected to suit the environment in which they are situated, including risers, equipment and store cupboard doors.

FD30 Fire Doors

• 30 minutes fire resistance (Integrity) • 44mm Certified core to BS 476 Pt22:1987 or *BS EN 1634-

1:2014 • Intumescent strips in the frame or the door (not both) • Certified glazing (insulating / non insulating)

<state door type and fire resistance required>


FD60 Fire Doors

• 60 minutes fire resistance (Integrity) • 54mm Certified core to BS 476 Pt22:1987 or *BS EN 1634

1:2014 • Intumescent strips in the frame or the door (not both) • Certified glazing (insulating / non insulating)

Door finish Doors should be suitable for on-site maintenance. Finish may be paint or varnish etc. but should be area / project specific as defined by the customer and must meet the requirements of Building Regulations.

Wood varieties include black walnut, oak, cherry, teak and maple.

<state door finish required>

Door furniture Hardware used on fire doors can significantly affect performance in fire. Guidance is available in hardware for fire and escape doors published by the Builders’ Hardware Industry Federation.

<state door furniture required>

Hinges Hinges should be stainless steel and should be adequate in size and number to suit the size and weight of the door.

All fire doors must be hung on three steel hinges, to resist bowing in the event of a fire and to bear the increased weight of the door.

<state door hinges required>

Height Door heights should not exceed 2.1m. <state dimensions of door required>

Vision Panels If a vision panel or glazing is required in the fire door or partition, then the glazing must be Fire Resisting Glazing of 30 / 60-minute integrity.

Glass types must be Pyro and not Georgian Wired. Pryo FR glazing should be identifiable by acid etching with the trade name in the corner of the pane and marked with BS 476 Part 22.

<state vision panels required>


Smoke seals/Intumescent strips

Smoke seals are recessed into the door as per BS 476 Part 31.1.

Smoke seals must be fitted to all fire doors. This specification is for a ‘night-time escape’ standard and so smoke seals are important to enable occupiers to escape down the protected route without being subjected to smoke which can be toxic, impede breathing and affect vision. Cool smoke, often given off by smouldering furnishings and electrical equipment, is exceptionally toxic and tends not to rise, therefore smoke seals on fire doors are essential.

Nylon brush or neoprene smoke seals (draught proofing kits) are acceptable. Smoke seals can be fitted into the door itself or, a better option is to apply to the door stop so that the fire door closes onto the seals. Fire door performance and integrity depends on the installation of such strips which can be fixed into a channel in the door or fitted to the frame.

<state smoke seals/Intumescent strip fitting location required>

Signage All doors must be clearly labelled using legible printed signs.

Additional signage can be provided.

<state door signage required>

Closers Fire resisting doors must be fitted with external dual action hydraulic type self-closing devices which are adjusted to close quickly but latch slowly so as not to wear the smoke seals or damage the door or frame. Perco-type closers are not suitable as they cause the doors to slam causing noise nuisance to occupiers and they tend to wear the smoke seals/frames causing damage over time.

<state door closer required>

Double Doors Where double doors are to be installed, the left-hand leaf should be fitted with top and bottom stainless-steel flush bolts. Mortice locks should be fitted unless otherwise specified.

<state double door fitting required>


Door stops and fitting

Door frames may be improved to have 25mm door stops which the doors close onto. The benefit of doing this is that it covers minor irregularities of fit, often found when working on existing door openings. Alternatively, if purpose made doors are used which have integral intumescent strips then standard doorstops can remain.

On completion doors must be reasonably close fitting into frames with a maximum gap of 3mm between door and frame. If doors are too tight then the self-closers do not work, there must be a certain air gap around the door. In addition, heavy fire doors may drop by a millimetre or 2 over time and so tight-fitting doors will stop closing and need to be adjusted.

<state door stop required>

General Customer specific requirements < >

All test evidence used to substantiate the fire resistance rating of our door sets, and door assemblies is carefully checked as part of DAM Group’s Quality Assurance Procedures to ensure that it demonstrates compliance that is applicable to the installed assembly. Small differences in detail (such as glazing apertures, intumescent strips, door frames and ironmongery etc.) may significantly affect the rating.

1. Unless shown to be satisfactory when tested as part of a fire door assembly, the essential components of any hinges on which a fire door is hung are made entirely from materials having a melting point of at least 800ºC. In addition, it should be noted that any hardware used on fire doors can significantly affect performance in fire.

*A Declaration of Performance (DoP) is provided with our complete fire door sets to ensure they have the appropriate performance either:

2. by their performance under test to BS 476- 22:1987 Fire tests on building materials and structures - Methods for determination of the fire resistance of non-loadbearing elements of construction, in terms of integrity for a period of minutes, e.g. FD30. A suffix (S) is added for doors where restricted smoke leakage at ambient temperatures is needed; or

3. as determined with reference to Commission Decision 2000/367/EC of 3 May 2000 implementing Council Directive 89/106/EEC as regards the classification of the resistance to fire performance of construction products, construction works and parts thereof. All fire doors should be classified in accordance with BS EN 13501-2:2003 Fire classification of construction products and building elements. Classification using data from fire resistance tests, (excluding products for use in ventilation systems). They are tested to the relevant European method from the following:


• BS EN 1634-1:2008 Fire resistance and smoke control tests for door and shutter assemblies, openable windows and elements of building hardware. Fire resistance tests for doors, shutters and openable windows;

• BS EN 1634-2:2008 Fire resistance tests and smoke control tests for door and shutter assemblies, openable windows and elements of building hardware. Fire resistance characterisation test for elements of building hardware;

• BS EN 1634-3:2004 Fire resistance tests and smoke control tests for door and shutter assemblies, openable windows and elements of building hardware. - Smoke control test for door and shutter assemblies.

Testing references: • Fire tests on Building Materials and Structures. Classification and method of test for external fire exposure to roofs:

• Part 4: Non-combustibility test for materials

• Part 5: Method of test for ignitability

• Part 6: Method of test for fire propagation for products

• Part 7: Method of test to determine the classification of the surface spread of flame of products

• Part 11: Method for assessing the heat emission from building materials

• Part 12: Method of test for ignitability of products by direct flame impingement

• Part 13: Method of measuring the ignitability of products subjected to thermal irradiance

• Part 15: Method of measuring the rate of heat release of products

• Part 20: Method for determination of the fire resistance of elements of construction (general principles)

• Part 21: Methods for determination of the fire resistance of load bearing elements of construction

• Part 22: Methods for determination of the fire resistance of non- load bearing elements of construction

• BS 476-23: Fire Tests on Building Materials and Structures – Part 23: Methods for determination of the contribution of components to the fire resistance of a structure

• BS 476-24: Fire Tests on Building Materials and Structures – Part 24: Method for determination of the fire resistance of ventilation ducts

• BS 8414: Fire performance of External Cladding

• BS 8414-1:2015 Fire performance of external cladding systems. Test method for non-loadbearing external cladding systems applied to the masonry face of a building

• BS 8414-2:2015 Fire performance of external cladding systems. Test method for non-loadbearing external cladding systems fixed to and supported by a structural steel frame

• Approved Document B (fire safety)


APPENDIX 3 – Amendments procedure

Amendments for this document will be issued by DAM UK Group as and when they become available.

It will be the responsibility of each responsible person to ensure that such amendments are immediately incorporated on receipt.

Amendments should be marked clearly and submitted to:

Address Tel Email

Amendment Number

Date Amended By Comments


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