quality check in building

Quality Check of “Product Manufacturing”

Mass producing a tested and complied design requires that the exact same steps be undertaken to

assemble / make the system / subsystems with the exact same components / materials.

The selection of raw material and the design of the product is dictated by the end application. This could vary

vastly for the same product.

Using the nomenclature of BS EN 1935, I would want to bring out the extent to which the applications of a

simple “hinge” can very. The European Standard written by BSI is a standard for single-axis hinges defining

its requirements and test methods.

Below is an image (fig. 12) explaining the 8 digits used to classify a single axis hinge.

1. How to create the testing environment

2. How to install the samples

3. How and which all parameters are to be

recorded during the test duration.

Below is a brief list of the steps for the above test:

Step 1. The sample is received along with detailed

drawings of the system.

Step 2. Before and during the Installation, evidence

is gathered to correlate the sample submitted with

the drawings. (fig. 1 & 2)

Introduction

The word quality is overused to an extent that it

has become a cliché. Most of what we see around

us is claimed to be of ‘good’ quality or of ‘high’

standards. This article relates the author’s

perspective on how quality can be defined in

building & construction focusing on façade &

fenestration elements.

It primarily focuses on three levels where “Quality

Checks” are critical. These are explained by

examples of curtain wall systems, building

hardware and partition systems. Below are three

levels of quality check:-

A. Product design

B. Product manufacturing

C. System design and execution

It is important for key stakeholders (developers and

owners, designers & architects, contractors and

manufacturers) involved in creating buildings to be

aware of these levels of quality as these will help

them pinpoint possible aberrations. Compliance to

certain or limited standards may give a false feeling

of quality compliance to manufacturers or users.

Any product or a system which will be part of a

building (glazing, hinges, window) has to perform

throughout the claimed life of the building and

should be in a position to endure known (high

Quality Checks forBuilding Façade

About Author:

An engineer and a post graduate in finance, Abhishek Chhabra handles the business development activities for Thomas Bell Wright Laboratories, Dubai. Over the last twelve years he has helped organizations expand their businesses by better understanding the supply chains of materials, services and quality.

Prior to joining Thomas Bell Wright as business development, he spent over six years helping Intertek’s (The testing, Inspection and Certification body) clients in India and overseas effectively utilize their testing and certification services to grow their business across verticals of products and services

winds, rain) and limited unforeseen environments

(like earthquakes, fire etc.) To develop and supply a

product or a system that displays consistency

repeatability of compliance evokes a satisfaction of

quality. Various tools that are used by organizations

to achieve these levels of assurance are discussed

below.

Quality Check for Product Design

It is common for companies to claim that their

products comply with a certain standard and hence

implying that these are a quality product. It is

critical to understand the extent and boundaries of

these standards.

There are a large number of standards (AAMA,

ASTM, BS, CWCT, EN, etc.) for products. A

standard can define either or all of the following:

test method

classification

practice

guideline

Fire rated curtain wall as per EN 1364-3

EN 1364-3 is a European Standard which specifies

a test method for determining the fire resistance of

curtain walling (full configuration) for non-load

bearing elements. The scope also defines that this

European Standard does not cover double skin

façades, over-cladding systems and ventilated

façade systems on external walls. It does not deal

with the behavior of curtain wall in case of fire.

Test method to check the compliance of a fire

rated curtain wall with EN 1364-3

Such a test is conducted to verify the fire rating (in

hours/minutes) that a particular design can endure.

The standard details on the following:

Step 3. Samples are carefully installed on to a

frame representing the standard conditions. (fig. 3

& 4)

Step 4. The system is loaded with thermocouples

and sensors which will help capture change in

temperature and other parameters to be recorded.

(fig. 5)

Step 5. The furnace is fired up. It is designed to

simulate the increase in temperature and pressure

as it would progress in case of a real fire (fig. 6 & 7)

Step 6. The test sample is carefully monitored

throughout the duration of the test for various

parameters like changes in deflection of structure,

rate of change of temperature, behavior of material,

release of gases etc. (fig. 8, 9, 10 & 11).

Step 7. The test ends in confirming the fire rating of

the curtain wall system in minutes till which the

system could withstand a real fire. (example 120

minutes of fire rating)

Step 8. A test report is compiled and issued

capturing behavior of the system during the test as

per the test standard.

This is a product level quality check and is the

starting point to prove compliance of future

performance of the product or systems in given

environment. Testing with many combinations of

systems, materials and environments may be

necessary before the design can be claimed to

perform as per desired expectations in unique

environments.

