conferdo GmbH & Co. KG External Quality, Environment, Health & Safety Management Manual with Integrated Welding Engineering Manual of the company conferdo GmbH & Co. KG STAHLBAU OHNE GRENZEN STEELWORK WITHOUT LIMITS Scope: Head office: 26897 Esterwegen, Südstraße 4 And all temporary production sites construction sites conferdo GmbH & Co. KG Rev. 3 / March 2014 Page 1 of 71
conferdo GmbH & Co. KG 2 Preface 10 Page 2 Page 2 Page IV Page 2 3 Terms and abbreviations 11 3 3 3 3 4 Quality, environment and health & safety management system 11 4 4 4 4.1 General 11 4.1 4.1 4.1 4.2 Quality, environment and health & safety management documentation 11 4.2 4.4.4 4.4.4 4.2.1 Quality, Environment and Health & Safety Management Manual 11 4.2.2 4.4.4 4.4.4 4.2.2 Process descriptions and quality procedures 13 4.2.3 Control of documents and date 13 4.2.3 4.4.5 4.4.5 4.2.4 Control of records 14 4.2.4 4.5.4 4.5.4 4.3 Other applicable documents 14 5 Management responsibility 15 5 4.2 4.2 5.1 Management commitment 15 5.1 4.4.1 4.4.1 5.2 Customer orientation 15 5.2 4.3.1 4.3.2 5.3 Quality, environment and health & safety policy 16 5.3 4.2 4.2 5.4 Planning 16 5.4 4.3 4.3 5.4.1 Quality, environment and health & safety goals 16 5.4.1 4.3.3 4.3.3 5.4.2 Planning the quality, environment and health & safety management system 16 5.4.2 4.3.3 4.3.3 5.5. Responsibility, authority and communication 17 5.5 4.4 4.4 5.5.1 Responsibility and authority 17 5.5.1 4.4.1 4.4.1 5.5.2 Management representative (QM/UM/AM representative) 17 5.5.2 4.4.1 4.4.1 5.5.3 Internal communication 17 5.5.3 4.4.3 4.4.3 conferdo GmbH & Co. KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 2 of 71 Seite 2 von 71
conferdo GmbH & Co. KG 5.6. Management review 17 5.6 4.6 4.6 5.6.1 General 17 5.6.1 4.6 4.6 5.6.2 Review input 17 5.6.2 4.6 4.6 5.6.3 Results of the review 18 5.6.3 4.6 4.6 5.7. Other applicable documents 19 6 Management of resources 20 6 4.4.1 4.4.1 6.1 Provision of resources 20 6.1 4.4.1 4.4.1 6.2 Human resources 20 6.2 4.4.2 4.4.2 6.2.1 General 20 6.2.1 4.4.2 4.4.2 6.2.2 Manpower planning 20 6.2.2 4.4.2 4.4.2 6.2.3 Induction 20 6.2.4 Further training 20 6.3 Infrastructure 21 6.3 4.4.1 4.4.1 6.4 Work environment 21 6.4 6.5 Other applicable documents 21 7 Product realisation (provision of services) 22 7 4.4 4.4.6 7.1 Planning product realisation (the provision of services) 22 7.1 4.4.6 4.4.6 7.2 Customer-related processes 23 7.2 7.2.1 Determining the requirements in terms of the product (the service) 23 7.2.1 4.3.2 4.3.2 7.2.2 Assessment of the requirements in terms of the product (the service) 23 7.2.2 4.4.6 4.4.6 7.2.3 Communication with the customer 23 7.2.3 4.4.3 4.4.3 7.3 Development 23 7.3 conferdo GmbH & Co. Co. KG KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 3 of 71 Seite 3 von 71
conferdo GmbH & Co. KG 7.4 Procurement 23 7.4 7.4.1 Procurement process 23 7.4.1 4.4.6 4.4.6 7.4.2 Procurement information 24 7.4.2 4.4.6 4.4.6 7.4.3 Verification of procured products 24 7.4.3 4.4.6 4.4.6 7.5 Production and the provision of services 24 7.5 7.5.1 Control of production and der the provision of services 24 7.5.1 4.4.6 4.4.6 7.5.2 Validation of the processes for production and the provision of services 24 7.5.2 4.4.6 7.5.3 Identification and traceability 24 7.5.3 7.5.4 Customer property 25 7.5.4 7.5.5 Product conservation 25 7.5.5 4.4.6 4.4.6 7.6 Control of monitoring and measuring equipment 26 7.6 4.5.1 4.5.1 7.7 Other applicable documents 26 8 Measurement, analysis and improvement 27 8 4.5 4.5 8.1 General 27 8.1 4.5.1 4.5.1 8.2 Monitoring and measurement 27 8.2 8.2.1 Customer satisfaction 27 8.2.1 8.2.2 Internal audit 27 8.2.2 4.5.5 4.5.5 8.2.3 Monitoring and measurement of processes 28 8.2.3 4.5.1 4.5.1 8.2.4 Monitoring and measurement of the product 28 8.2.4 4.5.1 4.5.1 8.3 Control of nonconforming products and services 28 8.3 4.5.3 4.5.3.2 8.4 Data analysis 28 8.4 4.5.1 4.5.1 8.5 Improvement 29 8.5 conferdo GmbH & Co. KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 4 of 71 Seite 4 von 71