Precautions to be taken while testing /choosing

a test lab:

1. Ensure the testing laboratory is accredited to

ISO 17025

2. ISO/IEC 17025:2005 specifies the general

requirements that determine a lab’s

competence to carry out tests and/or

calibrations, including sampling. It covers

testing and calibrations using standard

methods, non-standard methods and

laboratory-developed methods

3. Accreditation is a process in which certification

of competency, authority, or credibility is

presented. Organizations that issue credentials

or certify third parties against official standards

are themselves formally accredited by

accreditation bodies (such as UKAS- United

Kingdom Accreditation Service)

4. National Accreditation Board for Testing and

Calibration Laboratories (NABL) which is India’s

national accreditation body is a signatory to

Mutual Recognition Arrangement with

International Laboratory Accreditation

Cooperation (ILAC)

5. The International Laboratory Accreditation

Cooperation - is an international cooperation of

laboratory and inspection accreditation bodies

formed more than 30 years ago to help remove

technical barriers to trade. 36 laboratory

accreditation bodies from 28 economies

worldwide signed an arrangement to accept

each other’s accreditation. This helps bring the

test reports issued by laboratories accredited by

different accreditation bodies at par (Example

the report issued from a lab in India accredited

to a standard by NABL is equal to the report

issued by a lab in UK accredited to the ‘same

standard’ by UKAS and vice-versa)

6. The compliance testing should use a test

standard which guides to simulate the

conditions of the environment where the

product will be finally used. For example ANSI

(American National Standards Institute) is the

body that adopts standards from various

standard writing bodies like UL, ASTM, AAMA,

etc. to declare them as the standards that are

representative of the conditions prevailing in

USA. Like the ANSI standards for fire resistance

testing (for doors ANSI/UL 10C) makes it

mandatory to conduct a hose stream test at

the end of the fire rating testing. This is done to

simulate the practice that is followed in United

States where the fire department believes it is

mandatory that the fire rated partitioning

system maintains their integrity when the fire is

extinguished.

This standard helps create a test report to show compliance of the hinge design to the exact 8 digit code

using defined testing methodology. Consultants designing systems use these classifications to specify

hinges for their final system and need proof of continued compliance to these parameters.

Abhishek Chhabra,Business Development Manager

Thomas Bell WrightDubai

Product Certification for assurance of performance repeatability:

One of the most commonly used system to create evidence of future performance of products or systems manufactured or assembled is Third Party Product Certification.

Independent agencies which offer product certification services need accreditation as per ISO/IEC 17065 from an accreditation body. ISO/IEC 17065 is a standard defined as: - Conformity assessment -- Requirements for bodies certifying products, processes and services (replaces EN 45011 and ISO Guide 65)

An accreditation to this standard empowers certification bodies to carry out the following procedures:

1. Inspect & map the product’s manufacturing

2. Technically assess test data generated by compliance testing conducted by an independent testing laboratory accredited to conduct the requisite tests

3. Conduct surveillance audits at manufacturing premises to ensure repeatability of product performance

4. Issue a certification marking and maintain a directory (online) of the certification information.

After seeing the extent to which a simple hardware as a hinge is specified as per the its application you can

appreciate the need of a “third party certification” scheme which helps assure system designers and

manufacturers that their systems will perform to desired levels.

Having a third party product certification is the key to assure quality at the Product Manufacturing level.

Quality Check of “System Design and Execution”

Every project is unique and quite often structures & systems designed call for modifications in materials and

components purchased to build it. Most of the time systems like facades, fenestrations and partitions are

uniquely designed for each project. To ensure that tested and certified products and materials will perform in

the unique environment; systematic testing is required.

The geographical and climatic environment the building is being erected is a key factor influencing the

specifications of compliance of each element of the building. As an example the illustration below shows

two different project specifications. These two will call for different approaches of material usage as well as

testing to check quality. (table1, table2)

At this stage of the project the representative mockups of sections of curtain walls, windows, partitions and

other systems need to undergo tests which simulate the final conditions which are specified by the design

consultants.

Tools to create evidence of compliance of systems and workmanship:

Break down the design to critical sub-systems to check the uniquely designed elements for known failures as per prescribed standards and limits set by the design consultant.

Test these sub-systems with uniquely designed and fabricated mockups that simulate the project environment. Test standards specify methodologies of testing and data capture.

Use on-site testing to arrive as proof of compliance of the final work at the site.