conferdo GmbH & Co. KG 8.5.1 Continuous improvement 29 8.5.1 4.3.3 4.3.3 8.5.2 Corrective and preventive action 29 8.5.2 4.5.3 4.5.3.2 8.6 Other applicable documents 30 9 DIN EN ISO 14001 - Environment management 32 4 9.1 Planning 32 4.3 9.1.1 Environment aspects 32 4.3.1 9.1.2 Legal obligations and other requirements 32 4.3.2 9.1.3 Priorities, individual goals and programs 33 4.3.3 9.2 Implementation and operation 34 4.4 9.2.1 Resources, tasks, responsibility and authority 34 4.4.1 9.2.2 Skills, training and awareness 35 4.4.2 9.2.3 Process control 36 4.4.6 9.2.4 Emergency planning and risk prevention 37 4.4.7 9.3 Inspection 37 4.5 9.3.1 Review of compliance with legal regulations 37 4.5.2 10 BS OHSAS 18001 - Health & safety management 38 4 10.1 Planning 38 4.3 10.1.1 Identifying risks, risk assessment, definition of action 38 4.3.1 10.2 Inspection 38 4.5 10.2.1 Investigation of incidents, nonconformity, corrective and preventive action 38 4.5.3 10.2.1.1 Investigation of incidents 38 4.5.3.1 conferdo GmbH & Co. Co. KG KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 5 of 71 Seite 5 von 71
conferdo GmbH & Co. KG 11 DIN EN 3834 - Welding Engineering Manual 39 11.1 Introduction 39 11.2 Responsibility of the general management 39 11.3 Organisation planning 40 11.4 Quality requirements according to DIN EN 3834 40 4 11.4.1. Contract review 41 5 11.4.2 Design review 42 5 11.4.3 Traceability 43 17 11.4.4 Quality records 43 18 11.5 Subcontracting / temporary welders 43 6 11.6 Welding personnel 44 7 11.6.1 General 44 7.1 11.6.2 Welding personnel 44 7.2 11.6.3 Welding supervision 44 7.3 11.7 Welding joint testing 45 5 11.7.1 External testing situation 46 5 11.8 Maintenance of equipment for the workshop and parts 46 9.5 11.8.1 Welding processes 46 11.8.2 Welding systems 46 11.8.3 Auxiliary equipment 47 9.1 conferdo GmbH & Co. KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 6 of 71 Seite 6 von 71
conferdo GmbH & Co. KG 11.9 Welding activities 47 11.9.1 Production plan 47 10.1 11.9.2 Welding instructions 47 10.2 11.9.3 Recognition of welding procedures (procedure test) 48 10.3 11.9.4 Welding or work tests 49 11.9.5 Work instructions / briefing 49 10.4 11.10 Handling welding additives 49 11 11.11 Handling basic materials 50 12 11.11.1 Identification and traceability 50 17 11.12 Quality tests and welding tests 52 14 11.12.1 Tests before welding 52 14.2 11.12.2 Tests during welding work 53 14.3 11.12.3 Tests after welding 53 14.4 11.12.4 Internal and external tests 53 14.4 11.13 Complete sets of documentation for all orders 54 18 12 Manual EN 1090 55 12.1 Scope 55 1 12.2 Declaration by the general management 55 12.3 Factory production test 56 6.3 12.4 Assessment of conformity 56 6 12.5 Declaration of conformity 56 ZA 2.3 12.6 CE symbol 57 ZA 3 conferdo conferdo GmbH GmbH & Co. Co. KG KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 7 of 71 Seite 7 von 71