Utilize (if available) technical opinions (assessments) to extrapolate existing test data to prove compliance with certain modifications.

Conduct inspections to correlate the workmanship of fabrication system erection.

Points worth noting while conducting such tests:

The mockups should be erected by the same subcontractors and using the exact same design and materials which will be later deployed at site.

The inspectors reviewing final work done at site should refer to test reports which have captured the design, material and method of fabrication to check the workmanship of the final work.

Careful attention should be given to the design. The stakeholders should not attempt to achieve compliance to under or over specified requirements.

The third party testing or inspection agency should have appropriate accreditations to conduct the requisite tests.

This system level quality check is most prone to short cuts. Design consultants and governing authorities (like fire departments, public works departments, municipalities, etc.) are the guardians of quality. They set codes, guidelines and criteria of acceptance of buildings and their performance. These guardians can be tough or lax in their monitoring processes.

Conclusion:

With increased awareness amongst developers, owners and users there is an increased level of understanding for quality checks and the availability of the right tools and processes brings about a promise for more accuracy in curtain wall performances.

The above elaboration aimed at making quality checks more quantifiable. Empowered with correct knowledge and equipment the stakeholders can be mindful of the pitfalls and false quality claims.

| 36 WFM MAY-JUN 2014 |




















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.

fig. 1

fig. 2



























consultants.













Conclusion:



| MAY-JUN 2014 WFM 37 |










| 38 WFM MAY-JUN 2014 |











Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.

fig. 3

fig. 4

fig. 5

fig. 6

fig. 7



























consultants.













Conclusion:












| MAY-JUN 2014 WFM 39 |











Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.

fig. 8

fig. 9 fig. 11

fig. 10



























consultants.













Conclusion:






















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.



























consultants.













Conclusion:



| 40 WFM MAY-JUN 2014 |




















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.




fig.12
























consultants.













Conclusion:



| MAY-JUN 2014 WFM 41 |




















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.




fig. 13
























consultants.













Conclusion:



| 42 WFM MAY-JUN 2014 |




















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.



























consultants.













Conclusion:






















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.
















1. AIR INFILTRATION TEST ASTM E 283 Test pressure 600 Pa Permitted leakage fix wall 1.5 m³/hr/m² Permitted leakage window 2.0 m³/hr/m

2. STATIC WATER PENETRATION TEST ASTM E 331 Test Pressure 600 Pa Leakage Details No water penetration on interior surface

3. STRUCTURAL PERFORMANCE TEST ASTM E 330 Test Pressure + 2.67 kPa Acceptable Deflection - 3.40 kPa L/200 or 20 mm whichever is less,

4. DYNAMIC WATER PENETRATION TEST AAMA 501.1-05 Test Pressure 600 Pa Permitted leakage No water penetration on interior surface

5. SEISMIC TEST (+/-) 14 mm from Horizontal displacement normal position

6. HOSE TEST AAMA 501.2-09

7. STRUCTURAL PROOF LOAD ASTM 330 Test Pressure = 1.2 X design load + 3.204 kPa Acceptable Deformation - 4.080 kPa L/1000

Project 1 - Table 1












consultants.

| 44 WFM MAY-JUN 2014 |













Conclusion:






















Introduction













A. Product design




















below.






these standards.




test method

classification

practice

guideline

















& 4)




(fig. 5)























environments.


a test lab:


ISO 17025




















Cooperation (ILAC)
































extinguished.



























consultants.

| MAY-JUN 2014 WFM 45 |

1. STRUCTURAL PERFORMANCE TEST AS/ NZS 4284-95 Test pressure 1.6 kPa Acceptable Deflection L / 240 or 20 mm

2. AIR INFILTRATION TEST AS/ NZS 4284-95 Test Pressure 300 Pa Permitted Leakage 3.6 m³/hr/m² (1.0 L/s/m²)

3. STATIC WATER PENETRATION TEST AS/ NZS 4284-95 Test Pressure 300 Pa Leakage Details No water penetration on interior surface

4. CYCLIC WATER PENETRATION TEST AS/ NZS 4284-95 Test Pressure Cycle 1 150 – 300 Pa Cycle 2 320 – 640 Pa Cycle 3 480 – 960 Pa Leakage Details No water penetration on interior surface

5. STRUCTURAL PROOF LOAD TEST AS/ NZS 4284-95 Test Pressure 2.4 kPa

6. SEAL DEGRADATION TEST AS/ NZS 4284-95

Project 2 - Table 2













Conclusion:



quality check in building

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