conferdo GmbH & Co. KG 12.7 Special processes 57 12.8 Abbreviations 57 3.2 13 WPK Manual 58 13.1 Construction materials 58 4.1 13.2 Handling and storage 58 6.3 13.3 Identifiability 58 6.2 13.4 Nonconforming products 59 6.3.8 13.5 Welding additives 59 5.5 13.6 Cutting 60 6.4 13.7 Thermal cutting 60 6.4.3 13.8 Hot working 60 6.5.2 13.9 Cold forming 60 6.5.4 13.10 Flame straightening 61 6.5.3 13.11 Welding processes according to DIN EN ISO 4063:2011-03 61 7.3 13.12 Welders and operators 61 7.4.2 13.13 Assembly for the welding work 61 7.5.4 13.14 Welding work 62 7.5 13.15 Welding 62 2.4 13.16 Welding plan 63 7.2 13.17 Welding joint preparation 63 7.5.1 13.18 Hollow profiles 63 7.5.1.2 13.19 Weather protection 63 7.5.3 conferdo GmbH & Co. KG Rev. 3 / March 2014 Rev. 3 / März 2014 Page 8 of 71 Seite 8 von 71
conferdo GmbH & Co. KG 13.20 Preheating 64 7.5.5 13.21 Assembly and assembly tools 64 6.9 7.5.6 13.22 Stud welds 64 7.5.7 13.23 Filet welds 65 7.5.8 13.24 Butt welds 65 7.5.9 13.25 One-sided welding joints 65 7.5.9.2 13.26 Pipe branches 65 7.5.11 13.27 Gouging 66 7.5.9.3 13.28 Slot and hole joints 66 7.5.13 13.29 Stud welding 66 7.5.12 13.30 Inspection and tests of welded shear studs for composite structures made of steel and concrete 66 12.4.3 13.31 Acceptance criteria 66 7.6 13.32 Inspection before and during welding 67 12.4.1 13.33 Inspection after welding 67 12.4.2 13.34 Correction of welding connections 67 13.35 Visual inspection of welding connections 67 13.36 Additional non-destructive testing procedures 68 Additional documents 14. Overview of quality procedures 69 15. Overview of process descriptions 70 16. Process landscape 71 conferdo GmbH & Co. KG Rev. 3 / März 2014 Seite 9 von 71 conferdo GmbH Co. KG Rev. 3 / March 2014 Page 9 of 71
conferdo GmbH & Co. KG 2 Preface This Quality, Environment and Health & Safety Management Manual describes the most important specifications and conditions of the quality, environment and health & safety management system at conferdo GmbH & Co. KG and the corresponding core tasks and core processes in the company. In conjunction with a separate chapter, this Manual also serves as a Welding Engineering Manual to satisfy the requirements of DIN EN 1090-1 and DIN 18800-7:2002-09, Class E. Also, the WPK process has been integrated. The described specifications, workflows and processes are applied in the various areas of the company conferdo GmbH & Co. KG in compliance with the detailed descriptions in the respective chapters. This Manual does not generally define final specifications, but gives all employees in the company the freedom to voice ideas, suggestions and proposals about the defined regulations and documents in this management system. The contact partner for this is the quality, environment and health & safety management representative and also the general management. If necessary, and after approval has been given by the general management, the quality, environment and health & safety management representative modifies the QM/UM/ASM documentation to accommodate current circumstances and to ensure the continuous improvement process; it is then communicated to all employees in the company. The male form used in this Manual refers to both male and female employees. The quality, environment and health & safety management system, also called an integrated management system (IMS), in place at the company conferdo GmbH & Co. KG can be adapted flexibly to performance needs. The General Management Esterwegen, 10 th March 2014 conferdo GmbH & Co. KG Rev. 3 / March 2014 Page 10 of 71